The Iron Age 1915-03-11: Vol 95 Iss 10

sagnnitiit! VNUNLEUUENATODENENODUNANOEREUUONEODEOOUOUCHYOOUGUOGROODOONOUONOOONONUNGGUEUAGOUGONOOONALOENGUONGAOOENODO NOOO OUEUAGUANTDLAAALESOOUGGOOEEEAOOGELOERAUO EAA DULGEEYUSEOOUROOOUA ESS OU NEE REA TURTON TUNED EOAATUUAN UCLA AGU GATTO iT a HE IRON ACE : : 4 > ae ) y i y —> 2 e ame LUUEUEIUUUEUEEUELEUOADUUUEOEOAAETEDESTAOOCED EA OUAU EUAN EUSA AAA HDSUUDAVDELURADERAOUGDENDAULLODENUESUAUUENUANeNENEN ANNAN ENE Established 1855 New York, March 11, 1915 Vol. 95: No. 10 Acid Open-Hearth Steel for Castings Some Essentials of Good Furnace Practice —Make-Up Method of of BY EDWIN F. Steel for steel castings and steel for ingots pre- sent two distinct propositions. Though usually made by the same processes, each presents problems to the metallurgist involving important considerations of furnace practice. The main fact to be kept in mind is that the steel incorporated in castings must remain in practically the condition in which it is poured in he congealed casting, whereas in ingots the steel is later subjected to many deformations and heat treat- ents before it reaches finally the stage in which it to be used, thus involving decided altera- tions in crystal- line interrela- tion. It is only in recent years that castings have been sub- jected to any really proper treatment. What they re- ive to-day is isually anneal- ing, which re- lieves internal strains and mod- 18 the UCharge—The Introducing Proper Ferromanganese CONE and treatment of ingots, which castings. In the production of steel for castings in an acid open-hearth furnace, as well as in a basic furnace, there are certain fundamental principles that should be followed to insure the best steel in the final casting Concerning some of these, opinions are divided. It is is impossible in steel the object of this article to discuss a few of the principles involved in making acid open-hearth steel for castings. PROPORTION OF MATERIALS TO BE MELTED An impor- tant factor af- fecting the final state of the metal is the pro portioning of the charge to be melted. It contended by some that any amount of foun- dry open-hearth scrap can be used with the is fies the initial requisite struc a Photomicrographs (87 Diameters) of Sections, Etched in Nitric Acid, of Acid amoun of ig ¢ cture, af Open-Hearth Steel Castings Made by Adding the Ferromanganese in the Ladle a n nt . SF v fectin gz the The Casting from Which These Specimens Were Taken Was Only 6% In. Square iron, provided "sips The One on the Left Is An Unannealed Specimen and the One on the Right an An ‘ ; : physical prop- nealed One, Each One from a Different Piece of Metal But Both from the Same melting condi- erties in propor- Heat. The Physical Properties of Each Are As Follows tions are correct. tion. Even this Unannealed Annealed Heats of as high anv ; Tensile strength, lb. per sq. in. 72,000 78.000 aa 7h ; os i many cases is Elastic limit, lb. per sq. in. 42,000 44,000 as (0 per ce nt not thoroughly Elongation in 2 in., per cent 14 00 1 00 of heads, gates done Reduction of area, per cent ».30 8.80 _ siete we isi eh: — The Ill Effect of Occluded Manganese Sulphide, Slag, Etc., Is Manifest from These . ste ” a eatment is not castings ave to be compared been made ‘o the various rollings and temperature variations xcurring in the manipulation of the ingot to the fin- shed rail, shape or forging. lt is important, therefore, that every consideration f character of charge or furnace practice that in any Way can affect the composition or condition of the final ‘teel in the casting should be given careful attention— “veh more so than in the average melting of other steel, though of course nothing excuses carelessness in either case. But it should be emphasized that defects are o'ten corrected in the subsequent manipulation 55 1 where no injury to the steel was observable, when such melts have often been incorporated in one solid large casting. It is, however, contended that where such metal has been poured into castings of small section or varied design, defects have often appeared that otherwise were not usually apparent. At best it is poor foundry practice and usually unnecessary ex- cept in rare cases, mixtures of various grades of scrap usually producing the better metal. The ill effect of too much constant remelting of steel-casting scrap is undoubtedly a consideration to be emphasized. A 552 THE IRON AGE charge that has met with considerable favor is one of about 30 per cent. pig iron and the remainder plate and billet scrap, no foundry open-hearth scrap being used. This make-up has been thought espe- cially productive of the most perfect castings. The necessity for its use is questionable. Experience has demonstrated, in one foundry in particular where the loss of defective castings was very low, that a charge of 20 to 25 per cent. of low phosphorus pig iron, 30 to 35 per cent. of open- hearth scrap, the balance being plate and billet scrap, produced a metal less subject to checks, ex- cessive shrinkage and blow holes than any other. The Kind of Pig Iron.—The kind of pig iron entering into the charge for steel castings is prob- ably a matter requiring more care than in the case of ingots. It has become generally recognized that pig iron containing any more than 0.50 per cent. of copper cannot be safely used. If much more is used the resulting metal has a tendency to check. Pig iron containing copper has been successfully used if not more than 13 per cent. is charged. Many objections have been made to the use of English pig iron in making steel castings. It has been con- tended that whenever it has been used, checks and undue shrinkage have resulted. While the writer has had an experience of this nature, the cause could not be located at the time. It was at least a fixed idea in the mind of a pioneer steel foundry- man at that time that everything that went wrong with the metal was attributable to English pig iron. In any case it was not due to the composition, unless according to one theory an unusual amount of oxygen was present in it which might have caused injurious results. It is a general prin- ciple that it is better to use no more than two brands of pig iron at a time and not to use a mixture of