The Iron Age 1913-12-18: Vol 92 Iss 25

a Established 1855 New York, December 18, 1913 Vol. 92: No. 25 Making Reinforced Concrete Specialties Special Machinery at the Youngstown Plant of the Trussed Concrete Steel Company and the Uses to Which It Is Put (he increased use of reinforced concrete in building struction has caused a rapid growth in the demand steel for reinforcing purposes during the past two three years. Makers of steel reinforcing products have kept pace with the demand, or rather have to a large extent created it by bringing out new products for use in reinforcing work. By designing various forms of el reinforcing for special purposes they have broad- ened the field for concrete construction as well as en- larged their own market. This has been done not only by bringing out reinforcing products to suit various needs, but also by creating a de- mand for these products through efficient engineer- ing organizations that give the benefit of their knowl- edge and experience along these special lines in the planning and construction building work. Improve- ents in reinforcing steel have made possible and have gone hand in hand th improvements in con- crete construction. Marked progress has recently been ide in building construc- ion and the demand for etter types of buildings, structures that are fire- roof, factories and other uildings that are well ven- tilated and sightly has elped to add to the popu- larity of concrete in build- ng construction. In this nnection is the demand r well-lighted factory 6000 tons of steel is consumed per month in the manu facture of steel reinforcing and sash. The plant qonsists ive main buildings, all of which are joined at the front a depth of &8o ft., making a continuous structure over 800 ft. wide across the factory front. The narrow space that separates the rear parts of the different units is shown in the general plan of the plant layout, Fig. 7, is taken up with switch tracks and loading platforms that provide convenient handling of material that comes in the plant and the finished products that are shipped out Railroad sidings run into the grounds and along the vari ous loading platforms from the Erie Railroad that passes directly in the rear of the site. The factory buildings are designed and arranged for the particular requirements of* the manu- facturing processes and for the convenient routing and shipment of products. As the bulk of the manufactur ing work is done on ma chinery of the heavy type, mostly presses, all of the shop buildings are one-story structures. The main factory build ing includes the reinforcing department, 138 x 285 ft the Hy-Rib building, 100 x 300 ft.; the crating building, 50 x 350 ft.; the Standard steel sash department, 160 x 420 ft., and the special sash and door department, 136 x 4so ft. Adjoining the rein- forcing department a yard ildings in which the Fig. 1—Press for Assembling Vertical Sections of United Steel Sash. Space, 400 X 85 ft., 1s occu maximum amount of out- It is Capable of Exerting a Pressure of 450 Tons and Weighs pied by the storage and rib ide light is admitted. The ll for shop buildings with continuous glass windows has cloped a heavy demand for steel sash, the making of ich is an industry closely allied to the manufacture of nforcing steel. The Plant The growth of the steel reinforcing industry is well istrated in the Youngstown, Ohio, plant of the Trussed nerete Steel Company. Five years ago this plant con- ed of two buildings, one 30 x 250 ft. and the other x 156 ft. During the past five years the plant has en enlarged to several times its former size and 18 acres the ground space of its original 25-acre site is now in tual use for manufacturing and shipping purposes, being ipied by factory buildings and yards. The extent of production of this plant is shown by the fact that 120,000 Lb. bar department. This is covered by two crane bays, each served by a 6-ton Mor gan electric traveling crane. One bay is used for receiv ing and the other for shipping various reinforcing steel products. Back of the reinforcing department and ad- joining the yard just mentioned are two parallel crane runways 300 ft. long. These runways extend through the greater part of the reinforcing department building and each bay is served by two 6-ton Morgan electric traveling cranes with a 65-ft. span. One of the crane runways in this yard is used for shipping and the other for receiving The yards are also served by two 15-ton locomotive cranes. The power plant is located in the rear of the factory buildings and in the front is the administration building containing the order department, drafting rooms and shop offices. 1377 oI exnraediy wees tts 378 THE IRON AGE December 18, 3 Fig. 2 The Hvy-Rib and Lat \utomatic Roll Feed Punching Presses The plant is an excellent exampl rn efficiency [he simplest form of steel reinforcement made in both in equipment and construction. In general constru plant is the rib reinforcing bar. This is a diamond-s| n the m is been provide buildings which the var, being a specially rolled section with a series of small ost advanced ideas in regard t reproofing and in pt cross ribs, these ribs being provided to give additior iding an abundance of light from outside are carried out dhesive qualities to the metal and to insure a positiv. lhe ildings are constructed with long span trusses so as’ grip in the concrete \s the steel comes from the bar y give le greatest conveni handling the mate- mills rolled with the ribs on, the only work required in 1. Practically the entire si alls are made of United onnection with this product in the plant is to cut it to sash with a small curtain wall underneath of Hy-Rib length and bend it. This work is done in the rib bar neret nstruction. The roofs are built of Hy-Ril epartment in the yard. The bars are cut to length on concrett Several the buildings ar rovided witl six motor-driven shears located between the crane run- monitors which are equipped with continuous United sas! vays and are bent cold to any desired shape on three The plant is devoted exclusively to the manufacturt electrically-driven specially designed bending machines, s of steel building products for reinforcing, fireproofing that no