The Iron Age 1921-10-13: Vol 108 Iss 15

THE IRON AGE New York, October 13, 1921 ESTABLISHED 1855 EEE VOL. 108: No. 15 ~~) Improved Core Output from Smaller Space By Providing Improved Working Conditions for Girl Core-Makers, Better Product and a Higher Type of Employee Have Been Secured B voted maki : Nant TeENneyY met ted + ed Vy) luced nefor iY SUPIK inu pies Th f ti Al 1 + Tile Walls With Whict Y moving the core room from the north end of the plant to the extreme south end, and building an addition for girl workers, the capacity of the Electric Co. foundry at Pittsfield, Mass., was increased from 50 to 60 tons daily. The core room, immediately in the rear of two ontinuous melting Whiting cupolas, has been rted into a machine molding department. Added derived from this rearrangement are the ing of losses in temperature and a reduction time necessary in handling molten metal. proximately 13,000 sq. ft. floor space was de- formerly to core making. The new girl core- ig department involved 2530 sq. ft. additional floor space, but by the rearrangement of the al core-making layout the total space now de- core-making, including the new addition, is re- 9880 sq. ft.,or more than 3000 sq. ft. less than e. The relation of added core-making floor space creased output capacity, therefore, is all the more ng, and at once suggests, as is the case, improved facturing practise based on new production prin- ind modern equipment. is plant is given over largely to the manufacture ansformer iron castings, necessitating accurate high grade core work. Previously, cores were nade by male help. An elaborate system of Convenient Work Benches, Everything at Hand and No Outside Disturbances All Contribute to the E ; This Core Room Force Functions. At extreme right, a corner of the metal containers for core sand mayy seen, with two outlets near the floor 927 rails on which drying cars ran to and from the ovens occupied much valuable space, and necessitated larger handling and other core charges than desired. In planning the new core department, the number of women employees was increased, while the number of male core makers was diminished. And the question of Americanization as related to the problem took a new angle, due to the character of the foundry em- ployees. Effect of Comfort on Efficiency Previous core-room standards, as related to work- ing surroundings, are practically ignored in the con- struction of the new department. The utmost consider- ation has been given details looking to the comfort of girl employees, and its bearing on efficiency. The in- vestment represented in this plant addition and its equipment, amounting to between $40,000 and $50,000, bears out this statement. Here, exceptional construc- tion and arrangement features are to be found. Quality of work, volume of output, and elimination of core breakage are largely founded on the concentra- tion of the girl’s mind on what she is doing, by elimi- nating excess operations, on sanitation and on privacy. The new department consists of the core room, and locker, wash and rest quarters. It adjoins the larger core room, four exits, 5% ft. wide by 7 ft. high, con- | ea pe ee eR pie « FO i i Tg aect dinate is iia i re io vie 3 “es ey st ehh iis li de lee 928 THE IRON AGE necting the old and the new rooms. These exits have quick-acting roll-type metal doors. The new core room is 72 x 28 ft. and finished in white. The walls are of glazed white tile, extending 6 ft. from the floor, and of smooth brick, painted with cream white enamel, from the top of the tiling to the roof. The roof and steel trusses are finished in cream white enamel. The floor- ing is of dark gray cement, which does not show stains, and is tapered to drains. Dust proof corners are provided everywhere, and the tiled walls are washed down and the floors flushed off every night. Water connections are available al regular intervals along the outside wall of the room, which serve girls working at benches as well as the night cleaners. All working equipment in this room is raised several inches from the floor, to facilitate cleaning operations. The place is heated by steam, thus is quickly dried after being washed in fall and winter months. There are two large skylights, with generous ventilators, on the roof. These skylights and numerous large windows insure an abundance of light and fresh air. Artificial light is furnished by large candlepower drop lights inclosed in attractive glass shades. Privacy a Large Factor Girls enter and leave their core room by a private stairway located between their locker, wash and rest quarters and the large core room. Their doorway is 700 ft. away from the nearest point where male em- ployees enter and leave the plant, and has quick access to a highway outside the jurisdiction of the company. The girls have their own time clock, located where they naturally pass to and from the stairway and the locker and wash quarters. Bench accommodation is provided for thirty-two girls, who are under the supervision of a forewoman. The benches are made of hard wood