several in one heat. The latter prac- tice has been found to be productive of unsatis- factory metal and castings. INITIAL MANGANESE IN THE CHARGE The question of the percentage of initial man- ganese in the charge is important, but one to which very little attention has been given. It is con- tended by some that the total manganese in the various ingredients making up the charge be not less than 0.80 to 1 per cent. If the materials charged do not show this, then enough ferroman- ganese should be added early to the charge as it is melting down to make up the deficiency. The presence of the manganese is necessary to neutral- ize the oxides that may be present or formed in the melting and to flux out part of the other impurities, such as sulphur, etc. The resulting metal is purer and freer from included slag and oxides than when this principle is disregarded. Its adoption insures better metal and castings. A very effective method of introducing the initial manganese is to use a pig iron containing 3 to 4 per cent. of manganese. Such irons are easily obtainable and the added expense is warranted in the better quality of metal produced, with conse- quent less loss in castings. These provisions for initial manganese have been demonstrated as de- cidedly beneficial on a large scale in the experience of the writer. INTRODUCING MANGANESE INTO THE STEEL Of course the manganese initially in the charged materials or subsequently introduced as ferroman- ganese in the charge is dissipated as the melting and refining proceed and the charge when com- pletely melted is practically free from this element. To make good steel, manganese must be added to March | 915 this molten mass before it is cast into mold are two general methods of doing this: 1. Introducing 80 per cent. ferromanganes: bath of the metal in the furnace. 2. Throwing small pieces of the alloy into as the metal leaves the furnace. There is a contention among foundrymen and metallurgists as to which of these proced is the better. If the first one is followed, th: manganese in large lumps is placed on the breast of the furnace so that it becomes thoroughly heated through and is then pushed into the bath, stirred through the slag and efficiently mixed with th: metal. The ferrosilicon, 10 to 12 per cent been just previously introduced in a similar manner If the secondmethod is followed, the ferromanganes: in lumps about nut size, is thrown into the ladle as soon as the metal has covered the ladle’s bott: to the depth of a few inches. In this case als the 10 to 12 per cent. ferrosilicon has previousl) been introduced into the metal in the furnace as in the first case. As opposed to either of these processes the method of putting both 50 per cent. ferrosilicon and the ferromanganese into the ladle is sometimes resorted to—certainly a bad practice It is probably not wide of the truth to state that the second of the two methods is used by a majority of the acid open-hearth foundries of the country. MANGANESE IN THE BATH BETTER It is the contention of the writer that the first procedure is by far the better in producing good steel and homogeneous castings. This opinion is based on the general principle that wherever pos- sible it is better metallurgically and practically to finish to the greatest extent possible the steel in the furnace and not in the ladle. Otherwise the time necessary for the manganese to not only do the work expected of it is not sufficient in the ladle but also its thorough amalgamation with the steel is less likely. This being so, the resulting steel is generally likely to be permeated with aggregates of manganese sulphide, slag or mixtures of the two, greatly weakening its structure and strength. The two photomicrographs illustrating this article show what may happen in such a case. These are fron acid open-hearth steel castings poured from steel made by putting the manganese alloy into the ladle. Examination reveals their exceedingly poor structure, permeated here and there with globules of manganese sulphide, slag, etc. The normally expected uniformity in crystalline arrangement is badly broken up, large patches of ferrite being segregated around the foreign substances, slag, sul- phide, etc. The physical properties of the steel also tell more. EXPERIENCE OF A LARGE PRODUCER Further practical demonstration of the correct- ness of this contention has been impossible in the writer’s own experience. However, it is gratifying to be able to present here the results of the ex- perience of one of the largest producers of acid open-hearth steel castings in this country, a firm reputed to make high grade material and to adopt a definite practice only after thorough investiga tion. The opinion and conclusions of this company, as formulated by its general superintendent, are as follows: Some time ago it was our regular practice to pu! 30 per cent. of our ferromanganese charged in the ladle, breaking it up to the size of a hickory nut ° slightly larger. This practice was not entirely satis factory and in three extreme cases we had heats with the last two or three thousand pounds, from a ladle containing 50,000 Ib. of steel, giving us meta! a March 11, 1915 y high in manganese. In one case the analysis castings ran about 6.50 per cent manganese. acture of the castings was like that of chilled on and they were of course very hard, and the ese contained was verified by accurate analysis. ouble was attributed to ferromanganese which ‘come coated with slag and had not properly We have verified by actual tests that this alloy, has been intentionally covered with slag, is ex- hard to fuse. of the other conditions which we have found when we add ferromanganese in the ladle there ssibility of not getting a perfect mixture, and had castings which showed cavities on the ide below the surface which we could not at- to anything but manganese which was not thor- y fused when the steel entered the mold. metallurgist, who has followed this matter a deal, feels that our steel shows a greater ten- to hot eracks and blowy condition when man- is added to the ladle than when it is put through bath. Our laboratory records seem to indicate ve are not able to control our carbon and man- ese analysis within