The Iron Age 1909-06-17: Vol 83 Iss 24

THE IRON AGE Published every Thursday Morning by David Williams Co., 14-16 Park Place, New York. Vol. 83: No. 24. New York, Thursday, June 17, 1909. jae ta aoe ee Reading Matter Contents........ page 1970 Alphabetical Index to Advertisers ‘* 202 Classified List of Advertisers -“ 192 Advertising and Subscription Rates ‘‘ 1979 | REED F. BLAIR & CO. PRICK BUILDING, PITTSBURG, PA. STANDARD CONNELLSVILLE COKE “Wise Buying is the Art of Selling’”’ FOUNDRY FURNACE CRUSHED Subject: Some people will tell you that you can sell anything if it is advertised. Advertis- ing is a great power Yet an advertised article without selling points, without popular appeal, can’t compete with an advertised article that has an exclusive superior feature. U MC Shot Shells are Steel Lined, but no others are. ; We are advertising the Steel Lining to all American Sportsmen — ~ight to your customers, The original and only Genuine **STILLSON WRENCH ”’ is manufactured by WALWORTH MFG. co., Boston, v. s. A. And bears their registered Trade-Mark “er Is it safe to infer that you can sell ordinary unlined shot shells in competition with U MC Steel Lined widely advertised shot shells ? Get UMC Steel Lined Shells for the game season. THE UNION METALLIC CARTRIDGE CO. BRIDGEPORT, CONN, AGENCY, 315 BROADWAY, NEW YORK CITY WRITE FOR NEW BULLETIN No. 104 THE BRISTOL CO. Waterbury, Conn. WATER TUBE The Babcock & Wilcox Co., SAMSON SPOT SASH CORD BOILERS See page 55 ” ma a Ss : ', Minabepeislettinainty enti ee ” The Capewell” ———_—_ Samson Cordage Works, Boston, Mass. a Horse Nail is Best Suited | arent sheet oat ae To the every day requirements of all Horse- Gap MERRILL BROS. shoers and the nail which is by all odds the a ee ak most economical to use. AAUFE Pilling & Crane ieee | Real Estate Trust Bidg. PHILADELPHIA THE CAPEWELL HORSE NAIL COMPANY W YORK Suge mne. ev Ve Hartford, Conn., U. S. A. UFHIN RULES JenKins Bros. Radiator Valves | ADE IN AMERICA and are made of an excellent grade of new steam metal, and are recommended by THE ASEST IN THE WORLD | the leading architects and consulting engineers, because they are the heaviest, THE LUFKIN SS poe Mich., U.S.A. | strongest and most durable. Steam users are always assured of obtaining | New York London indsor, Can. entire satisfaction, as they are absolutely guaranteed. May we send you our Catalogue ? APOLLO *— JENKINS BROS., New York, Boston, Philadelphia, Chicago Special Electrical “Swedoh” Col Rolled Stee! ',i™: Drawing »« Stamping Sheets THE AMERICAN TUBE @ STAMPING COMPANY este 27 MAGNOLIA opeicrion METAL The Standard Babbitt of the World | We manufacture everything in the Babbitt Line. > MAGNOLIA METAL CO, pea akg ok Sl New York: 115 Bank St, Chicago: Fisher Building. Montreal: 31 St, Nicholas St. Iron losses—a minimum. A ging —eliminated. AMERICAN SHEET AND TIN PLATE COMPANY Frick Bullding, Pittsburgh, Pa. See our ad on page 18 2 THE IRON AGE THE HIGHEST |IBR ASS | OD The Plume ,& Atwood Mig. Co, Manufacturers of EFFICIENCY va Sheet and Roll Brass, Wire, is oe | Rods, German Silver and Brass ROD Goods in great variety OBTAIN ED SILVER WIRE | Rolling Mill Factories WHEN <ceecscaaaaniainibiiten Thomaston, Conn., Waterbury, Conn. . ffi Pat, leveled Sign Brass New York samen ies and San Francisco FQ LL A No Buckles, Clean Surface, IRON AGE READERS Polished or Plain Steel Stamps and Dies, Time Checks FLECTRIGAL . |{rst-uevereo cenian suver | "vSs"cicesse Polished or Plain for Soda Factory Time Che te Matthews of Pittsburg Water and Bar Fixtures Se ae STEEL Low Brass, Gilding and Bronze Metal, Sheet, Rod and Wire | SCOVILL MFG. CO. iS USED Manufactured Goods Scaehadaien of in Great Variety BRASS, GERMAN SILVER, FOLLANSBEE || Waterbury Brass Co.)} | 7" Rom Brass Shells, Cups, Hinges, Bettons, Lamp Goods. WATERBURY, CONN. BB ROTH E RS 1 Cliff St., New York Providence, R. I. Spectal Brass Goods to Order COMPANY Bridgeport Deoxidized Bronze|} warerpury, conn. MAKERS & Metal Co. NEW YORK aes BOSTON HIGH GRADE BRIDGEPORT, CONN. SHEET STEEL Phosphor and Deoxidized Henry Souther Engineering C0, Pp I TT S B U R G Hy Bronze HARTFORD, CONN. Composition, Yellow Brass and Alumi- Consulting Chemists, Metallurgists num Castings, large and small and Analysts. Complete Physical Testing Laboratory. Expert Testimony in Court and Patent Cases. Matthiessen & Hegeler Zinc Co. ArthurT Butter & Co LA SALLE, ILLINOIS £ i SMELTERS OF SPELTER AND MANUFACTURERS 256 Broadway, SHEET ZINC AND SULPHURIC ACID NEW YORK. Special Sises of Zinc eut to order. Rolled Battery Plates. Small tubing in Brass, Copper, Selected Piates for Etchers’ and Lithographers: use. Steel, Al 3 G Sil : Selected Sheets for Paper and Oard Makers’ use. er, amin, erman Siuver, Stove and Washboard Blanks. &c. Sheet Brass, Copper and Ger- ZINCS FOR LECLANCHE BATTERY man Silver. Copper, Brass and German Silver Wire. Brazed and Seamless Brass and Copper Tube. AGERMAN SILVER WHITE SI LVE WHITE \ Copper and Brass Rod. ME"=L ) MPHONO-ELECTRIO” In Sheet, Wire, Rods, Tubing and Blanks. Polished wide sheets, patent levelled, for soda foun- WIRE. “IT'S TOUGH” tains, bar fixtures etc. German silver for spinning. TROLLEY, NICKEL ANODES 224SS, BRONZE, COPPER TELEPHONE in all forms and \ THE SEYMOUR MFG. CO., Seymour, Conn. ) TELEGRAPH LINES. HENDRICKS BROTHERS on Nilts BRIDGEPORT BRASS COMPANY Manufacturers of Sheetand Bar Copper, CopperFireBoxPlates Postal T: oo eae and aia tw York and Staybolts, Wire and Braziers Rivets aa lim porters and Dealers in Ingot , BI . inet Soe, Maat cy eens aaa 49 CLIFF STREET - . NEW YORK muy) te RIVERSIDE N J The Powell High Speed Accelerating Cut Planer. The 24-in. planer illustrated in Figs. 1 and 2 is the first size of a line which the Powell Tool Company, Worcester, Mass., will place on the market. It is a new type, in that, among other characteristic features, it is equipped with a mechanism by means of which the cut- ting tool is started into the work at a moderate speed, which is then accelerated to a predetermined high speed, two or three times as great as that of starting the cut, which continues until the tool is almost at the end of the work when the slower speed is resumed. The points where accelerating and retarding