fabricating is required on the job. The same metal sash and other building specialties. The various machines are used for bending the Kahn bars referred products that have been brought out from time to time later. Rib bars are furnished in stock ranging fr indicate a rapid development of the steel building mate 4 to 1% in. rial industry. As different products have been added Another product that requires little manufacturing is manufacturing methods have been devised, which includ column hooping, a reinforcing for concrete columns. This is made from wire rods of any desired size which is re rolled to the required diameter on plain coiling machines ' \fter the wire is coiled to the desired diameter spacing the designing and erection of considerable special ma chinery to permit the turning out of the product in large volume and at a minimum cost Fig. 3—A Battery of Special Machines Each of Which Dries the Sheets Used in the Manufacture of Hy-Rib After Pickling and Then Beads and Slits Them ad ber 18, 1913 THE IRON AGE 1379 ee : Fig. 4—View in the Kahn Bar Department Showing a Row of 250-Ton Shearing Pr« placed lengthwise in the coils and each coil is_ five sizes and the diagonals ar it in a length from 6 in a notch in the bar so that the coils are kept to 36 in Che shearing is ne on powerful ible pit diameter and with uniform spacing This hoop man presses, of which there are seven, s vn in Fi 1, be instantly collapsed for shipping to secure each weighing 25 tons and ipabl f <erting a pres tness, and as quickly restored to its regular shape sure of 250 tons. The eared sectiot flanges are reaches the building for use ent in a diagonal position w the sa eration ginally the Kahn trussed ir was the principal is the shearing. Very large dies are re r this ict of the company. This is a patented reinforcement work, these dies weighing about 5000 | , se in concrete girders, beams, joists and floors, and = 3 te : ts of a horizontal bar with rigidity connected diag he Various Metal Sheet Products | shear members formed from the same section of \nother reinforcing product 1s ribbe ta 1s : The cross-section of one of the special sections 1 type of expanded metal nsisting of e1 yf straight square steel bar with two horizontal flanges or ribs or un tension me¢ ers rigidly ected by light projecting at opposite sides. In the case of a ross ties formed from the ume sheet of steel he ir the wings make a bar with a width of 1% in., ross ties are accurately spaced and-t ughly anchor 5 flanges. Bar sections in other shapes but hav the main ribs in the « ret Chis metal ide from a i milar flanges are also used in making the trussed special rolled sheet steel section that t] eneral \fter these bars are cut to the required length the appearance of the face of ul tion is . es are sheared at intervals and the sheared portions in. wide with a 3/32-i1 eb and 9 g in gh nt up diagonally from the main bar, to which they In making this product the section is pla on punching ridly connected, thus making a unit of the main presses of 300-ton capacity and slots of the required : P, nd its shear members. These bars are made in shape and length are punched in the thin portion of t ee a os EB 4 df eS iP =f a ye Fit 7 i == " —— — 7 cs — YF ee ee ee ee i sled. ~ Ll eo aT maa: = ££ — an’ a ee oe ip Cet tinal fo \ ew in the Floredome and Floretyle Departments Showing the Presses and the Shearing and .Corrugating Machine Used in Making These Products Fig. 6—Twelve of the 24 Cut-Off section between the ribs, leaving narrow strips of the web metal adhering to the ribs at the ends of the narrow strips. The complete punched section, which is in lengths of 18 ft., in Fig. 9, is then placed in an expanding machine shown and is expanded to the proper width. This is done by drawing the ribs apart after the outer edges of the section are clamped by the machine. After being ex- panded the strips of webbed metal not removed by the punching press are at right angles to the ribs, forming the cross ties. The 6%-in. meshes in seven sizes, the stock is expanded to form width of the finished metal ranging from 16 to 64 in., this width depending on the size of the mesh. The metal forming the cross ties is punched to form a range of sizes, 2 to 8 in. in length and the these ties being from and the same distance apart, the section of the ribs to which they are ties connected forming small squares. The ribbed metal is curved on bending machines to meet the needs of users as well as being furnished in flat sheets. An important development of the company was the bringing out of Hy-Rib, a new type of reinforcement for concrete and plaster work. This is a steel sheathing and consists of a series of deep ribs connected by a special expanded fabric, all formed from the same steel. The object of the ribs is to give stiffness to the reinforce- sheet ment so as to do away with forms when used in floors, roofs and walls, and to take the place of metal studs in partitions, sidings and ceilings. The making this product is one of the many interesting ones in the plant. The sheets used in the manufacture of Hy-Rib are first pickled. From the pickling tank they pass through a special machine, Fig. 3, that includes a rubber wringér roll for drying, a beading roll and a slitting roll cutting the sheets lengthways in the center. Between the wringer rolls and the beading roll are rows of gas burners, the process ot flames from which dry the remaining moisture. Two wn *§ @ | RikBar Ss i § 1 Der; 1 GSS lelei (REE ~; Rimi | BEB KY 5 i p 2st = " ¥ ISiSih Sik eimai “i iBi 8! ie | 8:8 | 1 i ,e iF; 4} i | 14 | Kahr Bar , iit get] | OF a wing / Rib Metal Fig. 7—Diagram Showing the Arrangemént of the Different Buildings Presses Used in Cutting Sash Sections to Length press operations are required before the product is fin- ished. The first is on an automatic roll-feed punching Fig. 2, on which the necessary cuts are made for expansion. These cuts are made on an intricate die com- posed of 84 punches made of pieces 7/16 in. square that cut on three of their edges. These punches are set in three rows, 28 dies in a row. The first set slits the metal, the second set shears it, and the third set forms it. Tw sheets are punched in one operation