The Iron Age 1913-07-17: Vol 92 Iss 3

11) U} Established 1855 New York, July 17, 1913 IE AGE | Vol. 92: No. 3 An Efficient Factory Purchasing System A Simple Method of Recording Orders, Keeping Track of Deliveries and Prices and Making Quick Comparisons \ urchasing system described in this article has been _ required g use for several years, and-has been developed ti r articles. ‘The he demands of the busy man, who may desire to keep the material and i himself or hands keeper, stenographer or ck clerk, and not make it urden for anyone The put the regulal ————— Ch _———- rors MB PURCHASE REQUISITION THE BAUER BROS. CO. onvenience and satisfaction realized utes’ time required each day tim e rim juantities, \ll requisitions for mate | ee wes > ial to be purch ised should “NL made out a requis — ——— * blank the stor per. The blanks should space re r the date Approved Ordered by the quantit) Baus yi! 3 . K ae : FY Ol The Requisition Blank its r tor the few min Order No Date Aocount of maintenance, the saved purchases, dates, prices, terms in looking up = |_9eaxTm Rareanal Wise are unusual. ORDER FROM THE BAUER BROS. COMPANY PURCHASING DEPARTMENT Springfield, Ohio, ss _19_ ar. endian aS “ Ship Via ened When Wanted Ship to See a et a F. O. B. . . al t gre d f lan} ’ I wf irranged meet litiéns \ftet rf rs | AV : tl quisition in I tly I } mt | arc 5 referen when 2 and . \ emient triplicate f{ rchase rder an 1wina! id \ irb fT ; es The iT u i ! ror wu in i regist 4 | added in f mm ti tyne [ phi N? 9788 This number must appear on Invoice} and any correspondence pertaining to this Order Promptly acknowledge receipt of this | Order and advise by mail when shipment will be made | Bill of Lading must accompany in-| voice for all freight shipments ; No charge allowed for boxing. | age or packing Quantity Price Per ‘TUE fox! EROWTER COMPANY, DATTOW, GHD. THE BAUER BROS. COMPANY Fig: 2—Origirial.of the Purchase Order Blank. Size 8%x10% In 117 8 : By, i ; ~~ BS ‘ + ot iy oe pe Sere apie e® ee > - 1i& THE IRON AGE THE BAUER BROS. COMPANY RECEIVER'S CHECK COPY ~PURCHASING DEPARTMENT | ORDERED BY NO 9788 Springfield, Ohio, | Ship Via | Ship to F.O0.B. Quantity Rec a, a Count Weigh | | | | | | } | Measure Gauge July 17, I¢ on ~~ } may have to be written hurrying de! { ery or for other reasons. By the use this “future date” file, the cards for orders which should have attention c up automatically each day and thus n can be overlooked. By making no on the cards it is not necessary to look up the correspondence, as it is shown. They should be filed ahe / from time to time, as required, uw the material is received, when the card is of no further value and should } When the material is received, ! ! ' ' ! ' ' i i ' t —* ' ' ' ' ' ' ' ' ' ' t ' i destroyed. record of the receipt is made on t receiver's check copy, Fig. 3, and turn in to the office promptly. From these slips the invoices are checked, and thx corresponding office copy removed from the binder. Both copies are then filed \ numerically in a loose leaf binder with _ So out index, and become a permanent lt en record. Date Received Fig. 3—The Receiving Clerk’s Copy of the Purchase Order Blank register is convenient for this purpose, and is always at hand, ready for use. Fig. 2 is the first copy, or original, to be sent to the party from whom the goods are to be purchased. The office copy is retained as a duplicate, for filing and reference. Fig. 3 is a portion of the receiving clerk’s check copy, which is filled out when the goods are received, and is used for checking invoices by the book-keeper. It will be noticed that the receiver's check copy has a perforated margin at the right which contains the quantity ordered and the price. This may be torn off, so that the re- ceiver will be obliged to count, weigh, measure or gauge the material received in order to enter the quan- eer tity on this slip. This also prevents prices paid being known to the receiving clerk, if this is desired. The office copies are kept in a loose leaf binder, with alphabetical divisions, and each division is in numerical order. A tickler card, Fig. 4, is then made out for each order, showing the name and address of the party with whom the order has been placed, the order number and date. Cards 3x5 in. are used for this purpose. They are then indexed in the left hand col- umn for the date on which it is ex- pected to hear something in regard to the order either by acknowledg- ment, invoice, bill-of-lading or let- ter, as the case may be. The cards are filed in a tray or cabinet, under the date marked on the card as above, a set of date guide cards being used for this purpose. To Goods are \ The Purchase Record } After the goods have been received, all purchase orders are entered on thi purchase record cards, Fig. 5, which ar indexed by the name of the material purchased, and_ filed alphabetically These cards are the climax of the system. Columns ar¢ provided for entering in the order named, the order num- ber, date, from whom purchased, the seller’s location quantity ordered, description of material, such as siz catalogue number or brand, price per unit of measure or count, terms, date received and amount of transporta- tion charges, if paid by the purchaser. Each subsequent order for the same material is entered on the same card, one being made out as required for each differ ent article or class of mat: rial purchased. There are quite a nun ber of uses for these cards for reference purposes. If, for example, it is desired to see where the last lot of ee | cement coated nails came Fig. 4—The Tickler Card for Following Up Purchases Until the from, the price paid, the Delivered date or quantity received, the sizes ordered, or any similar information, it can be quickly obtained by referring to the card marked “Nails.” At the end of any year, the quantity of every article purchased during that period can be ascertained, which is good information in determining quantities when making contracts for the new year. The enable this card to be quickly lo- cated after filing, a memorandum of its date must be made on the office copy. On these cards notes are made of all correspondence in regard to the order, such as the seller’s order number and