The Iron Age 1916-08-17: Vol 98 Iss 7

we, New York, August 17, 1916 ESTABLISHED 1855 VOL. 98: No. 7 Fissures In Rails Laid to Mill Practice Delayed Crystalline Transformation Near Cen- ter of Rail Head; Fracture of This Metal in Gagging and Growth of Fissures in Service N explanation of the causes of steel rail latter a longitudinal fissure is developed as well as failures through the growth of transverse the more or less vertical transverse fissure, with fissures has been offered by Dr. P. H. Dudley, which fissure it coalesces. The results of Dr. Dud consulting engineer for the New York Central Lines ley’s investigations were submitted recently to A on rails, tires and structural steel. The remedies H. Smith, president New York Central Lines, and he has also suggested, and the solution, in his opin- the report is given below. ion, lies altogether with the rail mills. Briefly, his The emphasis placed on the abgence of failure conclusions are that mill practice occasionally re- in rails rolled from reheated blooms—this as a sults in a delayed crystalline transformation of the means for securing a homogeneous crystalline stru metal near the center of*the head, that then this ture—and a suggestion that the supports of the heterogeneous metal is checked by the gagging gagging press should be given a greater span—thu press in the straightening process, and finally the to reduce the gagging pressure—are taken to indi nucleus of a fracture cate Dr. Dudley’s opin thus produced develops ion of the necessary con in service until rupture of the rail occurs. An important part of his contribution to the transverse fissure problem is his finding that the fissures are of two types: that corre- sponding to the rail which had a convex curvature of the base, ditions in mill practice “My investigat show that interior trans verse fissures in rail heads are induced combination of two o1 more exceptional cond tions of manufacture in an occasional rail head by direct rolling, which can and should be avoid and that corresponding ed,” begins the report : to the rail, the head of “Induced interio: which was convex before transverse fissures n the gagging. In the case of the former a checking of metal occurs basic open-hearth 1 are due in part to ar asional hot ra : z 7 2 Fig. 1 Intergranular type of interi ‘ Di —_ in the head in gagging, The nucleus is ove! © in. in diameter t! if > cooled so rapidly Dv tne shi] . ° t Majority ol the pecimens Rail re ‘ \ x ua ; a while in the case of the failed March 5, 19 rolls or so chilled os Fig. 3- 1009-Ib A SS. ¢ | sectior (‘y ; No. 1 show a for a . J found in a few rails Crack No general for the c« ; lescent type of fissure, and may be from 2 iz to 3 ft. long ne od n., 100-Ib. section, showing crack common to the Crack No. 3, showing that the nearly vertical interior trans Soh fissure due to the upsetting of the metal by the gag verse fissure has worked out to the surface, has been found in the head and lengthen the base. (See Figs. 5 and several rail heads The coalescent type of fissure when un- “ ; bearing surface of the head shows deformation, capped shows what Dr. Dudley calls the imprint of the gag and or veral railroads it has been found that an entire train in all cases as indicated in Figs. 5, 8 and 10 A cra similar may | over the head without the mark of contact for all to No. 3 is sometimes found on the gage side of the head in ; wheels exceeding ™% in. in width (See Fig. 6.) the intergranular type 339 340 THE IRON AGE August 17 gusts of air before recalescence on the hot beds, as to cause a lag of some of the transformations of the metal in the interior of the head. Induced in- terior transverse fissures can only develop in the track from the effects of preceding causes, either of which is no longer a mystery, and their pro- gressive stages of development occur in the follow- ing order.” The rest of the report follows: Conditions of Manufacture: First Contributory Cause: Delayed transformations of the metal near the center of the head, and chemical or mechanical defects. First Effect: Induced loss of strength; initial strains; physically a non-ductile core of hetero- geneous metal near the center of the head. Second Contributory Cause: Mechanical injury to the Fig. 4—Full size 100-lb. A. S. C. E. rail, rolled Feb. 23, 1911, failed Jan. 3, 1916. The crack was uncapped for investigation by removing the piece as exhibited in Fig Fig. 5—Full size photograph of rail and the cap, to show the effect of the gag and the “detail” growth from the checked nucleus caused by the wheel loads. _ The cap shows the ef- fects of the compressive and shearing strains produced by the gag to shorten the metal of the head heterogeneous metal, the nucleus checked by (See Figs. 2 and 3.) Second Effect: The produced defect of an invisible portion of fractured metal near t} of the head before the rail leaves the stee!| Conditions of Service: Third Contributory Cause: The conditions nary service for the interior fractured meta] abnormal. Third Effect: The checked interior metal j type is no longer able to restrict the strains wheel loads within the usual range of th: limits of the steel, as in the case of sound but there develop by “detail” growth, fro: around the checks, the specular surfaces induced interior transverse fissures until the tion ruptures. of When the induced interior transverse fissures by Fig. 6—Full size of the bearing surface of the head in Figs ft and 5 Rain had partially rusted the bearing surface of the head before the train had passed over the rail, and thé several wheel contacts only made the bright band about \ in. in width. The crack on the gage side of the head, similar to that in Fig. 2, was found by the trackmen and the rail removed before it broke growth crack through the metal to the air, the specular surfaces discolor and darken, as found in ruptured rails by the trackmen. (See Figs. 2 and 3.) Interior transverse fissures have not occurred in the countless thousands of rail heads of phys- ically homogeneous metal for the reason that they do not contain the conditions of the first contribu- tory cause, consequently, while the metal is length- ened or shortened by the second contributory cause. it is not