The Iron Age 1916-10-05: Vol 98 Iss 14

ES 3 4 A ! 3 WE aN \ oo 2 & Mira New York, October 5, 1916 ESTABLISHED 1855 VOL. 98: No. 14 a How a Worcester Plant Controls Production The Production Department and the Dispatch- ing Division of the Heald Machine Company Some Details of Its New Machine Shop BY W. E. FREELAND Ti problem of standardizing repeated opera storage of materials and direct work of th tions, centralizing their control and visualizing engineering department, which in t plant doe the actual conditions affecting production in not include the machine d n dey el he his plant is one of major interest to the modern engineering department plays part the 1 manufacturer. Just as every business has itself ing of the work because wu re been an evolution, so must every production system of tool equipment and upkee; d of 1 be an evolution. Local conditions always prohibit work preparatory to actual production. TI the establishment of a complete standard system assignment of jobs is delegated to the dispatc] adaptable in all its details to any machine shop or division of the manufacturing departm metal-working industry. Thus, as in the case of The routine following the receipt ( the Heald Machine Company, Worcester, Mass., a which would bring the stock of assembled machins production department separate in its functions low is this: The sales manager notifies the from the manufacturing department must take agement when sales of a particular type of machin MANAGER & ~ DESIGNING » W ACT. DE " FOREM t J q REMA . > {~ : ey T ; — a - Fig. 1—Organization Chart of the Heald Ma forms and adopt thods distinctiv he ple are r iz larger th: ‘xisting produc hed tf { iaOpt methods distinctive to the plant are running larger than existing production schec which forms a part. ules, and the management decides the number of _— rganization chart of the Heald Machine machines of this type to be made, the works man- Mpan interesting because it shows clearly ager setting the date of delivery and issuing his ow one ncern has divided the executive control instructions to the production department. I mf its y various activities. The production depart- For a concrete example, let us say that these harge of the general planning, issues instructions call for the building of 50 K-type ma- orders, supervises the purchasing and chines. The production department first proceeds 747 Ment has Product ete wid i We We mace: a $7, a nf i aaa RM ae WRT pa Meant nt ® th ee s =“ iliac Ate pO en to issue a general assembly order for the 50 ma- chines required, notifying the sales and manufac- turing departments of the assembly order and date. Its next step is to request from the designing department a complete schedule for 50 machines of K type. This general schedule consists of a con- siderable number of blueprint sheets (a specimen sheet shown in Fig. 2), bound together on a heavy fiberboard back. The first sheet forms a cover and bears general data regarding the schedule. Below this are several index sheets which give the names and numbers of the parts and units and reference numbers to the succeeding sheets upon which the drawings, units and parts appear. Following these are complete schedules of parts, these sheets having spaces for notations necessary during the progress of actual production. Upon the receipt of the schedule, the stores de- partment is asked for a report showing the finished parts on hand, parts in process, requirements on all previous schedules, and total of each part or unit available, thereby establishing the balance of each part available for the new schedule. Parts are not made for a specific assembly order, but on parts production orders, as many parts are used upon two or more types of machines. With this report in hand, the production de- SCHEDULE OF. “p6- re Ix ternal: Grinding: ‘Machi nes: NOOF MACHS.. J DATE= Gun REE, "22600 dune 25,/6 oOo 9° cbse oa seer Unit- “#ea Nai bicests poeta a Sp eee PAGE /O ————— zy aan earn ae aha eT = => ect . sy That r* ——— | PART: “DR=! ‘QUAN ON. | ORDER "DATE. QUAN seit. “NUMBER'SIZE} PA RT NAME FeO HAND; Mant! NUMBER) STARTED ; “MATERIAL Avo DIMENSIONS Kase ob Dey: Pinion “Sha ft.Col ae 1 | 48 | 300 |22 532 ine eee Screw ' k: Stock x 1-1 168. 101 [3/82 x 3/4: 28q. Head: Set Sorat ice ness As exe spmoUs Be" S< Cup: Pte (CeHe) | 1 EK~808: : f GES ‘Friction ‘Oup 14 32 | 400/ 22533 Gray. Iron Casting Esenedis fis: Wooaraft ‘Key P204L e Gh ‘auto: Peed Pinion’ = ELAS | 2S | 22534 4423/4" Samet oF 25 Pte. LE : : $3 S6"216-3/4". Long Ke3 581 Bebe Petetion eluteh : ise |3So0 2253S | (Gre y:tron: tasting: Use ohio a Pattern ‘E=3e2l. eae ple etion: Pinger Cone 1 30 | 390 22536 “2-9 Ae" Diameter. Scre* ; : Stock’ x: 2-1/4" long kas rey ett — — STN Tt - + - — ESA 19R St DEAT sin Table‘: Worm-Gear 1 BS Zoo 22837 Bronze Cory: oei tion: . = <a “BEB. bask SAAB: Diameter: x 1-1/2". Pin. Be b on ety iS (Mein: ‘Table: Morn: Gear Pin) 675 | THESE - PINS: “ARE ASSE EMBLED 4: WITH: ABP AARORD, TO K-479B:}-: mt eft att a B=375200$2:D Friction Clutch ‘Stud ee a et ee re Te ~~ aw B=376°°252:D “Peiebion: Pinger, SLE “ely <a |\2Qe0 | 225H¥0 Semi Steel Casting s J apt “t pl Sets 7 . - i : Le 4 | | rare at > - tS =65: iD “Priction: Pinger ‘Screw pal SHH OX ¢ 16 Digaicter: screw fio ' / * i332 “stock -x-1-1/8" long es f ott: BAe: -18>x Bie Hex: ‘Mut t | -. (Case. ‘Hardened ) D. 1 F He {Samant DRAWING: } be: }:- CK: UNIT #24 : I ‘ Fig. 2—This Schedule Is Typical of the Detail Sheets in the General Schedule Furnished to the Production Department Designing Department. The five white columns in the center are for the use of the production department. The first cv. shows the quantity of each part reported available by the finished stores department. The second column shows 4v« for which parts production orders are issued; the third column the parts production order numbers; the other t% ire filled in as the work progresses 748 THE IRON AGE Wain tapre clateh And” ‘Pinion. SE) 49 | 300 |2253F October 5. 