date, the promised date of delivery, the date of invoice and bill-of-lading and the route of ship- ment and also of any letters that Fig. 5—The Purchase Record Card 17, 1913 help the book-keeper as a reference for the terms rmer invoices, or from other manufacturers and job- and whether the freight is allowed when it is not on every ce. At inven- times the will save in pricing the ntory. ig. 6 shows an ression of a er stamp form stamping in- es. and for use en checking m from the re- ver’s check copy. en the invoice iid the date of yment, the her or check er and the unt to which the amount is to be charged can be noted the bill. operation the system is very simple, and will save h time and money in the course of the year. Other eatures can be added if it is desired to expand the system. mong these are a card index for contracts and quota- ns, which are usually filed by subjects, and one for cata- cues and other printed matter, which can be filed by the e of the vendor. This latter index should be cross exed by the name of the articles described in the printed tter. INV. REC.. GOODS REC PRICE FREIGHT DISCOUNT EXTENSION VOUCHERED VOUCHER NO CHARGE Fig. 6—Impression of the Rubber Stamp Used for Checking Invoices International Safety and Sanitation Exposition The American Museum of Safety, 29 West Thirty- nth street, New York, announces that under its auspices e first International Exposition of Safety and Sanita- n ever held in America will take place in that city, December 11 to 20, 1913. Safety and health in every branch of American industrial life, manufacturing, trade, transportation on land and sea, business, engineering in ll of their subdivisions, will be represented at this exposi- n. It will be the first step toward making a represen- tive exhibition of the progress of safety and preventive ethods in America. There will be no limit to the scope the exposition. It will embrace everything devoted to fety, health, sanitation, accident prevention, welfare and he advancement of the science of industry. By a spe- ial act of Congress exhibits from Europe and other oreign countries are to be admitted free of duty. By way of stimulating interest in this exposition, the Ameri- in Museum of Safety says: “European employers have cut their accident and death rate in half by a persistent campaign for safety. There are 21 museums of safety in Europe. All of these various museums will contribute to the American exposition. In e United States every -year 40,000 workers are killed nd 2,000,000 are injured, while 3,000,000 are ill from preventable causes. A conservative estimate of the wasted ige-earning capacity of the latter for one year is $400- 00,000. Thus it can be seen what America has to accom- lish in the way of conserving human resources. The nain object of the First International Exposition of fety and Sanitation is to point the way.” The Lehigh Valley Railroad is continuing the use of ecially heavy rails on sharp curves and steep grades here rail wear is severe. The rail is a 110-Ib. section of e same hight and base width as the roo-lb. standard, but web is heavier, 19/32 in. instead of 9/16 in., and the id larger and deeper, 17% in. deep instead of 1 9/16 in. ‘ix-bolt joint is used and a special outside splice bar ends along the side of the rail head for additional th and rigidity. There are now 77 miles of track laid this rail. he Trussed Steel Concrete Company, Youngstown, 10, has received a large order for steel sash for a new ding for the Ypsilanti Reed Furniture Company, Tonia, THE IRON AGE 119 Virginia Furnaces Ask Lower Northern Rates WasHInctTon, D. C., July 15, 1913.—Another important case attacking the freight rate on pig iron has been filed with the Interstate Commerce Commission. The Low Moor Iron Company, Alleghany Ore & Iron Company, Oriskany Ore & Iron Corporation, Princess Furnace Com pany, Virginia Iron, Coal & Coke Company and Pulaski Iron Company, making the group known as the Virgimia furnaces, have united in a complaint against the Chesa- peake & Ohio, Southern Pennsylvania and other railroads, charging that the rates on pig iron to Northern destina tions are excessive and discriminate against these furnaces in favor of furnaces located in New York and Pennsyl- vania. The complaint intimates that the rates are excessive because of the large proportion demanded and received by the Pennsylvania Railroad. The present rates on pig iron in carloads from the Vir ginia furnaces via either Hagerstown or Potomac yards to Northern destinations are set forth in the complaint as follows: To Rate Té Rate EBarrisburg, Pa. . .. «$2.40 [renton, N. J]. . -$3.25 Baltimore, Md ; 2.45 Newark, N. J.. ; .7. ae Wilmington, Del 3.00 Jersey City, N. J 3.35 Philadelphia, Pa 3.00 New York City. 3.95 Coatesville, Pa. . 3.00 Boston, Mass 3.75 Reading, Pa. ......... 3.00 The following table is given showing the difference in the rates accorded the Virginia furnaces as against com peting furnaces: To To To To Baltimore Philadelphia New York Boston From Miles Rate Miles Rate Miles Rate Miles Rate Low Moor, Va. 255 $2.45 351 $3.00 442 $3.95 653 $3.75 Roanoke, Va.... 319 2.45 362 3.00 453 3.95 717 3.75 Pittsburgh, Pa.. 329 2.15 348 2.25 439 2.45 652 2.65 Emporium, Pa 275 1.80 294 1.80 385 2.00 599 2.45 Saxton, Pa..... 207 1.50 225 1.60 316 2.05 529 2.35 Punxsutawney, Wal sediddiees 265 2.15 284 2.25 375 2.45 588 2.65 Youngstown, O. 395 2.55 414 2.65 505 2.85 727 3.05 Buffalo, N. Y... 395 2.45 416 2.45 411 2.45 498 2.45 The complaint states that the principal competitors of Virginia pig-iron makers have furnaces located at Pitts burgh, Emporium, Saxton, Punxsutawney, Josephine, Eve- rett, Youngstown and Buffalo. Low Moor and Roanoke. Va., are two of the principal shipping points of the Vir- ginia furnaces—one on the Chesapeake & Ohio and the other on the Norfolk & Western—and in the foregoing table they are used as representative of those furnaces in showing the distance and rates from the various furnaces in Virginia, Pennsylvania, Ohio and New York competing for business in Baltimore, Philadelphia, New York and Boston, these four cities being representative destinations. The complaint continues: “An examination of the table indicates that, generally