The Iron Age 1915-04-01: Vol 95 Iss 13

(iieuaeepenl HU Eee Hi + ablished 1855 Molding Cast-Iron Tunnel Linings HUPEEEEOOUAETUREEANETAREDUUAOUDRAUO UU ODETT ETAT TOLD TET EOE New York, April 1, Manufacture and Inspection of Segments for New York at Wheeling Mold & Works — Machine-Made BY LOUIS J The manufacture and inspection of the cast-iron tunnel rings for the New York subway system for the East River crossings are now in progress at the works of the Wheeling Mold & Foundry Company, Wheeling, W. Va. Nine segments and a key are required to make a complete ring, which, when as- sembled, is 17 ft. 6 in. in diameter. There are two Osborn Molding Machine Under Sand tions of tunnel segments, the heavy segments, th 9-in. flange, used in earth formation and eighing 13,408 Ib. per ring, and the light segments, 1 7-in. flange, used in rock formation and weigh- . 8576 lb. per ring. The equipment used including patterns, core- ‘es and core-prints are all made of metal, thereby nspector of steel, Public Service Commission, New Y The ] is copyrighted by the author rticle < ~~! — Hopper, Sh ut 1915 Vol. 95: No. < Foundry) Molds and Cores JOSTEN insuring tnat:the last mold and core are as accurate as the first. Nearly $40,000 for improvements and equipment for handling and making these castings was expended by the Wheeling Mold & Foundry Company, whose experience in this lin of long standing. The manufacture of these casting s don wing Sar Mix cs evor Mold <¢ LR mostly under one roof, a building 575 ft. long and 60 ft. wide, equipped with three over-head trav eling cranes, two traveling wall cranes and a sand blasting outfit. Starting at one end of the building is the foundry proper. The casting is put throug! its various operations until it reaches the other end of the building finished and ready to load on board a car for its destination, namely, New York Just ten years ago this same firm was working Rolling Oven Machir on an order of 63,000 tons of cast-iron tunnel seg- ments used in the construction of the East and North river tunnels of the Pennsylvania Railroad Company, but since that time wonderful improve- ments have made in the way of equipment. In the foundry and core-room, the molds and cores are now made by machines. been The cores are more uniform to size and shape than those made by hand because of the clean and accurate draw of the core from the core-box, which is held in perfect align- ment. The drag and cope molds made by the ma- chines will produce a casting even superior to those made by hand ramming. .My.reason for this as- sertion is that it produces a casting more true to pattern, as rapping of the pattern is necessary to loosen the pattern from the mold before drawing hand-rammed molds. This is sometimes done very carelessly by the molder, thereby enlarging the mold considerably and giving increased sections in various. parts of the casting which are not needed. * ile obapianiatcenesietedieitaseeiteialiipeiadeetimatinisaamiaeeatatoadiiermanined Fig. 4—Jolt Machine for Making Cope Molds THE IRON AGE Fig. 3 Mold on Car and Pattern Draw Machine molding does away with this uncer- tainty of careless rapping by the use of a vibrator It vibrates the pattern loose from the mold, the enlargement caused by the vibration being so small that it is hardly noticeable. This advantage over hand-rapping produces a casting truer to the pat- tern. The percentage of rejected and defective cast- ings is reduced. This is due to the fact that the machine does uniform ramming. The knack of ramming just right by hand comes only with con- tinued practice and comparison of the results ob- tained. This requires experienced and careful men. The ramming variation of the molds done by a gang of men on the same class of work is sometimes very great. The result is, if rammed too hard or too soft, the casting produced will be full of blow-holes, sand-holes, scabs or swells. While on the other hand, after determining the required number of blows that are necessary to ram the mold just right, Fig. 5—Drag Mold Ready for Pouring Floor 1, 1915 experienced man with no knowledge of foundry s put on to operate the machine with in- tions that each mold made upon the machine be given the same number of blows, as de- ned by an experienced foundryman. Carrying hese instructions, the operator of the machine duce every mold rammed upon the machine rmly the same, and thereby avoid to a greater those defects that are caused by soft and ramming by hand. \nother source of great trouble is blow-holes sed by poor venting of the molds rammed by d. This uncertainty is also avoided by machine molds, as we can depend entirely upon the sity of the molding sands, for the escape of es, and do not have to provide channels or vents the gases to escape. The use of swabs on ma- ne-made molds is also eliminated. Swabs are sed on hand-rammed molds to moisten the edges the sand around the pattern before drawing it the mold. Its danger lies in a too free use of the water ind the mold, which may result in blow-holes. ng into consideration the dangerous causes that The foundry swab is a dangerous erally produce defective castings which are or entirely avoided by machine-made molds, may safely say that the percentage of rejected | defective castings will be reduced considerably. Molds made upon machines can easily be held thin 4 per cent. of the required weight, while my rds on past tunnel contracts show a variation \0 per cent. in the weights of the castings poured molds rammed by hand. The explanation for is that no rapping of the pattern is necessary, eby not enlarging the mold. Another reason that they are rammed just right by a given num- f blows, thereby avoiding soft rammed molds ch is a common trouble created by hand-rammed ds. Soft rammed molds produce heavier cast- than those desired, because the sides of the are not strong enough to withstand the pres- e of the molten metal, under which circumstances ansion will take place, and in extreme cases ls will appear on the casting. More stock for machining is due to the fact that re is a uniform ramming of the molds and no pping of the pattern is necessary before drawing. is very desirous to obtain sufficient amount of k for machining so as to