19¢ partment issues production orders for the al available in stores, and sends a requisiti the purchasing department for needed raw m‘criah This requisition is made in triplicate on three colors; a green sheet goes to the p atee department, a blue sheet to the manufact y i partment in the traveler envelope, and ellow sheet to the cost department. When the 3 de- partment receives the raw material, it n s the production department, giving the quantity. the order number, the assembly number, and the part number if it is a casting. The blue sheet, which goes to the manufacturing department, rally reaches the cost department through the stores department. Orders for general assembly, unit assembly or parts production are made out in the same manner on sheets of three different colors. If it gen eral assembly or a parts production order, vhite sheet is retained by the production depart: pink sheet is sent to the stores department and a yellow sheet to the cost department. For a unit assembly a pink sheet goes to stores, a blue sheet in the traveler envelope goes to manufacturing and a yellow sheet to the cost department. From the pink sheets the stores clerk posts the requirements for each part or unit. ‘MACH, Nos So To 894 ASSEMBLY. NO Casting “$1..-Wells: Chem Agehe: Use: Pattern thé. pi ee Dill Rod 1=1/2"long 3/4: Diamete re Stock x 15/16" 1 ong Octo ver 5, 1916 THE IRON AGE 749 7 emg naan oa? 200° Be Ss Pa te | el 2 ae a EPLEEM QUAN EE) PART a OPERATIONS ASSEMBLY Eedaels cost pert. cory or re No Sa RES Astbly No. -22BOQ nese SHOP ORDER vont Noe MATERIAL requis! pect. No. <a ne ° om maremac APPUES 7 Mach. No. ——— od CRS orocr EEEEREM Quan as a TERIAL avar ‘ Keep Envelope and Contents With Work PART + ORDER ASSEMBLY m0. £-205 30. 22533 | 50. 22600 DRAWING BO. C.K-303 | ARTICLE _ PRICTION CUP MATERIAL _ GRAY IR0" Casting ROUGH DIMENSIONS osy PATTERN £-~303 « REQUIRED 400 < Deuivenen {.. DEFECTIVE STOCK, | FIMISHED INSPECTED BY : AGCEPTED By -o ot ocuvence ve aust me ie ATSB DERARIMEST 987" " Shi M9 a5 16 7 * __ aE wane“ B>. a fe } aoene JUMBa2 inl b— . a —— RICTION CUP . F a onier °-—~"99600 nan 07 5a eae } a per ner ee ~ g-308 al Reeeetiches eee j ne RES pert 6a— — on = sith ssor eeauie™ - on se HEALD MACHI } aareriae ae ga Mach ae gee _— f THE SHINE E =| — eee sire * as Dawe TUNRa2O-16 a k-303 pean eT og Ace MACHINE Cc jo ss —— D : LA S- ENT / « No ’ HE HEAL - } — pEPAR™ Orde! A ee 22600 - ny {ASING DEF \~ = 2-26-25 ; root puRCH sHoP oe ition Part NO 65 ope ro “s yuuke® a ent cern aaiiieenttiiemeien pial ® act. NO — ae ne Pe nse woreman ron (: io 0 —— Se te THE HEALD MACHINE CO. < rom A vat ane* «asa® ro our" Smet _ -16— -_ \ uy JUNE-25-16 K-303 oe of os —_ - or Date LATEs 2 ane _ eaves weaned sss ‘e , $3 . ; en Ss - = pex partis bly Ne 22600 N¢? 22553 { — note TivERED \ __ 409 wm pax] Bs os castise® PANT males , mabe THE ABOVE NAMED QUAMOITY OF FRICTION CUPS . rcs reels grat 12 “ 3 , B pennant 400 pattes A ae Leone : os sagned eae 4 hs slueprint and Instructions Sheets Belong in the Traveler Envelope. Also included are a triplicate parts production triplicate purchase order for raw mateial. The small card is the job card which is used in the operation of the ard The figures ruled off at the bottom of this show that there are four operations on this part The circle figure 1 shows that the tools for this operation have been ordered issued. When this operation is finished a red ss will be drawn through this number 1 The stores requisition is of same form as for unit assembly ne planning board occupies one wall of the ‘uperintendent’s office. It consists of a series of geable panels to which are attached tin card holders. The job tickets which are these holders come to this office in a envelope from the production department. veler is printed upon its face to provide r information concerning the part number, : nber, assembly number, drawing number, . na article, material, rough dimensions, num- iired, material available (date), number defective stock, finished, etc. The trav- eler contains a blueprint of drawing of the part and an instruction sheet. If there are several oper ations to be performed, two or more sheets (meas uring 5 x 8 in.) may be required. These instruc tion sheets give complete details as to the manner in which the operation is to be performed and the tools which are to be employed. It is planned t have at least one job and the necessary tools de- livered to each operator before the completion of the job which he has in hand. It will be noticed that in the illustrations of the job ticket and of the section of the planning board Soe RR ye ee neo ee ee pe bate this sa a ta enn ea ae. 750 there are various markings and stickers on the job tickets. In some cases the bottom section of the ticket when in the rack is covered with a strip of colored cardboard. These colored cards help to show the condition of the equipment, tools and work in process. Their use is clearly explained in the following copy of the instructions posted in the dispatching department: ' Salmon colored card indicates “Operator out Red colored card indicates “Machine broken dow: RE, Dihedlehirreattconed [S01 acme Si 45 cio eel 1 oe 1 sellin eel, | fae) hee 2 BS wWwen a Beso Be le heehee te oe | ee 1 Ee a ey oa Ct eee OL Td Baanaaes ” ny Beal | se oe le rh ee pare em Wb aS en th a Hea | ee d= Pee REECE ERT = —- ek A -] a} ite 3 a eta pS Green colored card indicates “Machine without operator aa but tooled for important work on White card stamped “Extra” indicates “Machine working aH on extra or special operation ce Yellow colored card indicates “Machine will be out of “e ? work in one hour.” pay of Green sticker on job card indicates “Work of first import eo ts , ance.”’ 24 Red sticker on job card indicates “Work of second import- em ance.”’ ¢ f THE IRON AGE October Blue circle around operation on job card ind ordered out.” Red cross through operation number on job « “Operation finished.” On the job card the with a straight black line. By referring to Figs. 4, 5 and 6 it wi! that each panel of the planning board j d place in the frame by buttons and can about as desired. The sign cards desig classes of machines are placed in large ho operations not used r a — 1 oo sooecH f “ar a : fl GABRARA Aneana R ire eb Ls ea) ted ta aakOon =r Figs. 4, 5 and 6—The Heald M chine Company's planning board composed of a series of inter changeable panels held in place ir a frame by buttons at top and bot ' tom. The larger cards designating tod ccs cl es « macl ; can be quickl ye seve | a pero | I ! nositior the } ’ they slide into p » OV Bx sie | Basse horizontal row of the smaller ul Dire | fur | ho rs im Biles HR ace The first vertical row of cards giv the type and shop number of the f © rhiee | y av0-26 | divic machines and concise , formation of their equipment, range Bier | [str | and capacity. The second row is La resey | | strt— | the job cards of the work in proces , on each machine The third and g «vier | | oct 2e | fourth row show the job ihead in Be vsion | yor ot | order of precedence Cards of other ihead of a machine are placed | 20500 | | pec—¥0| behind the front card in the fourth fais | Pe Be Twi speci panels give the as- | sre | Laas mbly order number and dates of Ea ara] leliveries of machines and magneti chucks Such a board furnishes a je neste | | ssc] quick reference for officials in servo? | charge of the assignment of jobs. acess The small partitioned space below the panel holds cards of different a colors which play a part in the working of the planning board attached to any part of the board over the smaller holders. lar to the job card holders, and are readily 1D These two features permit of great flexibility the general scheme of the board to meet changing conditions. The first row of cards on each pane gives the number of each machine and — details of its range and capacity. The eg xt row shows the job in process, and the ne Aus ehy tynite Pee ee . Oct ber 5, 1916 THE IRON AGE 751 " TOO =e : ~~ s > 2 7a 5 < z ASSEMBLING ce 52D " FLOOR P " 5 2/8 Py EANIN SCREW . , KEA 4 4 ROOM TREA vs the jobs ahead as selected by the operating iis. Other jobs ahead of any machine are behind the front card in the fourth row. board receives constant attention, being prac in continuous operation. Two separate els of different design show the assembly num- nd the delivery date of each assembly order chines and magnetic chucks that has reached the manufacturing department. Traveler envelopes stay with the work. Those over jobs not started are kept in specially lilt boxes in a rack with shelves within easy reach of the clerks in the office. All the travelers any one assembly order are kept together in a properly labeled box. An extra set of blueprints ‘ the instruction sheets is made and placed in a e-leaf binder to form a “progress book,” in vhich each operation is checked when completed, ind contingent notations are made on these prints. The progress books are checked twice each day. When a job is assigned, a tool order is issued ind sent to the tool crib. Among other items this der gives the hour when tools should reach the hat jal ——— == bad Be ef. —f aw p es et ; a. = Sg al poe .- oa yo) ~ aT s a tag , Di a Bip as: re d generous spacing of machines in the large % ~ & PT |\GRINDIA p An MF IC 4 ! pict : Heald Machir Comy nv tl flices and \ o ’ . " . . , ’ ci designated operator. The tool crib is also notified when a job is finished and promptly sends a lector for the tools. The traveler is sent with the job when it is assigned for the first operation. A simple form of notification slip is employed by inspectors and fore men to notify the dispatching division when jobs are completed. When the head of the inspection department receives notice that a job is completed he sends a move-man for the work, which is take to the inspection bench of the department where th« work was done. When he sends in his notice that the inspection has been finished, he sends the work and traveler to the department where the next ope ation will be performed. There is no need to send a notice as to which job ahead of a machine has precedence, as the work of the operator is cor trolled through the close timing of the tool issue The company has recently greatly increased and rearranged its equipment, being enabled to do this by the completion of a large addition. This addi tion, 160 x 190 ft., increases the total floor space of the plant to about 100,000 sq. ft. The new part, machine shop help in the tr sportatior ind machining of lots re al ; Eitan AR ma Senay te: om rites a Fig. 9—In planning the machine locations special attention was given to providing space for several conveyor platform loads near all machines which have a large output per day like the old, is one story high and has a saw-tooth roof. The longitudinal roof girders are of double steel beams and the transverse girders are heavy [-beams supported by steel columns. As first de- signed the saw-tooth portions were to have been supported by the usual steel trusses, but a con- siderable saving in cost was made without loss of strength by making the supporting members of heavy wooden beams. The absence of the steel trusses, with the consequent elimination of the ight-obstructing and dust-collecting properties in- herent in that type of construction, is one of the pleasing features of the new shop. The double channel-iron girders permit of flexi- bility in the hanging of shafting. In some cases the hangers are attached directly to the girders by bolting through the opening in the beams; in other eases parallel wooden beams are suspended below the girders by the same method and the hangers attached to them. An entire line of shafting when attached by either method can be quickly moved about to correspond with changes in machine loca- tions. The various motors are placed on platforms firmly bolted and braced to the vertical steel columns. A series of experiments has produced an un- usually satisfactory and economical artificial light- ing installation. As first planned by experts, the artificial illumination was to have been secured wholly from overhead lamps of 100-watt size, located in two rows in each saw-tooth section—one row Fig. 10—Assembling of machines is done by groups and not by individual machines. Thus all the machines on an assem bling order come off the floor practically simultaneousl\ IRON AGE October to be suspended from the peak and the ot points near the bottom of the southern the saw-teeth. These lamps were to bx in reflectors which would throw the lig ward in a cone of comparatively small As finally worked out, the lamps (four to formed by the girders) are of 60-watt the reflectors are of the