speaking, the rates from Virginia furnaces to destinations substantially equally distant from furnaces in Pennsylvania and New York are from 30 to 50 per cent. higher.” WL. t Reference is made in London papers to the testimony taken there in the vanadium steel suit of the Churchward International Steel Syndicate, New York, against the Carnegie Steel Company. Professor Arnold, J. E. Stead, and F. W. Harbord all supported the contention of the defendant that the value of vanadium was discovered and vanadium steel manufactured for some years prior to the registration of patents in 1906, on which the suit is brought. Professor Arnold was conducting researches as early as 1880, and in 1904 the results of these were ex- tensively published, placing the information before steel makers generally. The William B. Pollock Company, Youngstown, Ohio, which has the contract for the blast furnace work and ladle cars for the Broken Hill Proprietary Company in New South Wales, Australia, will not have the material ready for shipment before the later part of August. It is prob- able that a special train will be used to transport the equip- ment to Philadelphia, where it will be loaded on a steam- er for Australia. As yet the exact way in which the ma- terial is to be handled by the railroads has not been planned. The Wilson Steel Products Company, Forty-ninth building a The company makes a concrete-coated wire street and Southwestern avenue, Chicago, is warehouse. nail. “ > Seciabe glamee & upne ede - + rem ie. = ee i Be 120 \ new combination jar, roll-over, pattern drawing and swing-out molding machine designed eithe molds or cores has been brought out by the U, ing Machine Company, Cleveland, Ohio feature of this machine is its simplicity cylinder, which is used both for jarring fe used for controlling the supply of air. The e two common stop cocks, one of which is f ie and the other is for the exhaust. Th i 2 shafts with two handwheels. The shoes % : ; : * nions tightly against the shafts when the to be turned o\ these being set according to the hight prevent the raising of the flask higher than that air is not wasted. + tically on the trunnions so that the axis is near the cent of gravity when the mold is being turned justment of the plate is made with studs and double nuts ra Two taper pins, one on each trunnion, are the plates and flask in position after they ; All wearing parts are well protected from sand and the two guides on either side of the cylinder run in oil valves : o-4 : - ‘ ; 4 a "E> } vf re (at 4 bya > * 4 va 3 i . ia o* 9 seal tl Fig. 1—The Pattern Mounted Fig. 3—Drawing the Pattern VIEW SHOWING THE SUCCESSIVE STAGES IN THI New Molding Machine for Large Work important being, it is claimed, one of the simplest made pletely finishing the mold so that it is ready away on a crane. The machine is equipped drawing the pattern. No complicated cocks valves ar¢ trunnions move i loosely on upright shafts and are provided : with two hardened shoes, which are clamped against } er. Two stops are provided necessary [he plate which holds the pattern is adjustable THE IRON AGE July 17, 1 so that sand cannot interfere with the operation o machine. These guides run in long bronze bushings. swinging arm is ball bearing, so that a flask of any or weight can be swung around with little exertion. parts are held together with studs and double nuts all joints are machined to an airtight fit. No gaskets sed, and in other respects the construction has studied to reduce the liability to wear \ view of the machine with pattern mounted is g His n operation the flask is placed on the ma in the usual way and filled with sand and jarred. yp of the mold is next butted off by hand and the bott board is placed in position and clamped, after which exhaust pipe is closed. The flask is raised until the t: nions strike the stops on the shafts, when the trunni are inade tight to the shafts by the handwheels and 1 air-inlet cock is closed, allowing the air to exhaust throu the waste opening in the cock and causing the lower of the plunger and plunger plate. The mold is then roll over as shown in Fig. 2, after which the swinging a is swung over the plunger plate. Air is then admitted i: the cylinder and the plunger raises the swinging arm u is strikes the flask Then the clamps are removed, ibrator is put 1 n, i 1, the air cock is closed and exhaust is opened, causing the mold to be slowly dra away from the pattern, as shown in Fig. 3. The arm next swung around with the mold from underneath tl attern, as shown in Fig. 4, and the mold is ready to taken away. The machine is made in three sizes to take in flasks from 20 to 45 in. in length, inside measurement, and up t Fig. 2—The Mold Rolled Fig. 4—The Mold Completed OPERATION OF A NEW COMBINATION JAR, ROLL-OVER, PATTERN DRAWING AND SWING-OUT MOLDING MACHINE a & s uals Uoteauapth gape, at & yi” : S Ors width. The maximum pattern dra nder is from 4 to 8 in. in diamete the machine, and has a lift rangin sstown Sheet & Tube Company rsday, July 10, a fourth furnace steel plant of the Youngstow in} Y oungstown, Ohio, was put naces will probably start early records are already being made a ee furnaces turned out 6060 t ms of ste THE IRON Ww 18 I8 1n r, according *s Growth n the new n Sheet & in peration in August t this plant ning mill, built by the William 17 een in operation for several weeks. The er ing this mill was built by the Me Both are working most ly Chis mill is intended t pen-hearth works, but is the present billet and mills, so that either open r Bessemer billets and sheet illed on it or on the old ves the Bessemer de he ingot stripping for en-hearth and Bessemer done in one building, ilitating the rolling f open-hearth steel on This new steel plant has furnaces and is expected ut 1000 tons per day. The plant has two ipacity of 2500 tons per day The total is thus © tons per day for both plants, giv the company an annual capacity 050,000 tons of steel ingots. new blast furnace D will be over to the company about Au- and will go in blast shortly [he four blast furnaces will bout 2000 tons of iron per day. mpany is also taking the entire f Mary furnace of the Ohio Steel Company for this year converters semer ingots. tract made some time ago. le that later on it will build furnace, as it will need ns of iron per day. Be furnace is undertaken, how- likely that the company will duct coke ovens at vn to furnish its supply of A 10 Such a proposition has not been iken up as yet. Being in he company’s developments, it may at a reasonably early day Six Months’ Connellsville Coke Pr ke production and shipments for tl s the Courter, Connellsville, Pa., 21,000,000 tons annually, but the rec probably fall under this. By quart and shipments for the year were as 2000 Ib. Production aie de icncuce Saeee aS a Le . 