The Iron Age 1913-06-12: Vol 91 Iss 24

tablished 1855 7 rorge shop and foundry deliver their out- put to the chassis depart- ment or machine shop on the same basis as would disass iated plants. In the chassis department the ma- chine work includes the finishing of all pleasure-car chassis parts and in addi- tion the cylinder, trans- mission, gear and axle ma- chining for the trucks. The machine shop is divided into departments that are distributed through the four floors of four parallel buildings, constituting an aggregate assembly and machine shop floor space of 215,931 Sq. ft. The ar- rangement of these depart- ments is shown with a de- gree of clearness in the diagram Fig. 17, which is a cross-sectional outline of these four buildings num- bered in order in the direc- tion away from the general Preparing Chassis for Road Test Fig. 17—Diagram Cross-Section Fig 18—View Ir iting the Manne W Most of the ¢ the the "Bu gs Have De iO Re Being Er { , } Bi | iciemnnneingtial a ‘ | = i — — i nisshtieenetieaiet tx | _ i ? Continued from page 1354 of The Iron Age of June 5 New York, June 12, 1913 Some of the Interesting Equipment and Methods of Manufacturing the Packard Cars—A Notable Power Plant Ap AN Sf mV aA ae i ~ 7) AY BNES i / aN N Ya A F a <Y i. i _ BS. * nN cy of Machine Shop Showing Arrange ment 1415 Vol. 9 1: No. 24 Machinery Operations in the Packard Plant Iding, w shown would ‘ the ht. On each floor wher re than one department conducted th« are Vt in uUlanuram i I n the near end f the Iding to the far end reading downwart \ f e buildings t in the long buildin ‘ ng at right angles as shown in th reneral € r the plant Fig. 1. As previously mentioned and as indicated in tl dia gram, the machine w i livided into depart its orresponding e vat us parts of the car rather than to the various kind f machine eratior ept in the first uilding where department r led for isl ill tl and f ti g 1¢ rew icl rk In a rdance w plan bdi | | - of Departments = | | 1410 THE IRON AGE ready tor In tl where t! put toget with t!] springs the interes ing operat preliminar a side par up for this trated in one for channel. two Amer drills, belt spec d placed to full lengt! nel, drill al in each fl resetting s done ent i mplat immediate! the time ret Fig. 20—View of t Cylinder | ! lob in W Sev Cutt Operate Sir taneously na Seve changing IS Fé Spindle Milling Machine Built |! } x Smitt a minimum In the adj the machining f any part as a cyli ran is ! room the motor and transmissions are brought axle is practically completed in one department a1 e! embled frame and the entire chassis is assen taken from there is either partially assemb! ry y for the mounting of the road test gear an admirab! ssembly. Th irrangement, as opposed to that w nclosure has been provided by roofing overt groups similar machining erations and brings all part tween the two buildings as shown in Fig. 18 requiring the same operation to the machine, | ee! nels are entirely of ribbed glass. A_ similar adopted as offering greater flexibility where cars r sure between buildings Nos. 3 and 4 is used as than one model are being built and where these lels testing room. The many frame and chassis fixtures change materially from year to year. It will be noted that luding brackets for lamps and the control le the chassis frame and the heavier chass rts involvin juadrants, the body and wind shield fixtures the heavy machining and transportation operations are prt steering gear, are completely machined and asse1 pared for the most part in buildings Nos. 3 and 4, centering the same building. A large portion of this work round the delivery point for the assemble hassis n milling machines, the equipment including an Inger ‘ : + - 4 Fig. 21 View f a Planer Tyy oe xf af : q Ve Cutter on the Vertical Spindle Sweeping » HM Const: ed of Pipe and Fittings Is Shown ok Fi Igi3 il spindle, Whitney No spindle, a Milwaukee, a Garvin wni- two Brown machines. lso character Ss shop that methods of iS displayed er of opera- such as to sible a large n, the ma- tput is regu the subse ling and in- cesses. In method of e cylinders is shown planer ty] ichine of en, built by & Smith x i. 82 mounted | posts that the hin the cylin The cylir ut vibra- in perfect while the bs simultaneously THE IRON AGE = ig. 22—Another Milling Machine Set Up in Which TI 1417 on One Vertical and Two Horizontal Spindles sses on the top and two sides art for facing tl For this operation, the machin chine cylinde ven spindles, three vertical and four horizontal 1 traveling ich side ther special m: ichine built by the same two spindles time on the mpany nders are mounted simultaneously for the facins ire being s« ises and the boring of the cylinders. A central horizontal rotating table is arranged with fix- taneously is fourth side hucking two cylinders on each side. The cylin- with four se finished in four stages, the first and third pro r setting cylinders preparatory to the machining ns in the second and fourth. On the dating four described m: Where cy first side of hine, cylinders 1 and 2 are set up in preparation § are to be fin View of a Planer Type of Ingersoll Milling Machine Equipped with a 25-In. | Face of a Six-Cylinder Crank Case hree Crank Cases Are M ie bases; while on the secon le rs 3 and 4 are beins ichined by mean f head art inged wit! ross le in irryil fitted with end milling cuttes At the sam« third side of the machine, cylinders 5 and 6 t up for the boring operation which simul being performed qn linders and 8 on the of the machine by means of a boring head parate spindle \ similar machine commo- cylinders at one time supplements the above ichine linders of models other than the current vear ished the work is done on horizontal spindle itte on the Vertical Spindle Sweeping the Bottom P - oe . : eu 5 me i 34 oe nae y i, Be. H i ve 1418 | THE IRON AGE The the cran sents high-spee chine these, Fig. 21, is Ingersoll machine a 25-in vertical addition tion as sl setting, which 8-ft. fixe having tw spindles iI the vertical is provid tures arran; three taneously, Fig. 22 making through iS app! min. Si cylinder are also top side & omit aa rilling, { milling macl with ai I4-i1 Chere are als machines, 48 in. by 14 ft., of the vith seven spindles, four