take place are deter- mined by the location of the table dogs which operate the belt shifting mechanism. The dog which controls the accelerating, device has a latch which may be thrown down by the operator, converting the planer into the com- mon type so far as speeds are concerned. The high speed is for roughing out, the low for finishing cuts. The designer and -patentee of the machine, A. M. Powell, gives as the reason for this departure in planer operation the very different fundamental action of a’ plan- ing machine as compared with an engine lathe, drill or other similar tools. In the latter the cutting is continu- ous, while in the planer there is the shock or blow on the tool at the beginning of each stroke when it comes into contact with the work. If the speed is high and the blow correspondingly great there is a tendency to break off the cutting edge, necessitating the frequent grinding of the tool. Therefore, it is argued, the cutting speed of the planer at the beginning and end of the stroke should be reduced to relieve the tool of excessive strain at the in- stants of entering and leaving the work. That the sud- THE IRON AGE New York, Thursday, June 17, 1909. den release of pressure on the tool at the end of the cut is destructive has been demonstrated repeatedly in tests of high speed steels, Another benefit of the accelerating drive is that the maximum power required is made more nearly the same as the average, because it is at the re- versals of the platen that the greatest amount of power is required. In the new planer, if a moter is employed for the drive, its size will depend on.the power required to run at high speed after acceleration is obtained, rather than the power required to change the direction of motion of the parts. In a test of the planer on a piece of 0.4 per cent. car- bon steel 5 ft. long, with %-in. feed and 4-in. cut, it re- Fig. 1-—The 24-In. High Speed Forge Planer with Accelerating Cutting Speed, Built by the Powell Tool Company, Worcester, Mass. quired 12 sec. to go through the cut and reverse, using the machine without the accelerating device. With the latter mechanism the same work was done in 7 sec., a gain of over 40 per cent. The greater efficiency claimed is on long continuous work. Tight and loose pulleys are provided on the countershaft to permit of two different sets of high and low speeds, for planing cast iron and steel, Another test was referred to in last week’s issue in connection with an exhibit of high speed steels made at the Gould & Eberhardt works in Newark, N. J. Demonstrations were made by Wheelock, Lovejoy & Co. of Firth-Sterling Blue Chip steel tools as used in various high production machine tools, among them a 24-in. Powell accelerating-cut planer. With a Blue Chip tool cast iron was planed at a cutting speed of 130 to 149 ft. per minute, cutting to a depth of % in. with a \% -to % in. feed and for a length of 5 ft. The method of accelerating the cutting speed—that is, of increasing the speed without shock—is by a purely mechanical device of simple construction, driven by one belt for the cutting pulley and one for the return. The belt shifting dogs on the edge of the platen are adjusted Fig. 2.—View of the Opposite Side, Showing to the cut as in the ordinary planing machine. The cut- ting belt is first shifted from the loose pulley to the first or initia] speed pulley, which runs loose in one direction and tight in the other. This pulley acts as the regular driving pulley, except when the accelerating speed is in operation, which is effected by the striking of the ac- celerating speed dog against its tappet. This by means of its belt shifting cam throws the belt over from the initial to the accelerating pulley. Both pulleys have the same rim velocity, being driven by the same belt, but the ac- celerating pulley is loose on the driving shaft and has a gear on its hub engaging with differential gearing at- tached to the bed plate, and these gears in turn engage a gear keyed to the driving shaft. The speed of the driving shaft under acceleration depends upon the ratio of this gearing. In the machine illustrated it is three to one, or 120 to 40 ft. per minute, but very probably a ratio of nearer two to one will give sufficient high speed capacity for ordinary commercial usage. As the driving shaft in- creases in speed at the moment of acceleration it draws away from the initial pulley, which becomes loose, in an accurately increasing ratio until the full speed is reached. | Via Be LH a Wa GZ + HE TR) Kea F 4—p------41-4 + --- Ides THE IRON =—ss)- . SWZ AGE June 17, 1909 the Differential Gearing and Ratchet Pulley. This rate of travel continues to a point just before the end of the cut, where the speed is automatically returned to the initial rate, thus avoiding shock or strain on work- ing parts. The speed controlling mechanism is shown in greater detail in Fig. 3. Mounted on the shaft are the reversing pulley b and its idle pulley a, and the three pulleys c, d and e of the driving mechanism. When the planer is at rest the two belts are on the pulleys @ and c¢, both of which are loose. When the table reverses for the return the backing belt moves from pulley a to b, the cutting belt remaining on the pulley c. At the end of the return stroke the table reverses to the cut by shifting the return belt from b to a and the cutting belt from pulley c to d, the latter being a friction or ratchet pulley running tight in one direction and loose in the other. The table is now running into the cut at the first or initial speed, which is the same as that ordinarily used in planer practice. Just after the too] has begun to cut the cutting belt is shifted from pulley d to e by a special dog working through the belt shifting mechanism, which is of the standard flat cam type operated by means of dog } SB . cc) es | | <i} | | High Speed Accelerating Cut Planer. June 17, 1909 and tumbler. This special or third dog has a latch which may be lifted out of contact with the accelerating shifting mechanism, thus converting the planer into the common type of machine. The pulley e is loose on the driving shaft and has a pinion, f, keyed to its hub, engaging the differential gears g, which with the gears h