5,295,200 abeoeden 10,657,038 r record by months shows a sustained that probably explains the insistent rators for a fair price for their pr is as follows, in tons of 2600 Ib.: Production socks shdvdadebrtesdedeeeeee 1,867,336 acc Vewetddenh Hand ean bacon 1,716,525 $22 0c gh aeuee ahenneeearanen 1,777,977 6 odeacccdscinebnuet hbase 1,770,000 ccccdcccucneereeee da Feat een 1,823,673 o 0c-0n wheiqerete aera teen 1,701,527 site Jee on ace tee 10,657,038 Ft. Motor-Driven e expected oduction 1e first half she wa rat ord for the rs, the pro- follows, in Shipments 912,775 2 a,// AAT 10,385 10,623,160 strength to demand of oduct. The 1,699,815 10,623,160 Boring Mill with Rapid Power Travel Che ipplicati I ir separat not irive yn ring mill built by the Betts Machine Company, W ym, Del., has resulted in the providing of rapid pow travel. Another featur f this machine is the us« ill-geared feed t ‘ ads I I ‘ ' phasize nables workma \ t moving he he i it ‘ ] k t el ft 1e@a al pind! lire ! ve eed n ersa 5 il el rec I « c W rk The 1 neis i rive! entral | ng hea ch has gs vitl lef en 1 eed 1 \ it l | al I : ' ‘ +t : 1 th P. Rapid u Feed ne Hea be ' ndle e machin gs 124 ind will i I i \ K 62 2] nader t i] h Ide \\ 1) | 1% ’ ’ tomes . eo | . } \V esting! ise mojor drive 1s used y the chine, se] ‘ . » aan | } arate m rs being provided for the main drive, the cen tral boring head and for the elevating cross rail and for st he power travel. The main driving motor is a 20-hp nit. | , a speed range t 40 200 r.p.n the entral boring head is driven by a ». motor eed range varying from 400-1600 r.p.m. For elevating the cross rail and supplying the power travel, a 5-hp. motor running at a constant speed of 1130 r.p.m. is employed. The total weight of the machine, including the motors, is 80,000 | \ company has been rmed with a capital of $800,00 to acquire control of the waterfalls at Arrens (Hautes Pyrénées), capable of generating 7000 hp. of electricity and to undertake the electric smelting of zine ore From 16,000 to 18,000 tons of ore is mined there yearly, and it is proposed to manufacture white zinc, for which there is a good demand in France. Previously zinc ore has been treated in coal-fired furnaces at a considerable cost, the coal and ore mines being widely separated. The Ziv Steel & Wire Company, Chicago, which has been doing a brokerage business at 180 North Dearborn street, has been incorporated with a capital stock of $2500 by Aaron Ziv, A. J. Ziv and Hyman Ziv. AGE (21 “re ren ere : i ‘re. * a ae ‘ eo me ee I22 A Shaping Machine Efficiency Test Some Interesting Experiments to Secure Efficiency JENKINS* Data on Its Mechanical BY A. LEWIS The mechanical efficiency of the shaping machine has never been considered seriously important when com pared with its velocity diagrams, strength and convenience of operation. Many designs have been developed in striv- ing to attain a velocity diagram having a flat top curve for the cutting stroke in order to have the tool travel at a practically constant speed throughout the cutting stroke. A constant cutting speed tends to increase the life of the tool, permits of a greater number of strokes per minute and also increases the effort of the tool when in the mid- dle of the stroke, thus increasing the capacity of the ma- chine for taking heavy cuts. The effort of the tool may also be increased by im- proving the mechanical efficiency of the machine, and the lower the efficiency happens to be the greater are the possibilities in this direction. Upon investigation no data could be found and nothing has been written regarding methods of making such tests. To obtain some data on this subject a machine in the laboratories of the Uni- versity of Cincinnati was equipped as shown in Fig. 1. Fig. 1—View in Showing the General Arrangement of the Apparatus Used the Laboratory of the University of Cincinnati The efficiency was determined by finding the power in- put and the power output and dividing the former by the latter. The machine tested has been in service for several years; but may be considered as being in fair condition. Horsepower Input [he power input was determined by the cradle dynamo- meter shown in Fig. 2, which consists of an adjustable- speed motor of special design mounted upon a structural steel frame. The field frame F of the motor is supported by ball bearings which are concentric with the armature or pulley shaft and is free to rotate with the armature unless a resistance is applied to the arm A. The torque on the armature or pulley shaft reacts on the motor frame F, causing it to tend to rotate. Two methods were used in finding the pull on the arm A, which is supported by the spring balance S, and as the frame F and the arm A tend to rotate to the right, it was necessary to add the weight C. The displacement of the hook on the spring balance is proportional to the load, and the load multiplied by the effective length of the arm A is equal to the torque, The angular displacement of the rod K holding the weight B is also proportional to the torque. The up- per end of the arm E, attached to the supporting rod K, is connected to the piston of an ordinary steam engine in- dicator D, which is fastened to the structural steel frame by having a hole tapped in the top flange of the steel channel to receive the indicator cock. The spring was re- moved from the indicator and the piston attached to the weight by a wire passing through the indicator cock and a hole drilled in the lower flange of the channel. This “Associate professor of mechanical engineering, University of Cin- cinnati, Cincinnati, Ohio. THE IRON AGE July 17, 1913 used to