The Iron Age 1915-12-09: Vol 96 Iss 24

New York, December Y, 1915 ESTABI SHED 1855 VOL. 96: No me k Keeping in Addi " lding Machine Factory fi Stock Keeping in Adding Machine Factor J e > nao Suze , . Routing System of the Burroughs Adding Machine Company—Perpetual Inventory Pro- . ~ . ‘ vided—Convenient Stockroom Arrangements BY F. L. PRENTISS Efficiency in plant management requires a pra more intricate system than needed in a shop tical system for keeping track of the amount of where the parts are made comparatively few stock on hand and what is going through the shop The stock-handling and routing methods and the in the manufacturing and assembling processes and finished stockroom of the Burroughs Adding Ma convenient storeroom facilities for handling stock chine Company, Detroit, Mich., are of unusual ir so that it can be sent to the proper department when terest, because this company’s products require the required without delays. Stock handling methods manufacture of a very large number of parts, and are usually worked out to meet the needs of indi- because of the very complete, but not intricate, s) ’ . . . . . . 4 vidual plants and necessarily vary materially ac- tem that has been devised for issuing parts to de cording to the line of products. In plants making partments, routing, keeping track of parts in the . a large number of small parts the stock-keeping ar- plant and storeroom arrangement The company | rangements are of more importance and require a makes and keeps in stock approximately 10,000 dif for Taking Boxes of Stock Material to and from the tockr . - ‘ . > > Zacks, Chutes ; kroom Showing Arrangement of the Racks, Chute from and to the Finished Stockroom ind at the Left Racks along the Partition for Holding Stock Going 1347 1348 THE IRON AGE Decembhy 1915 ferent parts, including subassembled parts and The large number of different pa different sections for each class of machines. The _ indicates that a great deal of detail w ts ordering, tracing and storing of these parts come ‘sary in keeping track of the stock, no ‘ fal . . ° ° under the supervision of the factory order depart- simple the system may be. With the ment. A production schedule furnished this de- ployed and blanks used, a perpetual partment every three months is the basis for de- provided and a complete record is kept : termining the ordering of parts. All parts are the minute of the progress of the work t known by symbol numbers. Assembled parts are factory. This record shows the num} designated by dash symbols. part in the finished stockroom and ths STRAIGHT SYMBOL ORDER RECORD SYMBO. 368" 4. NO. | a : t- AA I 60¢ t Time per Piece | . i { i COST RECORD ¥ ' LABOR & BU AE a |_| 0 t o a ° u : GROUP OF FORMS MADE OUT BEFORE THE WORK STARTS THROUGH THE SHOP The Top Form Gives the Name of the Part and Its Designating Symbol, the Raw Material Used, the Oper i be Performed and the Various Lots Ordered from Time to Time. The Next Four Are Made Out Simu ager when an Order Is Received by the Use of Carbon Paper. The Shop Order at the Left Is Essentially a oP. Are Top Form, while the Tracer at the Right Serves to Locate the Job in the Plant at Any Time. The Other : a Oe the Order to the Stockroom for Material and the Cost Record Card. The Reverse of the Last Pair Is Ruled vide Space for Keeping Records ; THE 2OUGHS ADDING aCHINE OO. NOTIFICATION TICKET ORIGINAL DATE "Ng 1015 PARTMENT 3 LLOWING STOCK IS NOW READY FOR YOUR DEPARTMENT FURTHER OPERATIONS OPERATION QUANTITY BOX NUMBER O_| i | J cemeneninnseeesennnsiond a = 23/0. | renee J —_$————__ FOREMAN = tion to Giv the the very Ticket Sent to the Order Depart e Information Regarding the Prog- Work from One Department to An- * Factory. These Tickets Are Col- Hour and the Data Transferred to cer Sheet Shown on the Preceding Page ing Cle of Stock Is Done by the rks Using the Tracer Sheet Inventory it are in the various manufacturing depart This el iminates stock tracing in the plant, ng of stock being done in the office. goes through the factory in sheet metal nd for K order convenience all pans are numbered and the manufacturing departments n close touch by a report of the daily meet- the inv entory clerks and a representative ch of the production and inspection depart when matters relating to stock and produ liscussed. carrying out the details of the system a number ire used, and the first that may be referred naturé master order card. le in il order is the straight symbol order This card, which is the stock order department, shows the part, the symbol number by which gnated, the raw material to be ordered raw stockroom, the department to which s to go, the operations to be performed, tments and operations being designated ers, th pieces in a box or pan. int of ven, gths. n the arts n to and the In specifying stock required, the length of raw the stock usually being in 6, 10 and The date the lot finished is master symbol card. orders are issued, the master card the order clerks, who make out the e number of lots ordered is cards, which are essentially a copy of STRAIGHT SYMBOL__ cs —— 7 $$ -___— “ sme coe “= one Se ca ost on |< om = = ow ~— saa - 7 nee —— -— pee peeenn eens den 2a + ~_-- RECEIVED BALANCE O£Liverto Out out om enpeas —— for Section It 368° ~ 368 * ENTERS OASH____/ amO CONSTRUCTIONS mmr [scares = rece omens ay meres wr heen dpe : den ‘ + ++ qn he a Single Piece Giving the Symbol Number, Forms a Part of and the Data e a Record of Material on Hand at Any Time IRON AGE 1349 the master card with all the details pertaining to the quantity of parts to be made. At the same time a tracer sheet, order for stock and cost record are made out by the use of carbon paper. These shop order cards go into the various departments with the work in the order indicated on the cards them- selves, and the progress of the work through the factory is indicated to the order department by the use of notification slips from each department, which inform the order department that the work is going from one department to another. A record is kept of this progress on the tracer sheet, so that at all times the location and condition of all work in the factory is known. This information prac- tically eliminates the necessity of