horizontal spindles in tw 1 three vertical spindles in F erate at cutting speeds of ble feed of approximat: ling of the crank cas« e roughit ! nishis t : ! mounted in a Lucas boring ma ns g. 2 [The manner of carrying ( ng ir, which, as shown, is slung Fig. 23—Finishing the Crank Case Bearing Boring M ne The Second Cutter Bar Is Conveniently Suspe 1y13 THE IRON AGE noted. The ing of the face where made is ac- na Bea- combina- ine fitted grinder ear stm = ee . ear _— ) groups e Brothers radial of idial et a gether with 11 ree] one 20- nt 9 <r ena 7 Cae ald one I&- usch Ma- Company’s rilling ma- vided. vy above and are ma- the cylin- piston and ings art a battery & Johnson automa- MR Drege bie | = Sedkiameed cylindrical r the grind ylinders and ngs special ar } s have been In Fig. 24 are shown two cylinders mou internal grinder. There are several of these centric grinding machines. This last view sh nner of grinding one cylinder at a time, and als nner of connecting up the exhauster system for ng off the dust developed in the operation. Th and rings am li irr Pratt ent for grinding the faces of the piston rings is Whitney turret lathes, Whitney in Fig. 25. In Fig. 27 a novel type of exhauster vertical spindle disk grin s al itts ert ' kev r} 8 * -—The Machining of the Transmission Case Is Shown in This View on a Special Milling Machine with Three Spindles Mounted in Traveling Heads THE IRON ee J Fig. 27—Novel Arrangement of Exhauster Hood and Pipe for a Dis Grinding Machine seating machines are grouped in one section of the floor For the machining of the rear axle transmission case, a special tool has been designed by the Beaman & Smith Company, by means of which all of the operations are completed ye setting of the piece. This machine 1s shown in Fig. 26. .In the faci ( ral flange and bearings of this case , ished faces be at ith ea ( ( e} the necessity for completing this job out ng the piece. As shown in this view the operations of boring and facing the two opposed axle bearing nd flanges have been completed. This is done by means of a boring bat fitted with two cutters so that both ends are machined simultaneously. The finishing cut on th faces is made with the cutters shown in the illustration. By means of the third spindle at 90 deg. an inside bearing and two faces are finished and the irregular end transmis- sion case is finished from the same spindle by means of a fixture carrying feed to tak cross One of the interesting examples of a radial tube post and ha sufficient entire ental departm Fig. 28—Boring, Facing and Turning the Differential Be fevel AGE Jur arrangement of manufacture in this plant is which all gear blanks are machined. Here a Il’. E. Reed & Co. lathes and 12 Prentice Brothe lathes are used for this purpose alone. Fo; the square holes in the transmission pinion three Lapointe broaching machines are used partment is immediately above the floor for gears. The front gears of the motor are m laminations compressed in a hydrauli “4 press steel shrouds. For routing out the teeth of five Schuchardt & Schiitte machines are instal! rounding the ends of the teeth or beveling th: that a noiseless operation in the gears is insur: three Ingle tools. The front gears of the hobbed on two machines of the type devel Lees-Bradner Company, Cleveland. The cuitti: teeth on the transmission pinions where ther gears on one shaft and where there is no clea mitting the cutting of the teeth on a milling job is accomplished on four 36-in. Fellowes g machines. The steering worms are formed on & Whitney thread milling machines. For the ordinary gear machining there aré 28 No. 4 36-in. Brown & Sharpe gear cutting six No. 4 48-in. of the same make, two Gould & | hobbing machines, two Brown & Sharpe No. 13 a: Brown & Sharpe No. 12 milling machines. The m of the bevel gears and pinions for the differential of a preliminary gashing out of the teeth on five Br & Sharpe No. 13 geared milling machines and 29—Facing the Bevel Blank for the Large Differential Gear generation on four Gleason machines. The sequen involved in the complete machining large differential bevel gear is illustrated in the series consecutive 28 to Fig. 28 shows machining of the back of this gear on a turret lathe; fi 29 the machining of the bevel face of the blank; Fig the milling operation of cutting the rough teeth i blank, which is finished in a Gleason gear generating chine; Fig. 31 matching up the pinion and gear coupl Fig. 32 running the pinions and gear in mesh pressure to work the teeth down to a smooth running bearing. Immediately above the gear blank floor is the a matic screw department. An interesting variety of equ!) ment is presented including Gridley, Cleveland, Daven; and Brown & Sharpe automatic machines. The grou! Gridley machines includes two %-in. four-spindle chines, three 1%4-in. and one 2%-in. and one single spine 2M% There are three 3%-in., three 1! operations views, Figs. 20 34: ma 2%-in. machine. one 13-in., one %-in. and one 54-in. Cleveland and tw Davenport machines taking work up to 1%-in. round stock. The Brown & Sharpe equipment includes 28 © machines handling up to %-in. round and 30 N handling up to 1%-in. round. The large automatic ke studs and cap Its im a variety of sizes an rger Gridley machines the cross-head pin in th made, 4% 1n. long model and 4% in another model and 1'4-in. outside long by haracteristic which predotr S ry department of the nachine s » 1S } } . . ‘ } ; . ' ' which every nished part is tested and ' at ing the process of manutacturs I s is the view shown in Fig. 26, wher rtment is devoted to the inspectior urt yauges Between each machining ral erator turns in his material and time on th iterial passes through the hands in re it moves on again either to t next i ition or to an assembly. Fig. 33 is a portion ving room for incoming castings and forgings vhich is inspected, and Fig 1 s ial which has been found satisfactory at som manuta ring process. 