take up the backlash in the wire nection between the piston rod of the indicator anc arm E, and caused the pencil to faithfully reproduc: motion of the arm E which is proportional to the toruy It was found that the variation in the torque was siderable and the apparatus was so sensitive it was n« sary to dampen the vibratory action of the arm wit! dashpot G. weight was The shape of the cards varied considerably, but one shown in Fig. 3 is characteristic. The line AB resents the condition for no load and was gotten by p: ing down the arm A, Fig. 2, until it struck the st and then pulling the indicator string by hand. The pos tion of H was determined when running the dynamon ter with no load. The curve in Fig. 3 shows the path o the pencil when the indicator string was attached to th ram of the shaping machine in a manner similar to tha used in attaching it to the cross-head of an engine. The peculiar shape of the curve is of no importa: in computing the power delivered by the motor; some them being almost straight and some not crossing, depe: ing upon the load, speed and stroke of the machine. Th points on the curve can by no means be used in findin the power required at any point in the stroke because inertia of the heavy motor frame causes the motion the pencil to lag behind the variations in power, but area under the curve is proportional to the work put the machine during the cycle. A heavy frame on th: motor would cause the curves for both the forward an return strokes to be almost straight, but the area under the curves would not be changed unless the load wer changed. The lines DA and CB were drawn perpendicular to A by placing the card on a drawing board, and were not made by the indicator, The area ADFCB plus the ar ADECB divided by twice the length of AB gives the average ordinate, and this multiplied by the scale of the spring gives the mean effective pull at the end of the arm A in Fig. 2. It is easily seen that this method gives accurate results when it is considered that the torque o1 the motor simply produces a difference in tension in th two sides of the belt, whether the belt slips or not, and this difference in tension produces a torque on the driving pulley of the shaping machine, regardless of the amount of slippage there may be between it and the belt. An indicator having an outside spring was also use the piston rod of the indicator being attached direct! to the arm. This also gave very satisfactory results and did not necessitate the use of a dashpot for dampening the vibrations. Horsepower Output The shaping machine ram was loaded by attaching tool to the plunger of a hydraulic pump as shown in Fig 4 The plunger K was made from a piece of 3-in. heavy pipe with the outside diameter turned down to 3% in and the end working in the cylinder was closed with a plug. A hole was drilled near the other end of the plunger for a pin and the end slotted to allow the tool to fastened to it by against this pin and be two U- Fig. 2—Tlhe Cradle Dynamometer Used 7, 1913 THE IRON AGE pump cylinder consisted of a piece of 4-in. pipe long fitted with flangers at each end. To these - are bolted two other flanges having the same out- imeter and made to fit a 24%-in. pipe. A hat leather is held between the flanges on the end of the nearest the shaping machine, and, to prevent air entering the cylinder during the suction stroke, the the outside flange was bored about \% in. larger meter than the plunger. A piece of candle wick nserted and held in place by a wooden block pressed st a leather sleeve ahd forming a gland. A small was connected to the cylinder which allowed water w down between the stuffing box and leather packing rm a water seal, This was only needed in the pre- nary tests in which the desired hight of the suction was determined and the shock arresting apparatus the suction line developed. he water was discharged through a 2%-in. tee, a check valve and through a I-in. pipe, to a 14-in. x tank, T. By opening the throttle valve the water in tank was forced by air pressure into the barrel U, served as a reservoir and gave sufficient pressure ercome the friction of the valves and piping on suction line. The tank was filled with air at any re- red pressure by running the pump at fairly high speed lowing air to enter the suction. he suction pipe is 2% in. in diameter, provided witha n. check valve and about as straight and short as tould ade. The air chamber V, provided with a gauge glass, ‘ vs the operator to observe the pulsations in the suc- line. The air chamber did not have sufficient capacity ‘est the pulsations of the suction line when the ‘ing machine was running at high speeds, and it was nd desirable to connect the pipe near the air chamber th the barrel with a piece of fire hose. A hole was red in the bottom of the barrel for a 244-in. long nipple which had a coupling on the end inside of the barrel and ived the hose on the outside. To stop the flow of ter in the suction line and use the pump as a means of getting air into the tank, a piece of 2%-in. pipe was rewed in the coupling on the inside of the barrel, the end of the pipe extending above the top of the barrel. [he reservoir or barrel was elevated to give sufficient id to overcome the friction of the suction line, the exact ht being determined from the indicator card by getting line for the suction stroke to coincide with the at- spheric pressure line, These cards did not show any ition in pressure on the suction stroke. [he horsepower output was computed from the indi- ard by finding the mean effective pressure on the and substituting it in the regular formula. shaping machine was carefully set at the desired ke and the speed of the driving pulley and the posi- f the throttle valve were adjusted so the pressure air tank and the speed would remain constant for eral minutes. Cards on the pump and dynamometer then taken simultaneously and the speed of the driv- pulley and the pressure in the tank read. The speed of shaping machine was determined with an electric unter and a stop watch. eT i Efficiency \ few results of tests are shown in Table 1. About 500 ets of readings have been made and the efficiency "each set computed, It is the intention of the writer derive an