with metal cover- ings and have cylindrical metal supports. Each girl October 13, 1921 is provided with a jolt machine, air operated, large shockless type, fitted into the bench so that not in operation, its top serves as part of the compressed air system for cleaning core box tables, and a heavy metal core stand, designed substantial base, to insure against tipping 0\ allowing finished work to drop to the floor. | end of each bench is an auxiliary table contai metal pail for holding cutting fluids. Because of the character of the core work 1 great care is used in the selection and treat sands. These are mechanically mixed by n two stories below, and conveyed to the core floors by bucket and chain hoists. For the n room, the sand is delivered by metal chut: the hoists to two containers 9 ft. long, deep and 6 ft. high. These containers ered by glazed tile and located between exit large core room, and within easy access of gi) ing at the benches. They are divided into sections for the different mixtures of sand. Th on a level with the flooring, have-protective met which prevent sand from running out on the For holding nails and brads, two series of | structed of heavy wood and supported by i: are stationed between two exits, within easy r the girls. Practically all core box equipmer aluminum and made in multiples, hence the has a complete plate of cores with which The weight of the core boxes, sand and drying governs the number of cores made in one plate. Cor rods are shaped by men in the large core room, and then delivered to the girls. It therefore is apparent that each girl is furnished with everything needed fo: her work, either at or in close proximity to her bench Time required to obtain sand and nails is minimized and there is no other excuse for her leaving the ben to complete her work, nt Section of the Main Core Room, with One of the Doorways at Left (White) Leading into the Women’s Core Room. In fro of the door is a core rack on the electric truck which carries the racks to and from the ovens tober 13, 1921 THE IRON AGE 929 Women’s Rest Room Are a Regular Hospital Bed nty of Chairs. Each girl has her own white ocker, and the washing facilities are attractive racks, 4 ft. 3 in. wide, 5 ft. 6 in. high and long, with adjustable shelves, are run from ge into the new core room and stationed in between benches. These racks are picked up, and transferred by Baker R. & L. Co., (Cleve- vpe C electric trucks, operated by one man. ns in the new core room are in direct line with nsequently a truck does not have to twist or ile placing racks between benches, and little thus consumed in the operation. After a girl her core box, she lifts it from the stand and on the drying rack, this operation necessitating two steps. Cores Not Handled Between Making and Using rr 1e core room, the racks are run into ovens capacity for two racks. There are six of ns and one draw type on the end of the bat- oil fired and well insulated, each having a ey thermometer. After the cores are dried, the delivered to the storage department by the trucks, where each remains until all cores it e been used by the molders. In this prac- ores remain in the same position, from the are placed on the racks by the girls in the until they are lifted from the racks by the Excess handling therefore is eliminated, and reduced to practically nothing. core makers are on a piece work basis. The help used in connection with the new core is the man who operates the electric nd the two men employed at the sand mixing As their time is devoted equally with mix- for the large core room, costs involved here small. In addition, piece work charges for core rods by. men must be figured into the Increased production and the better the work turned out have more than com- i the General Electric Co. for the investment, ocker, wash and rest room, which is 24 x 28 s out of the core room. It is finished in glazed ughout and has a dark colored cement floor *pering to drains. A large skylight, with the same Bt} f ventilation as in the core room, is provided, anc ere is plenty of natural and artificial light, which, with washing down every night, keeps the quarters clean and refreshing. In the locker and wash room there are two toilets and a battery of wash stands with hot and cold water, everything being of porcelain and having nickeled fixtures. Two mirrors are provided, and each girl has her own white sanitary locker. Partitioned off from the wash and locker quarters is the rest room, which contains a regular hospital bed, chairs, tables, wash stand and an electric heater to allow the girls to prepare something hot for their lunch. Here the same color scheme is carried out as elsewhere. The company furnishes a victrola and a certain number of dance records, which are kept in the core room and used only during noon hours. A large number of the girls employed in the new core room are taking a lively interest in the various com- pany classes, with a view to bettering themselves educationally. The management has proved to itself, and to girl workers, that