1 the s rd he assembly wor conform is illustrated which shows the ip of the pis 1 the issembling the motor. Each piston must square gauge as shown \ general view of the motor y room, in the foreground of which this lining u ton is shown, is presented in Fig. 37 t n the in which the motor is mounted for will also be noted. This permits the motor tated to the angle most convenient for assembling Irame ular parts. lighter machining departments where the frame sis fixtures are finished and in the departi t steering gear parts are machined and ass led the operations are adapted to the turret lathe, ichine and upright drilling machine [In one partments the equipment is almost exclusively ip of milling machines, luty machines spaced in rows approximately 12 ft h the machines from 7 to to ft. apart, five No. 3 Brown & hines the including eight s¢ 3 B heavy duty, all spindle and six No number of are made in special forms, as utter for milling the teeth in the quadrant for the The turret lathes on which such parts as p and dash-board brackets, steering gear parts and ield brackets are turned include Jones & Lamson, & Whitney and Warner & Swasey machines. The drums for the rear axle are bored on Gisholt tur- nd the brake bands are turned on a Libby turret machines. On a these ma for example the 17 iever;rs. rk \s indicated previously a large part of the machine w THE IRON AGE ’ t . Fig i the trucks ne I ‘ ichining he Idi ‘ ‘ rent, in ntrast to the Ls epart ribed, p1 ies ; ntinu Or spa tabricating the f1 t Lv t ! issembly~ of the chassis : . la ning 1 this floor € ! } ; | > ixie ke drums nad < rt } ‘ sulla i Ve il t la ire | f the sprocket teeth is a Hi ( \ f ) rT? , ‘ »f ’ ne¢ \ " n il ‘ r { _ vear cut il! ( ) } ; Pr \ vi ( yen y : group « é } ‘ oO it leads to ‘ } Running the Differential Pinion and to Establish » Smooth Running Relatior ’ Fig. 33—One of the group, carrying as shown both the power and lighting cables and the steam and water piping. The power gen- erating station comprises a steam plant with 250 hp. Wickes vertical boilers equipped with Murphy, stokers supplying steam to Corliss com- pound engines driving genera- tors direct con- nected. An in- terior view of the main floor of the engine room of the power Inspections to Subjec ter Fig. 36—View of a Which Incoming Department Deveted to THE IRON Piston Is Gauge in the Adjusted Manner Indicated Indicating the Inspec Rigid During the Process of Motor Extent to Which P th yn Are Assem- Condemne ’ house and_ the well for the auxiliary and condens shown in Fig, 38 The generating units consist of one cross pound Wi sin Corliss en- gine with cylin- ders 26 and 46 x 48 in. driving a 1000-kw. West- ern Electric gen- erator, ing deliver- current at 250 volts, and two C. & G Cooper cross- compound Cor liss engines wit! cylinders 38 and 72X32 in. driv Accurate Inspection by Gauge of Machined Parts wi od \ 2 ‘ ‘ — a 7 THE IRON AGE kw. generators \ 300-kw. high-speed Bal a Western Electric generator produces current ghting circuit \ir is compressed by means ymmpound Hamilton Corliss engine with steam ends fron 32 x 42 in. built by the Hooven-Owens-Rentschler remoy ——__—___ = —E — Fig. 37—The Motor Assembly ~~ st a a, SOs 1424 THE IRON AGE Jun Fig. 39—View in the Tunnel Which Connects the Power House wit All of the Plant Buildings is.delivered by conveyor into the overhead hoppers hung above the boiler front and from which the coal is spouted down into the stoker hoppers. The ash drops from the stoker into a tunnel below and is wheeled out ’ (To be continued.) A Compact Autogenous Welding Outfit A compact, self-contained oxy-acetylene outfit for weld ing and cutting has been placed on the market by Georg: C. Schemmel, Wapakoneta, Ohio. It is furnished complet: with gas generators, welding and cutting torches, ete., and occupies a small amount of space In the design of the machine air and mixing valves, air pumy ind pressure regulators have been eliminated, with the id f making it easy to operate, even by a novice. Another advantag« laimed for the outfit is that the pecul ns tion of the torch enables the ope I work w 1 ( low pressure, The equipment illustrated has two 60-zgal. storage tanl which have been tested to a pressure of 200 Ib |. in The acetylene gas generator B has a storage tank which holds the carbide mounted on top of it The carbide is fed \n lmprdved Type of Self-Contained Oxy-Acetylene Outfit for Cutting and Welding into the storage tank by removing the cap there is automatically fed into the generat being regu.ated by the hand plunger at the top erator in accordance with the demand. From ator, the gas passes through the gas scrubber to the storage tank at the right. The oxygen ; at E, passes into the scrubber D and then int the two central tanks. Safety valves are provi scrubbers to prevent the presence of excessi in the tanks. Pressure gauges are mount: charge pipes from both geenrators as well storage tanks, the purpose being to prevent from opening the valves on the discharge pipes pressure in the generators is above that in the The torch is designed for both welding and Armored hose from the two storage tanks « different gases to the torch, where a mixing provided. Besides being designed for low pri torch is arranged so that it may be held in pla flame regulated with one hand while the othe: free to hold light work in place when this is necess Several sizes of welding outfit are made. The one has storage tanks of 30-gal. capacity, while t has two 20-gal. tanks New Type of Safety Guard for Punch Presse; As a result of an investigation made by the Hard Supply Company, Grand Rapids, Mich., into the of safety devices for punch presses for use in factory, an improved form of guard has been placed the market. One of the particular advantages clain for the guard is that it can be placed in any ordinary punch press in less than 5 min. without any machine work whatever. The bolt on the right side of the press, whi ‘orm of Safety Guard for Punch Presses holds down the bolster plate, fastens the guard, at can be removed or adjusted in a very short space of tim As will be noticed from the accompanying illustr there is an angle plate with a slotted arm, which under the bolt fastening the bolster plate in place as tioned lo this angle plate is bolted a plate having for adjustment and supporting the rocking bar to the guard is fastened. At the opposite end of th ing bar there is a chain fastened, the lower end of is attached to the treadle, and at the end to whi guide