as close a range by the first tice as we are able to do with the latter. While it is very hard to get any absolutely con- isive data, we are convinced from careful comparison great many tests which we have made that our will run 2000 or 3000 lb. per square inch higher timate tensile strength when the manganese addi- are made through the furnace rather than in idle. \s our manganese loss when we put all of the the furnace is between 30 and 35 per cent., the loss of ferromanganese on a 25-ton heat will little less than $5 per heat with manganese at rmal price. We generally add manganese to 0.60 to 0.70 per cent. in the castings. We feel that as far as we are concerned we are ed in continuing our present practice of putting nganese in the ladle, notwithstanding the in- ad cost. (his important evidence is of great weight so is the metallurgical phase and the desire to the best castings are concerned. As to the of cost, unquestionably introducing. the al- to the ladle is cheaper, as the loss of man- se in the furnace is at least 25 per cent. greater n the ladle. But cheapness is not usually the policy in the long run. POURING TEMPERATURE OF THE METAL (he question of metal temperature in pouring tings is an important one as is also the character slag. The usual aim is to secure a degree of ifficient to permit a pouring of various molds from one-half to three-quarters of an hour case of a 25-ton heat. Anything higher is erous as bordering on overheated metal with nsequent baleful results. A pioneer in the ss once remarked to me that he would rather light skull or ring in the ladle after pouring none at all, feeling certain then of proper OREING DOWN THE HEATS proper use of iron ore in eliminating car- ym the bath is another factor of extreme tance in producing sound castings. It can be as a principle of good practice that no ore be used after the carbon in the bath has d 0.40 to 0.50 per cent. From that point its ition should be natural and not forced. The elimination favors a quiet metal; the forced tion, a wild metal, often permeated with part of which often remain in the metal until lifies. The result is of course blowy metal fective or returned castings. The tendency ‘k this rule is inspired by a desire to make THE IRON AGE Doe ~ wy quick time or large output to the sacrifice of the best in quality. As to the use of aluminum and other medicines in the shape of some ferroalloys, this is a subject to be discussed by itself. For regular carbon steel castings, it should not be necessary to resort to any such cure-alls when proper melting principles are followed. Demand for better products is growing more in sistent. Producers desiring to keep pace with the pronounced tendency to a higher plane must take advantage of every point that makes for this end. Signs are not wanting that point to the possible fruition of efforts to make steel in an electric fur- nace competing with the open-hearth on a tonnage basis. Unquestionably electric steel is superior, other things being equal. But proper regard for fundamental principles in open-hearth practice al ways results in a first-class metal. Since much of the steel made in steel foundries is melted by men who are not metallurgists, too much attention can not be paid to the plain principles here recited New Line of Drill Grinding Machines The F. E. Wells & Son Company, Greenfield, Mass., has added to its machinery products a line of drill grinding machines, which are furnished in three types. The head and the grinding fixture are the same through- out, but in one the head is mounted on a plain column and is driven from an_ independent overhead countershaft; in another the counter- shaft is attached to the column and is belted di- rectly to the main line shaft; while in the third type the drive is from a motor mounted at the base, the belt being in side the column. As will be noted in the illustra- tion, the machine is of the standard type. A 6-in. cup wheel is mounted on one end of the spindle for’ the sharpening of drills, and a °%x6-in. point trim- eel ie ala ming wheel is on the ine of D1 Grinding i other end. ccuiananeaai aa ia ton in A portable oxy-acetylene welding and cutting outfit has been placed on the market by the Imperial Bras Mfg. Company, 1210 West Harrison street, Chicago, Ill. The principal feature of the apparatus is the mix ing of the oxygen and the acetylene. Before entering the mixing chamber of the torch, the oxygen, under high velocity, passes through a spiral groove. This imparts a whirling motion to the oxygen which is relied upor to mix it thoroughly with the acetylene before the gases reach the combustion point. A special alloy with a high melting point is used for the welding and cutting tips and the design of the latter is relied upon to pre vent burning out. The regulator which is of a special type w'll shut off automatically in case of emergency when the cutfit is being used for cutting The Parish & Bingham Company, pressed sheet metal products, moved March 8 to its new offices at 10,615 Madison avenue, Cleveland, Ohio. Student Engineers Teach Workmen’ An Important Movement to Enlarge the Worth of the Worker and the Perspective of the Employer BY J. These days of great industrial and social prob- lems in America produce many suggested solutions and great changes. The practical engineer and em- ployer of labor views these problems differently from the labor leader or the social reformer, but, as never before, he is sincerely interested in solving them in a way that will be just to all. The inevitable tendency of the day is toward ‘industrial betterment,” “safety,” “industrial edu- cation,” “efficiency,” and the many other things which have become so familiar to progressive em- ployers. There is no longer any question that these things are worth while from both the human and PARKE CHANNING ill-feeling, labor difficulties, and many strike not be avoided if such men had the right attit Is there any way of remedying this condit If this particular difficulty can be solved, it young engineers, many of whom are our « leaders of industry, can be given the right pers tive and the right understanding of these othe, problems in addition to fair, sympathetic met! of handling men, many of