intermediate type a cone considerably broader than as first The lights have been lowered so that t} just below the belts on the countershafts. An independent feed line, which is k all day, supplies current for individual! lamps supported by universal arm fixtures ha any operator who needs light for boring lay cutting and similar operations has it av: any time. It is believed that the present ; ment and sizes of lamps produce a more ey efficient illumination and with less eye str: any other of the plans tried. Yet this bette ing is secured usually by a combination r Fig. 11—The type of building construction lends itself adn ably to a rigid method of motor suspension lamps—an overhead and a drop light—with a tota of 85 watts in place of one 100-watt lamp overhead. One of the most quickly noticed features of this plant is the wide aisles and other open spaces about machines. This liberal spacing of machines 1s 4 helpful feature in the handling of large jobs and in the use of the numerous conveyor trucks with which the work is transported from place to place The shop is also liberally supplied with traveling cranes wherever heavy lifting is necessary. The origin of the Heald Machine Company 's found in the business started by Stephen Heald in 1830 in Barre, Mass. Wood-working and agt! cultural machinery were the first products, an¢ wire-drawing machinery was later added. Along in the 50’s an iron foundry was added and coal an iron brought by teams from the railroad 20 miles away. Two sons later entered the business, whic! continued until the death of Stephen Heald in 18°! The business languished for two or three years while the estate was being settled, and in 1890 was take" over by L. S. Heald & Son, son and grandson of the founder. In 1903 James N. Heald bought his father’s interest, moved the business to Woree* ter and organized the present company. The ma? Octoher 5, 1916 THE IRON AGE 1538 of grinding machines had become a large the business previous to the removal to i r, and since that time a comprehensive ternal and surface grinding machines, and ently a successful line of magnetic chucks, en developed, which have had a large sale, nestic and foreign. first shop in Worcester, built in 1903, con- it 9000 sq. ft. In 1907 additions brought of the shop to 23,500 sq. ft. and a boiler vas built. In 1909 an electric power plant w. capacity was added. In 1911 an addi- ) x 220 ft., widely described at the time of tion because of its new features, was built. een years the number of hands employed 1 9Or reased from 22 to 325. B. Morgan, treasurer Morgan Construc- mpany, Worcester, is president and James N i is treasurer of the company. Mr. Heald il manager; Cyrus N. Cowan, works man- d S. T. Massey, sales manager Press for Briquetting Metal Turnings ne of hydraulic presses for briquetting metal s, borings, ete., has been developed by the ilic Press Mfg. Company, Mount Gilead, Ohio ress is of the four-rod inverted cylinder type raulic Press for Briquetting Metal Borings, Turn- Remelting, the Material Is Placed in a Floating rted by Four Springs and Sliding Over a Station- iry Plunger and is built in three different sizes and pressure capacities ranging from 300 to 1000 tons, the last being the one dllustrated. It enables this class of scrap material to be put in convenient form for handling and to be remelted without loss of valuable ingredients and oxidation is prevented. One of the particularly interesting features of the press is the mechanism for forming a briquet. In operation the material is placed in a floating mold supported by four springs. When pressure is applied from above, the friction of the material on the sides of the mold causes the latter to move down over a stationary plunger projecting into the mold from below. This arrangement, which is somewhat unique in design and operation, causes pressure to be applied on both the top and bottom of the ma terial which, it is emphasized, gives a briquet of uniform density. All of the movements of the press are controlled by levers conveniently located for the operator. After the briquet has been formed the lower plunger is removed by a lever located near the main operating valve and the briquet is ejected from the mold by pressure applied by the main ram. Hy draulic push cylinders are employed to lift the float ing mold while the lower plunger is withdrawn or returned to place on this size of press and also the middle size, which has a capacity of 750 tons. In the 300-ton press a collar surrounding the plunger is held against the mold by a spring. When the briquet is ejected from the mold it falls to the base of the press and is removed by a conveyor. A surge tank located above the main cylinder is provided for this press. A simple movement of the valve lever brings the plunger to bear on the ma terial in the mold and the suction caused by th action fills the main cylinder with fluid. In this way the first stroke of the pump produces pressure upon the material being handled. When the press ing operation is completed the main ram is returned by an auxiliary one located at the extreme top of the press and the fluid is returned to the surge tank A Safety Manual for Blast-Furnace Workers The precautions to be observed by the foremen and other employees at blast-furnace plants to avoid acci dents are described at some length in technical paper No. 136 of the Bureau of Mines. The author, Fred erick H. Willcox, first describes the method of attacking the accident problem by using a plant-inspection com mittee composed of two to four men selected from the sub-foremen and workmen. The duties of this commit tee, which comprise a study of accidents that have hap pened and the inspection of the plant for improper physical conditions and unsafe practices, are touched upon and methods of obtaining co-operation on the part of the employees and of putting the recommendations of the plant-inspection committee into effect are outlined The larger portion of the paper is given over to direc tions for avoiding accidents, with detailed instruction to the various groups of employees, including the engins room and boiler house forces. These instructions are supplemented by numerous engravings illustrating the unsafe