revolve on fixed studs attached to the bed plate. The gears h in turn engage the pinion i, which is keyed to the driving shaft. The speed of revolution of the pinion i is dependable upon the ratio of the differential gearing, the effect being to increase the speed of the driving shaft. As the rim velocity of the pulleys d and e is the same, but the speed of the driving shaft driven through the differential gears by the pulley e is greater than its speed as driven by the pulley d, the ratchet hub turns freely in the pulley d and this pulley becomes for the time being loose on its hub. The cutting belt remains on the pulley e until just before the end of the cutting stroke, when the belt is shifted back from e to d by the shifting mechanism and the speed drops to normal, at which it . continues until the end of the stroke, obviating shock or jar caused by the tool breaking out of the work at high speed. This retarding also assists in enabling the table to return with greater ease. As the planer is now ready - 7 + ——— } LA PT we wren wlencwierimecemewey!! TT TT {PTE i lj : — f val zs o _ \ RSQ Ssg i cr SS | n (fa Whe aden € Ali a ‘ ¥ A if 4 A | | Sh | “4 hb ® FRaAAe in ra | Co ben fefal § 4 | See Ris ae iL Vy Vy Ww a Fig. 4.—-Detail of the Releasing Friction for the Feed Mechanism. to reverse, the reversing dog continues until it strikes the belt shifting rocker in the usual way and the cutting belt is shifted to the pulley c, and the return belt to the pulley. b. Another new feature in planer design is the friction feed mechanism, which operates in the same general man- ner as the usual arrangement of a crank shaper; by means of the sliding head j, Fig. 4, to which is attached the feed rack, having a vertical reciprocating movement di- rectly without connecting rods. It is operated by the ad- justable roll 1 moving in the slot in the face of the fric- tion plate m. The friction is the common releasing type; the length of travel of the feed rack and consequently the amount of feed is determined by the adjusting screw n in the sliding head, the amount varying as the roll is moved to or from the center. The amount of feed is shown by a graduated scale on the housing and a pointer attached to the rack. All of the shaft bearings’ and loose pulleys of the planer are self-oiling. Safety locking devices for the belt shifters hold the belts positively on the loose pulleys when the planer is idle, avoiding danger of accident while placing or removing work from the platen. The belt shifter movement may be controlled from either side of the planer. The planer can be made in all lengths up to 25 ft. The one illustrated planes 25 in. wide, 25 in. high and 5 ft. long, and weighs about 6000 Ib. #4 om. - - Dr. W. H. Tolman contributed a report on “ Profit Sharing and Mutuality” at the recent convention of the National Electric Light Association at Atlantic City. He THE IRON AGE I9II reviews the experience in Germany, France, the United Kingdom, Belgium, Holland, Switzerland and the United States, ——_9-e—_—____ A Waltham Multi-Spindle Drilling Machine. The multi-spindle drilling machine made by the Waltham Machine Works, Waltham, Mass., is designed for extremely close spacing, a special ball and pin joint permitting of less than 0.2 in. between centers of holes drilled. The connections between the driving and drill spindles are two to three times as long as is usual in machines of this class, thus making the angle very slight and the machine easy running, and reducing the wear on the joints. The drilling spindles are evenly spaced around a central gear, which is driven from the countershaft. The gears are inclosed and are accurately cut, so that they will run at high speeds with practically no noise. tate ee r) . A New Multi-Spindle Drilling Machine Made by the Waltham Machine Werks, Waltham, Mass. The drill spindles are held in interchangeable cast iron blocks, accurately bored to the desired location of holes. The holes may be drilled from either side of the work, as the blocks can be reversed, or, in the case of such work as clock plates, the upper and lower may be drilled from the inner face. The joints and spindles are of hardened steel and the latter have bronze bearings, easily replaceable. With the use of short drills holes may be accurately drilled without the use of a jig, and the ma- chine may be used for reaming and countersinking holes already drilled or punched, without a jig; but provision is made for the use of a jig if desired. The table carrying the work is operated either by a hand wheel or by a lever connected to a rack and pinion, and an adjustable stop is provided to regulate the depth in drilling. There is a screw adjustment for the vertical position of each spindle. The machine is built in two sizes, the larger with any number of spindles up to 14 and drilling any arrangement of holes within a 6-in. circle, while the smaller has any number of spindles up to eight and drills within a 3%-in. circle. The larger ma- chine weighs 240 Ib. and the smaller 50 Ib. New Molding Machines. The Murphy Rollover Machine, A new type of rollover machine has been developed by James A. Murphy, foundry superintendent of the Hooven-Owens-Rentschler Company, Hamilton, Ohio. It embodies several new and interesting features. In Fig. 1 the machine is shown with a gate of patterns attached ready to receive the drag. The rollover table is carried on trunnions at the ends and these are supported by two iron yokes, each resting on two pistons. The rollover device is located at the right of the machine and is not very clearly seen in Fig. 1, but is better shown in Fig. 3. Fig. 2 represents the machine with the drag flask in Fig. 1—The Murphy Rollover Molding Machine with Patterns Attached, Ready to Receive the Drag. THE IRON AGE June 17, 1909 easily. The mold is received on a small carriage which can be run forward from under the machine to facilitate its removal. In the particular patterns shown in the illustration the cope is a small flat back which is rammed up by hand on a plate or buck, as shown at the right in Fig. 3. The Murphy Jarring Machine, Mr. Murphy has also invented and constructed a new type of jarring molding machine which he has named the Murphy Bouncer. Its general appearance when re- moved from the pit for photographing is shown in Fig. 4. It will be noticed that it differs radically from other ma- chines. The principal difference is that in place of being Fig. 2.