empirical formula for the efficiency of this machine in terms of the speed length of stroke and pres- re on the tool, but as there are four variables involved, is necessary to take the data systematically and plot 5—A Characteristic Indicator Card from the Shaping Machine ly w Fig. 4—The Arrangement of the Shaping Machine Ram, Pump, Tank, Etc. curves between two variables at a time by having the other two constant in order to find the effect of each varia ble separately. Such a formula would be of no particular value because it would only be true for this machine Table 1—Results of Efficiency Tests on 16-Inch Shaper Length of Load Strokes of Efficiency stroke, ir tool, ram per mit per cent +i 44.4 f 2 83 14.8 6 1037 2.2 40 29 7.0 ; 41 - 4 622 44.4 4 i )37 0 622 48 48 207 6 207 41.4 8 830 2.2 4 Q 037 l( 415 14.8 4 1¢ 62 44.4 49 | 1037 22.2 50 20 37.0 26 415 14.8 46 622 44.4 46 3 148 4 137 26 41 14 415 2 38 16 207 249 2 16 622 26 53 16 830 22.2 52 To the writer’s knowledge this is the most extensive test ever conducted on a shaping machine and although there are a few objections to the method in that it does not faithfully represent the actual working conditions by not reproducing the side and vertical pressure on the tool, it will at least give results that would undoubtedly compare favorably with results obtained by a more accurate method. The method used has been criticised on account of the inertia of the pimp plunger. Another objection is that the load acts on the tool throughout the complete stroke. This method does, however, offer a satisfactory means of comparing different makes or types of machines It would be interesting to compare the results of tests con- ducted in this manner on geared and crank shaping ma chines of the same size. It also offers a means of com- paring the efficiencies of the various mechanisms devised to give an almost ideal velocity diagram Mechanical Engineers’ Gift to German Museum The German National Museum in Munich received last week from the members of the American Society of Mechanical Engineers, who have been touring Germany, a massive relief of the Panama Canal as a token of apprecia- tion of the hospitality the engineers enjoyed in the Father- land. The museum authorities asked the visitors to ac- cept a telescope manufactured by the famous German optician Fraunhofer as a return gift for their headquarters in New York City, The W. S. Tyler Company, Cleveland, Ohio, will shortly place contracts for the erection of a four-story brick and steel building, 55 x 144 ft., which will be used for office purposes. os pay bet +S he 4 i is >. 7 BB 7 J 4G oi aad P%. a3 are | F] * ® . ® ° ectric Smelting of [ron Ore in California Cc Steps by Which the Noble Electric Steel : Company Developed Its Furnace and Practice for the Making of Foundry Iron x " An account of the progress made at the plant of the necessary to have a furnace which would respond Noble Electric Steel Company, the first American plant to alterations in the burden and still be of large e1 ; for the electric reduction of iron ore, is given by the man ip to be efhciet rs ager, John Crawford, in the July issue of Metallurgical Historical Pa and Chemical Engineering. A liberal abstract follows: f The plant of the Noble Electric Steel Company is situ- vor some 25 years one ol the stockholders of i t ated on the banks of the Pitt River at Heroult, Shasta Company has controlled a deposit of magnetite of c¢ / County, California, a station on the Sacramento Valley & erable extent which is exceptionally high grade and i Eastern Railroad, which branches off the Southern Pacific YT low in sulphur and phosphorus. The following an Railroad at a station called Pitt, lying about six miles to analysis represents the average of several scarfs take: : : the west of Heroult. It consists of one 2000-kw and one 2CFOSS a quarry face 70 ft. wide and 45 ft. high Pg i 3co00-kw iron furnace of the long and narrow type, on quarry Tace has now been extended to a width of 1 a ¢ 2000-kw iron furnace of the shaft type (not now oper and 18 still in ore 5 : ated), one 2000-kw steel furnace of the tilting type (not co P now in operation), 20 charcoal retorts of the horizon- ALO j tal type of 2%4-cord capacity, a refinery to handle the by ed : products of the wood distillation, and four 5-ton unit lime MnO Pe 4 kilns of the continuous type. Beside these there is a power nar Ir "3 a substation and the necessary machine shops, office, resi Fess : 4 is % dence and furnace buildings, etc. € ; Conditions to Be Met Fe see. Sean SARS eR Mea Ress seetwerene 67.5 i , : Gs va epase aaah anes r To build an electric furnace for making pig iron which ~* --***:: coe evevecesccccsssereesorees v.02 1, can be operated as a technical success is quite an achieve In 1906 these properties were brought to the attent 4 ment, but this having been accomplished, there still r of H. H. Noble, president of the Northern California 4 mains the very considerable problem of making it an eco- Power Company, who, after some correspondence with Dr 4, nomic success. With approximately the same COCs FOF Paul L. T. Héroult, built in 1907, a 1500-kw furnace oe power, charcoal, and stock, local conditions caused the the three-phase resistance type. Pig iron was produced in t abandonment of the type of furnace which in Sweden 1s this furnace, but mechanically it was weak. > yperating commercially. a In May, 1908, there was designed by E. E. Cox and +! The principal users of pig iron on the Pacific Slop others under the management of D. A. Lyon, a furnac: and Far Western states are custom foundries. Specialty f , the shaft type embodying the principle of a shaft ter "hh foundries, such as those making stoves, bath tubs, pipe, minating at its base in abosh which was super-imposed o1 ? etc., are still relatively few, as are also open-hearth steel wn arche ucible through which the electrodes pen: ¥ furnaces: so that to operate electric furnaces successfully rated at an angle. This furnace, which was put in opera i mn the Pacific Coast, grades of iron must be produced in tl mer of 1909, by a singular coincidence - which meet the demands of general foundry purposes Wn identical with the furnace built at Trollhitter ; There is on