have as little strain THE IRON ~] ~) AGE the amount of stock left for machining is too great, it causes a great strain upon the . utters, dulling them, and therefore producing a rough and ugly surface. This trouble is also of great interest t the manufacturer, but he looks upon it in a dif ferent light. With him it means dollars and cents, for it is poor business policy to pay $14 per ton for pig iron to machine into borings which usually sell for $7.50 per ton. Fig. 1 shows an Osborn direct draw roll-over jolt machine, made by the Osborn Mfg. Company, of Cleveland, Ohio; also part of the sand mixing conveyor and a crane for handling the bottom plates. To the extreme right is shown part of the sand mixing conveyor. The old and the new sands in the proportion of one part to ten parts are shoveled into a hopper built below the ground level, from which the sand is conveyed by means of chain buckets to another hopper built about 6 ft. above the ground as possible upon the cutters. If machined level. From this hopper the sand enters the scree falling below to another hopper built below the ground level which contains two spiral screws These screws cut the sand and at the same time bring it forward to the elevating buckets, whicl convey it to the large hopper. Directly under thi hopper is the Osborn molding machine upon whic! the drag molds are made. Needless to say, it is upon this drag machine that the entire success of machine molding of the tunnel segments The ramming, the rolling over of the flask and the drawing of the pattern are all done by air power. The machine shows the flask securely pinned to the roll-over table with a wooden hopper placed above as a sand guide. After the flask and hopper are filled with sand, the machine is then ready to be jolted. Comparison of results has shown that 80 blows of the machine are re quired to ram the mold correctly. Next, the wooden hopper above the flask is removed, after which the men run a stick lengthwise across the flask to leve the sand with the top of the flask. This is followed up by putting on the bottom plate, which is securely fastened to the flask. The flask is now rolled over, as shown in Fig. 2, until the grooves rests. then of the roll-over table insert themselves upon the shafts of the hand wheels located on each side of the machine, which are afterwards tightened to hold After having ac- the flask and table in position. — Fig. { Segment Ready for Machining complished this, the mold-receiving car is then pushed under the table. The roll-over table to which the flask is fastened is then lowered upon the mold- receiving car. Any unevenness of the bottom board is taken up by the use of wooden wedges. The pins which hold the flask to the roll-over table are now loosened, the pattern being drawn from the mold as shown in Fig. 3. While raising the roll-over table, the vibrator must be in use. This will vibrate the pattern loose from the mold. There are two vibrators on the machine, one on each side of the roll-over table. One of these vi- brators can be plainly seen in front of the machine connected by a hose, which is also operated by air. The mold is now resting upon the small car which provides easy means for withdrawing it from under the roll-over table. This brings the mold entirely clear of the machine, from where it may be removed to the pouring floor. Fig. 4 shows a plain jolt machine on which are made the cope molds. (The drag and cope molds for the key can also be made on the machine.) They are raramed by power the same as the drags, but upon this machine there does not rest the credit of the successful machine molding of the tunnel seg- ment as it does upon the drag machine, for there is no rolling-over of a flask or drawing of a pattern to euntend with. After the mold is rammed, the molder builds the runner box for pouring on the machine before it is taken to the pouring-off floor. Fig. 5 shows a drag mold as it came from the machine ready to be carried to the pouring floor to have the cores set and poured off. It also distinctly shows the pouring-off floor. From close observa- tion of the large mold it will be readily seen that at each end there is a large opening. This is to ac- commodate the end core. The five end holes and bosses including half of the endside core-prints are all made in one core. The end cores are at present made by hand, but will be made upon a small Osborn roll-over machine with a direct pattern diameter as shown in Fig. 6, upon which are made the side cores. Eight side cores are made upon this machine at one time, the boxes being of metal and of one piece. They are drafted about one-thirty-second of an inch so as to have the core withdrawn from the core-box freely. Splitting of the core-box was ob- jected to on account of leaving a fin on the 45-degree chamfer. The greatest amount of care and skilled workmanship was put on these boxes so as to insure a close-fitting core in the core-print, the object being to avoid as much as possible fins around the outside of the boss when poured. This was accom- THE IRON AGE April 1, 1: plished by machining up a master core-print machining out the core-box one-fourth inch la; than the core-print. The master core-print js ; taken and placed within the core-box and bah} metal poured around, thereby insuring the sha, of the core and the core-print to coincide. Fig. 7 shows a rack of side cores ready to go the oven to be baked, which usually takes from { and a half to five hours. After setting the co) and enclosing the drags with copes, we are th ready to pour. This brings us to the question the iron. It is of a good quality No. 2 gray pig ir. remelted in a foundry cupola. No mill cinder iro; white or burnt iron of any kind, nor old fire-| scrap will be permitted in the composition. The test samples are cast from the same he: but as the heat in a cupola is a continuous proces a set of two test bars is required for every 2 tons of castings poured or fraction thereof aboy this amount. In case of a change of mixture du: ing the heat, one set of two bars shall be cast fo: every mixture other than the regular one. Th quality of the iron going into the castings is deter mined by means of the “Arbitration Bar.” Thi: bar is 144 