—Drag Flask Ready for Rolling Over. Fig. 3.—The Flask Supported on Blocks After Rolling Over. place rammed up and the bottom board clamped on ready for rolling over. After the flask has been rolled over it is supported upon blocks, as in Fig. 3. This is accom- plished by raising the rollover table slightly, inserting the blocks, and then bringing the bottom board to rest upon these supports. For an adjusting device, four pads made of sheepskin filled with curled hair are used, and these have been found to work very well. One of the most interesting features is the operation of the pattern drawing device, first by hand and then by compressed air. When drawing the patterns the lever shown at the left of the machine in Figs! 1 and 2 is lifted slightly. This starts the pattern and at the same time opens an air valve, admitting air through the sta- tionary plungers into cylinders formed in the yokes on the ends of the machine. This air completes the lift and makes it possible to draw a heavy pattern quite attached to the piston the table has been attached to the cylinder, the piston being stationary and connected to the base, while the cylinder is arranged to move up and down upon it and to carry the table with it. This construction permits the casting of heavy ribs on the outside of the cylinder walls to support the table. The impact of the falling table is taken on a series of steel pins shown about the base of the machine. The air for operating comes in from an opening on one side, and is admitted by a cutoff valve which is controlled by an adjustable tappet on the side of the cylinder. The valve proper rests on springs, and when air is turned on to the machine the table immediately starts up. If the tappet is adjusted to its lowest point the cutoff valve is consider- ably below port entry for the air when the stroke begins, and hence air will be admitted for a considerable portion of the stroke. As the tappet is run back, the springs ee eed —anaeegrenenpeseeares ere oonweeeeed June 17, 1909 throw the valve higher and higher, thus causing it to cut off earlier. This permits of using the air expansively in the cylinder, a feature peculiar to this machine. Nat- urally, when very heavy work is to be jarred it is neces- sary to use full pressure air for the greater portion of the stroke. When light work is being used great economy can be effected by cutting off the air early in the stroke. The exhaust port is uncovered when the piston reaches Fig. 4+.—The Murphy Jarring Molding Machine. its highest point, this port being through the walls of the cylinder and practically continuous about the cylinder. The exhaust pipe of the machine is connected by a hose to the stationary exhaust pipe in the pit. The arrange- ment as shown keeps all of the working parts free from sand or dirt. On the bottom of the base plate Mr. Murphy arranges a segment of a sphere, as shown in Fig. 5, so as to distribute the thrust equally to the foun- dation. The machine is mounted on concrete. As installed in the plant of the Hooven-Owens-Rent- schler Company, the machine is arranged with a flat iron Z LLL} g (ects a Vaasa aa ¥ 7 s ms ON A A < g Ls ee Be SSNS ai AY MOA WEN A Rr Y y VE Kd a Ua AS AO KS As Zi SS SS Pa =e at SSN y y aS oe —— Fig. 5.—Sectional View of Jarring Machine. table on each side, as in Fig. 6. The workman places on one of these tables a bottom board pattern and drag and shovels in the sand. As soon as the machine is idle the drag is slid along the iron table to the machine. It is jarred and immediately after is slid off to the table, where the parts are assembled. In the mean time the men on the opposite side of the machine have prepared a drag for ramming. In this way the crew keeps the ma- chine fairly busy. The patterns are ordinarily left in the drags until they are carried to the floor where the <opes are rammed by hand. Sometimes, however, Pridmore molding machines are THE IRON AGE 1913 used, these being mounted on casters and run upon the jarring table after the flask has been filled with sand. The machine is then removed and the pattern drawn in the ordinary way. In this way the jarring machine may be used for ramming the molds from two or more Pridmore machines. Fig. 6 shows the machine with a Pridmore molding machine upon the side table or plate after ramming. On the day the views were taken there were 53 molds on the floor shortly after 3 o’clock in the afternoon for castings ranging from 50 lb. to 2000 lb. This work was done by six holders, five apprentices and two laborers. All of the drags were rammed on the Murphy Bouncer, while the copes were rainmed by hand. In cases where flat backed copes are required these could also be rammed on the machine, but none of the molds above referred to were of this type, and some of them were quite complicated, requiring drawbacks in the cope or having the patterns so arranged that various parts had to be picked in during the pattern drawing operation. Mr. Murphy has not yet been able to work the machine to its capacity on account of the fact that he has not had work enough available on the floor. The machine crew do no pouring, and by working during pouring time they have on the floor a drag ready for each one of the regular molders to begin work on in the morning, so that the molders work a full day molding copes. One of the jib cranes serves the jarring machine Fig. 6.