and the material is fed through the press at the rate of about 15 ft. per mir When the steel this press it has cuts about 2 in. wide for expansion, between which are strips of uncut metal that form the ribs. The final opera- tion is on a forming press, which while forming the ribs also expands the metal to the required width. The ribs are 15/16 in. high and are usually spaced 4 in. on centers. [he metal is made with as many as seven ribs, in widths up to 24 in., in lengths up to 12 ft., and in stock of from No. 22 to 30 gauge. The material is furnished in bot! flat and curved sheets, special bending machines being provided for curving. After the forming operation the product is dip painted in a tank of asphaltum. The sheets are lowered into and raised from the paint tank with air hoists. Another product is rib lath with beaded ribs b the expanded metal. The manufacturing processes for this are similar to those used in making Hy-Rib. Among the more recent products of the company art steel Floredomes and steel Floretyle, these being deeply corrugated domes and tile, open on the under side for us in floor construction in place of terra cotta tile, being designed particularly to save concrete and to largel) reduce the weight of the floor. Floretyle is made wit! open ends, which lap with a tight joint. The stock used is No, 26 gauge sheet steel. The material is first cut to required sizes and then run through a plain corrugating machine. The next operation is serrating the bottom edges so that they will straddle the ribs of the Hy-R' reinforcement used beneath and engage in the mesh. Th: final operation is pressing the sheets on powerful forn ing presses. While being formed the metal is furthe: stiffened by deep corrugations being made across the to; Fig. 5 is a view of the department in which these products are made. Floretyle is 20 in. wide at the base and is mad: in depths of 6 to 12 in, Its standard lengths are 3 and 4 '' Floretyle is used with one-way reinforcement and Flor: dome with two-way reinforcement. The operations making both of these products are practically similar. The Manufacture of Steel Sash The most recent development in the growth of th: plant is the manufacture of United steel sash for use windows, monitors, partitions, etc. The sash is made a specially rolled deep steel section with a flange on on side against which the glass is set. Improved methods ©' assembling have been adopted to insure strength and eff ciency. Practically the entire sash is machine built. T! first operation is cutting the sash section to leng' Twenty-four presses are used for this cutting operatic! press, comes trom rows ot tween iber 18, 1913 and il of which are shown in Fig. 6. The length to the section is cut is the perimeter of the pane of After being cut to length four V-shaped notches ut on the flange of each section with notching presses notches permit the bending of the section to its re d rectangular shape, which is done on a hand bend machine. Thus the bearing section for the glass, red at its corners, extends continuously around each These sections or members are then joined together ndicularly by being placed side by side lengthwise by being united by wiring or bending with presses to langes of small I-beam sections that are placed be- the members. When a sufficient number of mem- ers have been joined together to form the length of the sh, several of the vertical members thus formed are ed side by side to form the width of the sash, and hese are joined by heavier I-beam sections placed between m, that are cut the length of the sash. The assem- ling is done by wiring or bending the flanges of the ms over the adjoining vertical sections, the operation ng done one horizontal section at a time on powerful weighing 120,000 lb. and exerting a pressure of ns, these presses operating a number of multiple This operation is clearly shown in Fig. 1. The press The Detroit Foundrymen’s Association t the regular monthly meeting of the Detroit Fou en’s Association, Detroit, Mich., held December 11, Moyer, of the Quigley Furnace & Foundry Com- presented a paper on the subject of core ovens. To even heat distribution in a core oven, he said, careful m should be given to the location of the enter regardless of the kind of fuel used, and also utlet flues. He spoke of the relative advantages sadvantages of different types of fuel and favored the fuel. because of its freedom from objections re common to other kinds of fuel He called spe ittention to the necessity of insulating core-oven doors r. Moyer showed about 60 lantern slides illustrating tions of core ovens, which have been installed us parts of the country in the last few years included car ovens, drawer ovens and reel ovens showed illustrations of various types of annealing and discussed the relative advantages of the bridge pe as compared with the down-draft oil-fired type were shown giving the results of tests made on aling ovens in which the temperature at six points he furnace had been held within an average of 12 t leg. of the desired temperature. 1¢ paper was followed by an interesting discussion, he course of which Mr. Moyer answered a number uestions as to the best type of furnace or oven for tain classes of work. The subject of powdered fuel came up and Mr. Moyer stated that on account of expense in installing the plant it would not pay t powdered fuel unless at least 15 tons per day is burned. However, he said that in large plants ing several times this amount in melting or heat \f ry THE IRON AGE 13st One of the Rib Metal Expanding Machines. In the Foreground Is the Punched Stock Ready to Be Expanded, Cut to Lengt Shipped operations are completed by joining the channel sections to the sash at the top and bottom. The joints are tl finished and made tight-fitting with pneumatic hammers \ special power saw is used ft iwing places on tl sash for fastening hinges When finished the sash dip painted, being handled for painting with an air hoist The method of construction and assembling is claimed to afford the greatest possible rigidity a1 treng ind to assure members that are symmetrical Che ish de partment is divided into three separate units, the machin ery equipment of each of which is