in. in diameter and 15 in. long, which ha to withstand a minimum breaking strength under :; transverse load of not less than 3000 lIb., and a de flection of not less than 0.10 in. After the bars have passed the physical tests, borings are take: from them for chemical analysis. Should any of the test bars fail, it would be an easy matter to pick out the castings represented by the tests, as the castings and the test bars are marked for ever) 20 tons or fraction thereof above this amount. The molds are poured from a large crane ladle. Much skill is required in pouring, and a molder must know the character of the work and judge whethe it must be poured fast or slow. In general, light work cannot be poured too fast. Heavier work is poured more slowly. Care must be exercised t keep the stream steady from the first, and not t Side Template i eae J Hook Gauge Depth Gauge Fig. 9—Templates and Gauges Used by Inspectors spill into the mold, as this may cause “cold shuts or leave “shot” iron in the castings. After the castings are sufficiently cooled, th flasks are shaken out. The company’s own foundr inspector now goes over them roughly to see the result of the day’s cast, rejecting all castings wher the injury is of such serious consequence that it impossible to use it, such as blow-outs, run-out cope drops, and poured short castings. These tro! bles are never put up to the Public Service Cor mission inspectors to pass upon, as they would n i: 1, 1915 ven any consideration at all. From the shake- joor the castings are then sand-blasted, and the temperature of the casting is still above leg. F. it is dipped in a vat containing tar, acts as a protective coating. After being ed, they are placed upon skids and allowed to off. They are then sent to the chipping de- nent to have the fins, risers, and gates chipped ig. 8 shows a general view of the heavy seg- as it leaves the chipping department, ready machined. Machining of the sides and ends iding the drilling and tapping of the grout hole he next operation. The side and end holes are drifted and then put up to the Public Service mission inspectors for final inspection. Fig. 9 shows the apparatus used by the in- ctors to check up the castings. The sides and | templates are used to check up the bolt holes in circular and longitudinal flanges. They are le of steel with pins one-fourth of an inch longer the full thickness of the flange, and represent- the bolts, and said steel pins, being one-fourth in diameter smaller than the size of the holes in casting, shall drop freely on to the flanges with he pins in the bolt holes, without straining, and so hat the ends of the templates representing the ma- hined faces of the segment shall not be in error vith the segment faces either way. The boss-tester ised to check up the faces of the bolt bosses, vhich must be true and parallel to the plane of the shed joint. The hook gauge, the width of the achining, and the depth gauge the maximum and inimum depth allowed the caulking strip. The istings are also gone over for surface inspection t this point, looking out for blow-holes, sand-holes, wells, scabs, cold-shuts, shrinkage cracks, twists, After having passed inspection, they are tamped, the machined surfaces are coated with vhite lead and tallow so as to prevent rusting, the eights are taken, and they are then placed on ard a car ready for New York. Vertical Machine for Heavy Driiling ‘ \ box column type of vertical drilling ma hine, intended particularly for heavy work in teel, has been developed by the Cincinnati Bick- rd Tool Company, Oakley, Cincinnati, Ohio. The ie is furnished with a screw support in addi- to being clamped on the column. A wide nge of spindle speeds and feeds is provided. As will be noticed from the accompanying en- raving, the machine is of massive construction is regularly furnished with four-step cone ilieys for a belt drive. This arrangement gives nt spindle speeds, ranging from 50 to 300 four through the belt drive, this number ng doubled by the use of back gears. The est step on the cone pulley is 16 in. in diam- while the smallest is 10.9 in., the belt used suring 4 in. in width. (he power is transmitted by a 4%4-in. belt, ng over tight and loose pulleys, 14 in. in eter, at a speed of 545 r.p.m. The bevel ng pinion is of high carbon steel, while the n the spindle is unhardened, and is made special mixture of steel. he spindle is a high carbon steel forging is 2-9/16 in. in diameter in the sleeve, and 5 In. above it at the smallest point. The the spindle conforms to the Morse No. 5 ard, and the spindle has a vertical travel in., and six rates of feed ranging from 0.007 49 in. per revolution of the spindle. ~ THE IRON AGE 719 \ Machine That Has Recent! Been Developed fo He Drilling in Steel The table, which is of massive constructio: and is supported by a screw from the base a well as being clamped on the column, has grooves or channels to take care of the drilling lubricant t A vertical travel of 12 in. is provided for the a table, the maximum hight from the floor being 30 in., while the maximum distance between the spindle and the table is 1 in. greater. The machine will drill to the center of a 30-i: circle and is 105 in. high. It weighs 5100 Ib Research Club The Steel Treating Research Club, Detroit, the name of which serves to indicate the scope of its activities has elected the following officers: President, C. N Dawe, chemist and metallurgist, Studebaker Corpora tion, Detroit; vice-president, William Tatio, Detroit secretary-treasurer, Charles R. Poole, chemist and metallurgist, Frost Gear & Forge Company, 133 Stew ard avenue, Jackson, Mich. The club was organized in Detroit in March, 1914 The active membership includes foremen and assistant foremen of case-hardening and heat-treating depart toolsmiths and tool chemists Steel Treating isi ments, hardeners, and metallurgists. The associate membership comprise , salesmen and representatives of concerns dealing articles and materials used by the heat-treating depart ments of modern metal-using industrial establishment The meetings are held in the rooms of the Detroit FE) gineering Society. The and equipment of the Roberts Mot Company, Sandusky, Ohio, have been sold to F. P. Zo