—Jarring Machine Used in Connection with Pridmore Molding Machine. floor; the traveling crane carries the drag from the ma- chine to the floor and later in the day takes care of the pouring, shaking out, &c. The stroke of this machine can be varied to suit conditions, but as constructed at the plant described it is % in. ee The nonmagnetic yacht Carnegie, in the construction of which practically no iron or steel was used, was launched at Brooklyn, N. Y., June 12. The only metal in the entire ship that is not nonmagnetic is that of the pistons, the gas producer and the range grates. The Carnegie goes in a few weeks on its first voyage with the object of obtaining correct records of magnetic varia- tions. It will be manned by a picked crew selected by the Carnegie Institution, Washington, D. C., for which the vessel was built. Among the papers to be read at the forthcoming con- vention of the on Institute of Electrical Engineers at Frontenac, N. Y., on June 28 will be that of H. C. Specht of the wicelaniodan Electric & Mfg. Company on the “ Function of Flywheels in Connection with Elec- trically Operated Rolling Mills.” The paper has been printed in the June issue of the Proceedings. The Great Northern Power Company, Duluth, Minn., has been buying electric motors recently and is largely in- creasing its commercial load. The company is making an active campaign for business on the iron ranges. Special Newton Cold Saw Cutting-Off Machines. Recently Furnished the Bethlehem Steel Company. A special equipment of cold saw cutting off machines adapted to the Bethlehem special shapes was recently furnished the Bethlehem Steel Company by the Newton Machine Tool Works, Philadelphia, Pa. The accompany- ing illustratiops show the machines which form two units, each unit comprising three machines and each set of three mounted on a long bed. The entire equipment weighs approximately 450,000 lb., and each of the long beds is 83 ft. long over all and 9 ft. wide over all and has a depth of 16 in. Fig. 1 shows the installation. These machines are of a spindle. driven type. The spindle is 10 in. diameter and has a bearing at each end 16% in. long. The drive is Fig. 1.—An Installation of Cold Saw Cutting-off Machines, 1914 THE IRON AGE June 17, 1909 As shown in Fig. 3, the motor shaft carries two pul- leys engaged by two Johnson friction clutches arranged to transmit motion to the pulley E on the main driving shaft through a 6-in. belt, and to the pulley F on the end of the feed screw through a 5-in. belt for the quick return to the saddle. The saw blade is of the inserted tooth type and is attached to the spindle by broad face collars and six bolts which serve as drivers. It will be seen from the foregoing that the machine proper has the standard Newton features, with the ex- ception that the machine is much larger than any before furnished. This machine was designed to cover the en- tire range necessary for the Bethlehem special shapes and to reduce to the lowest possible amount the time of machining. Special provision has been made for hold- ing these shapes before the saw blade. In Fig. 2. will be seen the shaft H, which is provided for elevating the parallel block I to bring the shape to alignment with the center of the saw blade. The middle machine as shown in Fig. 1 is fixed to the main bed, and the work table is Consisting of Two Units of Three Machines Each, Furnished the Bethlehem Steel Company by the Newton Machine Tool Works. through a steep lead spur gear mounted between the two bearings of the spindle and meshing with a pinion mounted on the inner side of the plate gear shaft A, Fig. 1, which in turn engages with the spur gear mounted on the worm wheel shaft B, giving a ratio to the drive of 114 to1. The worm wheel is a bronze ring mounted on a cast steel center. The teeth are of steep pitch and triple lead. The worm is of hardened steel and is arranged with roller bearings to take the thrust. The saw carriage has a bearing on the bed 33 in. wide, and is provided with underlock bearings cast solid. The adjustments are made by means of taper shoes. A con- tinuous friction feed is provided which is variable in rate from % to 2 in. per minute. Control of the feed variation is by means of the segmental lever C, shown in Fig. 2; which controls the friction roller on the feed plate D, as may be seen in the rear view of one machine given in Fig. 3. This roller shaft also carries a pulley which transmits motion to a No. 3 Brown & Sharpe geared pump, which is furnished complete with piping and at- tachments for lubrication. The lever C is arranged with a clamping lever to hold the feed variation roller in any position. Each machine is independently driven by a 25-hp. motor running at from 650 to 1300 rev. per min., giving a peripheral speed to the saw blade of from 33 to 66 ft. per minute and a quick return to the saddle of from 4% to 9 ft. per minute. arranged with two adjustable parallel blocks, one on either side of the blade, while the two end machines are adjustable in their distance from the middle one and have one parallel block each. Uniform vertical adjust- ment of these blocks is obtained by means of an internal elevating screw rotated by the shaft H through worm and worm wheels; the shaft H is in turn driven from the motor shown at J in Fig. 1. As shown in Fig. 2 a special power clamping vise has been furnished. The inner jaw K is fixed to the bed of the machine and is fitted with a saddle having vertical hand adjustment, to which are attached auxiliary plates having a contour corresponding to the shape to be cut. The outer jaw L likewise has a provision for carrying the shaped parallel pieces, and in addition has an in-and- out adjustment operated through the screw and nut shown at M. Power is transmitted to this mechanism from a 5-hp. motor on each machine running at 1160 rev. per min. The motors are wired in series for simulta- neous operation of the clamping vises. Each motor is provided with an overload circuit breaker. The motors give a movement to the jaws L of 53 in. per minute. The bed of the machine is arranged with three bearings on which the individual machines are fitted, to be held se- curely in any position by bolts engaging the parallel slots in the bed. The adjustment of each end ma- chine on the bed is effected by a 71%4-hp. motor running ea ea ieee a nnn nn ne ne eeeanibatiesmmtenaee ana es ee ees ee June 17, 1909 at a speed of 800 rev. per min., shown at O in Fig. 3. This motor drives the two rack pinions on each machine engaging with the racks on the bed, through intermediate gearing and two sets of worm and worm wheels. All of the motors are of General Electric make. The left hand machine can be adjusted from a min- imum distance of 74 in. to a maximum distance of 3614 ft. from the center of its saw blade to the center of the saw blade