the coast an abundance of scrap cast iron S en, about the same time. From the style of its 4 and foundries making what are spoken of in the East struction. it “iA wot be sy - be respond outa : heavy castings are few in number; het the popular de changes in the burden, and in order to make consistent! : mand is for a soft high-silicon tron which is a good scrap high-grade foundry iron this is an essential. In a blast 4: carrier and can be easily machined when in light castings furnace ¢ wrest an excess of cole tx the eee be ; Thus the problem became one not merely of making taken care of by increasing the quantity of air blown in 7 pig iron successfully but of making iron with a silicon put in an electric furnace this is not feasible, as the ox) i content of from 2 to 3 per cent. economically. When a gen would attack the electrodes. The excess of carbon i, blast furnace works “off,” it ordinarily means only a slight must be taken care of by an excess of oxygen put into the k concession in price to get rid of the low-grade iron, while furnace through increasing the ore in the burden. This ; at Heroult if iron runs under 1 per cent. silicon it means must be done, it is pointed out, by gradual additions and f a large concession in price to dispose of it. As electric to get the desired result sometimes takes several days ; furnaces, ke blast furnaces, misbehave at times it was Thus while the shaft type of furnace promises economic success operated on low-silicon, low-carbon white iron, known in Sweden by a term equivalent to “pig steel,” it had to be abandoned for the making of foundry iron. Following this, an attempt was made under the direc- tion of S. T. Wellman to work out the theory of reducing the ore with the proper charcoal and flux to sponge iron in a series of small, portable electric furnaces which were then picked up one at a time by a mechanical charging machine like those used in charging open-hearth steel furnaces and their contents emptied into an electric smelt- ; ing furnace similar in design to the arc-type of tilting steel i furnaces. Mechanical difficulties and inability to control oe the metallurgy of the process caused it to be abandoned +, after a very brief period of operation. 7% The Present Furnaces | + R. E, Frickey and others, after considering the causes aw ti , ai of f ailure of the previous furnaces, designed a 2000-kw three-phase furnace of the long and narrow type, having four electrodes delta-connected and suspended between five charging stacks. This is the type of furnace now Fig. 1—Electric Furnace No. 6 for Reducing Iron Ore at Heroult, — ee re wae 0 - operanom in No Cal. Showing Pig Bed vember, 1911, and has been working since, except fot 124 vhen operations were suspended to effect advan- hanical and electrical changes. All was not ing, of course, but the furnace promised eco- ess and a companion furnace of 3000-kw is built ve of furnace consists of a rectangular steel long and ro ft. wide, lined with standard fur- lhe lower part of the furnace is battered four re rresponds to the blast furnace crucible, whilk 5 part of the furnace corresponds to the bosh or aS ne of the blast furnace. The furnace is sur PE ve charging stacks, 18 ft. high, which are is to prevent the descending burden from Between the stacks the top of the furnace is 4 ver and through the center of these arches the netrate vertically into the charge. The elec- : are of Acheson graphite, 12 in. in diameter, % nnected with a tapered male and female joint ne rrangements have been made on these furnaces to at , a furnace gases,-:as the way in which to utilize be had to be studied rather as an economic than a es rgical problem; that is, whether the saving in char- fe ffected by circulating the gases back through the ‘ taking advantage of the reducing action of . ) is greater than the saving in fuel by burning them Ins, charcoal retorts, or elsewhere [he com- ~ ood ' A ns have ed it to adopt the latter jurse, Electrical Arrangements fe ae yphed by the Northern California Power hree-phase at 60,000 volts into the work’s sub- Ki Here are six Westinghouse 1500-kw oil-immersed oled lowering transformers wound for a ratio of 38,100 to 2200 volts, Y-connected on the tension side. The high-tension leads pass through a ral Electric oil switch by which the furnace load is r out e three 750-kilovolt-ampere furnace service trans- ers, set close up to the rear side of the furnace, fur three-phase currents at from 40 to 80 volts. They are illy designed General Electric transformers, oil- 4 mmersed and water-cooled and capable of standing an load of 25 per cent. On the 2200-volt primary side are ught out eight current taps for voltage regulation se are taken to an oil-immersed individual solenoid- ted yntactor panel which is connected with the Sis t ird to give fifteeff steps for voltage regulation a he connections from each of the transformers to the des on the low-tension side consists of eight pieces in. by 8-in. copper bus-bar connected in delta from ee transformers to the four electrodes. electrode holders are water-cooled cylindrical ng boxes made of 98 per cent. copper. The electrodes suspended in these from above and the annular space en the electrode and the holder is packed with a ally prepared graphite capable of being compressed i density equal to that of the electrode itself. This king material offers no more resistance to the passage current than the electrode and because of its unc- is nature permits the electrode to be raised and lowered hcut breaking electrical contact. Fig. 2-—Furnaces Nos. 6 and 7 7, 1913 THE IRON AGE 12 st Electric control is through a switchboard on wl mounted, in rows of three, a separate set of m« ir each phase \ set consists of a Thomps: nm ammeter, a (hompson voltmeter, aT) pson watt Weston power-factor meter. Beneath the last name: three hand wheels t ntrol the voltag« below these are three knife switches to control tl n the board. A s« ite recording w eter for ¢ s also set on this board For operating the voltage contr reaker, there is a 71%4-kw motor-generator set sing 1 \ i 1 ) { ; : BoA ti, - | > 7 | ™ \ Y X ) Cap < 25 it d e! genera I t nnectec i ) nd I m T ‘ ‘ I jane mounted a circuit-breaker, an ammete