linger, trustee for the bondholders. It is expected that plant the property will be turned over to the Roberts Motor Mfg. Company, which was recently organized and now operating the plant. The Mansfield Tire & Rubber Company, Mansfic Ohio, has taken over the management of the newly « ganized Columbia Tire & Rubber Company, Colum! ana, Ohio, and the plant of the latter will be operate: as an associated concern, but as a separate corporatic Automatic Machine for Fluting Drills For fluting twist drills 4% in. in diameter and smaller, the Bickford Machine Company, Green- field, Mass., has developed a special machine. It is fully automatic for both forward and return move- ments of the carriage as well as indexing between the two flutes of the drill and the angle between the cutter spindle and the line of carriage travel is maintained constant, a special device providing increase of lead and thus changing the angle of the cutting lips of the drill. In the accompanying illus- tration the view at the left shows the method of driving the feed, while that at the right illustrates how the spiral and the increase twist are obtained. From the cutter spindle the feed is driven through spur, bevel and worm gearing to the cross shaft which carries a crankwheel and imparts the movement to the carriage through an arm of peculiar L shape. It is pointed out that this special form of arm is needed to give a constant rate of speed when the crankwheel is making that portion of its revolution while the drill is being cut. Where the link from the upper end of the arm is attached to hine That Has Recentl Driving and Obtaining the the carriage the surfaces in contact are fluted with a view to preventing slippage, and this same ar- rangement is employed to attach the crank pin, an adjustment for different lengths of carriage travel being provided. The carriage travels on a frame which is arranged to swing on the bushings form- ing the bearings for the crankwheel shaft, the front end of this frame carrying the bushing through which the drill is milled. A lever underneath has one end arranged to swing on a stud provided with an elevating screw and clamped to the frame of the machine. The other end is carried downward by a cam on the crankwheel shaft during the forward movement of the carriage, the drop being increased materially at the end of the carriage travel. This lever is connected with the swinging frame by a short link, this construction being relied upon to provide the increase of thickness for the web of the drill and also to drop the drill free from the cutter during the return stroke. The drill or work spindle is connected through spur gears to a shaft carrying a bevel pinion in mesh with a bevel gear mounted on the side of the carriage, and a slotted arm which derives its mo- tions as the carriage moves forward by contact with a small roller, which is adjustably attached to the frame of the machine, rotates the bevel gear. A movement of 45 deg. of the slotted arm is suffi- cient, by reason of the ratio of the gears, to give 114 revolutions of the drill spindle, which is enough to give the required spiral. This is accomplished THE IRON Been Spiral and the Increase AGE April 1, 1: by setting the pin which carries the roller at < a hight that the arm will make the necessary sw from its vertical position during the time that drill is being fluted. As the pin travels in a h zontal direction with relation to the center of : bevel gear, the speed of revolution of the gear be constantly decreased, thus giving the incr: in length of the spiral to the flute of the drill. The upper end of the swinging arm carrie short shaft having a rectangular button at one e; and at the other a disk with four pins arranged ; that at each return of the carriage the button given a quarter turn by the latch in the top of t} carriage, and presents a side and then an end to block on the bevel gear. This gear is arranged to stop at a certain position as the carriage comes: back, and the button picks it up on its forward movement, the difference in position between th: contact of the side or end of the button being equa to a half revolution of the drill spindle. In th: engraving at the right the carriage is in the posi- tion where the button has made its quarter turn and is ready to pick up the block on the bevel gear with its end. A pull spring and chain running over _oainneaeenneaaeae Methods of Developed for Fluting Twist Doills, Showing the Twist a grooved pulley are relied upon to take up the back lash of the gearing during the return stroke, and a pair of gears having a ratio of 2 to 1 throws the feed worm out of engagement on completion of the second flute of the drill. A handwheel is attached for convenience in setting up the machine, as a single turn of it performs the entire operation of making one flute. The machines are intended to be placed in a row on a bench and a special form of guard and an oil spout enables the cutter to be flooded with oi! or cutting compound and carries the chips to a long trough. This conveys the oil to a supply tank after passing through a strainer from which it is pumped back to the machine for use. High-speed cutters are employed and the machines have a productive capacity of 30 14-in. drills per hr., a range of five different feeds for smaller drills being secured through change gears. A number of improvements are being made to the blast furnace of the Perry Iron Company, Erie, Pa., which will go in blast shortly. They will include the installation of a pig casting machine and a slag han- dling plant. Orders have been placed with the Whiting Foundry Equipment Company, Harvey, IIl., for a 100- ton ladle crane for handling several 75-ton ladles, which will be used for direct pouring, and a bucket crane for handling slag. Power will be supplied from a new 150 kw power plant. The improvements are being mad under the direction of Arthur G. McKee & Co., con- sulting and contracting engineers, Cleveland, Ohio. 1] \olding Machines and Pattern Mounting Interesting Analysis of Foundry Practice —-Adaptability of Various Machines Com- pared — Efficiency in Pattern Mounting BY J. FRANKLIN ERVIN* manufacturers of duplicate machinery re- wiring grey and malleable