on the middle machine, and the right hand machine can be adjusted from a minimum distance of 94 THE IRON AGE 1915 a tongue attached to the arm of an eccentric bushing shaft. The rotation of the blade lifts a finger, which in turn causes rotation of the eccentric bushing, which is attached through a connecting arm to an oscillating arm, to which the emery wheel it fitted, and causing the emery wheel to be forced nearer the center of the saw blade, thus grinding the front rake. The emery wheel is with drawn to a position for engagement with the next suc- ceeding tooth by the contraction of a spring. The saddles to which the grinding attachment is fitted has three distinct swiveling points in line with the center Fig. 3. Views of Opposite Sides of One of the Newton Special Cold Saw Cutting-off Machines in. to a maximum distance of 36% ft. from the center of its saw blade to the center of the saw blade on the middle machine. These adjustments are made by power at the rate of 81% ft. per minute. While all the important move- ments are made by power, each machine can be operated by hand independently. With machines carrying saw blades of 50 in. and larger diameter, a special automatic relief grinding ma- chine is furnished when desired, which is arranged to grind the face and side rake and radial clearance. The machine consists of a substantial base on which is fitted an adjustable saddle carrying a spindle driven through worm and worm wheel by a four-step cone pulley from a motor mounted on the base of the machine. In operation the saw blade is attached to the spindle of the machine and is caused to rotate. The saddle carrying the blade is then adjusted to bring the teeth into engagement with of the emery wheel, permitting the side and radial rake to be ground, in which case the finger before mentioned is arranged to draw the emery wheel into the side of the teeth, the slot having been previously set at the proper angle of clearance. The original inserted tooth blades were made with alternate oval and round teeth in order to split the chips, thus reducing the amount of power necessary to drive the blade on a given cut, but this has been found unsatisfactory, as absolute accuracy in set- ting the teeth with the adjusting wedges could not be ob- tained in a reasonable time. The teeth are now held in place by wedges that have no adjusting screws and are all of uniform shape, i. e., have square faces, and it has been demonstrated that as each tooth does its propor- tionate share of the work and is ground at an absolutely equal distance from the center of the blade, less power is consumed when taking even heavier cuts. 1916 THE IRON AGE June 17, 1909 The Westinghouse Double-Zone Bituminous Gas Producer." For a number of years extensive experimental work has been in progress at the Westinghouse Machine Com- pany, East Pittsburgh, Pa., having for its object the development of a satisfactory producer suited to the use of various forms of bituminous fuels. The requirements were a producer capable of continuous operation, produc- ing a gas free from tar, operating at such temperatures as would avoid troublesome clinker formation, producing a gas of normal constituents suited to high engine com- pression, and finally a producer that could be readily operated by a single attendant with comparatively little labor and skill. This latter qualification evidently neces- sitated a plant of the greatest simplicity. The experi- ments on various types covered an exceedingly wide range in producer design and with full sized models from 250 to 750 hp. tested for months at a time. These experiments included many forms of down draft and under feed systems, as well as various types of blowers and tar extractors, finally culminating in the present form of double zone producer, Fig. 1, which has proved suitable for the ordinary bituminous fuels. This ex- perimental work was recently concluded with a full year’s continuous testing with various fuels and operat- ing conditions, some tests lasting for a month, day and night, without shutting down. All of the results are based on the actual power developed by brake tests of the gas engine. These performance tests embraced both good and poor coals from the Pittsburgh District and lignites from northern Colorado, Texas and South America, with a trial also of garbage, crude meadow peat and other waste material. The period of operation ranged from 10 to 24 hr. a day throughout the month, generally at full or overload, also two months’ run to determine stand-by losses accurately. It is, therefore, believed that this series of tests constitutes an unusually complete demon- stration of the ability of this type to operate continuous- ly and satisfactorily with reasonable grades of bitumi- nous fuels. Type of Plant, The general scheme will be observed from Fig. 2, showing a complete plant with all auxiliaries. The pro- ducer consists of an upper shell, superimposed upon a lower shell, with a cast iron evaporator between. A hol- low air cooled top communicates with the evaporator through a downcomer and an uptake. A third down- comer connects the evaporator with a lower tuyere. The producer is supported from four concrete foundation piers on a cast iron mantle, the lower rim of which dips beneath the level of the water in the ash pit, forming a water seal. In the normal operation of this producer green fuel is fed through the open top, and during its descent to the offtake zone is completely transformed into coke. During its further descent to the ash line this coke is completely gasified to ash. There are, therefore, two independent fuel beds. In the former tar vapors dis- tilled from the fresh coal are transformed into fixed gas which mixes with the straight coke producer gas gene- rated in the lower zone. There are also two combustion zones in this pro- ducer, one at the extreme top and one at the bottom just above the tuyere. This is brought about by a double supply of vapor laden air. This air supply is drawn in from above. Circulating entirely around the hollow top, it is heated sufficiently to increase its capacity for taking up moisture; it is then passed over the surface of the water in the evaporator. This vaporizer is