our other problems be solved—not at once, but gradually and perma nently, as these men make good and become influe: tial in paths of industrial righteousness and indus trial peace. Many progressive employers of today How economic standpoint. cents. The very center of final success in improving con- ditions and increasing the efficiency of workingmen must be the spirit of fairness and a knowledge on the part of the employer of how to deal, sympa- thetically and intelligently, with his employees. Every progressive employer knows how greatly he desires foremen, superintendents, managers and others who possess these qualities. On the other hand, we are all familiar with serious mistakes made by young graduates of engineering schools who have had no opportunity to develop these quali- ties, and who have no real appreciation of the worth of the workers. Indeed, one wonders whether much They “pay” in dollars and *Extract from a paper presented at the New York meet- ing of the American Institute of Mining Engineers Feb- ruary 15, 1915 J. Parke Channing is vice-president, the Miami Copper Company, New York City. Part of the Noon Hour Is Taken Up in One Shop have enlarged their own perspective and realize the great importance of enlarging the perspective of those who shall follow them. How can it be done? For seven years a move ment has been making rapid progress in engineering schools with the purpose of helping to solve this very problem. It was started at Yale in 1907, by the Young Men’s Christian Association, when some engineering students were led to get in touch with workingmen and boys in New Haven. The idea was to render service by teaching them English ane other subjects and in turn to learn their ways, ideas customs, and how to deal with them intelligently Friendly, mutually helpful personal contact was the basic principle. This was the beginning. Do no! confuse it with “social service’—it was this, nd much more. The reaction on the engineer was the main object sought. The idea worked out 5° 554 Marc! 11, 1915 ully that a number of men saw great possi- ili in it, and the whole conception was greatly nlarved. Under the name, Industrial Service Move- t has spread to 200 other colleges and tech- ‘eal schools in the past seven years, and has justi- ged itself from every point of view. It is really helt in a vital way to solve the special problem ve have been discussing and other problems as well. t briefly : plan is to bring engineering students and al workers together to their mutual under- g and their mutual good. purpose is to get workingmen educated and jucated men to work. To send men out of college with a new sympathy, a new vision and a new de- termination to help. The principle is fraternity—not to go down to nelp others or to ask others to come up and be helped, ut rather to go with them, not in any sentimental vay, but in a spirit of common sense brotherhood. The method is to put college students up against real opportunities for the kind of service which ap- peals to them, such as teaching foreigners English ind citizenship; instructing American workingmen n technical subjects; leading clubs of working boys, te. There is opportunity for every leader’s peculiar ibility to assert itself, in any way that is real. Other methods will be described later. Accomplishment shows that during the past year 500 students from 200 colleges have engaged regu- irly in industrial service; 3000 graduates are ictive in industrial betterment as a result of interest quired while at college, during the past seven years, Leadership rests in the Young Men’s Christian \ssociation, through local branches, state commit- tees and the industrial and student departments of the International Committee. Co-operation provides for the movement working ocally through the Young Men’s Christian Associa- tions and any other recognized agencies for indus- trial and social betterment in the community. Pro- fessors and students, employers and employees, ‘ngineers and social workers heartily co-operate. The significance of it is that experience proves that men interested in this work at college go out nto the larger world with a new vision and a new ittitude and sense of responsibility. These men will largely determine whether conditions shall be good or bad and whether the human factor will be given fair consideration. How, better, can the problems of capital and labor be solved than by mutuality, good will, efficiency and character in ousiness? The nation’s hope is in the coming eaders who shall follow us and who possess such essential qualities of success. The development of such leaders, with their continually increasing ca- pacity for service, is the ultimate purpose of the industrial Service Movement. It may seem surprising that 3500 engineering tudents, each carrying a heavy course of study and vith many other interests, can find an evening or ‘wo each week to engage in some form of definite ‘ervice, without any financial compensation. But ‘uch is the case, and on the whole a careful survey ' their work reveals efficiency and permanency in ‘high degree. If industrial men are at first sus- ‘lous, their suspicion soon wears away in the face ‘rankness and friendliness. If the employer has ibts, they do not last long. One may travel ind the country and observe students teaching eners in railroad box cars, stores, clubs, halls, oms, restaurants, and boarding houses as ‘Ss in the more dignified meeting places— . churches, settlement houses, and factories. THE IRON AGE or or ur One may see American workingmen instructed in mines, shops, and labor-union headquarters. One may look with interest upon recreative games, talks, first-aid and safety promotion in all sorts of places at noon, afternoon, evening and midnight. And one may see 500 men crowded around the machinery of a huge plant listening to a straight noon-hour talk on clean living, character-building and vital religion. We have looked with amazement on 50 factory boys following enthusiastically a college football captain who took enough interest in them to organize a boys’ club or a factory athletic league. It has all been done in the finest kind of spirit, without patronage, with modesty and with efficiency. And