the core room of a foundry can be made one of the most satisfactory departments of such a plant, from the standpoint of both employer and em- ployee. Since this core room first was placed in oper ation, the personal character of the individual girl employed there has steadily improved, due to a higher and still higher class of workers being attracted by working conditions and surroundings, and to the in- fluence of surroundings and conditions in molding the social standing of the individual, especially those born in foreign lands or of foreign parentage. Naturally, the standard of cores produced progressively improves, as the character and educational qualifications of the individual girl worker improve. A meeting on engineering financing is to be held at the Engineering Societies Building, New York, on the evening of Oct. 19. It will be a joint meeting participated in by the New York sections of the me- chanical, electrical, civil and mining and metallurgical engineering societies. , The Hyatt Roller Bearing Co., New York, has ob- tained the contract for furnishing Hyatt roller bear- ings on the mill tables required for the new mills at the International Nickel Co. and the Mansfield Sheet & Tin Plate Co. eeeire B a —— arse Bea + ee ncn Trends ins hens BN 930 THE IRON Two Principles in Hot Drawing In his paper before the Iron and Steel Institute, on the subject of Hot Drawing on the Mandril, Eugéne Schneider brought out forcibly two principles relating to practise in that work. Extracts follow: Under like conditions of temperature, and with dies whose surfaces of contact are in the same state, the resistance to displacement increases as the angle of contact decreases. In other words, for a given pass, the greater the angle of contact, or the smaller the connecting radius, the less becomes the power necessary for drawing. If the angle of contact # is very small (Fig. 1) the value of cot £ is very great, consequently the friction in- creases, and, due to the normal reaction, the metal tends to wedge instead of to be displaced. If, on the contrary, assuming always the same re- a a e a | v| 2 BEES SEES oe ARES, —< “4 D- od D-* 3 duction of section, the angle of contact @ is very great “7 — decreases and the friction becomes (Fig. 2), cot negligible. The power necessary then becomes in the neighborhood of the minimum. The section of the metal to be displaced works at this moment under shear, and the effort of drawing can create tears on this section. From this it appears that it is advantageous to em- ploy dies of small connecting radius. However, to avoid tearing the metal, which would result from a very short cone, it is necessary to find a normal sec- tion, and experience has enabled us to determine this. 4 The angle of attack which seems to be the limit of the opening of the cone, is about 15 deg. For a larger inclination there is the risk of tearing the metal to be displaced. D—d , the die For a diminution of thickness of sides which permits working under the best conditions is that where the connecting radius is equal to about seven and a half times the diminution of the thickness of sides. This condition of efficiency of the die does not always occur in practise, especially where different passes must frequently be made on very different blanks. The fol lowing table gives the ideal values of the connecting radius r in relation to the pass of drawing: Reduction of Thickr fwW Mm It Mn li , ) 15 0.59 } t 0 1.18 6 0 j a. 29 8 2 60 Z.3¢ 10 0.39 75 2 95 LZ 0.47 90 3.54 14 0.55 10 4.13 16 0.63 120 4.72 18 0.71 L135 5.32 20 0.79 1590 5.91 The relation of engineering and management is to be discussed by Walter Rautenstrauch of the J. G. White Management Corporation, New York, at a meet- ing of the Bridgeport section of the American Society of Mechanical Engineers at the Stratfield Hotel, Bridgeport, Conn., on Oct. 20. The Maine Central Railroad Co. has placed a $500,000 equipment order with the Laconia Car Co., Laconia, N. H. The plants at Laconia will reopen at once and will be run on full time for several months. AGE October 13, 192] Exports of Metal Working Machinery WASHINGTON, Oct. 10.—Exports of metal working machinery during August, 1921, were valued at $ 563, according to the Bureau of Foreign and Dom Commerce. The value of exports of lathes was $51. . of sharpening and grinding machines, $61,711; of ar machine tools, $209,630, leaving a remainder of $60» for the other types. Brazil was the largest buy: lathes, shipments to the value of $9,081 having made to this country. England ranks second ir commodity, with purchases amounting to $8,712, and Colombia third, taking $5,983. Canada led as to sharpening and grinding machines. the value of exports to that country being $22.844: France was second, $7,550, and Japan third, $6. Under the classification of “other machine tools,” an the leading countries of exportation were British Ind $40,358; France, $32,119; Brazil, $22,244, and Cana $21,233. Under the classification of all other, Franc took more than one-half of the entire total, exports to that country being valued at $325,734. British India came next, the exports to that country being valued $76,325, and then followed England with $37.399: Japan, $36,787; Canada, $23,987, and Hongkong, $20 130. 