prac- tically in contact with the hot fuel bed at the center of the producer, where it generates the water vapor neces- sary for cooling the fuel bed through dissociation. This does away with an external boiler to supply steam to the National Electric Light Association, presented at the Atlantic City, N. J., convention, June 1, 2, 3 and 4, 1909. * From the report of the Committee on Gas Engines of the producer. Entering the vaporizer at the right in Fig. 2, the heated air divides, emerging at the left, part ascend- ing and part descending. Valves serve to control the relative quantity of blast to the two combustion zones. This relation constitutes practically the only variable in the operation of the plant. It necessarily varies with different kinds of fuels, but for any given fuel it should only be necessary to regulate these valves once. The automatic proportioning of vapor to air is otherwise pro- vided for in the design of the producer, so that the process of gasification is automatic through the entire range of load. With friable fuels it is important to reduce the velocity of gas as low as possible at the offtake to pre- Fig. 1.—Exterior View of a Double-Zone Bituminous Gas Pro- ducer Built by the Westinghouse Machine Company, East Piitsburgh, Pa. vent fire material being carried over. On this account the gas is drawn from the fuel bed at several points, all communicating with the annual header around the mid- dle of the producer. A rotary exhauster provides a posi- tive and uniform suction on the fuel bed. This type seemed to best fulfill requirements and incidentally avoid the uncertainties of operation encountered with the hand regulated blower. Thus the plant becomes virtually a double zone suction type. This exhauster, which is motor driven, operates at a constant speed and delivers gas to the engines always at a constant pressure of a few inches of water. This regulation is accomplished by means of a butterfly valve and a small gasometer, which arrangement by-passes such part of the gas deliv- ered by the blower as is not required by the engines, the remainder circulating through a small mixing header over head. In this manner, the necessity for a variable speed exhauster is avoided. A gas holder is not employed for the control of gas production as regards quality and quantity or delivery pressure. This reduces the cost of the equipment ma- June 17, 1909 terially and obviates an exceedingly bulky piece of aux- iliary apparatus. Cleaning and Operating. In the absence of tar the problem of cleaning the gas suitably for engine use resolves itself into the removal of dust and lampblack. This is accomplished by a static cellular type washer, in which the gas streams are spread out in thin layers and constrained to pass over the sur- face of still water, during which process the matter held in suspension is thrown down. This has been shown to reduce the quantity of foreign matter to about 0.02 grain per cubic foot, which affords a very large margin of safety in operation. In practice a large part of the foreign matter is thrown down in the downcomer by the action of a water spray passing freely to the overflow without entering the static washer. The static washer is practically indestructible and largely self-cleaning, owing to the skimming action at each level. The various sections are readily accessible by lifting off the cover. Between the producer and the washer is the purge stack, which contains a single seated stack valve in the ~ tae Ee ce as Mid Pee AE eee THE IRON AGE 1917 access to the fire at these levels, which is an important feature. The labor requirements are comparatively small, as the fuel bed seldom requires loosening more frequently than once per hour. Ashes are removed about once in 24 hr. Thus, with coal and ash separately handled, one man can operate at least three of these producers with- out difficulty. Coal may be charged at intervals of 15 min. to 1 hr., according to the load. Owing to the low temperature at which the fuel bed is maintained, the formation of large clinker is prevented, and this trouble was not encountered in any of the tests. Provision is made for flushing out the vaporizer at intervals to pre- vent the deposit of mud in case foul water is used. Operating Results, Reference has been made to various efficiency tests conducted at East Pittsburgh. This producer was put under fire in December, 1907. Several weeks’ run on Pittsburgh run-of-mine coal of 13,000 B.t.u. per pound as fired gave an average consumption of 1.2 lb. per brake-horsepower-hour continuous’ operation. After Fig. 2.—Sectional View of the Westinghouse Double-Zone Bituminous Gas Producer and Auxiliary Equipment. riser leading to the atmosphere and a water seal at the bottom controlled by a plug which is normally left open. When the plant is shut down, the closing of the plug valve floods the water seal, thus shutting off the rest of the plant,-and automatically opens the stack valve. This water seal also makes it possible to work on the auxiliary while the producer is at stand-by. The water seal of the producer proper may be par- tially drained by a rotating valve. In its up position this valve maintains a water level, as“shown in the section, Fig.2. When turned downward the water is drained 2 in. beneath the lower rim of the mantle ring, consequently breaking the seal and allowing ingress of air at all points. This is effective in the rapid starting of a new fire in which heavy draft is desirable. In normal operation the pressure at the top fire bed is slightly below atmosphere, so that when the charging cover is opened there is no tendency for smoke or gas to reach the producer room. Thus the most important part of the fuel bed is always available for inspection and can be easily worked down in full view. In addition, poke holes are provided, so located that the sides of both the upper and lower linings may readily be raked by a poker bar and the ash settled down as in the normal operation of a pressure type producer. These also give some slight improvements which then appeared to be necessary, the plant was again put into commission on March 31, and from then until April 3, 1909, the fire was never drawn. In the intervening year the following tests have been run: . (A) Three 10-hr. tests on South American lignite; (B) 15-day, 24-hr. test on Colorado lignite; (C) 15-day, 24-hr. run on Pittsburgh run-of-mine coal; 15-day, 10-hr. run on Pittsburgh run-of-mine coal; 30-day, 24-hr. run on Pittsburgh run-of-mine coal; (D) 10-day, 10-hr. run on Massachusetts meadow peat; (E) 10-day, 10-hr. run on Texas lignite, and (F) 45-day, 24-hr. run at stand-by Pittsburgh run-of-mine coal. Average Composition of Fuels. Runs. A. B. c: D. E. F. Moisture ....20.05 16.63 2.03 38.10 34.09 2.03 Volatile ..... 