checked. Basic open-hearth rails of the composition of the New York Central Lines specifications and rolled from reheated blooms have not, to date, developed interior transverse fissures. INTERGRANULAR TYPE OF TRANSVERSE FISSURES The specimens in my collection, after investiga- tion, I classified by June 9, 1915, into two general types: intergranular and coalescent. Intergranular: The nucleus, in effect physically a non-ductile core in the head, which is checked between the grains of the metal by the gag of the straightening press, and may be % in. in diameter, or as small as 4% in. The subsequent development in the track of this type of interior transverse ‘is- sure from the checked nucleus is through the grains, a “detail” growth of specular surfaces, in striking contrast to the check between the grains, the effect of the blow of the gag. This type develops in rails or a part of a rail which was cooled “low” on the hot beds, and was then gagged upon the base to shortel its metal and lengthen that of the head. (See Fig. 1.) A t 17, 1916 THE IRON AGE 341 The core of non-ductile metal, which becomes the checked nucleus by being gagged upon the head of the rail is practically similar to the core of non- ductile metal in the intergranular type which is checked by being gagged upon the base. The frac- tures of the two different types appear so dissimilar that their correlations are not easily traced or com prehended without extensive study and research, though the illustrations shown are ample for classi- fication. Supervisors should instruct trackmen to distin guish the induced interior transverse fissures in the ll size, 80-Ib. A. S. C. E, rail, rolled January, 1905, Tail heads herein described, from the now rare sur comaben, SOc tas ceaee ater alee ee The face crack which sometimes occurs where the imprint of the gag is deep and inclined at an drivers have slipped on the head of the rail and about 45 deg. ang as eat the coalescent type ._~—sihardened the metal, and then by “detail” growth develops down through the head and web to the base until the section ruptures. Two or more surface cracks may occur in the same rail length at stations and waterplugs. It is now usual to remove rails from the main line tracks where the drivers have slipped on the heads of the rails to a noticeable ex- tent. Such practice is to be commended. Figs. 2 and 3, one-fourth size, indicate some forms of the cracks of the coalescent type which break through the metal on the gage side of the heads of rails. The rails in the track should be examined daily for cracks which break through to the outside of Full size of the head of rail in Fig. 7, uncapped to wt mprint of the gag on the inclined black spot, nearly n the center and lower half of the head Three characteristic fractures of the metal ap- pear in the final rupture of the section in the in- duced interior transverse fissure of the intergranu- lar type. 1) The nucleus checked between the grains of the metal by the gag. 2) The “detail” growth through the grains of he specular surfaces. 3) The final fracture of rupture. + THE COALESCENT TYPE valescent: A checked longitudinal elliptical nu- cleus, the imprint of the gag on the non-ductile met to 54 in. under the bearing surface of the which enlarges to a longitudinal fissure by the ng wheel loads. This fissure coalesces through Fig. 9—One-half size, 5%-in., 80-Ib. rail, rolled Jan. 12, 1912, : nsverse or oblique crack at the side of the se tarcenti the wab bike tee Waas bale ae ee 1m shearing stresses produced by the gag, ially develops after two or more years of in the track into the nearly vertical interior erse fissure. The fracture is often conchoidal inction of the coalescence. The longitudinal e, and sometimes the vertical, open on the gage the head, and can be discovered by careful on before rupture of the rail occurs in the See Figs. 2 and 3.) This type develops or a part of a rail which cooled “high” on beds, and was then gagged upon the head *® rten its metal and lengthen that of the base the neutral surface of the section. (See Figs. inclusive. ) 10—One-half size of the head of rail of F capped to show imprint of the gag nucleus checked between the grains of the the longitudinal fissure by the gag is not the trackmen, but it coalesces through a erse or oblique crack to produce the nearly nterior transverse fissure which ruptures The nucleus checked between the grains disclosed onlv bv uncapping the head of the Fig. 11—Full size photograph showing the end of the sl k . of a pneumatic tamping bar which had broken from <- terior “detail” crack and welded with a “V" weld which - 1] : veloped in service the interior transverse fissure sho or llustrations do not show all the probable °° ier Seen eee "Tis weedieh tse ae fractures of the coalescent type which may this case is regarded similar in effect to the longitudinal erack wit! ts errations ¢ the coalescent tyne of nduced n the track in the different brands of rails. nterior transverse fissures found in r i 342 the metal, and when any are found the rail should be removed. These cracks are not all alike in the various brands of rails, owing to the different methods of gagging. To straighten the present stiff rails, the pressure of the gag is too severe on the metal for supports of only 42-in. spans, which I had increased from 30 in. in 1891. Since then no change has been made. Recent experiments show that with wider spans the rails can be straightened with less pressure of the gag and with consequent less injury to the metal, THE IRON AGE August 17. 