practically ntical The sash is made in standard units, which are n- nected by mullions to fit openings of any desired siz | types are made, including pivoted sidewall sas! sliding sash, center pivoted and top hung continuous sas! and also steel and glass partition and steel doors, the line covering, it is claimed, all the requirements of lighting and ventilating. The general executive and sak I n pany are located in Detroit, Micl Phe rpt ng and finishing products are manufactured i rate plant in Detroit, and tile plants and ware | ted it arious cities. The steel manufacturit lant was located n Y¥ stown to have vent el l ng furnaces savings uld fre t which were surprising, and that in many cases the entir¢ installation was paid r in tl H alled attention to the fact that pow lered coal ' table for core-oven fuel unless it 1 ng the plant for other purposes. The ri n for tl ict that no linary ré | xpense of maintaining t ! ssary dry indling plant. New Hand Traveling Crane with Cast Steel Ends For use in places where the headroom is limited, Brown Hoisting Machinery Company, Cleveland, Oh has built a mew crane which is designated as the sing] rhe One-Piece Steel Casting Truck Frame of a Recently Developed Hand Traveling Crane Which Supports the I Beam on Two Planed Surfaces I-beam hand traveling type. As its name indicates, the crane consists of a single I-beam of the standard size for the required load and span supported at each end by a truck frame which is a steel casting of special design, the lower flange of the I-beam serving as a track for tl trolley and the load. As will be noticed from the engraving the truck frame 1382 is a single-piece steel casting of light construction, whicli is designed to distribute the load equally to the two truck wheels. There are two planed surfaces at the center of the truck frame upon which the beam rests. Bolts are em- ployed at the truck frame to hold the I-beam in place and an additional fastening is provided by a dowel on the truck frame which fits into a small recess on the underside of the bottom flange. Emphasis is laid upon the fact that this simple type of construction enables the crane to be erected Ft easily and quickly, though the somewhat limited. The truck frame is supported on two truck wheels hav ing bearings on each side, U-bolts being supplied to fasten the bearings together with the axle and the wheel to th« truck frame. For cranes having capacities of from 4% to I ton inclusive, brenze bushings are used, while in the larger sizes steel roller bearings are employed. voir in the bearing is relied upon to give ample at all times. The use of a bearing on each side of the wheel, it is pointed out, tion irrespective of the side pressure even space available I» The reset lubrication keeps a wheel in a vertical posi- f the flange and also thus frictional resistance when the crane is trav under ft., have no permits small diameter axles to be used, reducing the ling. Cranes I-ton capacity, where the spans do not exceed 20 mechanism, being propelled along or pulling on the load. The larger a hand traveling chain and k traveling the track by pushing cranes have wheel, and the capacity sprocket largest sizes have traveling reducing geat which are relied upon to reduce the amount of. pull re 1 quired on the chain to move the crane A Large Blowing Engine Cylinder Weld An Interesting Use of the Oxy-Acetylene Process for a Vertical Repair The..welding of a large blast furnace blowing engine cylinder by the oxy-acetylene process was recently done by the Ohio Welding & Mfg, Company, 828 West Sixth street, Cincinnati, Ohi The casting welded was the 82-in. steam cylinder on a: vertical blowing engine at tl Aetna furnace f the Marting Iron & Steel Company . Ironton, Ohio. The cylinder was cracked in both the front and back walls from one valve cage to the other Each crack extended horizontally across the vertical wall of the cylinder about 6% ft. in metal approximately 2 in thick. The work was characterized by special feature such as the size of the cylinder, the length of real the thickness of the walls welded, and the wor } I vertical instead of horizontal walls \ feature that re quired particular attention was the taking care of th expansion and contraction. The total weight of the cylin der itself and the blowing tub and connections al was approximately 170 tons The cracks in the cylinder were caused by the loosen 84 In. in Diamete View of a Vertical Blowing Engine Before a Crack Extending from One Valve Cage to the Othe was Repaired by the Oxy-Acetylene P Cylinder, rocess THE IRON December 18 AGE ing of a part of the crosshead, thus permitting th: to drop far enough to hit the lower cylinder hea the result that it’ was shattered and the cracks The cost of replacing this cylinder was estimated ai and would have taken several months’ time, as th: no overhead crane in the building. In fact, there y room for one The usual practice of welding a broken castin lay the casting flat or in such a position that the be welded lie in’a horizontal plane. The crack hipped out and the casting is usually heated, when the metal is fused it will run to the bottom first. As more metal is added the surface 1 that of the surrounding casting. In the case of in a vertical wall this cannot be done, as the cast when it reaches the melting point will have a ter to run away from the weld. Apart from the fact that the parts to be welded wer on a vertical plane, another difficulty which entere: the welding of the cylinder was that of meeting tl pansion and contraction problems. The cylinder crosshead guides, crosshead rods, etc., extending uy from its top, and above this was a blowing tub with mechanism, etc. To weld the cylinder it was nec to loosen the foundation bolts, so that the casting not crack by the expansion of the cylinder. Th: required for the preparation and welding was about days and approximately five was required for the welding operation. The crack was chipped entirely th: from the upper side with an ordinary chipping han A steel platform first erected to approxit the same hight as the lower edge of the cylinder and a staggered firebrick wall was built around the outsid leaving from 6 to 8 in. of in which the