1} * Friction Tapping Device A friction tapping device, known as the Jarvis, FD, said to be capable of tapping holes in the toug! metal, with minimum breakage of taps, has been placed The Dotted Lines Indicate Size of Friction Cone on the market by the Geometric Tool Co., New H Conn. The outstanding feature is the cone friction controlled by directing greater or less pressure 0 spindle that runs the device. The dotted lines illustration indicate the size of the friction cone . tle pressure is needed to drive the tool and the chuck which is of standard design, yields easily. Start and stopping the tap while rotating is under fre trol. It is made in one size only, with a tapping rang from 0 to % in. The Harrisburg Bar Mill Co., Harrisburg, Pa., "4° been chartered under State laws to operate a plant oP North Sixth Street, near the city limits, for the manu facture of iron and steel bars, etc. J. K. White, for merly general sales manager of the Harrisburg P'pe « Pipe Bending Co., is president, and A. L. Ensinge? also previously connected with the same company, ' secretary. Figuring the Charges for Foundry Irons : Iron Mixtures and How to Figure Them Chemically—Classification of Castings and Suggested Analyses By Y¥. A. he chemical analysis of a pig iron shows that it tains 92.60 units of iron, 3.85 units of carbon, ) units of silicon, 0.05 unit of sulphur, 0.50 unit phorus, and 1.00 unit of manganese, then it is ent to stating that 100 pounds of such an iron D. ITOM ..-¢-. i 92.60 pe b. CAFDON .....-:. on ‘ 3.85 per I silicon ... S 00 per oe b. sulphur . 0.05 per phosphorus 0.50 pe manganese L.UU 100.00 in figuring mixtures of metal these points ce! orne in mind from the fact that the elemental on are figured on the percentage basis. , f \0-lb. charge of metal consists of pig iron 1,200 . 1.200 lb. and steel 600 Ib., then the charge per- will be: 20.00 per cent Stee crap 100.00 per cent total charge iron units are not taken into consideration in ilyses, only the carbon, silicon, sulphur, phos- manganese are figured. The carbon is ted, from the fact that any losses which during remelt will be adjusted by absorption from the coke bed. The factors which tend the total carbon in a mixture are low tuyeres ise of comparatively large quantities of low- xture of metals be used: Si 5 P 3 2 00 0.05 0.50 n 1.80 0.08 7 ) 0 06 nN oF following element units, per ompose the average mixture: LOO 132 unit of phosphorus Figuring Mixtures erial—preferably steel scrap. Suppose the MM 1.0¢ 100 lb. of 0.76 unit of manganese ential points to be borne in mind in figuring ¢ mixtures are the analysis desired or neces- certain kind of casting, and the purchase by the proper kind of pig iron to be used as a dase r controlling metal in the mixture. zEham, Ala. 931 Thus, DYER To illustrate the process of figuring a mixture, sup- pose a pipe foundry desires metal of the following analysis: Silicon 2.25 per cent, sulphur 0.08 per cent, phosphorus 0.85 per cent, and manganese 0.65 per cent. Because of partial oxidation in the cupola, the mixture will require average silicon (2.25 + 0.10) 2.35 per cent and average manganese (0.65 + 0.10) 0.75 per cent. Thus, in a 4,000-lb. metal charge there will be needed: nnn 4 0 lb. s or 100 8 1000 I ilphur 100 g 1000 34.00 Ib. phosphorus ( sOnK ) 00 lb. manganese 100 Then, assume that the pipe shop has the following materials on hand with which to make the mixture, and it is desired to use 25 per cent scrap and 40 per cent “4” foundry iron—what other grade of iron (silicon analysis) will be required to balance the mixture? Si S P Mn Foundry scrap 5 0.08 0.85 0.6 “4” foundr ror 1.75 0.06 0.85 0.60 Figuring the silicon content, the charges would be apportioned as follows: Per Charge Silicon, Silicon Materials Cent Lb Per Cent Lb Foundry crap 95 1000 ~ 2 95 100 92 50 “4” foundry iron 10 1600 xX 1.75 100 28.00 Needed iron 35 1400 x x 100 43.50 i) } 94 / ‘ n x 10 y i Other elements, sulphur, phosphorus and manganese, are figured on the same basis; deficiencies or excesses it elements being cared for by the use of desirable pig irons or alloys, as explained in the following examples: Suppose the shop should not have available the ne essary “2” soft iron, silicon 3.10 per cent, but had or hand the “4” foundry iron, silicon 1.75 per cent, and the melter desired to purchase a high silicon or silvery iron to use with 25 per cent scrap and 60 per cent “4” foun dry iron—what percentage of silicon will be necessary to balance the mixture? The assumed charge (desig nated as “X iron’) will be figured as follows: Per Charge Silicon, Silicor Material Cent Lb Per Cent Lb Pig, Si. 1.7 60 100 < 1.75 42.0 Foundry scra 5 1900 * . 