iron parts are con- fronted with the question of pattern equipment. Whether or not the manufacturer operates a foun- dry does not necessarily affect the question of the nattern and molding machine equipment requisite for the economical production of his product. It s the practice of foundrymen to furnish all equip- ment which is interchangeable, such as benches, squeezers, snap flasks, etc., while all special machines to which.a pattern is mounted, together with all equipment such as flasks, ete., are charge- ble to the manufacturer. The type of mounting has much to do with the economical production of accurate castings. Almost all castings of the light type, as malleable and gre) iron parts for agricultural implements, range in weight from a few ounces to two hundred pounds, and have a high ratio of surface area to total weigh This point is worth considerable attention, since a small amount of rapping for hand draft will easily add ten per cent. to the total weight, which is a direct loss to the manufacturer when castings are purchased by the pound and sold by the piece. Ac curacy in the product will warrant the expenditure of no small sums when large orders are called for in ble of Relative (‘os Machine Typeof Patter: : ne Total M nu hine or Method Cost Pattern Cost r'ype of Mount Coat Cost ture - pa | Hard sand . 1 Gate $25 i Match wood frame . a me | Hard sand $10 A Gate - } Match wood fr squeezer 0 1a ; 5 | Hard sand a ae ; , 5 a E { Match wood frame squeezer . 100 1 Gate “ es frame i over, single head cope and drag ; 2 ; 300 l Gate 2 . ‘aa ee . er for drag and stand for cope 165 1 Gate 9 : aoe sia ‘ . ryieate plate hand ram, one machine (1 cope plate cope and one for drag..... 150 1 Gate 9 ) 1 drag plate plate, power squeeze; one ma- 1 cope plate : or cope and one for drag... 300 1 Gate 95 ! ~ =e ; { "iL 1 drag plate ® . - io Hard sand A ind squeeze cope z ~00 l Gate ° M atch woos Methods pursued by manufacturers in producing their patterns and equipment vary little. A draw- ng from the engineering or experimental de- partment is sent to the pattern department where an initial or experimental pattern is produced in wood or metal, depending upon what is required of rial castings are then made by the foundry, following the testing and inspecting stages, additions, subtractions or alterations are suggested. These suggestions go back to the engineering or perimental departments where, after revision. pattern drawing is reissued to the pattern shop additional orders. After one or more trials, milar to the above, the machine is either adopted rejected. If adopted, the foundry problem yins. | (he foundry foreman is first confronted by the estimating department with the plain ques- How much will it cost to mold? The foreman turn must know the estimated annual require- ents and form in his mind a method of molding which he proposes to pay a certain fixed price. nless pressed for low figures, he starts with a price confident he will be able to better. order to meet the requirements of production price, the foundry foreman consults with the ‘ern-shop foreman and the designing depart- ‘, and the casting is analyzed in detail. These ‘ils are of decided importance in determining method of gating. The mounting is controlled ‘he quantity required, as well as by the par- ir design of the casting. nsulting engineer, Moline, Til. order to overcome any defects and avoid the return of large quantities of castings to the foundryman. The labor of inspecting and handling, coupled with more or less machine work done before defects are discovered, is a total loss. ITEMS OF COST The major item of foundry cost is molding and it is the one upon which all others are largely de pendent. The method finally adopted to satisfy al conditions must take account of the following fas tors: 1. Quantity required, 2. Uniformity of weight, 3. Accuracy, 4. Economical cost of equip ment, and 5. Cheap production. To determine the quantity required is a function of the sales organi zation, while uniformity of weight and accuracy are problems individual to the particular design of casting. The kind of equipment is also dependent to a great extent on the above named requirements, but is also governed by the methods adopted to promote cheap production in the foundry. Types of Molding Machines and Method mn General Us Floor molding 2. Bench or stand molding 3. Hand squeezer machines 4 Power squeezer mac hines 5. Roll over, single head for ope and drag, and hand Squeeze 6. Roll over for drag and stand for cope Drop plate, hand ram with separate machines for cops and drag 8. Drop plate, power squeeze with separate machines for cope and drag 5. Combination jolt and squeeze 10. Several other combinations, such as squeezing and drawing cope and drag at one operation with the pattern stationary; multiple molding and combina tions of two or more of the above simple methods 721 an ~ Sain sented bee a 722 THE IRON AGE April 1, for a pattern requiring a 10x14 in. flask, = An eve ryday foundry proble m is here ana- drag and 4 in. cope, which is cited i a ty; = lyze d in care ful de tail. example. : Types of machines and practical methods of ADVANTAGE AND DISADVANTAGE OF METHOD molding to specifications ~o ta} 5 a s ee oe fications are tabulated, to giv Each method of molding affords advantage the gist of the problem at a glance. disadvantages as applied to each individual The question of pattern mounting is empha- tern. The accompanying tabulation present sized and its importance in practice shown. general considerations. Floor molding is appli to a class of work too heavy to handle on benc! HAND, SQUEEZE AND JOLT RAMMING ADAPTING PATTERNS TO METHODS AND MACHINES Hand ramming has the advantage where irr: The adaptability of a particular pattern to a par- lar work is molded, since the molder can ram hard ticular machine can best be decided by an analysis soft according as it is necessary to give perf: of the advantages and disadvantages offered by castings. This method has the disadvantages each method of mounting. requiring an experienced molder on the job, The accompanying table of costs of a simple the time element, since 0.3 min. per sq. ft pattern with various mountings shows the