191¢ resulting in an improved line and smoother The half moon breaks in the bases of rails a. erally due to the locked-up strains produced gag. The causes which induce interior tra fissures in an occasional rail head, and the are stated above in their order of combination and the three different places and periods of occurrence. These facts can be utilized to prevent the condj- tions arising in the manufacture of rails which tend to induce interior transverse fissures in thé rface, gen- vy the Verse ffeets itput. Labor Cost Keeping in a Boiler Shop The D. « Connelly Boiler Company, Cleveland, Uses Only Two Forms and the Work Is Done by a Timekeeper VERY simple and accurate method of keeping A the labor cost in a boiler shop has been devel- oped by the D. Connelly Boiler Company, Cleveland. While the system was devised for use in this particular plant, it could doubtless be success- fully applied to other industries. The system re- quires very little clerical work and the entire record is kept on two forms, a workman’s time card and an itemized time sheet. It requires the employment of only one man, a timekeeper, who keeps the entire record and devotes his whole time to this work. Each order as it comes into the shop is given a shop number and every workman reports to the timekeeper before he starts on a job that has been given him by the forman. The timekeeper enters the man’s name and key number on the time card and stamps it with the date and time the man starts the work. On the card is printed a list of every operation in the shop and a check mark is made op- Dete Work Started Date Work Finished For Whom Fe apere = = ee 4 “| Lathe Work | Kind of Work Loading and Unloading posite the proper word to indicate the operation This card is kept in the timekeeper’s desk. When the workman finishes an operation he re- turns the card to the timekeeper’s office and it is again stamped with the time actually required. Space is provided on the card for entries of the total hours employed, decimals being used for parts of hours, the rate or man’s wages per hour and the total cost. At the time a workman turns in his card after finishing a job he is given a new card properly filled out and stamped with the time of starting work on the next job. It can be seen from this that each man has a different card for each job he works on during the day. At night all cards are rung in and stamped with the time spent on the job whether the particular operation indicated on the card is completed or not. If the work is un- completed at night a new card is made out the next morning. Our Contract No... .. Customer's Order No. . —— 7 ——— | Punchung Painting “| - | ; | de | I | | | | —$——+-— +--+. — ¢---+4 RR e eas 3 mer ed ad Fe elt ccalencleaiil tT | cecil + Hee maimed HH = << 4———+- + gs | | el td ° ° . ~y > ’ . ‘ i t Only Two Forms Are Needed in This System, a 4 x 6-In. Workman's Time Card and an 8% x 14-In. Itemized Tim« Shee Containing a Summary of the Cards August 17, 1916 filled-in cards are classified according to the key number and the total number of hours card, or cards, must equal the number of nour. he has worked during the day. The cards ar n reassorted, those having the same shop nut - being grouped together and those covering sin operations on the same job being bunched ¢ r. When thus grouped according to jobs wit b-groupings for similar operations, the time spe n the various operations is totaled and re- ‘orded on the time sheets. When this record has ransferred from the time cards to the time the former are filed away, all for one date kept together. » time sheet provided for each job and filled the workman’s time cards every day has ; for all the operations that are listed on the irds and in these spaces are listed the hours n each operation and the actual labor cost ) operation during the day. The time and r the day are totaled each day in a space d on the blank and the total hours and costs rried along each day so that a glance at the hows the amount of time and labor cost on hb at any time before the work is completed. time sheets which are filled out by the time- keeper are sent to the manager every morning so that he can quickly see by looking over the sheets every day how much work has been done on every active job. When a job is completed the hours of work and cost of the various operations are added up and a grand total of all operations in time and labor cost is made. The time sheets are kept in a binder in the timekeeper’s office until the job is com- pleted. This binder contains a sheet for each job that is going through the shop.. These sheets also have spaces for recording the order-book number, shop number, dates of starting and finishing the work, ete. When the material comes into the shop it is sorted out for the different jobs, each order usually being a special one requiring from 12 to 50 plates. rhe stock for each job is piled on the floor by itself | given a number corresponding to the shop num- er of the order. This makes it convenient for the rkman to get additional material as it is needed the job. A Fire-Resisting Material for Furnaces iterial for use as a mortar for pointing up brick- in furnace walls, gas ovens, retorts, boilers, walls and places subjected to high temperature en put on the market by William Clifford & Sons ny, 360 Union Avenue, Elizabeth, N. J. Besides putty form, it is also obtainable as a paint and has given the name Resisto. The company has ex- brickwork to temperatures approximating 3000 leg. Fahr. and the putty joint as well as the Resisto ‘overing appears to have withstood the conditions damage to the brick or the brick joint. The mpany has also experimented with a bolt and nut with about % in. of the putty and put in t of a blacksmith’s forge. The part of the bolt vered was fused and burned, while on removing tty the threads of the bolt were intact and the ild be serewed by the hand. The material has tested by the Bureau of Standards. Heated in an * vacuum furnace, with a temperature measured an optical pyrometer, the lowest temperature at the material could be seen flow, which tempera- was taken as the melting point, was 1500 deg. C., " approximately 2750 deg. Fahr. The material is marketed to protect firebrick, fire Deer | steel and iron work and, it is stated, requires ying out. The paint, it appears, vitrifies. The com- nas issued a little folder which explains the meth- ise. For example, in the case of bricks, they THE IRON AGE 343 ean be either dipped in the material or buttered in the usual manner, as it is expressed, but it is desirable that the surfaces should be clean and free from moisture and grease or oil. The material is the invention of Arthur Dunbar of South Melbourne, Australia. Flexible Shaft Portable Electric Tools In spite of their small sizes, portable electric drill- ing and grinding machines cannot always be used in close corners and on