1K ro EK X iron 15 600 » x 100 29.50 100 sH00 94.96 29 ) 100 x 1.92 per cent licor on needed 600 Therefore, it will require a 600-lb. charge of iron with silicon 4.92 per cent to balance the silicon in the pipe mixture and care for the oxidation loss. Other- wise, 73.6 per cent (2935 Ib.) of “4” foundry iron; 25 per cent (1000 Ib.) foundry scrap, and 1.4 per cent (65 lb.) of 50 per cent ferrosilicon would answer the pur- pose. If a foundry has on hand scrap iron containing 1.80 per cent silicon, 0.70 per cent phosphorus, and 0.70 per ieee A meio x a been See oes Cut gas re Re rane ai re ee 932 THE IRON AGE October 13, cent manganese, and the melter desires to make cast- ings with silicon 2.00 per cent, phosphorus 0.60 per cent, and manganese 0.80 per cent, with the use of 40 per cent scrap—what pig iron analysis will be nec- essary to balance the mixture? The mixture will re- quire an average silicon content of (2.00 + 0.20) — 2.20 per cent; manganese (0.80 + 0.16) = 0.96 per cent, and phosphorus 0.60 per cent. Assume 2000-lb. charges are . . 2.20 « 2000 to be used—then there will be required ( 00 0.60 « 2000 44 lb. silicon; ( )= 12 lb. phosphorus, 100 0.96 « 2000 . nd Se X SW } - 19.20 lb. manganese. The mix- 100 ture is computed as follows: Per Charge, Silicon, Silicon Materials Cent Lb. Per Cent Lb Scrap .... : Gavia 10 800 K 1.80 — 100 = 14.40 me cwnids ‘akae oe 1200 x x + 100 = 29.60 100 2000 44.00 °9.60 &* 100 x - 2.47 per cent silicon iron needed 1200 Phos- Phos Per Charge, phorus, phorus Materials Cent Lb Per Cent Lb. Scrap ... Si 10 800 xX 0.70 + 100 = 5.60 Mm SPOR sca ese ; . 60 1200 xX x ~ 100 = 6.40 100 2000 "12.00 6.40 x 100 i= —___——. 0.53 per cent phosphorus iron needed 1200 Man- Man- Per Charge, ganese, ganese, Materials Cent Lb Per Cent Lb ND ia edt. we chee pe i 800 X 0.70 + 100 = 5.60 X iron .. via ated . 60 1200 X x + 100 = 13.60 100 2000 19.2¢ 13.60 kK 100 x — 1.13 per cent manganese iron needed 1200 Therefore, it will require 1200 lb. for charge of an iron containing silicon 2.47 per cent, phosphorus 0.53 per cent and manganese 1.13 per cent, to balance the mixture and meet the required specifications. Probably a more simple method for some foundrymen to figure mixtures would be on the basis of unit per- centage of each element in the metal used, instead of total pounds of elements—which would be computed as follows for the mixture given above: 800 lb. of scrap iron to a total mixture of 2000 Ib. is (800 + 2000) = 0.40 per cent, and 1200 lb. of “X iron” to total mixture is (1200 - 2000) = 0.60 per cent—hence unit percent- ages of metal mixture are stated as follows: Per Cent Si P Mn Scrap iron 0.40 LAO 070 O.70 -~ > 142 , i iv X iron 0 60 2.47 it) Analysis of casting from above mixture will be com- puted as follows: Silicon *hosphorus Manganese Scrap iron : (1.80 * 0.40) 0.72 (0.70 0.40) 0.28 (0.70 X 0.40) - 0.28 X iron d (2.47 0.60) =—1.48 (9.53%0.60)—0.32 (1.13 0.60) =—0.68 z 20 9.60 0 96 Losses and gains 0.20 0.00 0.16 Metal analysis.. 2.00 0.60 9.80 Both computing methods produce the same net re- sults; the matter of choice lies with the foundryman to adopt the method which is simplest to his “turn of mind.” Computation by both methods will serve as a check on the mixture, and prevent errors. Varying mixtures may be melted in a cupola during a single heat period by the exercise of certain precau- tions. To avoid the possible mixing of the separate charges in the hearth of the cupola, it is advisable to separate iron charges by using blank coke charge of about 4 in. in depth. Such practice will hold the upper charge off until the excess coke burns to the melting zone, thus permitting the tapping of the metal in the meantime. By knowing the rate at which the cupola “drives” or works its charges through the melting zone, and timing the operations accordingly, the problem be solved accurately. The rate at which coke i sumed per minute per square foot of cupola ar solve the problem of burning away the blank charge. Classification of Castings The range of analyses for different castings is sarily more or less varying; for that reason, in t! lowing list of suggested analyses for various cas the medium weight work will be considered th: Heavier castings will admit of higher sulphur, manganese, lower silicon, lower combined and tota bon—hence steel scrap, low silicon scrap or low pig iron may be used more freely in such mix Lighter castings, as a rule, require lower sulphur dium manganese, higher silicon, higher graphiti bon to promote fluidity and minimize brittlenes phosphorus in all cases should be kept as low a sible, consistent with fluidity and other necessary tors of safety. Steel scrap in quantities may bx to advantage, as it will materially lower total ca phosphorus and silicon and add some manganesi author would strongly suggest steel mixtures strength, toughness, homogeneity and smoothnes essential factors. In addition to the analyses of special casting 1921 characteristics of which were explained in detail S 8, under gray iron and chilled iron, the foll general classification is given alphabetically as a « venient reference: Si Ss Pp Mn Cart Agricultural machinery : Heavy .... 2.00 0.09 0.60 0.80 Medium ... 