tota! flask area is required for hand ramming. cost of equipment to produce castings, and the Squeeze ramming is advantageous where wor portion thereof chargeable to the manufacturer is not too deep and no bars are required in t! j j of the idvantag ) rdivantages of the Different Methods of Molding \idvantages 1. Small cost of equipment Good for accu te wor n mate ¢ ope and drag, since cope s tched M advantages Molder required on worl Difficult due to stooping positi« of moldet Drawing pattern from sand by han 4. Hand ramming \dvantages: 1. Accuracy ol wor itching cope over drag Ease of handling due to position of molder Small cost of equipment Small cost of changing jobs “ isadvantages When cores are to be set mn cope When work is required on cope after drawing Drawing pattern by hand ; Molde required or work Hand ramming necessary vantages Accurac of work in matching cope over drag Ease of handling due to position of operation Low cost of machine Small cost for changing jobs Speed and ease of ramming 6. Machine man sufficient on jot ez Disadvantages 1. Cores in cope Work necessary or cope Drawing pattern by hand Unequal ramming (hand power machine) Unequal ramming—irregular patterns Advantages 1. When drawing pattern from sand is advantageous 2. When cores are set in cope. ;. When work is necessary on cope it. When difficult draws are in the cops Disadvantages ee ereen Single Head Cope and 1. Error of making cope and drag from separate plates e me ; ; 2. Necessary elamping to roll over. 3. Weight of working parts of machine to secure perfect alignment under stres 4. Complication of machine makes repair charges high Awkward position of flasks for closing Cope reverse side up for closing High cost of mounting. 8. High cost for changing patterns \dvantages: 1. Difficult draws the drag 2. No bars required in drag Where worl too heavy f« ‘ n to har ice ia ‘ . Disadvantages Cope ae ner 1. Error of making cope and drag from separate Clamping to roll over on drag High cost of mounting {. Initial cost of machine and equipment Cost of changing jobs 6. Hand ramming ’. Hand draft for cope Advantages Ease and iccurat i ai Speed possible lrawing Disadvantages Cost of mounting 2. Cost of machine lipment Drag reverse side up when dravt Hand ramming (this eliminated it ower squeezing machine) Cost for changing patterns Error of making cope nd drag fron eparate plates J Advantages and disadvantages are the same as for power squeezing, with the > idvantage that mold with deep and irregular drag can be rammed while thé s being shoveled 1, 1915 The reluctance of molding sand to flow pressure plays an important part in the possi- of squeeze ramming to uniform hardness rregular surfaces. Experiments by the writer hown that sand will not flow under a pressure lb. per in. upon a surface inclined at in 60 deg. with the horizontal. This causes nd to pack hard over thin surfaces and remain n the recesses. he area of the flask further defines the limits nomical squeeze ramming. A flask with an ' 2.5 sq. ft. requires about 742 tons pressure, is the equivalent of 80 lb. air pressure on a cylinder. A machine correctly designed to hstand such a pressure is heavy and cumber and not practicable where shallow and light ks are used. The use of other than snap flasks so prohibited without the use of a sand frame lar to that used with the jolt rammer, sinc and is rammed below the flask surface. Sq. JALYSIS OF OPERATIONS IN VARIOUS METHODS [he operations necessary, weights handled and fferential time elements give us the relative effi y of each method or type of equipment when pattern is taken as a constant. The cheapness olding is governed by the simplicity of opera ms and the amount of material necessary to ndle. The following related data is based upon a ple pattern mounted for the making of a mold each of the following methods. The mold and pment have the following specifications, using Sheets f Bight Different Methods ding ith Match Gated Pattern and Snap Flash Weights Time handled, elements Operation: in Ib seco! on machine or floor l flask on machine 6 sand on patter! S sand on patter? , ram . off ’ n drag board ' ver ‘ ve match 12 1 n cope flask th ‘ e sand on pattern 8 sand on putterr , i ram : off ‘ pe ‘ ¥ pattern hare . S mold : ve flask 12 Id on floor = & weight handle: '93 Ib 146 time hr & mir é Vated (ja 4 ~ Flash Weight rir il me machine ym macl ‘ f d on patter i on patter m fr lrag board queeze match ope flas} ‘ nd on patter: na on patter re ope board squeeze ope board ttern ham aa isk . nd drag or ! \ weight ndled O01 It time °* hr 1 mir THE IRON < 79° GE iz 2 Cost sheet that i n adouars and , 2 the relati ‘ ‘ ynomey arIious mr ¢é thoad producing a light casting j Syvmmarny >, Tie pernits a ea De lions nece ‘ se hié ‘ equired, ete Ba j erTrnod die ussed ‘ thé Yr wer rhe nine (1? is a flask 10 in.x 14 in. x8 in. deep, both cope ar drag having depth of 4 re j Ze ‘ ] bott« 4 it : ‘ > Ty ’ hi In the accompanying table of weights the efficiency method of machine is based upon the total time required t the total molding operations and upon of man required for the operation. The rated in relation to the molder of each man is the at and time molding perfor cla machin: a rat of 35 and 50, while the drop plate power squeeziny machine which requires the minimum time for pr: efficient is base withou ducing the part is rated as 100 per cent The production efficiency of each method wholly upon the merits of each method uf Pp W eligi ale Match on machine i Drag flask on n Screen sand on patterr Shovel sand on patter Veen Strike off Put on drag board Roll over Power squeeze Remove match Put on cope flas} Riddle sand on patter! Shovel sand on patter Peen Strike off Put on cope boar Power squeeze Remove cope |! Lift cope Draw pattern |! Close mold Remove flask Set mold on flo Tota we gl t I ! lent time > p ‘latch on macn Drag flask on m Screen sand on } Shovel sand on | Peen Strike off rut on dr ! Roll over Put on cop. 6 Riddle sand or ‘ Shovel tte reen Strike off Put ope poal ‘ Power squeeze Remove cope It cope Draw patter! (“lose mold Remove flash Set mold on floor Total weight oo Total time THE IRON AGE April 1, 1 Drop Plate and Power Squeezer with Separate Mach Weichts Time Cope and Drag, or Cope and Drag Duplicates fre handled, elements Same Machine Operatio It er Match on machine or floor 6 ! Weights Screen sand on pattert \ handlea Shovel sand on patte Operations lb Peen Hand rar Drag flask on machine ‘ 6 Strike off 5 Screen sand on pattern... 