tmeter, and necessary switches From an electrical standpoint, t type ft turna as worked far more smoothly than any with which the is familiar. When everything is normal inside of the fut nace the instruments will sl little variation throughout the 24 hours, except that the power-factors which averag respectively 90, 85 and 70 per cent., improve a few points after the furnace is tapped and gradually fall off again as the molten iron accu lates in the bottom of the cr ible. Operation Che stock is charged into the e charging sta the basis of 500-lb. units of iron ore. This small charging unit, while it entails extra labor on the feed floor, has th« advantage of mixing the ore, charcoal and flux as int mately as if the charge were bedded, and homogeneity of charge is very essential There has been some experiment with the possibility of utilizing coke or gas carbon instead of charcoal. But the 72-hour metallurgical coke tried offers two objecti First, its electrical conductivity is so good that much of the current passes between the electrodes in the upper part of the furnace. The smelting zone is thereby raised and the furnace runs hot on top with attendant melting of th arches and cold at the bottom. Second [his coke, be cause of its density and high crushing strain does not break down like chartoal as the burden descends; hence less surfaces of carbon are exposed to be oxidized by th: ore and there is a less intimate mixture of the two. Re duction of the ore takes place more slowly, the silicon in the iron is lowered, the power consumption per ton in creases, and thus the efficiency of the furnace is reduced However, with certain precautions in crushing the stock and feeding it, a mixture of 60 per cent. coke and 40 per cent. charcoal has given a fair degree of furnace efficiency and the grade of the iron was kept up to No. 2 foundry At present successful operation of electric iron fur naces depends among other things on an abundant and fairly cheap supply of charcoal This generally limits their field of activity to well-timbered regions which are usually isolated and where freight rates are high The author believes many coals which make a very poor metal lurgical coke for blast furnace use on account of their low crushing strain, might make a satisfactory fuel for electric furnace use. The fact that the ore is of so high a grade renders the metallurgical problem somewhat different from that usu ally encountered. The ore as it comes from the quarry will often run for weeks at a time as low as 2% per cent. SiO., and from 67 to 68 per cent Fe; so that to make pig - er G. e > iF a ‘= 3 “4 4 * a te oH aw > ~* et at SAE ln AE amas 598 ae ~ eS ee 120 THE IRON AGE iron which will run from 2 to 3 per cent, Si, it is necessary to augment the silica in the ore by the’addition of barren quartz. The requisite amount of lime or limestone is added so as to give theoretically a slag running about 47 per cent. SiO., In calculating the charcoal for the burden it is assumed that all the carbon burns to CO, as it is necessary any way to carry an excess of charcoal in order to make high sili con iron, Thus to make 2.75 silicon iron the theoretical quantity of charcoal (containing 85 per cent. fixed car- bon) necessary is 35 per cent. of the pig, whereas ther: is actually used about 4o per cent. Inasmuch as any necessary change in the burden is distributed over five stacks the furnace responds very rapidly and practically permits control of the silicon in the iron within a limit of 0.5 per cent. The iron is tapped three times a day into sand pig-beds. \ sample is taken from each bed from a pig to inches long cast for the purpose. The drillings from the several beds are ground together for analysis. The sow and pigs are lifted ‘from the beds by a traveling crane with grab- hooks and broken by a drop used in connection with an electric magnet. The system of grading is somewhat like that used in grading Southern iron, except that it is entirely by silicon content as the sulphur and phosphorus run uniformly under 0.04 per cent. when operating on charcoal alone. The system adopted by the American Foundrymen’s Association for sampling carload lots is followed and the company sells if necessary on a guaranteed silicon content within 0.25 per cent, limits. Analyses of lots shipped to various foundries and sold on a guaranteed silicon content and a maximum of 0.04 per cent. sulphur and phosphorus were as follows: No. 1, No. 2, No. 3, per per per y cent. cent. ent Silicon ..... lad Nie ers aie a ai 2.88 2.42 1.78 Combined carbon ............ 6a 0.09 0.27 0.60 [Ee UOREMR 5c cok scied tags rahe tees 3.3 2.94 2.86 NE idee ear ncew Ces k-acd WER Wied a . 0.028 0.036 0.028 PIN iss o-5 acs cer nes Rens sahe 0.031 0.023 0.030 Pig iron No. I was made on a guaranteed silicon con- tent of 2.75 to 3.00 per cent.; No. 2 on a guaranteed sili con content of 2.25 to 2.50 per cent. and No. 3 was sold on a guarantee of from 1.75 to 2.00 per cent. silicon and 0.04 per cent. maximum phosphorus. Furnace Efficiency—The Author’s Conclusions The efficiency of this type of furnace increases in slightly more than direct ratio to the increase in load, and it is of interest to note that as in the case of the electric steel furnaces the faster the furnace is operated the cooler the walls and roof are, and the smoother it works general- ly. In explanation is the theory that the faster smelting takes place the faster the cool charge can descend to pro- tect the arches and walls. In technical efficiency, the long and narrow type of fur- nace is pronounced not the equal of the shaft type carry- ing the same load, though at Heroult power consumption has been as low as 2200 kw-hours per ton of pig when carrying a load of 3000 kw,. but the long and narrow type offers a possibility of building several furnace units on each other like copper blast furnaces. By this means the radiation losses and electrical losses will be cut down and the efficiency of what are in single-unit furnaces the end- electrodes will be greatly increased. A bank of three or four units arranged in this way will admit of as simple metallurgical control as a single- unit and will have an efficiency, the author believes, equal to a shaft t