some kinds of shopwork. To over- come this manufacturers of these tools are employ- fr | ing flexible shafts. The | | | | | illustration shows the | latest line of portable ma chines equipped with flexible shafts brought out by the Standard Electric Tool Company, Cincinnati. The ordinary length shaft | furnished is 6 ft., but one | 10 ft. long can be used | when necessary. As will be noted the | motors can be suspended from the ceiling by aneye | bolt, but for shopwork, the machine can be mounted on a base with a convenient handle for transporting from one part of the shop to an- other. The motors can also be suspended from a traveler which in some cases is handier, and as a consequence a time-saving method of transporting | the apparatus. The motors furnished with this outfit operate on either alternating or direct current at an average speed of 1000 r.p.m. The flexible shaft is fitted with a drill chuck and this is interchangeable with a _ buffing arbor and mandrel oa for holding emery wheels, The Application of Flexibk so that many different Shafts to Portable Electric S : Tools Enables the Motor kinds of work outside of to be Suspended from ths si wg » . Ceiling or a Traveler and thé drilling can be pe rformed Power Transmitted in Almost with ease. Any Direction Hardened Steel Gears by a New Method The production of hardened steel gears as nearly perfect in shape as is possible on gear cutting and boring machines and doing this without subjecting the otherwise finished and hardened gears to a tinal grind ing operation, are the claims made for an invention on which a patent (U. S. 1,152,157) has been granted to Frank H. Farmer of Cleveland, Ohio, and assigned to the White Company of that city. The method con- sists in rough machining the gear blanks and then carbonizing them. The carbonized gears are heated up, quenched in oil and then annealed. The annealed gears are machine-finished and finally oil hardened. This treatment, it is claimed, does not warp or destroy the accurately shaped machine-finished product. The Burt Mfg. Company, Akron, Ohio, because of greatly increased business, has found it necessary to enlarge its manufacturing facilities. It is just com- pleting two good-sized two-story additions to its already large factory. Much new machinery will be required, orders for which have already been placed. The Burt Mfg. Company has heretofore devoted its efforts exclu- sively to the manufacture of oil filters, exhaust heads and ventilators, but it now proposes to embark in a general line of sheet metal work. otal Te Making Motor Trucks Some of the Production —The System of Shop ploying and Paying a BY F. In the plant of the White Company, Cleveland, one of the leading makers of automobile trucks, varying specifications have made every truck order practically a special one. This has necessitated a reversal of the practice of building cars first and selling them afterward to the plan of taking orders before construction. This change in conditions would make impracticable many of the production methods followed in plants having a large produc- tion of pleasure cars in a few models. In making a motor truck, however, most of the manufacturing methods are not dissimilar from those followed in Facing Both Ends of Cylinders on Beaman & Smith Double Head Milling Machine in One Operation : - So ok : ae ints " , ’ 7 ¥ 7 Schumacher & Boye Lathe Equipped with a Special Fixture Crank Cases L. in the White Plant Methods Followed Management, Em- nd the Hospital Service PRENTISS building pleasure cars. The same motors are used. the transmission is similar and numerous parts that make up the chassis assembly allow the same shop methods and do not necessitate one machining de- partment for car parts and another for truck parts, In the White plant accuracy in machine work js emphasized rather than quantity production. But recent developments in the plant have been along the line of using new fixtures for more rapid pro- duction and consequently increased output, and the improved production methods have, at this writin ing made possible a daily production of about twenty 1 to 5 ton trucks over several months in addition to the regular daily output of about 10 passenger ears. The general plan is followed of doing all machine work on the various parts in their own departments rather than grouping work according to various kinds of machine operations. However, should the machines in one department be unusually busy, work is occasionally transferred to some other department where machines of a similar type are available. The engine department, which is in charge of a general foreman, is divided into various sub-depart- ments, each in charge of a functional or sub-fore- man, who has an assistant to set up the work. These sub-departments include lathe, turret lathe, milling machine, drilling machine and crank turning oper- ations and assembling small parts, assembling motors, cleaning motors and final inspection of motors. The first operation on the cylinders, facing both sides, is done on a Beaman & Smith double-head milling machine, an adjustable fixture being pro- vided in which cylinders of different sizes can be Having Fixed Spindles for Each of the Five Centers fo Cutters removed 344 st 17, 1916 d. Both ends are faced simultaneously, first riven a roughing and then a finishing cut. cles are then drilled on a three-spindle drill- chine and two of these holes form centers perfect alignment of the work in all the ng operations of boring, drilling, reaming inding. crankcase is bored on a Schumacher & Boye vith a special fixture with five fixed spindles ling for the crankshaft, and the timing gear imshafts. The crankcases are located on the es by base holes on the cylinder face. first machine operation on the connecting- lrilling the piston pin hole, is done on a three- e drilling machine. After facing, a special e is used in milling the lock on the crank end » connecting-rod. This operation is performed amping four rods in a special fixture and mill- the four simultaneously with gang milling actically all of the machine screw products the company are made in its own screw ne department. Besides the hand machines are 70 automatic screw machines in sizes