3 8 Drop patter! Shovel sand on pattern Put on drag board 3 Peen Set drag on bench Strike off Put on cope flask 6 $ Drop pattern Riddle sand on patter . . Put on drag board } Shovel sand on patter! Power squeeze Peen , Set drag on bench ° 33 Hand ram s Put on cope flask... a ; 6 4 Strike off Riddle sand on pattern : S § Drop pattern Shovel sand on pattern 22 Close mold Peen . ° Remove flask l Strike off .. Set mold on floor ) Drop pattern a ° : Put on cope board ‘ awe } Total weight handl t rower squeeze a oan sean aus Reg lie Remove cope board Tee. ; 4 Close mold . “is 33 l temove flask .... ; 12 Oo D Sta or ¢ Set mold on floor o oe ignite Total weight handled 220 Ib 104 , a , Total time j ; ‘ 1 hr. 44 n Drag flask on machine b > . ) Scree sand on patterr ‘ Roll Over wonres Head sat eee ees We ights . - ieenit cians se aa handled, elements Strike off er. - ’ Put on drag board rag and cope flasks on machine 12 8 Clamp Screen sand on pattern 16 Roll over . Shovel sand on pattern i6 Draw pattern hand Peen ... - ] Roll back pattern 0 Strike off : o's f Set drag on bench Put on drag board : 8 d Put on cope flask f Clamp eee : 8 Riddle sand on patter: Roll over 4 10 Shovel sand on patter! Hand squeeze 10 Peen Draw pattern power “ 8 Hand ram Roll back pattern 8 Strike off Remove cope board 4 3 Draw pattern hand Close mold 11 10 Close mold Remove flask 12 Set mold on floor Set mold on floor ‘ee os 9 Total we 61 Total weight handled . 197 1b 122 Total } Total time 2 hr. 2 min Operation Nosy Operations doing Per cent work Per cent. cost of Tota Total but not Total produc- produc Type Machine and patter? opel! weight handling time tion effi- tion effi- man juipment tions handled weights required ciency ciency required sench—-with match and gated patter1 93 hr. 26 min 71 50 Molder Hand squeezer, match and gated pattern ; ,01 > hr. 10 min 80 80 Machine mar Power squeezer, match and gated patter? 23 01 ° hr t min R4 84 Machine mar Power squeezer, double faced aluminum match 21 76 ) 1 hr. 55 min 90 90 Machine man Drop plate, hand ram { S -hr. 12 min 79 55 Molder Drop plate, power squeeze ( g lhr. 44 min 100 100 Machine man Roll over, hand squeeze, single head cops dr on one head 2 hr 2 min RF R5 Machine man Re over drag, cope « t I 2 hr. 23 min 73 51 Molder any regard being taken of the rate of the operator. The weight handled on the squeezer, which is the least efficient on this basis, is approximately six times the weight of the mold, which verifies the necessity of having all parts, such as pattern, matches, flasks, boards, etc., as light as possible. Should the mold used for comparison pay two cents ach, or $2 per hundred, the operator would be paid $2 for handling 15 tons of material, which is at the rate of 13 cents per ton. German Steel Works Union’s Review The of the German Steel Works Union, issued after its regular meeting on February 25, 1915, gives the following general review of the condition of the German steel trade: In semi-finished material domestic demand has been better and continued improvement is Prices for the second quarter have increased 7.50m. ($1.82) per ton, though these do not suffice to equalize the large augmentation in cost of production. Export bounties are discontinued. tral countries has increased and forecast continued improvement. In railroad permanent way material the Prussian railroads have made additional for statement anticipated. been with neu inquiries Business orders and inquiries rail fit- tings for 1915. The Saxony lines have increased thei original demands for railroad material so that they amount to nearly three-fourths of last year’s require ments, but the orders of the Bavarian roads are not half those of last year. Business with neutral coun tries continues on the increase. In rails for mines demand is on the same level as in former months, and domestic and foreign business in tramway rails is quieter. In shapes customers are trying to cover require ments and specifications are increasing. Prices fo the second quarter are advanced 10m. ($2.43) pe! ton, with export bounties also discontinued. A mate rial betterment is reported in foreign demand and th requests for delivery from neutral lands more active ¢ The structural engineers in Illinois have started the battle for the licensing of structural engineers by th State, and to remove the advantages which, it is serted, the architects have had since 1898, when a lav was passed making their approval necessary in the design of buildings. This law puts the structural e! gineer under the architect, no matter what sort o! building is put up. The work on large buildings of today, so far as safe loads and design are concerned, is done the structural engineer. The architect’s work is f quently of minor importance. I, ‘+hine for Facing Large Pipe Flanges facing the flanged ends of large pipes, the k & Harvey Machine Company, Baltimore, has brought out a machine consisting essen- of three parts. These are a threaded head- carrying a rotating facing head, a vise or rest iding the pipe to be faced and a bed for sup- ng the parts. If desired, a small crane for porting the outer end of the pipe can be in- ed. Two sizes of machine are built, one having pacity for handling pipe up to 24 in. in diameter the other having a maximum diameter of 38 in sizes of machines have a number of speec nges giving sufficient variation to cover the en- re range of work. The design of the headstock is similar to tha in engine lathe, there being a cone pulley an k gears for driving the spindle. The width o he driving belt is 2% in. in the case of the smalle- achine and 4 in. for the other. On the front end the spindle is mounted a large faceplate, having . slide way and a tool side, which has an automatic feed from the periphery of the faceplate to the enter, the feed being obtained by a shaft extend- ng through the hollow spindle. Differential gear- ng at the rear end of the spindle drives this shaft, vhich in turn