charcoal used for heating the casting was placed. After the fire was once lighted it was kept burning steadily until the job was finished. The cylinder was heated from both the outside and inside and was kept at a dull red heat. As this necessitated the welders working against a red-hot wall of cast iron 2 in. thick, special care was taken to protect them from the intense heat. Two welders were at work simultaneously and the work was continued both night and day. It is stated that a perfect weld was ob tained and there were no cracks either in the weld or in any other part of the cylinder. The lower portion the cylinder below the weld was drawn out of shape little, which it is stated was probably caused by applyir i little more heat than was necessary to avoid the danger yf cracking. The cylinder was, however, machined now in operation In addition to the welding of this cylinder, the Ohi Welding & Mfg. Company has performed a number other difficult One of these was the welding of tw large mortise gears of approximately 12 ft. in diamete! in place at the plant of the Fulton Light, Heat & Powe: Fulton, N. Y. These gears were the drivin ones at the upper end of the driving shafts on some lars waterwheels. In order that the wheel should not pour it was necessary that the space between the wooden teeth where the break occurred, be accurately maintained. Other -— rack was space onl TODS Company, work performed includes the welding of cracked Corliss engine shafts as large as 18 in. in diameter, rolling mil engine beds, large cracked flywheels and steam pum cylinders. Silicon Carbide Furnace Linings.—A distinguis! property of silicon carbide is its infusible and refra nature, but it has the disadvantage of a heat conduct five times that of firebrick. Frank J. Tone, of the C orundum Company, Niagara Falls, N. Y., in a patent (1,078,525) combines this advantage and disadvantage has devised a lining in which the working portion exp to a high temperature and requiring stability and stren is formed of silicon carbide of high refractibility and low thermal resistance. He backs this up with silicon cat which, though lacking in strength and refractibility, a high thermal resistance. The first portion consists bricks made of dense silicon carbide while for the sec portion he uses bricks made of a porous silicon carbic both obtained by special processes. This composite silicon carbide lining may be backed up by the ordinary ste¢ furnace shell. er 18, 1913 -w Variable-Volume Air Compressor nteresting installation of a new type air com- uilt by the Bury Compressor Company, Erie, Pa., ntly made at the Erie works of the General Company. This is a three-cylinder variable- mpound electrically-driven machine with the rectly connected to the compressor. Previous to lation of this machine there was in use at the a Bury duplex compound variable-volume com The three-cylinder machine was selected for the il installation as it was considered an improvement duplex type. The machine is claimed to be more | for the reason that it is more elastic because j + ided by the quarter instead of by the half as in x compound type. By unloading by the quarter er input is cut down and the machine automatically s almost immediately to the increased or the de- demand for air at the close range of 1-lb. drop sure and it also automatically takes care of the variation in the call for air at any intermediate THE IRON AGE L383 he high-pressure cylinder, automatically keep the load of the machine balanced on both sides. When the low pressure cylinders are unloaded by the quarter the air ot the intake is discharged to the atmosphere and the power input is reduced directly in proportion to the unloading ; } of the machine by the quarter or in accordance with the actual amount of air compressed. The mechanically oper ated inlet alves are design uir into the cylinder without trictior ; nd als so that the weight of the valve and the pressure bac »f it when closed keep the valve tightly seated to pre vent any possible air loss. The patented cushion poy lischarge valves are made of drop forgings, are selt iligning, easily removed and replaced and are claimed to be noiseless and practically indestructibl These seat mn their own guides The Bury automatic pneumatic force-f system, with which the machine is equipped, serves th main bearings and other working parts. The oil is filtered and cooled by passing through water and strained so that only pure. cool oil is used for lubrication The oil rhree-Cylinder Variable-Volume Air Compressor The Valve Gear and the It can be arranged, therefore, so that the power the compressor can be automatically kept constant eriod of time to supply a given number of cubic air required. This, it is claimed, results in a large vhere current is paid for according to the daily ge peak load. Other advantages claimed for the ressor are that there is no wire drawing or choking any part of the load, no overheating of the com air delivered, no vacuum in the air cylinders or ler at any part of the operation, the air delivery s high and the power cost per cubic foot of air is low. Bury proportional unloading system used permits hine to be unloaded at no load, one-quarter, one- ree-quarter and full load by the close variation drop in pressure by the quarter. The three-cylinder volume compound machine illustrated has two ssure cylinders on one side and one high-pressure on the other side. The low-pressure cylinders in diameter and the high-pressure cylinder is 1¢ liameter. The stroke is 20 in. The machine has lisplacement of 2000 cu. ft. per min. The air is ssed to 100 Ib. per sq. in. The machine is driven hp. General Electric synchronous motor riable-volume unloading valve is provided on each each of the two low-pressure cylinders and these iutomatically in connection and in unison with lar valves, one on each end of the high-pressure These valves are regulated by four independent regulators attached to and operating the four ng valves on the two low-pressure cylinders. These rs are governed by the air pressure from the re- so as to unload the four variable-volume unloading at 1-lb. drop in pressure by the quarter. The four s, being operated in unison with the two valves on Photograph