during the past year those 3500 student leaders reached over 60,000 workingmen and boys in a very personal and directly helpful way. The secretary of this movement has talked with hundreds of em- ployers and college professors throughout the coun- try and all seem enthusiastic over what has been accomplished. But what has this to do with engineering? Just this—that every one of these 3500 students would be willing to say that he has gained far more than he has given. Furthermore, a study of the situa- tion proves that he has gained in large measure the very qualities he needs—an appreciation of work- ingmen, adaptability, leadership, a knowledge of how to deal with men in a way to get results and to avoid harmful labor difficulties. In general, he learns that all men are men, regardless of race, nationality, color or creed, but that men must be dealt with very differently; he learns that it pays to win the leaders of men if one desires to win the men themselves; that the work, home and leisure life of industrial workers play a large part in deter- mining efficiency; that a man’s working associates may largely influence the quality of work he does; that helping men to concentrate on their work, though not at the expense of mental and physical welfare, increases output; that friendly competi- tion, without driving men, helps break records; that reasonable relaxation and recreation pay both from the human and economic standpoints; that visita- tion of other plants and stimulation of new ideas in various ways may mean a money saving to the company ; that loyalty of the men is one of the em- ployer’s greatest assets; and that character counts most of all. More than this, he learns to understand men, he learns how to sympathize with the other fellow’s point of view and how to handle men suc- cessfully. Is this not worth while? Who can fore- see what the future will hold for these men in the way of tremendous opportunities and responsi- blities? An Interesting Test of a 10-In. Hacksaw Blade A test of a hacksaw blade, which was calculated to show its non-breakable qualities, was recently made by E. C. Atkins & Co., Indianapolis, Ind. In this test a 10-in. Atkins non-breakable blade was coiled down to lin. After the test the blade was straightened and ran to the full life of an all-hard blade. It is emphasized that breakage due to an awkward thrust or the blade being permitted to bind in the cut, which has heretofore been a source of great expense in operating hacksaw blades, is entirely eliminated with this new one. These blades can be supplied in lengths from 8 to 10 in., and in widths from % to 9/16 in., the number of teeth rang- ing from 14 to 32 per in. The Utah Junk Company, Inc., Salt Lake City, has under construction a merchant bar mill which will be completed about the middle of April. The officers of the company are: President and general manager, N. Rosenblatt; secretary and treasurer, S. Rosenblatt. A new company is to be incorporated to operate the mill. hf Economical Handling of Odd Machining Jobs Suggested Operation Schemes for Occa- sional Lots or Single Pieces of Hori- zontal and Vertical Turret Lathe Work BY ALBERT A. DOWD The machining of odd jobs or single-piece work in the factory is usually attended with considerable loss of time which can in many cases be avoided by a re-adjustment of the conditions under which the ODE Ps SC | Some Cl icteristi eces of Horizontal Turret Lathe Wor work is done and a little more care in the handling of work of this character. Cylindrical pieces are especially expensive when made up one at a time or in lots of four or five pieces, the cost often running two or three times as much as it need to. As a general thing pieces of small size are machined on a lathe, while the larger variety of work necessitates the use of a larger machine such as a vertical bor ing mill or other machine of similar nature. Some of the reasons why short jobs cost so much are setting up time and preparation for the work very slow; feeds and speeds used too conservative; lack of proper equipment for handling work of this character to advantage; poor judgment on the part of the foremen in giving out the work to men of insufficient experience who spend so much time in determining how to hold the piece and looking up blocks, clamps, etc., that by the time they have de- cided and got together the necessary tools, a more experienced man would have finished the job and been ready for another; fussiness over unimportant dimensions and loss of time studying over a blue- print. It is a fact that in many cases the operat not know what his next job is going to be, foreman may not give him a new job until | finished the one on which he is at work. | job is given out in advance the operator or rk man has a chance to look over the blueprint get together the necessary tools for the new wo, while the old one is still in the process of mach so that there need be very little loss of tim tween jobs due to lack of preparation. In factories where the premium system is in vogue it is times possible for a man to have two machines jy operation at the same time or to start a piec work and let an apprentice finish it. To avoid un- necessary fussiness the foreman giving out the work should inform the operator how accurate is to be, so that a loss of time will not result fr extreme accuracy when this is not essential. A suitable tool equipment is a great advant on work of this kind, and blocks, parallels, straps and bolts should be easily accessible so as to assist in setting up. Take a lathe job for instance, in a department devoted to the manufacture of special tools, boring bars, reamers, cutters, etc.; it will usually be found that one or two of the men are naturally rapid and quick to grasp the requirements of a special job. These men should be selected for odd job work in preference to some of the others and may be allowed to keep a certain amount of equipment ready to hand for this purpose. In this way a considerable amount of time can be saved and the work produced to good advantage. In screw machine work the manufacture of spe cial screws, studs, etc., in lots of from 4 to I pieces, is usually costly, for the reason that ther is a lack of