stock tracing in the plant, all tracing of stock being done by in ventory clerks by the tracer sheet and notification tickets received hourly. In case it is desired to have part of an order fin- ished quicker than it would be in the regular rout- ing, part of the order sent through the shop ahead, and notation of this fact is made on the order card. In case of a rush order, a stock order card having a red top is made out. These rush orders are given a preference over all other work in the departments that the rush work reaches in its rout- is ing. When an order is completed, it is inspected, sais ia nia o arene ie ‘ ' FINIGHED STOCK REQUISITION ‘ | ATE oerr. wo. * | YMBOL 9ROER N aco’T voce © mene, + wanr . « ar carr 164 44 7 £0 er Oavre POR FEO ar j | REQUISITION FOR STOCK ORDER ri 265A DATE SYM. NO QUANTITY ”~ ORDERED STYLe | | LOT WO f cow#sisers oF ven aor # } ue * r Vs DUE OATE 191 (SSUEO BY A / j sition or k ished St« ‘ Materia } yuir | I> irtment and the Sto On Issued |} th I Cler th Factor when It |] Desired to Rep! } | aehe« Sf } 1 4 ’ ' Part receipted for and the date stamped on the shop order card by the inspection department. The card then goes to the finished stockroom, where the num- ber of pieces received is written in and the date is again stamped. The stock order card is used both for single pieces and for the assembled sections. When any department requires parts from the finished stockroom, it issues a finished stock requisi tion which bears the date, the department number, the symbol number, the number wanted and a space on which to indicate the number delivered. When stock is taken from the finished stockroom on a requisition, the proper entries are made on inven- 1350 Operation nd Tool Record Prepared by the Productior tl ng the tory cards, of which there are two, one for single parts and the other for dash parts or small assem- bled sections. The record kept on these two cards forms a perpetual inventory. The inventory card illustrated is for single pieces and shows the symbol number of the piece, the number of the dash of which it is to form a part, the date, lot number, number of pieces ordered and delivered and the balance in stock, after a certain number of parts are received or delivered out of stock. The dash part inventory card is similar to the above, except that space is provided on the form for entering the symbol numbers of all the pieces that are used in the assembly and the number of each piece required. Opposite the words “High Mark” and “Low Mark” space is provided for entering the maximum and minimum number of pieces to be kept in stock. These restrictions apply to small parts that are common to most classes of machines. The inventory card always shows with close accuracy the number of each part or symbol in stock, some variations, however, being due to the fact that the number is determined by scale count. When it is desired to replenish finished stock of a certain dash part, a requisition for stock order is issued by the inventory clerk giving the symbol and lot number and number of dash parts to be The Angle-Iron Rack in the Raw Stockroom for Storing Long Pieces Which Are Kept from Spreading by a Concrete THE IRON OPERATION ano TOOL RECORD Department Mach AGE Decem! When an Entirely New Part Is to be M nes and Operations Entering into Its Produ ordered. This requisition is used in conn: a master dash operation card, a form ( dash number and list of parts requiré nd the operations and routing. It will be noticed by reference to som« blanks that the work in going through th divided up in lots bearing lot numbers way the cost department has an opportu figure the cost on each lot and to compare th: of one lot with that of a similar lot made at previous time. Each day a preferred stock list is issued. A copy of this goes to each department, and the depart- ment foreman looks it over to see if there is any work on the list for his department. If so, this is given preference over other work. When an entirely new part is to be made, the production office and tool designing department pre pares an operation and tool record, this sheet con- taining a description of the part and also one of the operations and specifying the tool to be used, and this becomes a permanent record for that part. The stockroom at one side of the main manufac- turing department, from which it is separated by an aisle and wire netting partition, is of metal construction throughout, and arranged for conve- nience both in storing a large number of parts and Built Up from the Floor 9, 1915 ng those parts throughout the plant when r manufacturing and assembling pur- is a two-story room, the upper floor or ing built of iron gratings. The balcony rgely for the storing of lighter parts or ections, as they are bulkier and lighter ngle pieces. Standard racks are used for irposes, each 8 ft. high, 8 ft. long and 4 each rack being divided into two 4-ft. sec- he racks are very strongly constructed of 2 gage sheet steel with channel iron rods and he partitions, and each shelf is supported olts. The racks used for shafts are made | an extra heavy load by having a reinforce- pipe along the outer edge. All the racks are shelf racks so that they can be r the storage of either loose parts, assem- i sections or pans. Between the racks are 4}-ft. sles, and electric lamps reach down from the ceil- to the top of the racks in the center of each Parts are placed in the racks according to THE IRON AGE 1351 record is kept up to the minute, the steek keeper can tell at a glance the condition of his stock. In the raw stockroom the angle-iron .rack for stock in long lengths that is kept in a vertical posi- tion is supported at the top with braces attached to the ceiling, and at the bottom of this rack on each side a concrete shoe is built up from the floor to prevent the stock from spreading. Stock is stored on each side of this rack. The construction features are made clear in the illustration of the raw stock room. Cast Vanadium Steel Dies The use of alloy steel castings for dies has lately come into prominence due to important de velopments which have been made in the last few years by steel foundries specializing in such mate- rial. Cast steel dies are now