2.30 0.07 0.65 0.70 Lah «sss 2.60 0.06 0.75 0.60 Very light. 2.80 0.05 0.85 0.50 Acid resisting castings :* Anvil blocks :* Armor (chilled) :* Automobile castings :* Base plates: Heavy .... 1.30 0.10 0.50 0.70 Medium... 1.80 0.08 0.60 0.60 RMI. 36 css 2.25 0.06 0.70 0.5¢ Balls—grinding and polishing :* Boiler castings—fronts, doors, headers: Heavy .... 2.00 0.08 0.50 0.7% Medium... 2.25 0.06 » 0.60 0.5' Brake shoes :* Carwheels :* Columns: (Same as base plates.) Chilled castings :* Crusher jaws:* Cylinders—air and ammonia: Heavy .... 1.25 0.08 0.30 0.80 Medium... 1.65 0.06 0.40 0.70 RS 660k s 2.00 0.05 0.50 0.61 Cyiinders—steam and water: Heavy .... 1.25 0.08 0.30 1.00 Medium 1.50 0.06 0.40 0.80 Light .. » 2.26 0.05 0.50 0.60 Dies :* Dynamo castings—frames and spiders: Heavy .... 2.00 0.06 0.60 0.61 Light .. s 2.50 0.06 0.60 0.61 Electrical castings—magneto parts and armature cor: Medium . aoe 0.05 0.50 0.50 Light ..... 3.00 0.05 0.60 0.50 Engine frames: Heavy .. 1.80 0.09 0.50 1.04 Medium... 2.26 0.07 0.60 0.60 Enamelware, bathtubs, sinks: Heavy .... 2.25 0.08 9.80 0.50 Light ..... 2.50 0.06 0.80 0.50 Flywheels: Heavy 1.25 0.09 0.40 0 75 Medium 1.75 0.06 0.50 0.65 Light 2.25 0.05 0.60 0.56 Friction clutches: Medium... 2.25 0.10 0.60 0.75 Light ..... 2.50 0.08 0.70 0.50 Geirs and pinions: Heavy .... 1.75 0.09 0.50 1.00 Medium ... 2.25 0.08 0.60 0.70 Light ..... 2.60 0.06 0.70 0.60 Grate bars: 1.50-2.25 0.05-0.08 0.30-0.50 0.50-0.60 *See Tuer IRON Aap, Sept. 8, pages 585-8. October 13, 1921 THE IRON AGE 933 na e - “ om in demanding that protection be complete, supplying ron:* goggles according to a code. asain’ Striking reduction in eye accidents is shown by the 9 25-2.50 0.06-0.08 0.60-0.80 0.50-0.60 3.50 American Locomotive Co. The number of accidents istant—grates, furnaces, etc. : ae medical attention in the company’s plants saat a 0.08 20 0.90 339 Was 52 in 1915, while during 1910-13 it was 448. In Medium ... 2.00 0.06 0.40 0.70 3.40 1915 only two eyes were lost, while during 1910-13 Boa 2.25 0.06 0.50 0.60 3-45 the loss was 10.5. The number of injuries per 1000 + molde:® full-time men per year was 15.7 in 1915, while in the ry castings—general ; 1910-13 period it was 38.9. In the American Steel ae 0.10 0.50 1.00 3.29 Feundries the number of eye accidents has been re- : ce OER OR eR See ; A caeee am man « " That correction of sub-standard vision produces an permanent : E : _ imerease in return that will pay for its cost is the 3 1.50 0.08-0.10 0.40-0.50 0.75 3.25 conclusion of the management in plants where sev- glass: | ie — ai as eral years of trial has provided a basis for judgment. si ; r ie Excess eye fatigue results in conditions which must al castings—manholes, meter boxes, etc. : ,_. produce a time labor loss from reduction in quantity 1.75-2.00 0.08-0.10 v.59 0.50 3.35 and quality production. Sub-standard vision was ental castings—and white-ware : . _ found to be of great frequency. An examination of re 3°50 0.06 1.00 0:60 ot. more than 10,000 employees in factories and commer- 2.75 0.05 1.25 0.50 3.55 cial houses found 53 per cent with uncorrected faulty d fittings—soil : vision. Of 675 employees in a typewriter company, 58 1.80-2.25 0.08-0.12 0.80-0.90 0.40-0.50 3.40 per cent were found to be in need of correction by ale glasses. Of the rejections in the army, 21.7 per cent , BS 0.05 0.45 0.75 3.35 were because of eye trouble. ts One estimate placed the production loss due to vater and gas: Ss faulty conditions in this country as above the entire a oes O06 oes 060 — cost of illumination. In 446 plants investigated only 8.7 ae per cent were found to be in excellent condition, the mere other ratings being: Good, 32 per cent; fair, 29.1 per ta cent; poor, 18.8 per cent; very poor, 3.5 per cent; ; partly good, partly poor, 7.8 per cent. 7 sie — ated ue 2 86 Improved lighting systems have increased output adi ae 0.06 0:60 0.60 349 2 per cent in steel plants and as much as 10 per cent ht 2.50 0.05 0.75 0.50 3.50 jin shoe factories where work is more exacting. The blades :* cost for providing adequate illumination for the en- panies tire industry of the country would amount to 0.5 per ae animes 7 ; so, cent to 1 per cent of wages. The cost per capita of wary s* ae oes 070 O50 249 ©correcting vision, instituting and carrying out meas- nachine castings: ures of protection against hazards and bringing the 2.75-3.00 0.06-0.08 0.70 0.55 3.50 lighting up to good standards, is definitely greater in ute the small plant than in those employing 2000 workers 2.25 0.08 0.80 0.60 3.45 or more—and the small plants are in the large ma- 2.50 0.06 0.90 ; 0.50 3.50 jority. r castings: (Same as sewing machine.) These smaller plants are therefore less ready to ee ti ie ae ~~ take up any of these measures unless the early returns i 175 0.07 040 0.80 339 Of a dividend can be clearly shown. Reports of more 2.25 0.06 0.50 0.70 8.45 study, the example of the earlier ones to take the steps, rods :* must be brought before them constantly so that ef- n—sash weights, etc: forts to check preventable loss along these lines may 