bar is attached there is a coil spring of pian which carries the guard back to place when the tr is released When the treadle is pressed downward, the chain on the forward end of the rocking bar and this the guard bar upward and forward, forcing the oper hands away from the dies. If the hands are resting the guard bar with sufficient weight to keep it down press cannot be tripped, it being necessary for th to be thrown upward before the trip will operate this way, it is emphasized, an efficient protection aga!! injury to the hands is securéd by the guard, which same time is not in the way, nor is it any hindran annoyance to the workman. (2, 1913 THE xhaust Turbines in Disston Plant Utilization of Exhaust Steam in Disston Saw, Tool and File Works w power plant has been built for Philadelphia, Henry L/iSst equipped with mixed-pressure st s for utilizing the exhaust from rolling l and steam hammers. The plant has been built additional power required, as well as to secu ynomical and convenient arrangement. I: works, which makes saws, tools, files ducts, there are located at different points twenty team engines, having a total capacity of go00 hp f these scattered engines and 6 large steam s, the hitherto unused exhaust steam, correspon 4000 boiler horse power, is now collected and ugh a system of covered pipes, running m building to building, to a central point whi r plant has been erected Chere aré ee miles of this piping of a diameter rangin the most distant points to two 24-in. pipes, whicl to a steam separator for eliminating oil and wate: separator the steam is carried to a header, fr the turbines get their supply. e power house is 28 x 92 ft. in ground plan, and tories high. The proportions of the interior of the ng partake somewhat of those common to power s for public service corporations, in that the ceil cane ce wit es as if si Pt Sd - Ee SD eat z= ~ ok a - ed es » 2 Mixed-Pressure Turbine Power Plant of Henry Disst re lofty, making the building substantially equivalent ur-story structure. The power plant is located at River end of the affording rable location for the collection of ution of giving r condensing purposes. In short, a « ply of cold water is available only a few feet fr laware steel works, power, and also access! ? ntinuous ulding, from a river 20 to 30 feet deep and a mi le. Eight of the engines supplying the steam, ranging 200 to 1000 hp. capacity each, are concentrated in buildings for driving the rolling mills. IRON steam and the vility to AGE $25 Che turbines, generators, vat ! pur Ss, x ind switchboard are | cated n the ippel wer house, leaving the condensers $ generator air cooling systems tor the ere ire I et K¢ pressure Cu ‘ , n rectly nnec 22 i SO-K W ‘ r ? | , ¥ 1 CTta iW Sa Lit ia ¢ 1 nm reset! ne ecite ts ; + t ‘ ' ' rec me c ste S WwW | ; I i S i signed ' if S I Lcuun } ( ense! he : im HE t gy iss I lg \ y ; 1 1 ‘ | 1 es ek I ( R 1 spans tne wer is ” ] ‘ » +} 1 it ' ' S idicate n ‘ i ‘ ] r ; , *? S i a 2 ) ; ‘ ' i I j , @iving tacilities 1 1 | ¢ | ni 2 I v eavy ichiner 1 ca im a f ‘ ' I t nis l T ven i ie¢ A x nad lant t 7 1 ( l it 114 i . +> ‘ | . Open-Hearth Mechanical Draft Now Chimney Menti n vas made n ry ly " ! é, Sentember »f the pulling down of the open-hearth furnace sta ut . ; : ss : the plant of the Ohio Steel Foundry Company, Lima, O by the boom of a locomotive crane running into the \ ew aoa f Sons, Showing Tu e- Drive I n Foregr = oan wire attached to the stack The furnace was afterward #2 operated by a mechanical draft supplied by an 80-in. ex = haust fan Views of this furnace, which was probably the pais rst one ever operated by a mechanical draft, were given, gia! nd the exhauster supplied the blast satisfactorily for a f riod of four and one-half months A concrete chimney ye 129 ft high has een erected to take the place ot the Ss old stack, which was only 115 ft. in hight and had an in- 2a side diameter of 50 in. The diameter of the new stack is j 8 in. at the bottom and 51 in. at the top, the outside tee lameters being 100 and 58 in., respectively tes oy . t Manufacture and Uses of Malleable Cast Iron’ The Proper Annealing of Heavy Sections Need of Co-operation With the Foundry in Pattern Design—Automobile Specifications ry ENRIO BY RIQ Although malleable cast iron, as compared with steel enters into automobile construction to a limited extent only, the actual amount used im the industry is large. | believe it will be admitted as a general proposition that the constructing engineer, while thoroughly posted on carbon and alloy steels, knows less about this material than pos- sibly any other passing through his hands. There is a widely prevalent misconception that when any part of a malleable casting exceeds 3 in. in thickness of section, the change that normally takes place during the annealing process, whereby the hard and brittle white iron castings that come from the air furnace are converted into soft tough and ductile ones, is but imperfectly accomplished The Process The malleable iron process is conducted in two steps, the first of which consists of melting gray pig iron upon the hearth of an air furnace, when a certain amount of the original silicon, carbon and manganese is oxidized, and thus removed from the iron while it is being melted and subsequently raised high enough in temperature to run the castings successfully. The following three facts are well known to those who possess even an elementary knowledge of the metallurgy of iron and steel: 1. Most of the carbon content of gray pig iron exists in the form of graphite; that is, free. If a pig be broken and the fractured end be gone over with a stiff brush, it is easy thus to remove the exposed little flakes of graphite held in mechanical mixture with the iron and always separated from the iron during and for an interval after I ro EDA graphite can be changed into an iron in whicl its carbon will separate out as graphite if this melted in such a manner that a certain amount con content be removed from it through oxidati the silicon content is in excess of a certain prevents the carbon from combining chemically iron, while if it be removed gradually from a ; which the carbon would normally have existed as ¢ a point will finally