being used by drop forging manufacturers, by plow manufacturers for making plowshares, and by sheet metal workers for forming dies in the production of sheet metal Pattern for Cast Steel Forming Die Is Sunk in the Flat Surface. At the Showing the Tenon Cast on the Die. In the Middle Is Dies Are Cast ol numbers that run in regular order, and this arrangement brings parts of a similar character together. For example, one section or aisle is used exclusively for shafts, another for screws, nuts and pins and another for special parts. Stock for repair parts is kept in a separate stockroom. A few of these racks are inclosed, and some are covered with curtains to keep out the dust. When stock is stored pans, it is kept in the same pans that carry the through the shop. Part of these pans are in. wide, 2314 in. deep and 91% in. high, and e remainder are the same width and height but twice the depth. A unique and convenient method is used for taking material to and from the balcony of the ‘tekroom. At the side of the stairs, as shown in the illustration, is a chute. Instead of carrying a n ot stock down these stairs, a man at the top ‘s It slide down the chute, and it is caught by a at the bottom, or the man above walks down ‘he stairs holding on to the pan in the chute with a took as he descends. In the same way a hook is ‘sed to pull the pan of stock up the chute to the 4cony. A convenient method is used for taking Pans of stock to the stockroom without requiring a to enter the enclosure. When a pan of s to be taken to the room, the workman places n one of the racks built in the partition and Own at at the left in the illustration, and the stock “per pulls the pan out from the rack on the other tock keeper has a blackboard adjoining his “< on which he enters all stock shortages of parts _. semblies that may be holding up orders in the lepartments. Entries are made on this | as changes occur, and as the blackboard Die for Drop Forge Work. Right The Impressions for the Is the Back View of a ¢ 1 Pair of ¢ Steel Dies is Shown Breakdown Are Cast to Die for Making ing Plowshares Shape Plow The ist Steel ist for Mak specialties, kitchen-ware, etc. Various alloys have been tried for cast steel but, according to C. R. Messinger, vice-president Sivyer Steel Cast- ing Company, Milwaukee, the most satisfactory ma- terial so far introduced is vanadium carbon steel. The Sivyer Company has made a specialty of cast vanadium carbon dies under the name of Siv- ver die steel. Exceptional wearing qualities are re- ported, together with unusual resistance to crack- ing or breaking under the battering to which dies are subjected. For example, a run of 40,000 auto- mobile brake support forgings 20 in. long, was made from a pair of. Sivyer dies without, it is stated, any great amount of wear. In another in- stance a plow manufacturer claims that his dies last at least six times longer than cast-iron dies for forming plowshares, and are considerably cheaper than hammered blocks. For general drop forge work the company con- siders the best practice is to cast the dies with the tenons and with the impressions for breakdowns approximately to shape, allowing a small amount for finish. The impression for the die is then sunk in the solid block. For plain forgings, the impres- sions also are sometimes cast in the dies allowing some metal for finish. In dies for making plow- shares the entire impressions are cast in the dies, allowing about %4-in. metal for finishing. Forming dies for sheet metal are also cast approximately to shape with some allowance for finishing. After annealing and machining the general practice with cast vanadium dies is to heat to 1500 or 1550 deg. Fahr. and quench in oil for a fairly hard surface and in salt water for a hard surface. In most cases no additional heat treatment is re- quired; that is, the temper should not be drawn. dies, 1352 THE IRON AGE Cast vanadium dies, it is explained, generally cost a little more per pound than hammered carbon blocks. However, it is held that the saving in ma- terial from casting approximately to shape more December 9, 1915 than counterbalances this and in addit less material to be removed. The reproduced photographs illustra methods of preparing patterns for cast President’s Proposed Tax on Iron and Steel Twenty-five Cents a Ton on Pig Iron and the Same on “Fabricated” Iron and Steel WASHINGTON, D. C., Dec. 7, 1915.—President Wil- son’s recommendation for the raising of additional revenue to meet the deficit in the treasury and to cover the cost of the national defense program are not only surprising to the iron and steel industry, but in their entirety have dismayed many Democratic Senators and Representatives, who realize how unpopular some of the suggestions will be in the agricultural regions, which are the chief hope of the majority party in Con- gress, because of the high prices which the farmers’ products have obtained since the beginning of the war. The suggestions in the message, however, will greatly encourage the movement set on foot some time ago for a tax on war material and there is likely to be much competition among Senators and Representatives, each anxious to be known as the originator of any war munition tax measure that may be adopted. The suggestion of the President that all the money needed by the Government in excess of current rev- enues can be derived by reducing the exemptions and increasing the rates of the individual income tax is likely to receive very respectful attention as affording a method of securing the necessary funds without tak- ing up other propositions of doubtful expediency and popularity. It is improbable, however, that the income taxes will be increased sufficiently to close the gap be- tween prospective receipts and expenditures, hence the President’s alternative recommendations are of great importance, especially as Senators and Representatives may decide that it will be safer politically to “support the President” than to put forward original proposi- tions, which, should they prove unpopular among the voters, could not be laid at the door of the “captain of the team,” as the President is fond of describing him- self. These alternative suggestions include taxes of