and safe ways of performing various operations Notes on first aid are included British Imports of Manganese Ore British imports of manganese ore in August were 46,606 gross tons, against 10,611 tons in August, 1915, and 33,817 tons last July. The total for the eight months to Sept. 1, 1916, is 306,005 tons, contrasted with 164,769 tons to Sept. 1, 1915. The receipts thus far this year are at the rate of 38,250 tons per month, as against only 20,596 tons per month for the first eight months of 1915. The manganese ore situation in England is therefore easier now than at any time during the war. s ™ = Pe —s we here ~ ee eR. as. OR Er THE FINISHING EDGES OF DIES How Threading and Blanking Types Are Made on a Special Machine The Anderson Die Machine Company, Bridge- port, Conn., has designed and built a die-forming machine. As the name indicates it is intended for finishing blanking and threading the dies and simi- lar work after the core or surplus stock has been drilled out. The machine is driven by a motor re- ceiving power from the nearest lighting socket, and it is emphasized that the machine is more rapid than a filing machine of the reciprocating type, since the cut is constant and change of contour of the surface operated on does not necessitate a cor- responding change of cutter. The machine consists of a main frame contain- ing a vertical work spindle which is driven by a shaft at right angles to it that is connected to the motor by a semi-flexible coupling and to the spindle by a pair of spiral gears. The work table or platen Finishing the Cutting Edges of a Threading Die in a Specially Developed Die Forming Machine is adjusted to give a surface at right angles to the center line of the spindle. The cutters, which are mounted in a collet, operate on the principle of a hardened ratchet screw to shear material off the work operated on when rotating at high speed. The pitch of this screw is relied upon to cause the work to be drawn down on the platen and also carry the chips down and leave the line marked out on the blank visible at all times. This arrangement, it is explained, does away with feed screws, slides or vises in which to hold or control the work upon which the machine is operating. The collet is opened for the removal or changing of cutters by a lever conveniently lo- cated at the front of the machine. Tuis lever is pivoted on the frame and when raised comes in contact with the lower end of the draw-in spindle, thus compressing the spring and forcing the collet upward and open. The main spindle is hardened and ground and runs in bronze bearings, the upper of which is of the double angle type, while the lower is straight and adjustable for wear. An adjustable thrust collar bearing on the lower face of the upper bearing is provided, and a knurled ring on the end of the spindle is relied upon to prevent chips or dust from entering the bearing. When threading dies are being finished, the die, which has previously had as many holes drilled in it as there are cutting edges required, is dropped into a central opening in the work holder or lever. vey IRON AGE October Putting the Finishing Touches on a Blanking D with a Cutter Receiving Power from the Spindl chine through a Flexible Shaft Connecti The die fits freely into this opening and a former of machine or tool steel which has been hardened to resist wear is placed over the die. This former has four or more projections, depending on the number of cutting edges on the die, and these are the same width as the portion of the finished die that will produce the thread. A special cutter hay- ing a blank portion where it comes in contact with the projections of the former is inserted in the collet. This blank portion is relied upon to limit the amount of material to be removed and also serves to establish a uniform tooth width. The die holder is moved back and forth by a handle and the die is rotated until the cutter comes in contact with the portion of the die to be operated on. A special type of controlling mechanism is pro- vided where it is desired to finish the sides of a die at an angle with the base. In this mechanism the bar A extends across the machine at right angles to the side of the rectangular machine table, this bar being secured to the main slide, which yuides it at right angles to the die or the table. A strip or bar B extends nearly across the bar A and has a series of holes in the top face, while the outer end is threaded. A knurled nut C is located The Mechanism Controlling the Movement of the Die Being Finished with Relation to the Cutter 5] Oct ver 5, 1916 hreaded portion of the bar and is secured e motion by the bracket D, which forms a the main slide. Turning the knurled nut in rection causes the bar B to be moved cor- The main slide is secured to the a dovetail, and together with the bar A oved by hand in either direction. A plate ed to the lower side of the block to give fit at all times. If desired the main slide cked with a screw. A bar F' passes through slide and extends toward the back of the the rear end of the bar being threaded. G is fastened securely at the rear edge le and a knurled nut #J is secured in the prevent movement in either direction. The this nut in either direction causes the move either forward or back. A set screw nted in the slide and is designed to engage F, thus causing the main slide to move in e direction as the rod. The slide J is on the bar A and normally can be moved d in either direction throughout the width le or locked in any position by the screw nurled plug passes through the slide J and the holes in the bar B. If the slide is per to move freely, a fine adjustment of-it on r A can be secured by turning the knurled An arm L is also mounted on the slide J be swung at any angle in relation to the bar edge being graduated to indicate the degree arity. Two holding memb2rs M and N are the bar L and set gly. screws © are em- nz Finished by Milling Away the Re After the sugh Core Has Been Drilled Out | to fasten the die or work being operated on holding members, which are locked in their ons on the arm L through the screws P. operation the die is secured in place and the is engaged in one of the holes in the bar B. the main slide is