be reached at which its infl forcing the carbon to separate out as graphite wil Removal of Silicon It is an easy matter, then, to start with pig iron yray in fracture and in which all or most of th exists as plates of free graphite, and end with an ir is white in fracture and in which all of the carbon bined chemically with the iron. It is a question sol getting rid, in the air furnace, of such an amount con as will accomplish this end. It thus becomes that the manufacturer of malleable iron castings, by of his air furnace, experiences no difficulty whatever converting gray pig iron into white cast iron; which ope: ation constitutes essentially the first step of the process Many years ago it was discovered that if hard, brittle white iron were surrounded tightly by an oxidizing pack ing, such as iron oxide in any form, and then raised to and maintained at a temperature of about 1500 deg. Fahr. for a few days, it would not only be changed into very soft and ductile iron, but some of its carbon would be re- moved during the interval. This constitutes the second ; solidification. step in the malleable iron process. Consequently, the first 2. When pig iron is uniformly white in fracture, no step toward getting soft and ductile castings in the mall graphite is ap- able iron pro- parent upon in- cess, is to get 4 spection; instead hard and brittle of the carbon castings, in , separating out in which all of the ; whole or in part catbon is con as graphite, it is bined chemically 4 all combined with the iron as t with the iron carbide of iron, ( chemically. the hardest cor ef 3. A pig iron stituent in either at having most of iron or steel +" it 4 ¢ * x Fat Fig. 1—Photomicrograph of Polished, Unetched Section of Gray Pig Iron. Fig. 2—Polished Section of White Iron. Fig. 3—Ann a Malleable 4% in. from Surface. Fig. 4—Annealed Malleable Between Surface and Center. Fig. 5—Annealed Malleable at ee Center of Bar i i ° . } th 74 ~ , .; - ‘ Ba > of i i rbon, both eB *A paper read at the Summer Meeting of the Society of Automo- ; irbide of iron into carbonless ae nee i h what re! bile Engineers, Detroit, Mich., June 5, 1913. of them soft. By the aid of photomicrograp its carbon in the form of The second step is to break up 1426 auring he second step of the process, that 1s innealing ovens where the white and brittle placed to be converted by time and temperature hed castings, will be explained in a non-technica Changes in Carbon States illustrates a polished, unetched section f a pie e jig iron, the object of which is to show the plates of graphite that separate from the metallic iron, silicon is sufficiently high in the iron to force on thus to separate. It will be noticed that there ally no regularity of either size or distribution flakes; therefore it is not to be wondered at that n test bars show great irregularity in strengtl hen poured from the same ladle of iron shows a polished section of white iron, white ts silicon content was too low to force any of it to separate out as graphite. The whole of th consequently remains chemically mbined witl tallic iron, invariably in the proportion of 6.67 rbon to 93.33 per cent. iron. This extreme iron is shown mostly in the white areas, t 12 per cent. of the dark areas consists of this hard ent also, the reason for which it is not necessary nsider for the purpose of this article reviously stated, carbide of iron is the hardest uent that can exist in either pig iron or steel, but itely, as already indicated, it has been discovered it be heated to about 1500 deg. Fahr. for many it can be split into little nodules of free carbon 1ass of practically pure iron, the former being very having no strength, and the latter being bot luctile and possessing high strengtl An inspe the polished sections of annealed malleable ir 1 and 5, will show that these little nodules of { (the little black areas in the photomicrographs) ar« mly distributed throughout the entire section and ar: in size, differing in both particulars from t in which the graphite occurs in gray iron Uniformity of Heat in Annealing S¢ ntend that white iron castings over 3 inch in unnot be annealed as efficiently as castings of less ss, is to contend that a piece of white iron over section cannot be heated uniformly throughout its section to a temperature of 1500 deg. F. or over s manifestly absurd, for it must be admitted that in lifferent processes ponderous pieces of steel are be ited daily throughout their mass to any required rature. The sole precaution in any case is to see that of time be given the operation. As it happens that nnealinge process in the manufacture of malleable THE IRON AGE 1427 l y l ( 1 the 1 os ¢ | ey vil I é st t] sect t tainly not t icl time llow the ( eat form! + lore er ‘ I ever in unta { perature ul int un ! ) ek il Thickness of Section [The direct question can now be put, What is the limit f thickness of section beyond which white iron will not e efficie ] and co! le innealed: that is, not have ill of the hard constituent completely replaced by little lules of free irbon and practically pure iron The nsv is plain At t ness f n t ‘ gh! and ealed | n M state have the wv le of it irbon content as carbide f iron It has een shown that whether the carbon existS as Cal de r as graphite it 1s simply a matter iow low or w high the silicon may be in the casting It has also been shown that the adjustment of the silicon s under the complete control of the manufacturer. If e silicon is as low as 0.30 per cent. it is possible to ob- ( tain easily sections as thick as 6 in., in which all of the arbon will exist as carbide of iron, although in this ex treme case to break up all of the carbide and completely replace it with free carbon and iron, a higher temperature than that normally used during the anneal is required In sectons 3 in. thick all the carbon will exist as carbide of iron when the silicon is around 0.50 per cent., in which event neither a higher temperature nor a longer anneal than is customary in ordinary practice will be required I have therefore placed this as the limit of thickness for » & . as 7 * 1428 THE IRON efficient and complete annealing. The trade, however, does not call for malleable iron in which the sections