0.50-0.75 0.15-0.20 0.80 0.20-0.30 2.80-3.00 become more nearly universal. THE IRON AGB, Sept. 8, pages 585-8 Care of the Eyes in Industry accidents are revealed as a chief source of lable national waste in a report of the Commit- on Elimination of Waste in Industry of the Amer- q in Engineering Council, following an investigation ny States, started by Herbert Hoover. total number of industrial blind in the United is put at 15,000, or 13.5 per cent of the total population. The eye is involved in 10.6 per cent permanently disabling accidents. esent protective methods applied in large plants vreatly reduced the number of injuries. The use egles is one of the chief protective devices. At \merican Car & Foundry Co.’s plants there has a reduction of more than 75 per cent through of goggles and the percentage of reduction be much higher if. the men would wear goggles conscientiously. - Experience has proved the of the theory that the wearing of goggles by ‘rial workers only jeopardizes sight the more, on int of the liability of injury to the eyes from the sen glass of the goggles. ‘Not an injury to the eyes from broken glass has been ‘corded since goggles were introduced into the shops t the New York Central Railroad. All employees of ‘he Union Pacific Railroad Co. are now required to ' goggles on eye-dangerous work. (he Bethlehem Steel Co. management is very rigid wear The committee is composed of J. Parke Channing, chairman; L. W. Wallace, vice-chairman; L. P. Alford, George D. Babcock, William R. Basset, F. G. Co- burn, Morris L. Cooke, Harrington Emerson, Ira N. Hollis, Edward Eyre Hunt, C. E. Knoeppel, Robert Linton, Fred J. Miller, H. V. R. Scheel, Sanford E. Thompson, John H. Williams and Robert B. Wolf. Headquarters are at 29 West Thirty-ninth Street, New York. Makers of Electric Steel Castings Meet The operating officials of several companies special- izing in the manufacture of small electric steel castings recently held a four-day meeting at Wernersville, Pa. These companies for more than a year have been closely co-operating along technical lines through R. A. Bull, their research director, whose time is exclusively given to the operating problems of these companies. The foundries co-operating in the work are those owned by the Electric Steel Co., Chicago; the Fort Pitt Steel Casting Co., McKeesport, Pa.; the Lebanon Steel Foun- dry, Lebanon, Pa.; Michigan Steel Casting Co., Detroit, and the Sivyer Steel Casting Co., Milwaukee. Frequent meetings of the representatives of these companies are held. At the Wernersville meeting uniform inspection standards, which the group had voluntarily put in force, were revised as the result of a year’s experience in their application. Those present at the meeting report entire satisfaction on the part of all with the results of the first year’s co-operative work in attacking the problems which face steel foundrymen. ' Ce re” ager 2) BR 8 6 tO FI ve dabeeer Aerie x 38: 52d epg ~ ~~ ad PN EE ets Sree i } a sD ' Pa , . * ’ ¢ ¢ Ba + , a me be pe Needs | 934 THE IRON AGE TREND OF PRICES Decline About $10 Per Ton Since Jan. 1—Up- ward Turn of Some Products Recently In the third quarter of this year, pig iron and steel prices have dropped to the lowest points since 1915-1916 and within the same period some commodities, includ- ing pig iron, sheets and wire, have shown the first de- N » > —4 \>- | a \e . o: os i ne. he =~ \ \ \ \ + . Ov\\> \ YS \@ ook > oX "a ~ ~~ x Xm —_ | os bm ‘ NT ~~ x > cA cS te ‘\ me, % \ Sh Pies na ~! S | ts ~ Sok This Chart Illustrates the Decline in Principal Steel Products During the Nine Months of 1921 Ending Sept. 30 cided upward turn since the price decline began in the fall of 1920. Although pig iron prices have shown an upward tendency in nearly all markets within the past few October 13, 192) iron in the Valley dropped from $30 to a September average of $19.12, or $10.88 and Bessemer iron at Pittsburgh declined $12, from $33.96 in January + $21.96 in September. The decline in steel prices in the third quarter was greater than during the first half. For example, the January average for steel bars was 2.35c., Pittsburg! and the June average, 2.05c., a drop of $6 a net From the end of June to the first of October, th was a drop of about $9 a net ton. Steel plates hay dropped $21 a ton and structural shapes $17 a ton Accompanying charts and monthly averages of principal products, compiled from THE IRON AGE quo tations, illustrate the steady decline which has take: place within the nine months’ period. Recent British Developments in Stainless Iron The extent to which stainless steel has revolutior ized the Sheffield cutlery trade is well known, but it i not so generally appreciated, the London Times Trad Supplement points out, that stainless iron is of eq importance. Both materials, says the Times, were d covered seven or eight years ago. Stainless steel was first manufactured, and soon after it was found that stainless iron could be produced by much the same process, with the exception that a smaller quantity ‘arbon-free ferrochrome was required. Stainless iron has been largely used for the produc- tion of golf clubs; it has attracted the attention of makers of stove grates and is being used for kitch ranges, grates, and fenders. An important and usefu direction in which the material has been applied is i: the fitting of motor cars; it is supplied in sheets for making hoods, and there is in contemplation its greater use for bodies, and since it does not tarnish, for replac- Prices of Leading Products for Nine Months of 1921 Jan Feb No, 2X pig iron, Philadelphia $33.34 $31.09 No. 2 Southern, Cincinnati 7 32.65 oe Rs ere ; 31.50 29.00 Basic, Valley furnace... 