from to 644, in. Six tons of steel and brass wire are a day and the production has reached as high as 342,000 parts in a week. Wheels for trucks are machined on Bullard ver- tical boring mills. The steel casting for a rear heel for a 5-ton truck weighs 700 lb. and the wheel when finished is 35 in. in diameter and has a 12-in. face. The first operations in their order are hucking, boring, threading and turning. Then the wheel is turned over and the same operations are performed on the other side, and at the same time the face is turned, 4% to % in. of metal being re- ved from the face in the machine operation. The machine work on a wheel is completed in 2 hr. It has been the usual practice to use German tubing for ball bearing ring blanks 1%4 in. and larger, but now that this tubing is not available chrome steel bars are used for ring blanks 4 in. in diameter and under, and hand-forged chrome steel ring blanks are used for larger size rings. These blanks are forged in the steel mills to inside and nn SS the Heat-Treating Department, Showing Bellevue Case-Hardening and Heat-Treating Furnaces with F THE IRON AGE 345 outside diameter. Bearing rings are made up to 8 in. in diameter for the rear axle of 5-ton trucks The first operation on a large bearing ring is facing one side of the forged blank. Then the inside is bored, the outer diameter is turned, and the opp site side faced. After these machine operations the rings are hardened and ground. The first grinding is on the sides, which is done on a Heald grinder, the work being held in place by a magnetic chuck. The outer diameters of the rings are then ground on standard grinding machines, first being accu- rately centered by placing several rings in an arbor in a 90-deg. centering device and being bolted in place and held by a collar at each end of the arbor. The final operation is grinding the ball-bearing race. This is done on a battery of seven special grinding machines built by the company and on a special type of Landis grinding machines that are equipped with ball-bearing spindles. The method of cutting 38 teeth on the large roller chain sprockets is a departure from usual practice. The bulk of the stock is removed with Milling Lock on Connecting Rods on No. 4 Cincinnati Milling Machine, 5 Rods Being Held in a Special Fixture el and Air Pipes THE IRON Special Universal Jig So Holes Can Be Drilled at Angle from Eith End Jig on a Swive I L ¢ nter an eight-spindle drilling machine, the drill holes being made as close to the edge of the blank as possible. The teeth are then finished on a Hendey Lincoln type of milling machine, four blanks being located on an arbor clamped to the face plate of an indexing attachment. Heat-treatment of parts has been extended so that now nearly every minor part down to bolts and step-irons is case-hardened or heat-treated to secure maximum strength, and where possible to reduce the size and weight of the part. Transmission gear blanks are first rough cut, then carbonized and an- nealed, after which they are given a final cut and then hardened. By this method of procedure there is only a low heat hardening operation after a final cutting and danger of distortion is eliminated. All forged parts that are liable to breakage are tested with a scleroscope and are kept within certain limits. After being tested with a scleroscope each part is stamped with a number, showing the hard- Bullard Vertical Milling Machine Turning Truck Wheels AGE August 17 1916 ness number. Such parts as steering knuck! arms, lamp brackets and spring yokes are oi] | so that their strength may be maximum { weight. For case-hardening and heat-treati; and oil-fired furnaces are used. The furna located in the center of the heat-treating « ment, so that escaping heat is carried throu; windows of the monitor above. Oil for quenc} cooled by passing through coils of pipe around water from the factory water supply circulates Orders from the general office are sent car order department in the office of the genera) superintendent, who is at the head of the produc. tion department and under whom are several assist- ant superintendents. Here the orders are dissected. and each department that has anything to d the filling of the order is furnished with its part of the order. All the work in the car order depart- ment is attended to by its head and four assistants. The one important report or schedule that is pre- pared and on which the production operations are based is the material and production schedule. This is made out on a typewriter without the use of a printed blank and copies are sent to the vari foremen. These schedules classify the various models and special trucks and specify the number of each model to be turned out weekly and some- times daily for a period extending over several! weeks. The totals for each model are carried along from week to week in tabulated form to the close and ited witr WiLN £0 CuPLOneEgY mavanemane Recommendation for Employment 9 THE WHITE ad COMPANY inti S 2 name ADORESS "Town OvT of Town HOW MUCH EXPERIENCE HOW LONG ACQUAINTEO WITH RECOMMENDED BY APPROVES BY NOTE —S0NOLY FILL OUT THIS FORM IN DETAIL WITH INFORMATION ABOUT SOME ONE WHOM YoU THe ¢ 'T WOULO BE OESIRABLE FOR US TO EMPLOY RECOMMEND ONLY te7 CLASS MEN Employees Recommend Men for Employment of the last week on the schedule. Sometimes these schedules are in effect for several weeks without changes or revisions. Each department has a clerk who acts as an order clerk, and work is planned and material ordered by the foreman and his clerk, ac- cording to the requirements as shown on the pro- duction schedule. Assembled and completed parts are taken to the erecting department according to the production schedule. The superintendent’s office also furnishes the erecting department an erecting schedule show- ing the number of cars to be erected each day and the individual number of each car. Efforts are made to keep the erecting schedules made out five weeks in advance. Each order number becomes 4 car number when it reaches the erecting depart ment and a complete record of each car by number with its specifications is kept by a card index sys tem in the erecting department. The different departments are kept