unlocked, the amount of | to be removed in one cut is adjusted by pulating the nut C, after which the die is fed sliding the bar A by hand. After this material been removed the operation is repeated until lesired depth has been secured. To remove in the opposite direction, the slide J is and the rod F is secured to the main slide et screw J, so that when the nut H is turned can be adjusted to have the cutter take off per amount of metal. The handles Q and R ) assist in feeding the die against the cutter. way, it is pointed out, practically any sur- n be finished by swinging the arm L and ie J to give the various angles required. hing touches can also be put on a blanking and by connecting a flexible shaft to the f the machine by a special fixture and using rotating cutter. THE IRON AGE ~] A Semi-Universal Milling Attachment A new design of semi-universal attachment has been developed by the Valley City Machine Works Grand Rapids, Mich., for use on its No. 1% milling machine. The particular advantage claimed for the us: of this attachment is that the operator can get closet to angular cuts without sacr \lthough the attachment j ise on the builder’s machines, it can also be applic to other makes with slight modifications. The attachment swings and if desired may be reversed. ng rigidity of support was de signed primarily a inder the overar! When the spindle is a vertical position the hole through it is readily acc sible, a feature that is made possible by offsetting thi spindle of the proper. The attachment spindle rotates in ths as the main one, and is fitted with a No. 10 taper. Thi drive is through a splined pitch mite gears, an intermediate ball-bearing shaft and a pair of heavy steel spur gears as the final drive A clamp base, which is bored to fit the spindle box and is secured to the column with screws, is furnished with the attachment clea! attachment from that of the machin ame directio arbor, coarse Franklin Institute Lectures Fhe Franklin Institute, Philadelphia, has arranged a program of lectures for the winter of 1916-17, in cluded in which are the following: Oct. 18, 191° Scientific R dustries,”"" by Charl Pr. § General Electric Company, S$ Dec. 14, 1916—“The Cooling of Water for Powe Purpose * by < ( Tho is. pl r of mecha l« er ng, Johr Hopkins Universit Baltimore, Md Feb. 1, 1917—“The By-Product Coking Indust: Ramsburg, vice-presider H. Koppers Comp d burgh By-Vroduct Coking Comp y, Pittsburgh, VP : March 1, 1917—-‘Developmer nd Progress AY ! Motors, I H Souther, « ulting g ! tion, U. 8S. A ; Depar Wasl to a : March 1 ] & ( nd I . Modern M \ I e. i o>. ¢ A Steel Plant for Siberia A new iron and steel plant in Siberia is contem plated. The plan, as a result of a recent meeting be tween representatives of the Russian Government and of the iron industry, is to raise a capital of 20,000,000 rubles, the interest to be guaranteed to the banks sub scribing. The government is to lease the district of Kusnezk, where the works are to be located, to the com pany for 60 years, the company to supply a fixed ton nage of rails and other railroad material yearly at cur rent prices. This district has coal and iron deposits estimated at 1594 million poods, the ore having an iron content of 58 to 65 per cent. Agricultural implements are also to be made. c Effect of Sulphur on Low-Carbon Stee! A Comparison of the Static and Dynamic Properties of High and Low Sulphur Steels Uniformly Heat Treated — Sulphur Detrimental in Shock Tests -BY CARLE R. steel manufacturer and often no effort and expense have been spared in order to reduce it to a small per cent in the finished product. This condition is due to a general conviction that in many cases where steels have failed in service, sulphur has been the cause. But there has been a growing feeling in recent years that the verdict against sulphur has been unnecessarily severe. In cases of segregation it was present in augmented amounts along with other impurities, but it had not caused the segregation. High sulphur in pig iron is caused by poor fur- nace conditions and the sulphur is merely one indi- cation of an iron that has not been properly re, duced. No amount of subsequent treatment under S ULPHUR has long been one of the banes of the a ga Leads Galvanized Tron e: Magnesia WYYyy a Yi Yyyy £ Us \V/pyy SS Alundum Muffle Crose Hatched Portions except Muffle ang Specimens are Asbestos Board SECTION ON ab Sections of the Heat-Treatment Furnace Used in Treating the Low Carbon Steels oxidizing conditions in the open-hearth furnace can remedy the defects, although the per cent of sul- phur may be considerably reduced. In other words, the causes of bad steel can frequently be traced back to bad pig iron, and sulphur is merely one indication that the pig iron is bad. The writer re- cently visited a steel plant where a mass of evidence had been accumulated which substantiated this fact, and the superintendent was emphatic in stating that high sulphur was not harmful provided the steel was not otherwise poor due to insufficient reduc- tion in the blast furnace. The presence of a moderate amount of sulphur is desirable from the standpoint of the man who ma- chines the steel. The low-sulphur material drags and the production of a smooth surface is very difficult. A slight increase in sulphur enables the machinist to produce a smooth surface without diffi- culty. Since, therefore, such large quantities of steel are subjected to machining, it becomes highly important that the sulphur controversy should be *From a paper to be presented at the meeting of the American Institute of Mining Engineers in New York in February, 1917. The author is assistant professor of mining engineering and metallurgy, Massachusetts Institute of Tech- nology, Cambridge, Mass. 756 HAYWARD* settled, and if its presence is proved to be harm| the ban on it should be lifted. Among the recent papers on the effect of phur on steel is one by Dr. J. S. Unger, manage: tral research bureau, Carnegie Steel Company.