transmits power to the feed screw perating the tool slide through bevel gears. The eed is disengaged by a clutch. Bronze bushed idjustable bearings and adjustable thrust bearings re provided for the spindle. The device for holding the pipe consists of a arriage mounted on the bed and having an adjust- nent toward and away from the facing head by a rank handle and screw and a pair of vise jaws. The latter resemble a lathe steady rest, but are made in two parts and are operated by a right and eft hand screw to facilitate rapid chucking and re- oval of the pipe. For squaring up the work in That Has Recently Been Developed for Facing the Flanged Ends of Large Pipes icking, a removable device which fits into the end the spindle is provided. Four smaller radial s having an adjustment for varying diameters flanges are fitted to the rest or vise jaws, which lamped by a locking bolt provided at the top. ine Triumph Ice Machine Company, Cincinnati, , Is booking numerous orders for refrigerating ma ry, accessories and fittings. A list of recent sales tions buyers in practically all sections of the coun- nd includes one in Australia. 1915 THE IRON AGE 725 Polishing Lathes with Underbelt Drive The Gardner Machine Company, Beloit, Wis.., has adapted its regular underbelt type of ball bear ing polishing lathe for use where there is not suffi- cient headroom beneath the floor to permit the 4 Portion of a Group of Ball Bearing Polishing Lathes Equipped with an Underbelt Drive That Has Been Developed for Use Where the Space Beneath the Floor Is Not Sufficient To Permit the Use of Countershafts placing of the countershaft there. With this ar- rangement the lineshaft passes through the bas near the floor and runs in ball bearings. The driving pulley is mounted on the shaft with in each base and connected to the spindle pulley by a slack belt. An idler pulley mounted in ball bear ings is forced against the belt by pushing down on the lever at the front of the machine. This re- moves all slack and starts the spindle revolving, the lever being locked in position by the notches in the quadrant on the front of the machine. To stop the spindle the lever is raised, thus removing the ten- sion from the belt by the retraction of the idler pulley. The spindle pulley and the belt are inclosed b a metal cover placed on top of the machine, and it is the general practice to cover the lineshaft in in stallations of this type. Practically any number of machines can be connected to the lineshaft and driven in this way. Sweden’s Iron and Steel Production in 1913 Official statistics of the Swedish iron trade for 1913, only recently issued by the Swedish Board of Trade, show the production of iron ore in that year to have been 7,475,751 tons from 295 mines, as against 6,669,226 tons from 300 mines in 1912, an increase of 11.6 per cent. These figures do not include bog ore, of which the amount was small. The pig-iron output in 1913 was 730,257 tons, compared with 699,816 tons in 1912. This 1913 production included 31,966 tons of pig iron made in one electric furnace against 17,561 tons from the same furnace in 1912. The total ferroalloy and pig-iron output of this same electric furnace in 1913 was 44,100 tons compared with 24,464 tons in 1912, a decided gain. Blast furnaces numbered 148 in 1913, of which 31 were out of blast, against 147 in 1912 with 28 out of blast. Of 590,887 tons of steel ingots and castings pro- duced in 1913, against 515,310 tons in the preceding year, 353,696 tons was basic as against 307,637 tons in 1912. Crucible and electric steel were 5661 tons in 1918 against 3941 tons in 1912. Electric furnace castings amounted to 350 tons in 1913 and only 69 tons in 1912. The output of semi-finished and finished iron and steel was 426,204 tons in 1913 and 393,150 tons ir 1912. Of the 1913 output, 140,975 tons was for ex port. The 1913 coal production was 363,965 tons; copper ore, 5458 tons; zine ore, 50,752 tons and copper, 6891 tons. The Wheeling Corrugating Company, Wheeling, W. Va., has opened a branch sales office at Portsmouth, Ohio. in charge of J. O. Entiekin. Court OF ABUNDANCE ; — TELL.OORPO Pom “Ag san max nl *‘hotograph from Point a Looking Out Main Entrance I Rais, STECLTICS SPCCIA z "Atcor gf _BARS. STRUCTURAL STecL -! Svteie StL PuuNG «6h S si STECL MINE TIMBERS, CTC WIRE AND WIRE Lat @ River Transport * Com. MINING COKE MAKING mae G nee ° LL. EXPORT Derr. RAWROAD | BR DGES}AND | K Prooucts \ OCEAN STEAMSHIPS _[TRANSPORTATION| Sy TRUCTURES et oe ee ee ea cc > , Froas. SWITCHES. CROSSINGS ICTU | THEATRE SHEET Steet & TIN PLATE SPEcian TRACK WORK ALVANIZED SHECTS X SEAMLESS PiPc— AND TuBuLar PRooucTs Wire FENCING Piece FITTINGS PORTLAND CEMENT ced Photographs Were Taken of the United States Steel Corporation's Exhibits in the Mines Metallurgy Palace of the Pat uma-Pacific International Exposition PMD ' wm / \ LX. Ka WK / os Sat a Products Exhibits and Model! of Coke Oven Modern Coal and Coke Plant in from Point d, and the Carnegie, Illinois ompanies Products in fackerol Gm) Le EDL kis « eh ice — es ¥ lel Showing Uses of Apollo S Photograph from Point f, Showing Part of the Large Exhibit of the American Steel & Wire Company 7 Westi iwshouse Electri we) Westinghouse Locomotive for Pennsylvania Railroad on an American Bridge Turntable in the Transportation Palace Sa Part of the Universal Portland Cement Exhibit, Viewed from Point o 728 |. | Poe Hath Ce ee oe get 4 I he of the Uses of Wire as Seen from ‘ational Tube and Kewanee Products from Point m Shelby Exhibits from Point k Safety and Sanitation Exhibit from Point g, Showing Long Fa re time Duplexing at the Maryland Steel Works The Process Adapted to the Removal of Chro- mium From the Iron—Five Methods of Opera- tion—Fuel Consumption and Quality of Steel BY F. It is not the intention of the writer to into a discussion of the relative merits of the duplex process as compared with the straight scrap and pig-iron process, working under the same condi- tions, but rather to present in a general way several modifications of the former process, and then de- scribe the method adopted by the Maryland Steel Company, as best suited to local conditions, and also to meet the metallurgical problem presented in the remov