are so heavy. The statement can be made that if the process A rt 7 \ j lesccnnesiniii — _ —_—— - \ \ \ \ J Amount of Metal in t Cast is fully understood by the man the silicon content in accordance with thx f the work, no trouble from this source should 1¢ ever will. Referring again to Figs. 3, 4 and 5, graphs were taken from an annealed malleal section 2 in. in diameter and several inches in lengtl The sample was cast at my request from a heat in the regular course of the work. While the company makes fairly heavy cast ings, none of the parts approaches this sample in thick- ness. Still, as will be seen, the silicon in this company’s white irom was low enough to cause all of the carbon form carbide of iron in a 2-in. round. This sample was annealed in the oven with the company’s other castings, in exact accordance with the regular practice of the s Fig. 3 was photographed at a spot about % in. from th surface; Fig. 4 at a spot midway between the surface and the center; and Fig. 5 directly at the center: \ close spection and comparison of these three illustrations should satisfy the most skeptical that this piece was annealed throughout, and that all of the hard carbide was broken up into free carbon and soft iron. Accompanying this sample was another, 4-in. in diameter, the central part of which I found contained considerable graphite in the form of flakes, which from their shape could be identified as having resulted from the separation of some of the carbon during the solidification of the white iron, showin this case the sili on in the normal mixture was not sufi ciently low to have forced all of the carbon t mbine with the iron, although had the silicon been somewl lower, there should have been no difficulty in this pat ticular Removing the Skin It is often said that if the skin of a malleabl casting be removed and the core tested the latter will | found to be more or less worthless, and that malleable castings are strong and ductile by virtue principally of the metal in the skin. There is n vuestion whatever that the metal in the skin of well-made malleable cast iron is slightly superior to that which constitutes the main bulk of the casting, but only in the cast f poor malleal cast iron can a really great difference in strength betweer skin and core be noted. The poorer the malleable the more pronounced this difference Mall 1s : unique in this particular, for the metal in th steel castings is stronger than the central part of the inz. although not for the same reason tl case of malleable cast iron. The skin of malleable cast ings is practically decarbonized iron. tl tructure being uninterrupted by the presence of any little nodul ret carbon. The structure of th re, h that of the skin only in that throughout it little nodules « free carbon are interspersed. That in ¢ 1 malleable iron these little particles of free carbon do not tina wav injure the structure to any appreciable extent, I have satis- fied myself by numerous tests from time to time. To illus trate this fact, I have secured castings of an automobile AGE June 12. i913 clutch ring, shown in Fig. 6. The 7/16-in. thick casting was machined down to a thickness of which it was subjected to repeated heavy blov hammer to test the ductility and strength of left after machining. It will be seen that the m core in this instance was of great strength and and was able to withstand great punishment wi eloping cracks of any magnitude. It is most that the metal in the skin of this casting was slig! rior to that in the core; but I feel confident tl ference was not great, and I repeat that in go. stings, while the metal in the skin is a littl that of the core, the difference is but slight Faulty Patterns Cause Trouble Some manufacturers of malleable cast iron cept pace with the advances made in malleable ome do not even understand the rationale of th: r lack of good manufacturing equipment; a1 rtunately, these do not predominate, thers them in existence to throw much undeserve n one of our important and growing industri nvinced, however, that the constructing engineer iperly designed patterns, has contribut« rous instances to this situat rst offenders in this particular, however, ar: neers for the railroad car builders ally mm nume If the question of shrinkage and contractio 1 properly considered, if the apportioning of thicl sections be not 1 cipies, no idjusted in accordance with corr matter how superior may be the metal failure is the certain outcome. The remedy sl ybvious. Practically all of the makers of malleabl ings have on their staffs men who are proficient design of patterns from which to cast malleable. M1 delay, much irritation, and a great deal of injustice will | eliminated, and a much stronger casting for the sam weight of metal will often be produced, when closer re e Pattern for Malleable Casting (Upper) and How vas Changed When Made in a Steel Foundry ship and co-operation exist between the et designs a malleable part of any particular ™ and the malleable patternmaker at the foundry. La 2, 1913 THE IRON AGE prevented my securing more glowing examples 5 Casting provide t \ t nes here shown, of how small need be the alter- exists in th : ca f it pattern, In many instances, to produce good re tions are correct. the better wil re ad ones previously obtained The changes I have shown that the manutact e! Fig. 7, although very slight indeed, made th his silicon to a point where all of ti etween success and failure. The same remat s carbi al th * t} oe fans n the case of Fig. 8, the change producing wut this elimination depends w atistactory casting but one containing less the sections. It is exceedingly rat nnection with the center plate shown in fi he silicon t ig) ( ing are the facts: Complaint was made by th nalvs safeguard tl All t these malleable castings were failing 1m reakit in ra S ( lanufacturer of the castings mad ind that the e be permitted to alter the patterns in a rd tic carbon in the t his experience indicated re \ wrt | thar ; privilege was not g ted. J t illeable iron castings « Id 1 I particular case; so vas ce { ol! 5 eel ( S eel the pattern al ‘ I ( 1! ( } wed not only ( £ e¢ erere ( I t n the se il i w ¢ a ' vork at he 1 ' Physical Properties , ical