le. per gallon on gasoline and naphtha, 50c. per horse- power on automobiles and internal explosion engines, a stamp tax of 2c. on bank checks and a tax of 25c. per ton on pig iron and of 25c. per ton on “fabricated” iron and steel THE PIG IRON AND “FABRICATED” STEEL TAX The proposition to impose a tax of 25c. per ton on pig iron and an additional tax of 25c. per ton on “fabricated” iron and steel, which presumably (in view of waste in manufacturing) would represent a tax of over 50c. per ton on much of the output classi- fied as “fabricated”—whatever that may mean—is en- tirely novel and is believed to have originated with the President. It was not suggested in Secretary McAdoo’s comprehensive statement issued a week ago and if the item has been in contemplation for any length of time that fact has been carefully concealed. Just what the President means by “fabricated” iron and steel is not clear. Obviously, he does not use the term in the technical sense in which it is used in the industry as applied to structural material cut to specifications and punched and fitted for assembling. It may be as- sumed that he refers to all iron and steel manufac- tures, but if so it would be interesting to know whether “fabricated iron and steel” would include for taxing purposes only finished products ready for final con- sumption or such intermediate forms as billets, rods, etc., which, while the finished product of one mill are Munitions Tax Apparently Constitutional but the raw material of another, as well as | plates, etc., which are the raw material industries. The obvious unfairness of imp specific tax per ton on manufactures of iro: which range in value from a few dollars, in | billets and bars, up to hundreds of thousa: ease of finished watch springs, is likely to the adoption of some other basis of tax if attempt is made to follow out the President gestion. MUNITIONS TAX ADVOCATES ENCOURAGE! That the advocates of a tax on war munit be greatly encouraged by the President’s sugg for levies on iron and steel goes without sayir ready this project has made very substantia and is receiving the attention of influential! men of both houses, not to mention half a score of elected Representatives who hope to attract attention to their work at the very outset by | ing to turn into the Government’s coffers a gen portion of the widely advertised profits of the munit makers. Senator Walsh of Montana, a prominent ber of the Senate Judiciary Committee and of unquestioned legal attainments, is making haustive study of the subject and, as stated correspondence last week, hopes to devise a met of imposing a munitions tax that will not rur to the prohibition of the Constitution against taxes exports. Senator Walsh has decided that nea the propositions heretofore suggested are un tional for the reason that they either prov cifically for a levy upon war*material upon its exp tion, or for a tax on production which will mitted in the event that the goods are consumed i United States. This latter proposition is design: lift the tax on all munitions manufactured f United States Government, but, in the opinion of Ser tor Walsh and other legal authorities, the exempt would prove fatal as it would render the tax only on exported products, which the United States > preme Court has declared to be unconstituti WAR MATERIAL TAX CONSTITUTIONAI That a tax on all war material, whether portation or for the use of the United States Gov ment, would be constitutional is believed by thos have given much attention to the subject to hav finally determined by the United States Supreme ‘ in the case of Cornell vs. Coyne, 192 U. S. 418. | case a manufacturer of filled cheese, which was § jected by law to an internal revenue tax, brought action against a collector of internal revenu cover the amount of such tax paid on certal! ties of his product which were exported, on the £1 that any tax levied upon articles exported was rep’ nant to Section 9, Article 1 of the Constitution, W' provides that “no tax or duty shall be laid on art exported from any State.” The court in deciding ' ease against the manufacturer quotes the constitu! provision referred to and then lays down th doctrine. But this means that no burden shall be placed tation, and does not require that any bounty be ¢' Congress has power to encourage exportatio! pecember 9, 1915 “is manufactured at home as it has power to inufactures by duties on imports, yet the Con- not compel it to do either the one or the other encouraging is illustrated by section 11 of this requires all imported filled cheese to pay, in mport duties, an internal-revenue tax of t times as much as that manufactured at home articles exported the tax which is cast upor rticles consumed at home, while perhaps not bounty on exportation, has some of the elements this act all filled cheese is subject to a manu of le. a pound. To remit that tax in favor exported may encourage the manufacturer to rather than a home market; but if the full led cheese manufactured is required for the Government, the remission of part necessitates some other source. Doubtless the remission is of widening the market and increasing the it that is only a possibility of the future, whil« revenue is a fact of the present. Subjecting inufactured for the purpose of export to th: | other filled cheese is casting no tax or dut rted, but is only a tax or duty on the mar rticles in order to prepare them for export which is asked in this case is the return of ge tax there is nothing in the constitutional pro nguish between a manufacturing and other the plaintiff's contention be sustained as t tax it would follow that the Government w d all prior taxes imposed on articles exported raise cattle with the purpose of exportatior x<port them. Can it be that he is entitled to roperty taxes which have been cast upon thos rue construction of the constitutional provisio1 en by way of tax or duty can be cast upor of articles, and does not mean that articles relieved from the prior ordinary burdens of rest upon all property similarly situate ittaches to the export and not to the art tio! {1 seem to be clear from this elucidation of tutional prohibition against export taxes nilar articles when consumed in this