preparedness for short jobs, and as consequence such work is frequently done by a! apprentice in the tool department at a low labor cost. There are, however, several other ways which odd lots of this kind can be economical! produced, these being dependent upon the condi tions which obtain in the factory. Each manufa turer must decide upon his own method of pr cedure according to the demands of his output. I! many jigs and fixtures are being built constant! there will be many small pieces to be manufacturec and it may be found profitable to have a couple 0! operators using different sized machines to whom work of this kind can be given. When the nature of the general run of work will permit it, thes men should not be given large-lot production work but should be kept as far as possible on small lot: s If these operators are provided with adjustab turning tools and a conveniently available eit ment of dies and holders, screws and studs in spe cial sizes can be produced very rapidly even when wanted in small lots of four or five pieces. The turret lathe should be provided with a cut-off slide. I have seen a man experienced on this class of work set up his machine and make up eight ae ial screws, 34 x 414 in., with extra large head |! 45 min. This time included the changing of calle jaws and die-heads. This particular man often turned out in the course of a day 12 to 15 lots of M: 11, 1915 sere of various kinds, in lots ranging from 6 to 10, it is obvious that in cases where the amount | odd lots is sufficient to warrant it, no more orofitable method could be asked for. This opera- k a great deal of pains to group his work as as possible in order to avoid the necessit; ging collet jaws and dies. The greater part work was required within a day or so, some- n even less time than this, but even on rush was found more economical to do the work way rather than on a lathe. In the case of having short jobs continually given him, if at all ingenious and clever at the work, he be- expert in setting up and adjusting tools and advantage of every short-cut to reduce the production time. It is decidedly unprofitable to e out short jobs of this kind to Tom, Dick and Harry, because in many cases they spend so much e in setting up the machine that the cost of pro duction is increased to such an extent that there is economy in the method. single-piece chucking work ranging from 24 in. in diameter a vertical turret lathe with turret side head may be used to good advantage. ‘he nature of this type of machine is such that it be quickly adapted to a variety of work on cast- r forgings, and although it is considered more fitable to keep it on regular production work, it often be switched off to handle a single piece ood advantage. When the odd pieces are not iired immediately they can be set aside until a rtain lot of the regular production work has been pleted, after which they can be handled suc- essively according to the needs of the particular ases. In many cases the tooling requires very ttle changing and the observation stops, which ave been used on the preceding job, need not be turbed. As a matter of fact, the machine can handled by an experienced operator much as an gine lathe might be, obtaining the various diame- calipering. There are occasional instances en it may be found profitable, as in turret or rew machine work, to keep one machine and oper- on short jobs and small lots of production k, but this depends entirely on the class of work handled and the number of odd jobs. Some he advantages derived from the use of a ma- ne of this type on work of the character men- ed are the ample power available and the facil- vith which the machine can be set up. The in- of the operator, ability to read and grasp essential points on a blueprint rapidly and the iracy of his work are all important factors must be considered in attempting to handle gle-piece work on this type of machine. With perator having these attributes, both light and hucking work within the range of the ma- in be handled usually with a saving of from (5 per cent. over lathe methods. A few ex- work in small lots which can be profitably ed on either turret lathe or vertical ma- re given here with suggestions for tooling. examples of horizontal turret lathe work ted form a group of characteristic pieces lots of from 2 to 10 are frequently ma- either on the engine lathe or in the tool de- and with the single exception of the stud, the second piece from the top, they machined to good advantage on the hori- pe of turret lathe. Take the screw shown top for instance, which has an extra large ead, but which aside from this one point is dard size. Four of these screws are called if machined on an engine lathe would re- rom 14% to 3 hr., depending on the skill of ; THE IRON AGE 557 the workman. The actual machining time on a Pratt and Whitney horizontal turret lathe was 20 min., and the operator spent about the same time in preparation, making 40 min. in all, a saving of at least 50 per cent. The locating stud cannot be profitably handled on a screw machine on account of the portion, at the left, as there was but one piece to be made, so the engine lathe in this case has the advantage over the other machine. The four bushings, which are next to the bottom piece, were made from bar stock on a screw ma- chine, but were finally turned on a lathe to ensure concentricity. Stock was drilled, bored and reamed on the screw machine and cut off to length, includ- ing setting up time of the machine, in 80 min. A man would have spent from 2% to 3 hr. in doing the same work on an engine lathe. Here also a saving of approximately 50 per cent. is apparent. There were six special studs, which are shown at the bottom, to be made anid the screw department completed them in 65 min., including the setting up of the machine. It would have taken a man a half day to machine them on a lathe. Many other instances of work of this kind could be noted, but the cases illustrated are representa tive of pieces commonly required in small lots which can be economically machined as noted. The various pieces of vertical turret lathe work illustrated are odd jobs suitable for machining on the vertical turret lathe, and with the single excep 