+ The re. sults of an exhaustive series of tests are given and the conclusion states: The author does not advocate paying no attentioy whatever to sulphur content in steel, but believes firmly that a steel containing less than 0.100 per cent is not necessarily bad, and that it will show little, if any. difference in quality when compared with the same steel of much lower sulphur, other conditions being the same. The present investigation was undertaken at the suggestion of A. H. Annan of the Rhode Island Too! Company, who co-operated by furnishing the steel] and machining the specimens. The results are pre- sented as a contribution to the general knowledge on the subject. THE STEELS USED It was planned to use three steels of different sulphur content, but with the other elements the same. The manganese was an exception, however, for with this element part is in the form of MnS existing free in the steel and the remainder is dis- solved in the steel. It is evident, therefore, that the manganese should vary, but that the amount in excess of MnS should be constant in the different steels. The steels finally selected were in the form of *4-in. round bars. Two bars of each grade were required to furnish sufficient specimens. The an- alyses are shown in Table 1. Table 1—Analysis of Steels Used in Equipments Total Excess Man- Man- Phos- Carbon, ganese, ganese, phorus, Silicon, Sulphu Per Per Per Per Per Pet Mark Cent Cent Cent Cent Cent Cent 1 0.18 0.55 0.48 0.007 0.01 0. 1A 0.18 0.57 0.50 6.009 0.02 0.04 2 0.17 0.67 0.52 0.008 6.01 0.086 2A 0.18 0.70 0.55 0.010 0.03 0.08 3 0.18 0.80 0.54 0.006 0.02 0.152 3A 0.17 0.80 0.55 0.011 0.03 0.14% THE HEAT TREATMENT In order to make a comparison of the steels under different conditions it was decided to heat all the specimens to a temperature just above the crit ical range, quench in water, and reheat different lots to 300, 400, 500 and 600 deg. C. respectively. For this purpose the bars were cut in 7-in. lengths, which was sufficient for tensile specimens and spec’ mens for microscopic examination. The furnace used is shown in the illustration The muffle is made of alundum and is 2 in. high, 9 in. wide and 16 in. long. It is wound with No. 19 excello resistance wire. In order to obtain uniform heating of the specimens, they were supported on an asbestos rack, as shown. Asbestos shields were placed on the sides and ends of the rack so that the specimens were practically in a muffle within 4 muffle. A platinum, platinum-rhodium thermo #THE IRON AGE, Jan. 13, 1916 Oct: er 5, 1916 vas introduced through the back of the muffle center of the heating chamber and con- to a Siemens and Halske recording galva- procedure in heat treatment was as follows: furnace was heated to 880 deg. C. and nine ; introduced. This caused the temperature to 550 deg. C. and it took about 40 min. to again 30 deg. When the latter temperature was it was maintained constant for 15 min., after he specimens, except as noted below, were in water and a new lot introduced into the This was continued until about 18 of the ns had been treated. Nine of these, consist- hree high-, three medium- and three low-sulphur vere removed from the furnace and allowed to air. The remaining nine, consisting of three of sulphur content, were allowed to cool in the lrawing the quenched specimens at the vari- nperatures, the procedure was as follows: furnace was heated to 600 deg. C. and nine ns, three of each sulphur content, were intro- The temperature fell and it required about 30 to come back to 600 deg. It was maintained here min. and then the specimens were withdrawn enched in water. The furnace was cooled to eg. C. and another set of nine specimens was in- luced. When the temperature had regained 500 was maintained constant for 10 min. and then imens were withdrawn and quenched. Follow- similar procedure, sets of nine specimens were | at 400 and 300 deg. C. respectively. THE TENSILE TESTS After sawing off *, in. from each piece for micro- ; examination, standard test specimens were prepared with 2-in. gage length, 0.505-in. diameter nd threaded ends. These were pulled in an Olsen nachine in the testing laboratory of the Massa- husetts Institute of Technology. The results ob- ned are given in a table in the paper. The aver- ves are retabulated in Table 2. The designations Vv and H refer to low, medium and high sulphur ntont iverage Tensile Results of the Treated Specimens Break- Elon- Reduc- Yield ing gation, tion of Point, Load, Per Area, Lb. Per Lb. Per Centin Per Sq. In Sq. In 2 In Cent S60 deg a and n ice water 57.900 85,600 23.5 63.1 53.600 77.700 27.7 70.1 . 56,900 86,000 22.0 60.7 S60 deze. C. and still air 43.200 58,400 41.5 &7.8 $6,000 58.000 41.3 68.5 42,600 59.400 39.0 63.9 Xi deg, ¢ and Irnace 36,500 52.600 $0.5 £3.° 86.800 53.000 40.3 61.6 35,100 55.000 88 0 63.0 S60 dee in ice Neheated to 300 deg 5,900 T5,675 26.5 70.0 59.500 75.000 26.7 71.4 57.500 87,800 21.5 60.7 S60 deg In ice Reheated to 400 deg 60,300 76,300 28.8 72.1 62,600 76,600 26.3 70.0 62,400 83.200 22.3 62.4 860 dee in ice teheated to 500 deg 57,000 72.700 32.0 732.5 59.700 73.300 29.0 71.8 : 60,900 78,000 26.0 67.0 S60 dee in ice eated to 600 deg 52.200 68,800 34.2 75.5 53,600 71,100 33.0 73.5 55,200 74,600 30.5 70.7 re is not sufficient variation in the results to n effective plot, but Table 3 summarizes the by giving the order in which they occur from to low. THE IRON AGE 757 a After concluding the tensile tests, it was thought desirable to determine the effect of varying sulphur eontent on specimens subjected to shock. SHOCK TESTS Through the kindness of the testing department of the Watertown Arsenal, their Charpy machine was obtained for this purpose. The remaining *4-in Table : N } of Tensile Tests Showing Hank Redus Yield Break Elonga tik Point ing Load tion of Are L MBL MHL MAL SM Quenched in ice water BS a eS 8 3 Se. e a Cooled in still air. 2 l ; 2 ; 1 l 4 3 2 l Cooled in furnace ; [i= ae aes 1 2 } , 8 Reheated to 300 deg.. 3 l 2 2 ; l 3 l 2 } l Reheated to 400 deg... . a. a as oe oe oe ke Reheated to 500 deg 2 l 3 2 1 l 2 3 1 Reheated to 600 deg 2 1 ae We ae eo Totals 17 11 14 18 17 7111219 13 12 1% Order of totals 3° tame ve 23 a: 2 € ee stock of bars marked 1, 2 and 3 were sawed into 2-in. lengths and the specimens subjected to heat treatment in sets of three under the same condi tions that obtained in the case of the tensile speci mens. After heat treatment, the specimens were machined to