country ted to the same tax, there can be no consti- jection to a tax on munitions when ex- here is reason to believe, however, that there much more formidable than legal techni the way of imposing taxes on war ma- he investigation of the subject made by the venue authorities has developed a hundred practical difficulties and it is the belief of that a large part of any tax not confisca dimensions would be eaten up by the cost In the case of many establishments it solutely impossible to differentiate war om other products and, even where there line of demarcation, it would be exceed- t to determine the proportion of profit de tively from munitions and other material. tute as is proposed could hardly be less com in the income tax law, which the courts have to construe, although in force for more years, and it is probable that the execution would involve the compulsory adoption by ers of special systems of bookkeeping, to 1y the Government, even more elaborate ow imposed upon the railroads by the lh mmerce Commission. r ARMERS AGAINST GASOLINE TAX position to tax gasoline has already brought ' protests to Washington from all parts ntry. Manufacturers of automobiles and bustion engines have been prompt to take the basis of Secretary McAdoo’s announce their protests have been followed up by ' complaints from the agricultural regions rywhere are writing to their Representa- gress describing the burden that would them should the Secretary’s project go Every owner of an automobile, no matter the car, it is asserted, is already required gistration tax and in some cases a personal in addition. A federal tax would about urden and an increase of one cent per gal- gasoline consumed would in the case of the tomobile user quadruple the load. President THE IRON AGE 1353 Wilson’s proposition to tax the little gas engine of the farmer, through the aid of which some of the most arduous “chores” of the average farm have been in a measure lifted from the human toiler, is likely to arouse a feeling the intensity of which can hardly have been anticipated. W. L. C. High-Explosive Shell Marking Machine The Noble & Westbrook Mfg. Company, Hart- ford, Conn., has recently developed a special mark- ing machine for shrapnel work. It is intended for \ marking the bases of the shells to conform to the +1 Ul requirements oO! i@ various foreign Government specifications. The general principle of these machines is the same as that of the builder’s Dwight slate marking machine. The roll die, which specially furnished in each case after a print or sketch of the shell to be marked is received together with the inscription and the number of changes necessary to take care of dates, etc., passes over the base of the shell. The table on which the shell is placed is raised by a foot lever to any desired depth of die which is relied upon to give an accurate impression. Two sizes of machines are built, the one illus trated taking care of shells 6 in. in diameter and ranging from 12 to 21% in. in length, while the other machine is designed for shells under 12 in. in length. In the smaller machine a single pull of the hand lever revolves the die and completes the mark ing of the shell while in the larger machine gears are employed to increase the power and give the desired pressure on the larger shell. In either one of these machines it is possible to mark shells on the base practically as fast as they can be lifted from the floor to the machine table and removed, as the operation of marking requires only from 5 to 10 sec. The Niles Car & Mfg. Company, Niles, Ohio, will add to its present line of products the manufacture of motor trucks and accessories. > ps -——— i i el es ee es ae OO AM ie te ET na a wee co Coke Ovens Heated From Above German Tests Showing Influence of This Method of Heating—Composition of the Gases—Output of By-Products An article by Prof. Oskar Simmersbach, describ- ing the new Collin ovens at the Radbod mine near Hamm, Germany, at present the largest in the world, and giving the results of some experiments, appears in Stahl und Eisen. The tests were car- ried out to determine the influence of the method of heating used in these ovens, which is an alter- nation of heating from above and below, on the coking, and particularly on the temperature condi- wee Rh Fig. 1—Cross-Section Through the Flues of a Coke Oven Using tions in the space above the charge. Also on the composition of the gases, and in connection with this the output of by-products. An idea of the heating system is shown in Fig. 1, which gives a section through the flues. The washed gas comes from the condenser house under pressure to the mains c; and is introduced, alter- Table 1 Pe Cent of Constituents, by Lower heating Tes (*t) al le N plu H H CO CH i N B.t H2S per cu. ft 05 1.55 2.45 3.7 0.20 5.55 48.50 ) or 7.15 720.6 2 2.5 > 80 1.95 $45 O.80 5.45 2 RO 17.60 115 624.5 } 4.5 3.15 1.70 3.65 0.40 4.20 38.40 41.80 6.70 623.9 4 6.5 3.10 1.65 3.70 0.35 4.40 36.70 41.05 9.05 602.8 5 10.5 295 1 ) 05 0.10 5.50 40 4 } 9 20 567.2 12 00 1 } ».45 4.55 32.65 46.70 8 an 569.9 7 14.5 2.00 } 5 5.00 0.70 44.80 11.25 540.5 s 16.5 2.1 1.25 55 4.90 5 49.05 6.70 560.9 9 18.5 ] > 0.95 2 0.45 4.75 85 51.50 4.45 565.9 10 20.5 1.00 0.75 2 > 0.50 4.80 295 46.05 11.30 ; ; ll 22.0 1.15 60 2.60 0.45 4.2 1.25 52.10 65 526.2 12 24 1.25 0.30 2.15 0.35 4.7 7.05 60.20 95 493.3 13 26.5 1.10 0.15 2.05 0.10 4.6 ) 60.40 $35 «6497.4 14 28 1 5 ) ) | ) »60 5 > 30 ¢€ 55 12.65 363 15 29 0.95 1.1 2 6.80 ( 12.45 42 9 Heating gas mixture 2.71 «-. 