4 f pense “ | | ln cesta + ~ é ’ Up h < “4 ~ < } eee / eh ek, 4 é é j - ‘ flan ile « — « ~ > ] i i nH I J Sie J. EE = . — a “= j (sdd Pieces Suitable Machi gt \ tical Turret Lathe tion of the bottom piece only one of each was re quired. There were two such pieces to be machined from heavy ring forgings to the thin contour shown. The top piece is a large spur gear, and the next two are respectively a clutch pulley and a fixture body. The surfaces to be finished are indicated by finish marks on the drawings. The tool layout and method of machining the bottom piece are clearly shown, and attention will be called to the general utility of the set-up in con- nection with the machining of the other pieces. Ny ae 558 The layout for the most difficult piece is shown principally to illustrate the ingenuity displayed in setting up and machining a difficult piece of work in such a way as to produce it in the least possible time and without causing distortion. Previous to the machining -operations shown, the steel ring forging a is taken to an upright drill- ing machine and a hole drilled to receive the short pin b which acts as a driver against the side of one of the chuck jaws. By using a driver in this way it is not necessary to set up the jaws as tightly and therefore less distortion is apparent in the work. The piece is set up on the table so that it rests on the shoulders of the three jaws c, and the work is gripped by the inside as shown. While held in this way a clamping groove, d, is cut on the inner surface of the ring by a tool, e, in the tool holder f in the main head turret, the tool being grooved on the end to break the chip and make the cutting action easier. After the recess has been cut the three clamps g are placed in position close to the jaws with the wooden blocks h acting as supports for the tails of the clamps. The bolts at i are of the T-variety and enter the table T-slots, so that adjustment can be quickly obtained. Before setting up the clamps some of the pressure on the jaws is released so as to avoid distortion, thus allowing the clamps and driver to do most of the work. The main head turret is now indexed to bring the tool holder j carrying the roughing tool k into position so that it can be started in removing a portion of the stock at l. The tool m in the side head takes a roughing cut across the top of the ring and then is fed down along the outside of the forging. The in- side and outside tools can be working simultaneous- ly, and being opposite each other they serve to sup- port the work while cutting so that there is less liability of its being sprung out of shape. Two roughing cuts are taken on the inside of the ring, and during the second of these the recess n is cut by the tool o in the side head, the width of the tool The Tool Layout of a Vertical Turret Lathe for Machining the Pieces Shown THE IRON AGE March 11, 1935 being slightly smaller than the size of the re. oss. g, as to allow a light finishing cut to be tak. The finishing tool p in another holder, gq, in the maiy head is used to complete the inside finishiny whi). the tool r in the side head works in conjinctioy with it on the outside of the ring, the final { cuts being very light in each instance. The tool s separates the finished piece from the remaiy der of the forging, leaving the work complete in on, setting, machined accurately to size without tion. It should be noticed that all the tools requireg are of the simplest kind, such as are ordinarily found among vertical turret lathe equipment, and the labor in setting up the machine ready for work requires very little time. The flexibility of the equipment is such that the upper pieces can be readily machined by it by the addition of a suitable boring bar, t. The top piec¢ is held by the inside in the same set of jaws re. versed so that the tail of the jaw is toward the center of the table. Side head tools m and r ar used to turn the outside of the blank, while k and p face the rim and hub. The boring bar at ¢ rough and finish bores the hub with the slip cutters u and finally reams the hole with the flat floating reamer blade v. Tools for this type of bar are a part of the essential equipment of a vertical turret lath and may be obtained in a variety of sizes to suit any size of hole. The second setting requiring only the facing of the hub and rim is done by the same tools as those used in the first setting, the work being held in a set of soft jaws by the surface pre viously machined. The second piece is held by the rim in the first setting and machined with same tools, but the main head turret is set over to produce the correct taper in the hub hole, which is bored to size and not reamed. The rim is partially undercut by the too! e, which is transferred to the side head for this purpose in substitution for o or s, which are super fluous. For the second setting the piece may be located on a vertically floating tapered bushing on a cylindrical stud in the center hole of the table or it may be held by the outside finished surface in a set of soft jaws as in the preceding case, depending somewhat on the requirements for accuracy. The bushing method will give more accurate results but requires the making of the parts used, while the soft jaw method simply requires the boring of the jaws in position on the table. If care is used, the latter method can be made to give very satisfactory results and is both cheaper and quicker. The third piece can be set up with the smootn side uppermost in a set of standard jaws on raising blocks and held by the outside of the rim while it is faced and bored with same tools previously used with the exception of the boring bar, which must be exchanged for another of smaller size. In the second setting a plug in the center hole is used as a locater and the work is driven by screw dogs 10 the table T-slots. The facing operations are per formed by the same tools used in the first setting both the side and main heads being utilized. Many other examples of work could be given illustrate the possibilities of this type of machine on single-piece work, but the instances noted are sufficient to give an idea of its flexibility and the methods by which it can be adapted to a variety