in close touch by frequent meetings. The assistant superintend- ents hold a meeting every morning and separate daily meetings are held by the foremen and order clerks. To secure the more frequent co-operation of the men, to arouse their interest and give them 4 voice in the factory management, each department has a committee of 10 to 20 employees. Each com- mittee meets every two weeks with its foremen and Aucust 17, 1916 ses working conditions, safety matters, im- ment in shop methods and various other topics terest. Suggestion boxes are provided in each tment and these suggestions are opened by ymmittee and discussed. Complete minutes proceedings at the committee meetings are and these are typewritten and sent to the ntendent. In this way matters discussed at mmittee meetings are brought to the super- lent’s attention and he is kept in close touch the men all over the plant. Copies of the com- reports are also posted in the locker-rooms employees not on the committees may know s being done by the committees in their lepartments. The committees not only are a im by which the men reach the superintendent, means by which the superintendent reaches en. Whenever the superintendent has under leration anything that pertains particularly to en, he does not make the proposed change with- rst putting it up to the men through their committees, and in this’ way he learns the ent of the employees. employment department is in charge of an ment manager whose duty is to secure proper for possible openings. The actual hiring is the departments in which the men are to oyed. When a man is wanted the foreman stal Card is Supplied for Reporting Absences es a requisition to the employment depart- t for men for certain work and the requisition is proved by the assistant superintendent covering he foremen’s department. The employment man- ager secures a man he thinks suitable for the work | turns him over to the assistant superintendent | foreman, who pass on his qualifications. In way no workman is forced into the department the employment department. A man seeking work sees the employment manager and if there possible chance of needing his services he makes ritten application.on a blank form provided and application is put on file. As the requisitions re the employment department, letters or phone messages are sent to the men having applications addition to the application file the company sa plan of having its employees recommend men r places. A recommendation blank has been pre- pared, copies of which are placed in the hands of foremen of different departments who distribute them to the employees. Any employee having an cquaintance whom he thinks will make a first-class vorkman can fill out one of these recommendation anks. One copy of the blank goes to the em- ment office and the other to the man recom- mended, who uses the filled out recommendation Klank as a reference when calling at the employ- office. Men are paid every two weeks. Complying with xpressed wish of the men, no bills in larger THE IRON AGE 347 denomination than $10 are used in paying. A day or two before pay day, the men’s time cards are figured out and delivered to them for purposes of checking with their own records. The card is made out for so many hours’ pay and not for the actual amount of money. When a man receives his pay, which is distributed while he is at work, he gives up his signed time card as a receipt. A report on an employee is made out on a blank provided for that purpose when occasion requires; that is, when he is hired, discharged, quits, per- manently or temporarily, or is transferred to an- other department or when his pay is changed. Space is provided on this card for comments on the man’s qualifications. One copy of this report is kept by the foreman, one goes to the timekeeper and one is kept in the employment office, where the proper en- tries taken from this card are made on the em- ployment record kept on the back of the man’s appli- cation card. Employees are furnished with stamped Cutting Teeth of Truck Driving Sprocket on Hendey Machine 348 postal card forms for reporting to the company when they are unable to report for work, giving the length of time they expect to be absent and the reasons therefor. Notification of absence by tele- phone is not accepted. To insure prompt delivery without the delay of passing through the regular mail channels at the general office, these cards bear a printed address of a post-office box-number and are taken from the post office every morning by a messenger. The works hospital is fully equipped with first- aid appliances and is in charge of a surgeon and three nurses. No first-aid treatment is allowed in P73 ia aad IDENTIFICATION CHECK ---- | Accident No.....2, 721 Dressing Dressing Extre SJ. Form Record Cards of Works The fore TY THE IRON n’s report has rulings on the back AGE August 17 tion check stub which the man presents » calls for treatment. He must report to the |} daily until released by the nurse in charge. hospital cards are moved daily from one another so that the nurses can tell by a gla the rack at the end of the day if any man has to report. An automobile is kept in readin all times for emergency cases, taking the in to a hospital or to the surgeon’s office. An en absent on account of sickness or any not rey to the hospital is kept in close touch with by) made usually by his foreman. Workmen’s insurance is carried by the con FOREMAN’S REPORT TO HOSPITAL. loyee hax been injured, In cases yeltere ir n be made out and sent ia after enh for the nurses’, expense and o records REPORT ON TO EMPLOYMENT DEPARTMENT THE WHITE COMPANY DEPARTMENT REQ. No ADDRESS KIND OF WORK DISCHARGED TRANSFER TO DEP'T N NEW AS A WORKMAN iS HE—POOR REASON FOR ACTION HAVE ALL TOOLS BEEN TURNED IN L PERSONAL PR WOULD YOU RE-EMPLOY IN YOUR DEPARTMENT APPROVED BY SUPERINTENDENTS F-156 s000 Mm One Copy of This Report is Kept by Goes the plant. When a man is injured he is sent to the hospital by the foreman, who makes out a report stating the nature and cause of the accident and other detailed information. Each accident re- corded and every dressing or treatment given is noted on a card that is kept in an ordinary time- ecard rack. Attached to this card is an identifica- is DEPT WORKS AS Pp ox EMPLOYEE RATE CLOCK 060 cee IN TO TAKE EFFE (oate) HANGE RATE FROM vn: OO “GIVEN RTY LOCKER KEY RETURNED —..