600 150 5.05 29.10 49.70 10.35 479.4 135 nately, through the pipes d from each oven at the same time either to the lowe tribut. ing flues e or the upper flues e,. The a bustion comes either from the regener: flue, h, under the length of the oven, it passes to the vertical combustion flu the openings o, and burns the gas entering a or else on reversing from /* to a second flue h, p; allel to h, and by means of narrow vertical fy, c A we rrererr ery Sa ~ ~~ —— = yoy iy 2 / beds Sth DAA ID 7p addi sidddaagidnadddaadaiadddeaRanc ia ids ddbddaddddddbdpiciddadiadéiaddddddiddédddaad A a B 4 0 a Sous eo Se — ae ae ae ee ee Se the New German Method of Applying the Heat from Above i to the expansions n where it meets the gas en- tering the vertical combustion flues from ¢,. As mentioned before the ovens are very large, being 5.5 meters (10 ft. 9 15/16 in.) high. Two tests were carried out, one with the ordi- nary practice and a 30-hr. coking time, the other with stronger heating and a coking time of 2! hr. The results of the temperature measure ments of the first test are shown in Fig. 2. Nos 1, 2, 3 and 4 were taken in the gas space uncer the four charging holes. No. 5 was taken in tt charge one meter from the bottom under the frst charging hole, the one nearest the gas collector No. 6 was taken in the same position, but uncer the second charging hole, while No. 7 was taxet in the charge 2.2 meters above the bottom uncer the third charging hole. The temperature in the space above the charge was very uniform and an average of slightly over 241% hr. was required before 700 deg. ©. ¥* reached, which means that it was only reached # the last part of the coking period. Compare with the Koppers oven, the top temperatures Wer very low, and the roof much colder. The temper®* 4 9, 1915 ‘harge 000 egin to cot 0) deg. 900 TT ne fif- ir, and 800+ - quickly : erside 3™ this ia ven 18 =) d heat tse | is bet- eS eee eee a high- a ¥00- eee eee perature analyses ises are THE IRON AGE 1355 began to rise from 100 deg. C. at the end of the tenth hour, at the narrow end of the oven, and at the ; end of the thir- ae j teenth at the r, cL. other end. Z } Average anal- ff Ly yses of the coal and coke are given in Table 2. 4. The small per centage of vola tile matter shows that in both tests Table Uy | the coke was good. The samples GSAS H¥ECSOV BE IWN BBWS 38 23 29 35 26 37 28 39 The results also taken from Coking Time in Hou show that with the flue eading to Fig. 2—Temperature Measurement t I Ts suitable arrange | llecting ments for heating The results eS ee aoe from above high clearly the BB EEE EEE EEE EEE top temperatures nfluence of § , NH PETE are not produced, w top tem- SS she ~=«temperature res. The 2 stort IOUSSCSSESSSESSSRSeCaeeeeeeceeasecueeeess of 800 deg. C., in the = “HS HS eee ~swhich is the min- ompletely § Oooo SESS SSE SSSSSSSORSEEEe eee eee e ee sseeeeeaseseess: imum required in ff in the © ERR Ssthe «space above hour, §& EERE EEE St the gas for the corre= § 4SCCC EEN] decomposition of nds to sample BEE SSS] ammonia, is not . » ot lll Tv ) Sa : oO PAG DIR sosasesssesas ot c oH B ttt reached. Che al- | j Cobing Time in Hears ternate heating as bee Fig. 3—Some Benzol in the Gas in the Twenty-eighth Hour trom above and With ovens high top temperatures, the benzol soon dis- ars completely from the gas, but as Fig. 3 in this case it is still found at the twenty- th hour, that is, almost to the end of the coking The influence of the lower top temperatures } seen in the case of the methane. the second test the temperature of the space the charge reached 700 deg. C. in 19 hr., the end of the coking time was at 785 deg. C. » results and conclusions of the first test were med. In regard to the charge the temperature A Rhyming Market Letter of 1910 Evans & Co., Chicago, have reprinted by re- their rhyming market letter of May 20, 1910, strikingly applicable to developments in the trade this year. The letter, which will un- ibtedly be enjoyed by our readers, is as follows: “The pig-iron salesman makes his rounds when the i.ggeth low, and covers the old familiar grounds g-iron buyers know. He argues the higher re, he argues of booms long past, and ques- labor costing more, can these low prices argues until in the face he’s blue and when done the buyer says a decline is due of fifty ilesman travels his weary way and life seems thing till something touches the spot one the bells begin to ring. Then Ho for the code telegraph! and Ho for the telephone! and salesman’s time to laugh and the laggard’s oan; for those who argue or hesitate are miss their chance, and have the joy to par- a fifty cent advance. ontract-clerk’s on the job once more, he e midnight oil; and who cares now for the or the price of the workman’s toil? The bright and the clouds are few, the chill from below brings . about an even heating of the walls with high ovens. so that Table Analysis of the Coal and Coke T i, per Vent lest 2, per Cent Coa \ 5. 68 6.14 Wa > 2 Vola \ 1.14 Tota 1.49 } f f Ash \oltatile matter N4 with this method coke ovens could be built 4 meters high (12 ft. 3.5 in.) without danger G. B. W. the air is gone; the sky is the only thing that’s blue when a buying movement’s on. The buyers buy and the sellers sell and life hath a rosy hue. If you listen well you can hear the bell! We’re ready right now "7 are you? Redesigned Vertical Shrapnel Milling Machine The Newton Machine Tool Works, Inc., Philadel- phia, Pa., has redesigned its extra heavy vertical mill- ing machine. The changes include the application of alternating-current motor drive with a _ speed box, a counterweighted spindle saddle with power vertical feeds and fast power movement and the inclusion of reversing fast power traverse to the table motions. The spindle has speeds ranging from 8% to 232 r.p.m. and the changes are secured without re- moving any gears from the speed box. The circular, in and out and cross table motions have reversing power feeds and hand adjustments, all of which are controlled from a centralized position. These machines can be used with end mills as small as % in. in diameter for die sinking or for handling heavy locomotive work. At the present time many of them are being employed for milling solid shrapnel forging ends, as the circular feed is continuous. eRe : v, ar a Electric Welding as Developed to Date Three General Processes, Supplementary Rather than Complementary to One Another—Pos- sibilities Only Beginning to be Understood BY C. There are three clearly defined processes of electric welding—arc, incandescent and _ electro- percussive—of which the last is very recent. The arc processes are autogenous in that welding can be accomplished without pressure, simply by allow- ing the metals to melt under the influence of the electric current, then to mix and unite as they cool; the incandescent and electro-percussive processes, however, invariably require pressure as a necessary adjunct to