was Taken from the High-Pre re ‘ ! S ow-Pressure Cylinders used over and over again with very little los Che lubricating system can be used either as a foree-feed sys tem or a gravity feed system rhe oil flows to a well attached to the bed of the machine in which is located a pneumatic plunger pump operated from the compressor After being purified, filtered and cooled the oil is forced a glass reservoir above the machine and from there it is forced by pressure or descend by gravity to the bear ngs. The machine is built both with the motor mounted lirectly on the shaft and with a flywheel for belt driv from a motor. It is equipped either with a synchronous motor or with an induction motor when mounted on the shaft, and it is adapted to any irrent available Th frame is of the heavy rolling mill inclosed type. Th mach neé des gri¢ 1 fe f tl ha est I na nftinuow servi é An ins tion of the large plant n t nts which build steel passenger cars is being made by Antoin I Thieux, chief engineer of the International Sleeping Ca Company, which operates cars i1 ral European ! tries. He has in view the introduction of similar car Europe, stating that the number of deaths du urning of cars in railroad accidents has caused the dir tors of the companies seri yusly to cor ler a change chief handicap is stated to be the weight limitations in Europe, the heaviest sleeping cars there never exceeding 62 tons, whereas all-steel American car th 80 ton The Railway Commission of Wisconsin has ordered the Chicago & Northwestern to reduce its rate on scraj from Sheboygan, Wis., to Milwaukee, Wis., from 5 ner too Ib to 4c a ft Pets Cutting Power of Lathe Turning Tools’ Some Interesting English Experiments + et ‘id Ve i BY WILLIAM RIPPER The question of the definite measure of the output of work, or of the removal of material, of which lathe tools y little infor- mation readily available, and it was for the purpose of de- termining the behavior of cutting tools over a fairly wide series of working conditions, and of deducing therefrom some practical results, that the following experiments hav: been undertaken. are capable, is one about which there is very The object of the tests includes the determination of the st i Letter of Breaking ( t identi- load intons Percentage of ) I fication Material per sq. in elongation per sq ( ote Ww Mild steel...... 24.8 28.8 74.8 xX Medium steel... 33.5 21.7 90.0 Y Hard steel..... 39.5 23.3 106.8 Z Very hard steel. 51.2 1.3 128.0 High-Speed Ste A Mild steel..... 27.2 8.4 81.2 B Medium sstee! 33.5 21.7 on 0 ( Hard steel 50.5 0 126.4 way in which the output, of both high-speed and ordinary carbon steel tools, is affected by such elements as the speed of cutting, the depth of the cut, the -feed of the tool per revolution of the work, the shape of the nose of the tool, and the physical properties of the metal upon which the cutting tool is acting. In particular, the question of the association of a high speed and a light cut versus the asso- Microsce pe ELEVATION SECTION OM DE Tr . 7paaet A B=CUTTING EDGE SECTION ONA.C. Fig. 1 Fig Fig. 1—Elevation, Sections and Plan ¢ of Carbon Steel Tools. ciation of a low speed and a heavy cut received considera tion with a view to finding the relation of these two factors to maximum output. Further points were to determine whether the above relationships are, on the whole, as regular and uniform as they may reasonably be expected to be when the conditions of the tests are approximately uniform; or whether they are irregular and erratic, as they have sometimes been re ported to be; also whether the usual workshop notions as to the durability of tools at varying cutting speeds are firmed by careful experiment. con *From a paper read before the Institution of Mechanical Engi- neers at Manchester, November 20, 1913 +University of Sheffield. The tests described in the paper were made in the machine-tool laboratory of this institution. AND G. W. VERTICAL SECTION ON X Y 1384 with Carbon and High-Speed Steels on Bars of Different Degrees of Hardness BURLEY? Two classes of tools were tested, ordinary carbo: tools and high-speed steel tools. By the former is tools made of ordinary tool steel, as distinguished those made of self-hardening steels and high-speed Tool [he ordinary carbon-steel tools tested were made x % in. bars, 6 in. long, and the tools were ten in : ber. The shape of the tool nose adopted as the stan Carbon-Steel Tests sitioy Test Bars Sil 1 Manganese, Sulphur, Phos; per cent per cent. per cent. | 1 Tool Tes ).23 0.027 0.45 0.025 { 9 0.075 0.50 0.030 54 0.053 0.60 0.032 ).82 0.030 0.36 0.032 Tool Tests 0.29 0.100 0.42 0.037 ( 0.39 0.075 0.50 0.030 60 0.249 0.83 0.053 shape for the first set of tests was that indicated in Fi in which an elevation, sections and plan of the nose ar shown. The test bars on which the carbon tools were t were steel bars of various chemical compositions and physical properties, as given in the accompanying table, four different classes being worked upon, marked W, X, Y and Z, and varying in composition from 0.23 per cent of carbon to 082 per cent. of carbon. The bars about 30 in. long and 6 in. in diameter when finished. The tests were made in a 6-ft. x 6-in. lathe fitted with that fine adjustments of cutting through a fairly wide range, t! 300 ft. per min. on a diameter } were variable-speed gear, so speed could be obtained range being from I0 to 6 in W=Dumension Measured \ | wo i j j B Fig. 3 ste Fig. 2—Diagram Showing the Method of Measuring Tool wit 1 Comparatively Long Cutting Edge [he method adopted in testing these tools involved t! microscopic examination of the cutting edge, this being found to be the only possible method of establishing standard of measure of the working life of the tool. | tool was allowed to cut for a certain number of minutes. at a selected speed with a selected depth of cut and ieee of tool per revolution of test bar, at the end of which time the tool was removed from the tool holder and t placed under the microscope for the purpose of examinin g the cutting edge to see to what extent the edge had bee? blunted. A micrometer screen in the eye piece of the microscope enabled the amount of the blunting t b measured. The dimension which was