characteristics ot all familiar. However, I hav ( vy malleable castings that you will en severe ly ibused (ne 1S rently illustrates the fact that wher ca made by those who underst possess Many valuable characteristics art en toughness and ductility, ease of ichinn ire considered, | not know w e successfully with good malleable ca I nsile strength of good malleable cast tron w en about 38,000 to 56,000 Ib. per sq. in. Whe can be obtained only by a sacrifice of ductil lastic limit of good or of even indiff equal to that of wrought tron and frequent > - - When comparisons are made et nd other metals, it would be more tau n elastic limit rather than the ultimate strengt e former upon which the engineer tually ba \ n fe n The elongation and reduct: ld to | aT ire, of course, considerably less than { é ‘ ngs n or soft steel. That both of these properti he S et 6 Aw ugh to impart great ilue tf nalleable ist ill ‘ lat . npressively attested by the illustration f the ne er saw and 1 ne ever will ing previously mentioned le it r 1 qual custom of plants of tair s { run "tT ed certain pré ito! re tal n mixtures for different clas f wor ide between certain elemet m one furnace is not well adapt t ne le t eas t N ting as to some otl If the t ‘ t lv take the nu fa er into h th ‘ he se to whi ! particular v t e effect vork expected of it in servict | n r ! vill be avoided, and a super ght, but tually the ext f tured. Some consumers are under the fal e tolerate } American hat for competitive reasons the ld light rials all SO rm ent. a ngs. This zenerally necessitat the introduc t tl far t hie] f cores into the mold. the result that tl ‘ : ‘ bliged ¢ chargee more nd . ‘ Automobile Specification 1, 1e that specifications are of more interest tl 1] 1 hip than perhaps any other one question in ! vith this material. I have no desire to usurp th: f the committee having this matter in hand, tl hich in all that has been done has been so con ar few words in connection with the Societ Ramid Micl October 10-2 Or ile Engineers malleable cast iron s1 -atior tte ist, he taken in the spirit in which they are in n I th 1 , I believe that a mistake has been made in spec ti f the eet 11 ner limit for silicon As a matter of fact, it is hetween the ciet nd the ¢ lintted Seat wn that the higher the silicon in the white iror ni ‘ ° ! | et i 35 J. in. n | ee ictility is desired, it is manifestly mcompati a high tensile strength. As in the case of carbon vith malleable iron, ductility goes hand in hand | ultimate strength. If high ultimate strengtl ik 1420 . 7: i Ca sae ‘ ery wi nm ti & p . ‘ rae }, ‘a it re ‘ i I I ee ‘ l t ‘ 8 ‘ ' | } i i nce©rne i é nad t * em =r 4 EF wal hte", evan 1430 A New Automatic Torsion Spring Machine Wide Wire Range Combined with Di- versity of Forms the Special Features Sleeper & Hartley, 98 Beacon street, Worcester, Mass., have brought out an automatic torsion which is designed to meet the every-day spring machine needs of the man- THE IRON AGE Jun ere gages the large gear b, having on one fa ways for the adjustable head c. The hea crankpin connected by the rod d with the s| The rack meshes with a pinion on the lower shaft f, at the upper end of which is a clut clutch member formed on the face of the gear g. This gear is loose on its shaft, and the pinion A on the arbor spindle i, having end the worm j, which engages a stud fixed t work of the machine. As the arbor spindk engagement causes a rising or falling moven ing to the direction of revolution. The lowe; spindle takes the spring coiling arbor k, whic! with a collar, /, that carries the stud necessary ing process, holding the initial coil on the adjustable stop m regulates the degree of movement to conform with the desired dimen work. The wire is taken from a reel and pass straighening rolls m and the feed rolls \ ways is the plate p, and adjustable upon this, ar angles to it, is the plate gq having a steel bushir which the wire passes on its way from the f the arbor. Sliding on the front of the plate the motion of which is controlled by a cam n the shaft r, carrying a cutting bar which shear predetermined intervals. \t the beginning of the spindle is in coiling its lowest position, with the ar! The diameter of operat stud ready to receive the wire. Fig The New Sleepe & Har \ S Ma, ufacturer. It combines a wide wire range with a largé diversity of spring forms. The wire 1s n from tl coil and is fed, coiled and cut automatically. Spring forms may be wound either right or left hand, with any desire number of coils up to the capacity of the m ne. TI wire ends may be left any required length up to 7 in. and 12 in. respectively and at any angle. One end may b put across the coil, and, in some cases, bend be mad in the wire ends. The wire range is fr No. 20 to No 8. Wire from No. 20 to No. 14 may be sprin of from 1 to 22 coils and in the larger from to 13 coils \ two-speed countershaft an output 18 or 30 springs per min P The details of the mechanism are shown in | Power is transmitted from a pull 1 1 at the opposite end f which is th pinior = t en ——— any ? : = j 4 > 9 va F 2 . 7, P | 111-6. } ip. | i | se = ————— f | i . -—o tT en | > of “to 3] Ee / ei >| RO) hd eee Sh ae Sea EEL SIDS LUIUIE SIREN r ant 7 3 . ane . a r wy - : : Fig. 2—Plan and Flevation Views of the Machine Showing Mechanical Details and the number termines that of the spring, | number of « determines the worm fixes the distance sepa! and worm are removable, an and springs the arbor arbor different ( ils lhe sizes types of faking for illustration the spring shown in t! eft corner of Fig. 3, the wire is passed betw« and the stud a _ sufficient distance to form one \fter the coils are formed, the reverse spindl y the reversing of the rack e¢, Fig. 2 the slight coil in the spring has taken place, du elasticity of the metal, the cutting bar forming the other arm of the spring. severs The elast ev causes the spring to separate from nd it drops into a receptacle. The length of the art determined by the position of the plat ays [he machine requires a floor space 30 x veighs crated 1700 Ib According to Charles R. King in the Ens Magazine, steel castings are used very little tive engine frames in Saxony or in Europe in They are usually made of