of conditions are clearly apparent in the examples shown. It will be found profitable for any factory manager to inquire into the methods by which single-piece work is produced in his own factory, 5° that he may be able to judge whether he would be the gainer in adopting some of the processes me? tioned in this article. So much depends upon the “Hing rting ing aistor- March 11, 1915 onu.tions governing the work in different factories, that it is obviously impossible to practice a method factory under certain working conditions wh may be entirely at variance with the condi- \btaining in another factory where the method have proved successful. Each executive must n himself in accordance with the requirements own factory, but it is the hope of the writer ; article that some of the suggestions given rove both interesting and profitable. A New Line of Cutting Tool Holders \ cam lock for holding metal cutting tools has een developed by J. H. Williams & Co., Brooklyn, \. Y., and is the distinct feature of their new line of turning, cutting-off, side tool and threading tool ers. A cam made of specially hardened and tempered tool steel has been substituted for the rulation set screw. It has a very slight rise to vive it high gripping power. The cutting tool is ked by a turn of about 30 deg. When the cutter s loosened and removed the cams can be slid out the holder. Both countersunk and hexagonal types of cams are provided. Drop-forged wrenches are provided for locking and are designed ve so large a binding force that the workman not be tempted to strike the handle a blow, which is often the cause of damage to holders, etc. ; mentioned that this cam type of lock eliminates more or less general damage that occurs from twisting off the set screw head. Both right and left hand turning tools are provided, with straight r offset shanks, and straight or drop heads, and each type is furnished in six or more sizes to take ‘utters from %4 in. to %4 in. The cutting-off and the side tool holder is com- bined in one, furnishing a material reduction in the shop tool investment. A suitable variation of the is used for this tool, as shown in the accom- panying illustration. It is designed to bring the broad edge of the tool at the top, which adds to its ife by carrying away the-heat generated in the utting better than does the usual narrow one. A threading tool holder for both roughing and final finishing touch has been brought out with a lockable spring head. This consists of a special headless cam that is easily removable when the spring head is desired for the finer finishing cuts. The boring tool holder is of entirely different de- It is made to take all sizes of boring bars, rounds, hexagons, ete., within its proper limits without the aid of shims, bushings or other fillers. Chis is accomplished by a cap, provided with large and The cap holds ‘mil. ind small grooves on opposite sides. the bar against the grooved shoulder of the holder lank, by means of two tightening screw nuts. oring bars are made in four sizes, from 3/16 in. to .in diameter. In the illustration a sleeve bar shown in place in the holder. It is a new type of var. The end is tapped to receive the clamping . which has two holes to take the tool in either ‘ Straight or angular position. The sleeve with ‘imiar holes butts against the bar. When the cut- ‘ing tool is slipped through the holes in the sleeve id bolt, the latter is tightened and binds the tool ‘ace. A plain bar is also supplied for similar i's, equipped with set screws. Each type is made sizes to take bars from 14 in. to 1% in. in Cs. ‘he new planing tool holder has 28 adjustments, pared with seven in the standard tools now This multiplication is attained by 28 radi- - errations, corresponding to similar ones in her or adjustment ring. To prevent the fs > t Y THE IRON AGE ~ Various Types of Cutting Tool Holders At the top Cutting-off and Side Tool Holder next, a Plain Boring Bar in the center, Right and Left Hand Turning Tool Holders next, a Planing Tool Holder it the bottom, Boring Tool Holder with a Sleeve Bar in place nd Cutter Set in Angular r’osition well-known and annoying wearing down of the cut ter seat, this ring is hardened. The locking nut has a spherical seat which brings it in line with the strain, doing away with all side strains here as well. This holder is particularly adaptable to heavy lathe work, and wherever offset tools might be used. Six sizes are provided to take cutters from 5/16 in. to 14% in. in diameter. The line of tool holders is supplemented by a knurling holder, provided with three sets of standard knurls. A complete line of cutters is provided for each different holder and purpose. New General Electric Mazda Lamps The Edison Lamp Works of the General Electric Company, Harrison, N. J., has developed a line of vacuum Mazda lamps in the 25, 40 and 60 watt sizes The lamps, which will have a rated average life of 600 hr., are provided with concentrated filaments that are believed to give a greater vertical distribution of light than the regular Mazda lamps of the same sizes. For this reason the lamps are designed to be used where natural distribution of light downward is required, and can be placed in existing sockets and fixtures, the bulbs being the same size as the corresponding regular lamps The Dominion Iron & Steel Company, Ltd., Sydney, N. S., is to install a plant for the utilization of by- products of the coke ovens to manufacture toluol and benzol. Making Instruction Cards from Time Studies How: Time Study as a Part of the Taylor System of Management Is Establishing Standard Times BY DWIGHT V. MERRICK* Analyzed In manufacturing, there are two things which, except in a few instances, have been woefully ne- glected. One is the matter of standardizing the machines used in manufacture, including the tvols used on them. The cther is the matter of knowing accurately how long a time is required to do a given piece of work. A few words will suffice to describe the matter of standardizing the machines and tools used on them. In a shop there may be two engine lathes of the same capacity, but of different makes, used to pro- duce the same part. Unless these two lathes are to all practical purposes alike, fro