measured in eac! case is indicated in Fig. 2. The degree of blunting ws not in any case of a uniform width along the nose of the iber 18, 1913 it the width actually measured, W, was the great- that could be found under the microscope in se. To determine the limiting duration of the test unit bluntness three and sometimes four tests were made on each tool, and area of cut, the tool after each test, and then in exactly the same condition and position in was when removed from the lathe. Thus, the W corresponding to three or four durations tained, and the duration of the test which corre- | to what was adopted as the “unit” or “standard was found. The “unit” or “standard wear” adopted was 0.005 in., as this was found to be about the amount of blunting which is usually allowed on edge of a carbon cutting tool in practice before resharpened. In the plan, Fig. 2, the squares are the micrometer screen to the standard width, and shown equal to 1.9 units or 0.0095 in. uce roscopic examinations constant cutting speed easured for bluntness Hing Tit durations for standard or unit bluntness at the cutting speeds were red, and these were util- to form speed-duration s such as are shown in sto 8. These four figures in representative curves for of the four test bars. curves, owing to their ney to become horizontal, to indicate that there is a ting speed for each area of 1 each test bar, beyond the tool would last more THE IRON AGE 1385 amount of wear is reduced. The relationship between the increase of speed and the reduction of time is not simple one. The duration of cutting is approximately in- versely proportional to the fifth power of the cutting speed. a very To systematize matters it was decided to make a standard test, which should produce a condition of unit bluntness of the cutting edge of the tool after a 60-min. run. This bluntness could be obtained in various ways by a series of combinations of speeds and areas of cut. These results were then combined into one curve, as shown in Fig. 9, the upper curve representing such a series for the mild-steel test bar W, and the lower curves representing respectively the other bars of gradually increasing hard- ness X, Y, Z. With each given area of cut there is a certain speed which will produce standard bluntness in 60 min., this speed having been termed the i ~utting speed for the given area of cut. In this h rt I und it Nas n been f necessary or possible t “associated” series yf depth of cut and feed, which make up the area of cut, because ’ with Cat n t separate the two factors ols in practice the cuts are comparatively light, and the of duced by changing the ratio of differences result { ro- these factors are so small as to be almost negligible. The rela- tion between the area of cut and the associated cutting speed is found to obey approximately the law that the product of the area of the cut and the square of the cutting speed in feet per minute equals a constant the value f ss indefinitely under the which depends upon the compo conditions, but if this sition of the bar. is exceeded by from 15 fo From the curves, Fig. 9, the per cent., the conditions are speed associated with each area h that the tool will fail some- Fic. 4 of cut was measured, and with $0 50> t T a or —— 4 Ny —_ = y Boo - | 5 s $ Sern ~ ; | a \ 30 +—4+—_+-__} : a” : 1 jj} + ¥ ~ :? 20 © 20 — ee \ 3 te | j } St % ae > “Yo @ 7 » Ben oe . 0 teendreams wo 0 w #0 60 80 400 «1200 «0 0 O0025 6.005 0.0075 0-010 Duration tn Minutes Duration in Minates. Arew of Cut uv Sq tne éo } | | : , | 3 | ‘ 5 Rs x s Cubic Inches per Hoar oS 7 ” @ a a | 20 40 60 & 0 10 440 af 0 co we Duration tn. Minutes. Duration in Mirartes. i 20 : Speed . Feet per Minute Fig. 5 Fig. 7 Fig. Fig. 6 Fig. 8 Fig g. 4—Relation of Output to Cutting Speed, Feed and Depth of Cut for a High-Speed Tool Taking a Cut on a Mild Steel Ba Fig Curves Showing the Relation between Cutting Speed and Duration to Produce Standard Bluntness of a Carbon Steel Tool when ng Bars of Mild, Medium, Hard and Very Hard Steels. The Feed in Each Case was Constant, 1/24 In., and Four Cuts 0.02, 0.0 1 0.12 In. Deep Respectively were Taken on Each Bar. Fig. 9—-The Relation of Cutting Speed to Area of Cut to Produce Standard of a Carbon Steel Tool in 60 Minutes when Cutting Steel Bars of Varying Degrees of Hardness. Fig Effect on the Ou n Steel Tools of an Increased Cutting Speed with an Accompanying Reduced Area of | rapidly, and its life would then be shortened. these factors the number of cubic inches of material re- omparison between the four test bars in regard to the tion between the cutting speed and the cutting time with rea of cut of 0.040 x 1/24 in., and the tools run at a speed until they reach standard bluntness, showed for any given cutting time the harder the bar the r the cutting speed, the ratic of the cutting speeds for given life of the tool being approximately equal to the ratio of the carbon content of the bar. For all rse bars, the high cutting speeds are associated with the rt times of cutting, so that if the cutting speed is in- ased the time of cutting required to produce the standard moved per hour was calculated, and the curves, Fig. 10, plotted. It will be seen from Fig. 10 that for any given cutting speed with its associated area of cut, to give the tool a life of 1 hr. the volume of metal removed is greatest with the softest bar and least with the hardest. It also shows that large output is by no means associated with high cut- ting speed, but that as the cutting speed is reduced, with, of course, a suitable increase in the area of cut, the output is increased; in other words, a heavy cut is better than a high cutting speed. Hence, as a general law, it may be 1386 THE IRON AGE stated that for maximum tool output the area of cut em- ployed is a maximum, and the associated cutting speed is correspondingly low. In other words, a low cutting speed and heavy cut combination is preferable to a high cutting speed and light cut combination from the point of view of output. To determine the relative hardness of the material turned many methods were tried, but it was ultimately found that the test of the tensile strength of the material was the most reliable and conveniently made test