rolled plate or forge: though the Saxon Engine Works has built Canadian with frames of “molded” steel. The bar typ frame is not trusted by European engineers, thous advantages are many. The plate frame is the typ survives more as an institution, even though |! nomical. a i ; f gines e eco- 13 THE IRON AGE 13 ere Air Pump for Condenser Service | also possesses large f1 * pump which operates to cause intermittent 4, ; : i a3 P S operat I is | ' hee loped abroas ce vh | lines " i] tT erTretl n 3 ult e V { : hs! exter! eye rn ( We p I ‘ ; , fo tor or ' 5 $ oy % g draw! ‘ the ipl I il is 1 +] imp consis ' ‘ ( ' is Y ' T) ‘ ‘ ' ‘ tes ( ! \ S ed f+ ' = ’ \7 Struthers Furnace Company eases Vine t I ; : ; ri ma ; \ \ \ | P ‘ - { I il nd S } ae | ‘ nd tor é 11 * bined in h t : ‘ 1 the surface ¢ ny i a 1 j + t n l l lOZZiK { ; ¢- 4 ; nere 18 a part whi [ i e i vin eravi ; | | } . er, W h f£ the nar ; W ( t the nnular air ni¢ s rling water impeller the 1 for the water of condensation and the other t the ' er water and air, are formed within the sing] eoiatabae 4 wis i it as far as operation is concerned, the tv n the Ishnemir entirely independent Among the advantag r this arrangement are that the n the condenser and pump is reduced an space ordinarily required by the two pumps reports net n t . nd the water of condensation is greatly re- I 13, at $4,150, ; th pumps are driven on a single shai I ! tere the le ' turbine with a resulting saving in power imed that pumps of this type will maintain a the close of the last fiscal t is $2,131,; nst i from 98 to 99 per cent. of the theoretical $2,372,667 tl re 5 ur lividend et rresponding to the temperature of the hurling e past year, a surplus rema ; a. ng water or temperatures ranging from 32 to 90 workir ets, Mar totaled $7,860,125 nd higher. decreas ! 530,020 se The World’s Supply of Manganese O; India Leading Russia and Brazil as an Exporter—Changes in International Com- petition Due to Developments in Russia f ferromanganese the Rus est li inere ha influenced the Duma to inere { ‘> inganes¢ re rom )2 mark t to at M ( s iturl ores are thi I 1 ( ‘ trade which is carried on u . In Ta 2 is given th ‘ ‘ m these ports \ ve ‘ ( ) 19 9 as ie stor the manganes« ( { The low gut ted to unfavorable political conditi vith Turkey explains the falli IN sually high figures of 1912 are expi , | t that poor shipping facilities, cause: a i to an accumulation of son orts hich could not be shi } 0 I nt ( vill probably see i | a nution im export f Caucasian ore Lhe ; rable to mining and labor large! f Iding the Caucasian Railway. Th ' l tio! ! a decided deterioration in the \ . sphorus content now being o.18 \ rs ; Manganese Ore Market of India ’ the Vizegapatam dis wth came with tl mM it ’ of thy Ind i P sibl devel nad ; he mit S lox ter | é res ¢ India « lf . rei I rger lumps al hei ‘ é el he 1 : f Ve The Manganese lr istry of R ( res it is plain that I1 : ( I n ti Caucasian regior le n metric tor . »and 19ott, during which time it t manganese producing countries Ort port, 443,173 tons leavir ainst 49,867 and 51,612 tons f1 respectivel The destination « uted as follows in 1912 1 | : | a () il s B Ge a te of Fr Holland is Tisecl . ae : ecause of low wages and easy mining the ‘ . : * Bret ' , [ Indian manganese is low, from 2.75 to 5.50 2 d a : mi Saget ae ree ta eae fon, or an average of 4.15 marks. This will ines grow deeper. The transportation c ee using ] ae sh cok ee 221 , ' + ; 2 at rs —_ high, most of the mines being ‘situ ay land using Russian manganese o1 ee 400 5 o km. distant. The \ izegatapam mine she Russian ferromanganese indust: oa ‘bout 90 km. away. From the inner provinces the last few vears: production in 1olr 1 ioe cf entage ¢ res are shipped. The ocean freight F . edo ; “s "s ; : i¢ 18 marks per ton. ' tons and is steadily growing | eas urther the "he author states that the manganese mining "Stahl und Eisen, April 24, | India has a great future. Low costs and the w ad 2, 1913 THE IRON ry in raw materials, such as iron ore, lime and also make it appear evident that the Tata Iron mpany will develop decidedly. Steel works of ld supply all the lands washed by the waters of ind Great oceans Production in Brazil : . ‘ ss tne Indian, the Brazilhan ines ‘ r rent is attributable to tl / ¢] 1arket Table 4 shows the export net } ’ l I s Ve 414 19 92¢ 1908 208,260 é 1 ent ; t] S se ' ‘ h freight rates sd il ested a « erative s ‘ ¢ T+ - 1 aoa Gross nea tne Bol 1 The World Situation ation it can be said that the pr nt situa , re? r] £ ¢] 14 ‘ inganese ore market the worl i varated s irces Of sup] ly, Russi 1 if take care in normal times of tl ye nand But it should be borne in mit ] F emminin neciall ‘ } 91 as I mining, especially in tl ( cas! | +h oe al } ‘ ‘ | cause the rich res to be exhaus I tant Recourse will be had of 1 sity t with a consequent increase in cost \ man crisis like that of 1908 is not likely to re ince the various sources of supply the German supply depends very nq ' 1 market The extent t which this f 523,125 tons Russia furn tons, India 12 n 3980 tons The imports from Russia wer .614 tons, Brazil 20,857 cent. of Germany’s total Dr. Kern ure become independent of the unreliable Russian langanese and to look about for other suppli les with an interesting table showing the rela pe n of the different classes of { , ‘ . 4 his it is evident that the cost of transporting the pe is about 8o per cent. of the price of the ore Of course, the ocean freight fluctuates, because itions principally In quiet times the the Black Sea is about 10 mark ised to between 3 to 5 marks Keeping the Shafting in Line line shaft is originally erected, it is pres true, and the hangers and bearings N rted are, or should be, accurately aligned ar ired. It is unfortunately true, however, that installations are permitted to remain in_ the elations in which they have been placed. Varia vading upon floors, settlement of piers, unequal ses, burden of pulleys and especially frequent tions and reconnections, combine to affect the the whole and to prevent it from keeping in line r such circumstances, it is essential that the proj igned transmission system should include ampl ity for self-adjustment and for local correction idamental requir