34.44 33.78 34.98 40.54 30.33 34.98 Fixed carbon..30.85 42.22 56.22 17.86 26.32 56.22 BMD 60 840900 14.66 7.37 6.77 3.50 9.56 6.77 B.t.u. per Ib. as fired.. .8,032.00 8,599.00 13,305.00 6,410.00 6,950.00 13,305.00 Besides the above, there have been numerous short runs under special conditions to determine the various factors entering into successful operation of the pro- ducer. The following table shows a summary of the tests on Pittsburgh run-of-mine coal and Colorado lignite : 1918 THE Test on Bituminous Producer. Colorado eee ee ee Pittsburgh Bituminous. lignite. NC ee os ol 5 4 0» 0h May 8-23. Aug. 4-25. Apr. 16-29. Seer 24 hr. 10 hr. 24 hr. PE oc wc cre tecscvacnses 297.75 514.0 314.0 Engine running hours........... 239.5 168.5 312.75 EE BE IO iss 6.0 6 os seen 58.25 345.5 1,25 Pe Re NOE. so 3 5.40o0%ieos 53,935.0 35,647.0 60,939.0 NE TENET AOUMER oa 4 0 36,0.05.0 01980 ash 31,143.0 ey: Tin. ; co asin b eee ae 0-06-06 i 4,504.0 at Pounds of coak per b.h.p., total... 1.12 1.24 1.61 Pounds of coal per b.h.p., net.... co 1.08 big producer etiiciency (per cent.).... 77.0 ae 78.5 Combined efficiency, including stand- Sy SE cok ssi vess verses 17.0 15.74 16.6 Excluding stand-by (per cent.).... ais 17.91 ost Se i as 6k bd Bk hoe OSS 13,305.0 13,145.0 9,589.0 DO Da i ent ca eae ee sh es) 6.77 10.76 7.37 Fixed carbon in ash............. 14.9 na Percentage of carbon lost........-- as §.92 vy Average load on producer......... 172.0 170.0 122.0 In general, an economy of about 1.1 lb. per brake- horsepower-hour was obtained on ordinary Pittsburgh coal with 24-hr. operation. With 10-hr. operation, in- cluding stand-by of 14 hr., the economy approximates 1.25 lb. per brake-horsepower-hour. For lignite the econ- omy averages 1.6 lb. per brake-horsepower continuous service. The stand-by loss, when under proper draft, is extremely light, averaging for a 175-hp. producer 10 Ib. per hour by actual test of a month’s duration, and this includes the gas lost by blowing up the fire each morn- ing of stand-by run. The efficiency of the producer did not vary more than 10 per cent. from full load to no load on the plant and approximates 77.5 per cent. on total heat value, or 71.5 per cent. on effective power value basis. Samples of refuse taken from the producer during the tests on Pitts- burgh run-of-mine coal show the following composition for an average of six samples: Ash, 85.1 per cent.; fixed carbon, 14.9 per cent. As the original coal contained about 7 per cent. ash, the actual percentage of combustible wasted was 14.9 x 7 + 93 = 1.1 per cent. The rate of firing varied from 13 to 22.8, averaging 18.5 lb. per square foot of fuel bed area per hour at the green fuel zone. This higher rate might have been main- tained indefinitely without vitiating the gas from exces- sive oxidization or without clinker formation. The tem- perature of the gas leaving the fuel bed averaged about 900 degrees F., low enough to prevent clinker. When the fire was allowed to become much hotter the heat value of the gas fell slightly. This temperature, therefore, serves as a fair index of practical limits in regard to fuel bed temperature. The average samples of gas taken from the engine show a heat value of about 115 B.t.u. effective power value; a considerably higher value could be obtained by using more vapor and producing higher hydrogen con- tent. But high gas was not desired, as it would not per- mit the use of as high compression in the engines for which a gas of moderate heat value is better suited. During all the tests a 175-hp. engine was kept under brake load, receiving all of the gas from the producer except when the latter was being forced beyond the capacity of the engine, and has provided a practical demonstration of the gas quality. As the engine gas was metered in both gas house and engine house, a check was thus available between the two meters and the extra load upon the producer determined. Under normal working the average gas samples at the discharge of the exhauster showed from 0.015 to 0.025 grain of solid matter per cubic foot of standard gas. During a week’s test on the auxiliary washing plant 25 determinations showed a range of solid matter from 0.006 to 0.043. This solid matter contains no tar, con- sisting entirely of dust and lampblack. The greater part of the heavier matter is generally thrown down at the discharge nozzle of the producer by a water spray. This producer was opened on April*3, 1909, for the first time in one year. During this time the producer had been under fire continuously, under various operating conditions from maximum load to no load. There had been no repairs to the producer lining or other parts dur- ing this time of operation. The shutdown was made in IRON June 17, 1909 AGE the presence of a number of officials of the United States Geological Survey, as well as some prominent commercial representatives. After examining the producer and not- ing the normal condition of the fuel bed, the quality of gas, as well as the load carried by the engine, the fire was pulled, affording a demonstration of the condition of the fuel bed inside of the producer after this long run. It was found that the producer lining was practically intact, even in the regions of the hottest fire zones. The wall of the evaporator was also in good condition, as were the tuyeres at the bottom. Previous to the demon- stration the plant had been in operation only 10 hr. a day for about one month, and, although a straight air blast was employed in starting up, practically no clinker was found in the entire fuel bed. From 1 to 2 ft. above the lower tuyere the fuel was practically all coke in the various s