their successful accomplishment. Arc Process ZERENER PROCESS In the Zerener process the apparatus employed resembles certain types of direct-current flaming arc lamps, the carbons being inclined toward each other and automatically adjusted by a suitable mechanism as they are consumed. By means of an electro-magnet, the arc, which is formed between the ends of the carbons, is directed downward in the shape of a pencil point. The metals to be welded are brought within the influence of the arc where they are then melted or fused as desired. The apparatus is complicated and does not lend itself readily to the carrying of large currents. It is not used in America and only to a limited extent elsewhere. BENARDOS PROCESS In the Benardos process, the arc is drawn be- tween a carbon electrode, which forms one terminal of a direct-current circuit, and the metal to be welded, which forms the other electrode. The weld- ing apparatus itself, aside from the current supply, is exceedingly simple, and there is little to get out of order. As a minimum, 15 kw. at approximately 70 volts should be provided, though rather greater capacity is desirable especially when large work is likely to be undertaken. The voltage across the arc will ordinarily range from 40 to 50 volts, depend- ing upon the class of work. SLAVIANOFF PROCESS In the Slavianoff process, the arc.is drawn be- tween a metal electrode, which forms one terminal of a direct-current circuit and the metal to be welded, which forms the other electrode. Other- wise, the apparatus is similar to that used in the Benardos process, although the minimum current supply necessary in this latter process may be said to be the maximum supply required in the Slavianoff process. The voltage across the arc is also lower in the Slavianoff than in the Benardos process, ranging from 18 to 30 volts. TEMPERATURE OF ARC The temperature of the carbon arc has been vari- ously estimated to lie between 3500 and 4000 deg. C. All metals may be readily melted by it. In a direct-current carbon arc, the greatest energy con- * Abstract of a paper presented at the International Engi- neering Congress, San Francisco, Sept. 20-25, 1915. #Director of standards, processes and materials, Westing- house Electric & Mfg. Company, Pittsburgh B. AUELt sumption and, therefore, the highest temperaty,, occurs at the positive terminal. . When using the Benardos process, ; the metal to be welded the positive elect , as is the practice, melting of the metal should and doo: take place at a faster rate than if the carbon trode were made the positive. In the latter eas, it is exceedingly difficult to weld at all below 500 amperes. The reason for this may lie in the fae that the conductivity of an are depends in great measure upon the kind as well as the quantity of vapor in it. As iron and steel are more readi| vaporized than carbon and their vapors better ductors than carbon vapor, there is, for a give) current and with the metal forming the positive electrode, a greater quantity of metal vapor in t! arc than would be the case were the polarity re. versed and therefore current flows more read from the metal to the carbon electrode. In the Slavianoff process where both electrodes are of metal, the limitation just explained does not exist, and welding may be effectively done with either the work or the electrode as positive, though it is more usual to make the former positive. There might, however, be occasions when it would per- haps be of advantage to reverse these conditions and make the metal electrode positive so that the melting and therefore the deposition of metal would be more rapid owing to the greater heating effect at the electrode. In both the Benardos and the Slavianoff pr esses, there are required, in addition to the direct current supply with its necessary controlling a paratus, electrode holders and electrodes, coveri! for the operator and the work, fire clay or car! blocks, etc., for molding purposes, fluxes and met filling material. Direct current, at approximately 70 volts the Benardos and 50 volts for the Slavianoff process is necessary. A higher voltage may be used, but !s wasteful and is only to be recommended where tht amount of welding required is either so small so infrequent as not to make advisable the instal tion of a separate outfit; and any excess voltagt must first be reduced to the proper amount by introduction of suitable resistance into the circu! Satisfactory welds may be made in the Benar process with 15 kilowatts capacity and even it is, however, preferable to have more where larg pieces are to be handled or where more tha! single operator is to be employed, and similar re sons govern in the Slavianoff process. If curret is obtained from an independent source the dynam should be compound wound with an over-compou! ing of about 5 per cent. CONTROL OF THE CURRENT np Means for controlling the current supp the voltage across the arc must be provided, S! / welds of different kinds will require varyine *"” rent strengths at varying voltages across - ats This is attained by the use, generally, o! Spaniel introduced into the main circuit, though some"! no the ning the same result may be secured by weakenité © 1356 pecember 9, 1915 gold dynamo. This latter method is, how- extremely limited in its application as it can ed when a single operator is at work; other operators on the same circuit eriously handicapped. Fig. 1 shows a rcuit in practically its simplest work- and in which barrels of water are em- resistance. esistance grids can be substituted with antages for the water barrels, as the lat- require to be replaced due to the hoops ay; furthermore, the resistance of the ges as it becomes heated, necessitating 5 al readjustment; and, finally, if the out- at is worked very hard the water boils over, involv- ypage of work in order to allow the water \ll other schemes of connections are but of the above. In theory, such schemes to advantage over the simple diagrams of described; but, in practice it is re- nd simplicity that are essential above y else, and a dynamo, when especially de- r welding, should withstand such loads as upon it. Further, too much stress is efficiency, whereas it is of secondary im- since current is