of relative hardness, the hardness being practically directly propor- tional to the tensile strength. The relation between tensile strength of material and cutting speed of tool follows a straight line law: (67—T) X 0.0185 A where S =the associated cutting speed in feet per minute. T =the tensile strength of the metal being machined in tons per square inch. {=the area of cut in square inches. To determine the effect of a change in the shape of the nose of the tool, and in the disposition of the cutting edge with respect to the axis of the test bar, tools having a Speed Feet per Muutte Oo O-0025 0-008 OOO? o-010 Area of Cut in, Sq.Ins. Fig. 11 Fig. 12 Fig. 11—Diagram Showing the Effect of the Shape of the Nose Upon the Length of the Cutting Edge of the Tool. _ Fig 12—Curves Showing the Effect of the Length of Cutting Edge on Cutting Speed shape of nose as represented in Fig. 3 were tested against tools of the shape of Fig. 1, as is shown in Fig. 11. The same conditions as to test were adopted in each case, and the tools were tested for wear of the cutting edge, with a standard tool life of 60 min. Under these conditions the relation between the cutting speed and the associated area of cut was determined. This relation is indicated graphically in Fig. 12, the curve D being obtained with the form of tool nose represented in Fig. 3, and the curve D, with the original, or standard, shape of nose, Fig. 1. It will be seen that for each area of cut the associated cutting speed is less for the standard shape of nose, which has a comparatively short cutting edge, a b, Fig. 11, than it is for the second shape of nose, which has a longer cutting edge, a c. These speeds have an average ratio of 1 to 1.40, which ratio is also approxi mately that of the length of the respective cutting edges of the tools in contact with the work. In other words, for a given depth of cut the associated cutting speeds of tools for a given amount of wear are directly proportional to the length of the cutting edge of the tool in contact with the work—that is, a proportionately greater output can be obtained with the tool having a longer cutting edge. In all other respects the angles of the tools were the same. High-Speed Steel Tool Tests The high-speed steel tools which were put under test were made from % x % in. bars, as in the case of the car- December 18, 4:2 bon steel tools, the tools being made about 8 in. in | he shape of nose adopted for the first set of tes that used for the corresponding ordinary carbon sté tests, and as illustrated in Fig. 1. The tools wer: of a high grade of high-speed steel, shaped entir grinding in a universal tool grinder—thus dispensing the necessity of forging—and then hardened accor: the directions of the maker. This size and shape « were adopted so that the tests would be comparab! these made on the carbon steel tools. \ further series of tests have since been made to mine the relative effects of area of tool steel sectior the possible output, as measured by the relative areas « which the tools would respectively take, the conditio to cutting speed being similar, and a series of factor tained, so that when the output with the given secti known the output with a tool of any other required s may be obtained by the aid of a factor. The tests were made on the large electrically-d: experimental tool-testing lathe installed in the macl tool laboratory of the University of Sheffield. This | was built by Joshua Buckton & Co., Leeds. It is an 1 lathe, the bed, however, being of the size usually prov on 20-in. lathes, thus giving extra stiffness. The over length, including the bed plate of the main driving n is about 25 ft. The dimensions of the largest test bar which can be carried between the centers are: Lengtl 10 ft., and diameter, 25 in. The test bar is held by four independent dogs .or jaws mounted on a large driving plate, which is carried by the main driving spindle. At the loose headstock end the bar is supported by an ordinary ‘enter of ample proportions. The lathe is driven by a 40- hp. direct-current motor. This motor can actuate the driving plate on the main spindle in the headstock either directly, by a tongue on the headstock end of the motor armature shaft, and a corresponding slot in the motor end of the main spindle of the headstock, or indirectly through gears. In the headstock any one of three sets of gears can be used for transmitting the power and motion to the driving plate. They are so arranged that only one set can be in action at the same time, and are controlled by levers on the front of the headstock to give speeds of from § to 202 r.p.m. Altogether eight different feeds can be obtained The feed shaft drive from the independent motor is through a motor feed-gear box containing spur gears and clutches, so that fast and slow feeds, varying from 0.09 in. per min. to 200 in. per min, can be obtained. The bed is graduated in inches, so that the travel of the slide rest in any given time for any given number of revolutions of the test bar can be determined. A revolution counter is con- nected to the main spindle of the headstock, so that the number of revolutions made by the test bar in any given time can be determined. The test bars used were three in number, and of dif- ferent chemical compositions and physical properties, as given in the table on page 1384. Their approximate original dimensions were: Length, 9% ft., and diameter 20 in. Their identification letters are A, B and C. Test pieces were cut from each end of the respective bars and tested. The bars were found to be practically of uniform quality throughout. With the high-speed steel tools it was not necessary to submit the cutting edges of the tools to microscopic ex- amination, as it was found possible to obtain a definite point at which the tool failed to cut, or broke down. This s the point at which the working cutting edge collapses and, instead of continuing to cut, causes the surface of th bar to become highly polished. The exact instant at whic! each tool broke down, or began to produce this polished surface, was observed, and from this the exact duratiot f the test was determined. In these tests a standard life of tool of 60 min. wa selected as being a c