__ YOU THINK ADVISABLE ») EMPLOY ELSEWHERE EMPLOYMENT SUPERVISOR n the Employment Of under a provision of the Ohio workmen’s compen- sation law that allows an employer to conduct !ts own insurance department, payments for injuries being required to be as much as those allowed ») the state for similar injuries. The company finds that the men prefer to have injury claims adjusted directly by the officers of the company with whom 17, 1916 ne in contact rather than by men connected e state industrial commission. itual benefit society is conducted entirely mployees and has the high executives on its ship list. This society, with an initiation $1 and bi-weekly dues of 25c., pays a sick $8 per week for the first 12 weeks and $5 for the second 12 weeks and $3 a week for the 2 weeks. A shop store is maintained by the es and profits have averaged over $400 per Of these profits 70 per cent goes to the enefit society and 30 per cent to an amuse- | RRINGBONE GEAR MACHINE nglish Machine Tool Employing Recipro- cating Gears as Planing Cutters helical or gears with teeth either in a straight line or staggered is by the Power Plant Company, West Dray- , England. It is a development of the inderlying the Fellowes gear-shaping ma- the cutters employed are themselves gear The teeth of the blank are generated by the of the cutter upon it and it is claimed tters used in this machine are accurate to extent than is commercially practicable in the hobs that type of gear nine. double well as hine capable of cutting herringbone teeth as ile sex used in gener- base of the machine consists of two rigid bed bolted together at right angles to each other. two cutters which are employed, one to cut the belonging to the left-hand helix and the other esponding to the right-hand helix, together with echanism for reciprocating the cutters and twist- them to give the helical motion required are d on the longer of the two bed plates, while ank is mounted on the other. The blank and ters are caused to roll together with the velocity orresponding to the number of teeth on each each revolution of the blank the fed toward the cutter, this process being con- ntil the full tooth depth is obtained. The ng motion of the cutter, it is explained, the clearance between the two sets of teeth each cut both the cutter and the blank are through a small angle by a ratchet mechanism. nk is rotated by the wormwheel A, which in its motion from the change gears at B. tate the operation of the machine the driving successive erives THE IRON AGE wheel of the changé { rea nas tl mie numbe ot teeth as the itter, while ne ! eth in the driven wheel corresponds to the number it the blank The two cutte heads ( nounted on shaft which are integral with the pur gear D This gear meshes with another mounted « the rifle bar EF, which passes through a rifled hole in the rmwheel F’, When the machine is i: operation this worn wheel rotated by bevel gearing deriving its power from the blank rotating mechanisn [The driving member of these bevel gears is coupled by a clutch to a shaft which connects through other bevel gearing at its opposite end with the feed shaft G, the adjustment of this clutch varying the relative angular position of th two cutters to each other. The feed shaft is actuated by the ratchet wheel H, which is driven by a link from the shaft /. At the other end of this shaft is a disk crank, J, that actuates one of the saddles through which the shaft carrying one of the cutters passes, the other saddle deriving its motion from the shaft K. The ratchet wheel H is connected to the change gears B, which provide for the rotation of the blank, through additional bevel gearing. As the cutters are essentially planing tool require relief on the return stroke which is provided by pivoting the heads carrying them to give eno freedom of motion to supply the desired relief for the tools without interfering with the engagement of the gear D with its mate. Reliance is placed upor the friction rod L that slides in a fiber bushing, the grip of which « an be adjusted by the friction bolt, to in sure the cutter il clearing the work on the return stroke The resistance offered by this bushing on the returr stroke is employed to swing the cutter clear of the work e for Cutting the Teeth of Herringbone Gears Ranging from % to 25 In. in Diameter with Reciprocating Cutters 350 The handwheel M and the screw which it actuates serve to adjust the work saddle to accommodate various sizes of blanks ranging from % to 25 in. in diameter and also to feed the cutters to the egrrect depth. If desired the interconnection of the cutters can be broken, thus providing for independent adjustment. It is possible by a slight modification to cut straight- tooth gears, and it is explained that as both cutters operate simultaneously and have a large range of travel, it is possible to turn out a quantity of these gears at one time. An Extensible Coupling for Mill Drives The Cutler-Hammer Clutch Company, Milwaukee, has developed a new type of coupling for use with mill drives, particularly where herringbone gears are used. The extensibility of the coupling is independent of the amount of torque transmitted and is the same at no load as when full power is being transmitted. A certain amount of flexibility is also present in the clutch and this too is not affected by the amount of torque trans- mitted. The coupling was designed for use with a set of rubber calendar rolls but, it is pointed out, is capable of a number of other applications where an extensible An Extensible Coupling fo! the Pinion to Align Itselt Unaffected bv the Mill Drives Designed to with the Gear and If End Thrust of the Shaft Permit cemain coupling is desired. In designing this coupling three factors had to be taken into consideration. The coupling must transmit the necessary power between the motor and the herringbone driving pinion and at the same time leave the latter free to align itself with the gear with which it meshes and also not transmit any end thrust caused by the lateral motion of the driving shaft to the