drawn from the dynamo irregular THE IRON AGE 1357 position with the electrode holder in one hand and the hood (for the Benardos process) or the shield for the Slavianoff process) in the other. Bring- ing the electrode as close to the metal to be welded as possible without actually touching it, he then pulls the hood down over his head or raises the shield in front of his face, touches the electrode to the work and instantly pulls it away the required distance, thus striking the arc, which, when a metal electrode is used, will approximate 3/16 in., while when a carbon electrode is employed, will vary from 14 to 2 in. or even more in length, according to the work being done. In using the carbon electrode, the arc should be given a rotary motion by hand, thus heating the metal to be welded more uniformly and preventing burning. It should also be borne in mind that the longer the arc, the less chance there is of carbon entering the metal and producing a hard weld. When the metal reaches a molten condition, filling material is added to it, bit by bit, the are being interrupted only just long enough to add such mate- rial, then being struck and played upon the mass again; or the filling material can be used in the form of a long rod, one end of which is inserted in the molten metal and the are played upon it um until the end is possibly || melted off and fused 15 to 30 Steel Rirmunal Plate r—|| with the mass. it of every v) |fA)) In joining two ven when the Carben Fiectrode a TT ru pieces of any but the in constant Av, i. — thinnest sheet metal service, / {/ & FONE together, the abut- arbon electrodes [ Aetei Table | | ting edges should | range from 4 : aa } Si ee | first be chamfered n. diameter Ly \vseollie 4 | at an angle of about 6 in. to 12 ft. Sice/ Castine Gasp diane _— ae ey 145 deg. either from gy, depending up- , - one or both sides, the class of weld- Fig. 1—Diagram of Arc-Welding Circuit, Bernardos Process, Water depending upon the ing, whether large Barrel r small, and both ‘ these higher limits may be exceeded in certain lhe carbons should be solid, should neither rumble nor spindle, and should preferably e graphitic rather than common, as the former s of higher electrical as well as thermal con- Metal electrodes will range from 4% to 5/16 in. meter by approximately 12 in. long likewise ‘nding upon the class of welding. For welding wrought iron and steel, nothing can excel the ne Norway or Swedish iron. FLUXES AND FILLING MATERIAL No flux is needed for welding either wrought ron or steel, the field to which arc welding has thus ‘ar proved to be particularly adapted. For welding ight iron or steel, various filling materials may * used, among them being Norway—or Swedish— ‘on rods, boiler iron, scrap, bits of steel castings, ast or malleable iron, Norway—or Swedish ds or special cast-iron rods with a high of silicon. ne Benardos process, the carbon electrode onnected to the negative terminal of the the metal to be welded to the positive either directly, or if more convenient, indi- being laid upon a metal table, Fig. 1, to positive terminal has previously been In the Slavianoff process, welding may ‘ed regardless of the connections. The re- the circuit should next be adjusted to leemed to be the proper amount, after © circuit-breaker or relays and the line closed. The operator then takes his wr at Whier Re sistance thickness of the ma- terial, and the cham- fer should extend entirely through. As soon as the weld has been completed and while still at a white heat, it should be briskly ham- mered in order to give the metal a finer grain. All oxide and other impurities should, of course, be kept out of the weld. The metal to be welded should accordingly be chipped or machined in the vicinity where the weld is to be made; or the same result may be accomplished by tilting it to a suit- able angle, then turning the carbon are upon it and allowing the slag, in melting, to fall away by gravity. Heating the metal preparatory to welding is always beneficial as preventing and relieving strains, but is not resorted to except in special cases. Annealing is also desirable at times but like preheating, is not done except when absolutely nec- essary. A very decided economy can sometimes be effected by repairing a defect discovered during a machining operation, by making the repairs with- out removing the piece from position. METALS WHICH CAN BE WELDED Both of the electric are processes are particu- larly well adapted to the welding of wrought iron and steel of various kinds; and, while certain other metals including cast iron can also be welded, the work is not, generally speaking, done to any advan- tage over some of the other processes. Welds in cast iron will prove quite variable when made by the average operator, being frequently glass hard and uncertain as to strength, so that at the present time, it would be rather unwise to make any pro- nounced claims for are welding in this connection. “> 1358 THE With malleable iron, the results obtained are even more variable than with cast iron. COMPARISON OF ARC PROCESSES With the Benardos or carbon electrode process, more welding can be performed in a given time than can be accomplished with the Slavianoff or metal electrode process; and viewed from this standpoint alone, the former is the cheaper. As with cast iron, the welds will, however, at times be decidedly hard, so much so as to be occasionally impossible of machining due to carbon from the electrode entering the metal; but when no subsequent machining is necessary, hardness is no disad- vantage; and, in some kinds of work, such, for example, as the rebuilding of the ends of roll- ing mill wabblers, pinions, etc., this very con- dition is a decided advantage. In the Slavianoff process, the difficulty of hard welds is largely overcome. The welding of thin sheets can be more readily done and, in fact, a finer grade of work of the lighter kinds performed than with the Benardos proc- ess; finally, the ability to reverse connections may be an occasional advantage. CUTTING AND OTHER APPLICATIONS In cutting wrought iron or steel with the Benardos or carbon arc the cut will be wider and the edges not comparable in smoothness with any of the oxy-gas cu