conform to the following specifica tions: Length 55 mm., cross-section 10 by 10 mm., notch across one side, midway between the ends, 1 mm. wide Radius of cutter edge, 2/3 mm. The Charpy machine consists of a heavy pendu lum which drops from a fixed height, strikes the specimen supported at each end and breaks it at the notch. The pendulum then continues its swing and the height it reaches is registered. Knowing the weight of the pendulum, the height it falls and the height it rises, a simple calculation gives the energy consumed in breaking the specimen. (Photomicrographs of some of the specimens are given in the paper.) CONCLUSIONS Table 3, which expresses the summary of the tensile tests, shows that the high-sulphur steel has for each treatment the highest breaking load while the yield point ranks first for two treatments, sec ond for three and third for two. From this we may conclude that the sulphur does not lower the tensil strength. The figures for elongation and reduction of area show that there is little difference in ductility be tween the low- and medium-sulphur steels, but the ductility of the high-sulphur steel is slightly lower than the other two for most of the treatments. The average figures for the shock tests, except for the air- and furnace-cooled specimens, are high est for each treatment in the case of the low-sulphur steels, and lowest for each treatment for the high sulphur steels. The widest difference appears in the steels which have been quenched and reheated. It is difficult to draw definite conclusions from the results because of the newness of the shock test and the difference of opinion among engineers regarding its value. The tensile tests are not un favorable to steels with moderate amounts of sul phur, while the shock tests show a decided falling off in strength as the sulphur increases. Until the interpretation of the results from the Charpy ma- chine is more fully understood, it is impossible to say to which set of tests the most importance should be attached. Further light might be thrown on the subject by making alternate stress or fatigue tests. It : 43 ' i a ed wg . tS + LA i oe a e aa i ‘a — via 7 5 ‘ a 7 : eo : “ om ae ee aoe 758 would be important to learn whether the results would confirm the tensile or shock tests. Unfortu- nately, however, the stock of steels used in the previous work was exhausted, and whatever the results of the fatigue tests there would be an un- certainty in their interpretation because of differ- ence in stock. It was, therefore, decided not to include this series in the present investigation. Salvaging Rails with a Motor Truck An interesting use of a motor truck is being made by the Black Hills Transfer Company, Nahant, Mont. This company has the contract for salvag ing the rails on an abandoned logging railroad con necting the station at Nahant on the Burlington system with some timber lands 35 miles west of the town. For this work the company is using a 114-ton White motor truck. The line from which the rails are being recov ered was abandoned several years ago on account of the exhaustion of timber and the enforcement of the forest reserve act. Several obstacles con- fronted the transfer company when it received me tae THE IRON AGE October 5, i91¢ Carriage Builders Hold Annual M« tin; The Carriage Builders’ National Associ: its forty-fourth annual naan at the Hot Cincinnati, Ohio, Sept. 26, 27 and 28. The n called to order by President P. E. Seen and the address of welcome was made by May Puchta of Cincinnati. Manufacturers from a the country were present and exhibits were h banquet hall of the Hotel Gibson. On Wednesday an interesting address was Charles E. Adams, president Cleveland Hardy pany, Cleveland, who spoke in part as follow and iron products are selling to-day at a pric: not decrease before 1919. As steel goes, s world and its products. The man who sells a ¢ at less than current prices because he was enough a few years ago to lay a large supply is an industrial suicide. . He never will agair to duplicate the prices of 1913. Nor will lal: be as cheap as before the European war. The man of this country has been given a touch « and unprecedented prosperity and will not ret the wage scale of a few years ago. He has begun to demand an annual vacation. He doe quest it. He is America’s most independent predict that the highest priced labor in the oa Using a 114%4-Ton Motor Truck Equipped with Flanged Wheels to Recover the Rails of an Abandoned Lumber R The Truck Also Hauls a Standard Flat Car asa the contract. It was not possible to use a locomo tive to haul the rails because the forest reserve laws require oil-burning locomotives and only those burning wood were available. The track was not, of course, kept in repair and the cost of putting it in shape to enable a heavy locomotive to run over it was prohibitive. A rank growth of long and tough grass over the rails, in some cases 18 in. high, had woven a network that completely obstructed them from view which was another objection to the use of a locomotive. When the truck was received from the builder it was fitted with flanged steel wheels and a special rear truck provided. A standard flat car was also used as a trailer and with this equipment it was possible to haul 12 tons of rails into Nahant each trip. The truck made two round trips a day, 140 miles, climbing several grades as steep as 7 per cent. In the first month the truck was in service it covered approximately 3300 miles, or an average of 108 miles per day. In several cases more than 10 miles were run on 1 gal. of gasoline. The total number of controlled establishments under the Munitions of War acts in Great Britain is now 4212. Trailer, the Capacity of the Two Being 12 Tons States wil! be the day labor, and this will come befor« July 1, 1917. The cessation of immigration has caused this condition. The United States to-day has 2,000,000 less foreign laborers than in 1913, and the foreign elk ment that once used the pick and shovel has since graduated to a position where skill is required.” C. P. Heindell, Charlotte, N. C., who made an ad- dress on “The Buggy in the South,” disputed state- ments recently made by automobile manufacturers that the horse-dra