pinion. The construction of the coupling is simple, con- sisting of a number of thin disks bolted together to form the disks of the coupling. The use of thin disks was decided upon as the deflection of a thin circular plate under a given load varies inversely as the cube of the thickness. While the torque transmitted by the single disk % in. thick is the same as that transmitted by three %-in. disks, the flexibility of the latter com- bination is nine times that of the former. In this coupling, which is 32 in. in diameter, it is stated that the correctness of this theory has been satisfactorily demonstrated, the forve necessary to cause a deflection of almost 1 in. being much less than the end sliding fric- tion in the bearings. Imports of Graphite Much Larger Graphite or plumbago imports are better than for some time, so that the crucible situation should be some- what easier. The following table is from Government figures, in gross tons: Per Month Jan. to June, 3.142 Year 1915 Year 1914 Year 1913 1916, 5 months 15.711 20.605 or FoF =9,4809 The present monthly rate is about 50 per cent larger than the 1913 rate of 2148 tons per month and nearly double the average for 1914. THE IRON AGE August 17 Machinery and Machine Tools in Peru, and Chile The Bureau of Foreign and Domestic Co) announces new information now available al markets for machinery and machine tools jy Bolivia and Chile. This information is contained jy . report prepared by Special Agent J. A. Massel. of a previous work on similar markets in Arve; Mr. Massel is a mechanical engineer who has traveling for the bureau in South America express purpose of getting together this material, Hp has made a careful analysis of the industries that machinery and machine tools and has pointed out a) the worth-while opportunities. The prospects for futur developments are explained carefully, and lists are given of the principal users and dealers. The report contains 88 pages and may be obtained for 10c. from the Superintendent of Documents, Washington, or from the nearest district office of the Bureau of Foreign and Domestic Commerce. ise e Pneumatic Tools Used in Restoring Oil Tanks The pneumatic tools built by the Chicago Pneumatic Tool Company, Chicago, played a prominent part in re- pairing twelve 17,000-gal. oil tanks recently. These tanks, which were 10 ft. in diameter and 30 ft. long, were damaged in a recent fire at the distributing plant of the Texas Oil Company located at Birmingham, Ala. In addition to being warped by heat, the tanks also had a number of holes in them as a result of the explosions which occurred during the fire. The rivets in the dam- aged portions of the tanks were removed with Boyer rivet busters, and pneumatic hammers were used to cut the plates and straighten them where they were not too badly damaged. The plates employed in repairing the tanks were riveted with Boyer riveting hammers, and Little Giant pneumatic drilling machines were used. The Johnson & Barry Steel Company, North Birming- ham, Ala., had the contract for doing the work. Making Tungsten Malleable To render tungsten malleable and ductile is the ob ject of an invention of Alexander Just of Budapest, Austria-Hungary, covered by a patent (U. S. 1,179,009 April 11, 1916), which he has assigned to the Gen- eral Electric Company. He subjects to fusion a mass comprising metallic tungsten and not more than 2 per cent of boron or boron nitride. It is known that tung- sten, when melted or solidified, is not malleable and ductile, so that it cannot be worked or drawn into wir Boron seems to overcome this property. It is surmised that at the fusing temperature of the tungsten, tung- sten boride is formed and that this, either independ- ently or in the form of a fixed solution formed with the tungsten, prevents the formation of large crystals which make the metal especially brittle. The A. O. Smith Company, Milwaukee, manufa turer of pressed steel automobile frames and other automobile parts, has taken out a group insurance policy covering the lives of its 1800 or more employees. The company is noted for its welfare work. A recent innovation is a provision for motion-picture exhibitions twice a week. Each Monday and Friday, at noon, pic tures are thrown on a screen in the main shop, wher the men congregate for lunch. The annual outing given by the company to its employees and their families was held at Waukesha Beach, Wis., Aug. 12, and 5000 people were entertained. H. M. Robinson & Co., Inc., Philadelphia, has been incorporated with a capital stock of $10,000 by —_ and Harris M. Robinson, 3117 Westmont Street, @"° Lillian R. Dwell, 1418 South Sixth Street, to conduct a general smelting business and to deal in metals. The Eastern Tool & Mfg. Company, manufacturer of wire shapes and builder of special machines, as moved from 74 Richmond Street, Newark, N J., % Bloomfield Avenue and Erie Railroad, Bloomfield, N.J. August 17, 1916 Nev Boring Tool with Worm Adjustment ew boring tool simple in construction and easy st to the exact size and position wanted is being yn the market by the Clark Machinery Company, ntario Street, Cleveland. It is adjusted by a d wormwheel accurately fitted and actuated Boring Tool Is Adjusted as Shown by Wormwheel Segment Worm and ench, making it unnecessary to tighten the tool ljustment and eliminating screws to be loosened ghtened in making adjustments. point is held in a holder by one set screw, and be broken, can be replaced by a new one from high-speed steel. It is designated as versal boring tool for the reason that it can be ded with a left-hand point. The tool is made in ve sizes and all wearing parts are hardened. It is o be a particularly valuable tool for a tool Triple-Turret Boring and Turning Mill \ high-speed, triple-turret vertical turning and mill has been built by G. Wilkinson & Sons, Road Tool Works, Keighley, England. The the machine, which was illustrated in a re- er of London Engineering, change gears for all au- novements and a crane for the work on the table and \]] tools can work simultaneously and one, it will be seen, is on a turret head fitted with holders. This head has a inger and lever arrange- issure alignment with its Automatic, vertical and elf-acting f