30.00 27.50 Bessemer iron, Pittsburgh ; 33.96 31.46 Bessemer billets, Pittsburgh. 43.50 42.25 Wire rods, Pittsburgh........ 57.00 54.50 Steel bars, Pittsburgh........ eae 2.35¢ 2.15¢ Tank plates, Pittsburgh sat ie ios 2.65¢ 2.33¢ Beams, etc., Pittsburgh... on ‘ 2.45e. 2.26c Wire nails, Pittsburgh (per 100-lb. keg) $3.25 $3.21 months, the net decline on all grades averages more than $10 a ton since the first of the year. No. 2 X iron, delivered at Philadelphia, declined from $33.34, its January average, to $21.22, its September average, x P= ne Tr er ed SS _ 7 \ ‘ i an FZ — So;,- ™~ _— A ~S NZ 4 ar SCq ; ~ICy ~ ry ~~ ‘ Ky. P= * © OS; ———— = SLry a ‘ ~. \ ec + > F< et . inden . i ees, \ ~~ ‘ SSeS \ << 4 20 | } + at a | . _— 19 eo _se-4 g ——__+ —_ nln | 1 exceed Me eseeanmentn | s 4 i > a => o + & v S = = s s 3 @ Ss ere = * = = 5 * v2 The Course of Prices During the First Nine Months of the Year on Bessemer Billets and Pig Iron Is Shown in This Chart a drop of $12.12. No. 2 foundry, delivered at Cincin- nati, declined from its January average of $36.75 to a September average of $23.50, a net drop of $13.25. No. 2 foundry at Chicago declined $9.75 per ton, basic March April May June July Aug Sept $27.59 $26.26 $25.71 $25.50 $23.55 $20.64 $21.22 29.80 28.00 26.70 26.37 24.75 23.50 23.50 25.60 24.00 22.80 20.75 18.87 19.55 21.75 24.25 22.88 22.00 20.75 19.37 18.00 19.12 28.16 26.96 25.96 24.71 22.83 21.96 21.96 38.40 37.50 37.00 37.00 32.25 29.75 29.00 52.00 49.00 15.00 48.00 42.75 2 00 39.58 2.00c. 2.05c. 2.10¢c. 2.05¢ 1.83¢e 1.75¢ 1.f 2.04c. 2.10¢ 2.20c. 1.95¢ 1.85e. 1.80¢ 1.64 2.08¢ 2.10c. 2.20C, 2.10« 1.92c 1.83¢ 1.f $3.02 $3.13 $3.05 $3.00 $2.81 $2.75 $2.86 ing nickel-plated parts. It is made up into a wide variety of kitchen utensils and is used for shop signs and door plates. One British firm is producing the material in wire form, to be made up into door mats, and it is also being used for spring mattresses. Another important development in contemplation is the use of stainless iron for the furnishing of railway carriages, engines, and rolling stock generally. The proposal is that it should replace brass for door han- dles, brackets, and many other fittings. Stockholders of the Commercial Shearing & Stamp- ing Co., Youngstown, Ohio, have authorized an increase in the capital stock from $350,000 common to $1,500,- 000, consisting of $400,000 preferred and $750,000 common. Proceeds will be devoted to enlarging the company’s plant and will also be used as working cap- ital. A plant addition to cost between $125,000 and $150,000, exclusive of equipment, is to be built and 1s to be completed by spring. Of the increased capital, only the preferred will be marketed at this time. Rob- ert Carnick is president of the company. The B. Greening Wire Co., Hamilton, Ont., com- menced Monday, September 26, to operate its plant at full time, whereas previously only three days a week had been worked by the 350 employees of the company. Increased orders made the full time shift possible, and the company expects to keep going at full time from now on, although there is no assurance that this can be done. Crane Operating Costs at Blast Furnaces Locomotive and Ore Bridge Cranes Shown to F Save Much Money, Compared with Hand 4 Methods Formerly in Vogue—Analyses of Costs yy BY GEORGE L. COLLORD” r fT WoO of our three blast furnaces at Sharpsville, if | Pa., are equipped with Brownhoist equipment, onsisting of all the machinery necessary for the blast furnaces and handling the finished m. Practically all the machinery was manufac- and installed by the Brown Hoisting Machinery i the system has proved itself a great labor device. nsisting primarily of a Brownhoist ore bridge , iipped with a 5-ton grab bucket, the span covered ft. 9 in., and the bridge is arranged to travel back rth on a stretch of track 890 ft. long. When the vhich this bridge covers is filled to capacity, it cross sectional area of 6480 sq. ft. This is ent to a capacity of 432 tons per lineal foot; e the yard is 890 ft. long, the total capacity is road cars come in along one side of this yard elevated trestle, from which they dump ore, coke ‘00 Per Year, as Compared with the Cost Under na limestone into bins beneath. One track runs over and limestone bins and another over the coke A third track is overhung above the storage d is used for delivering ore and limestone into K pile, from which it can be handled by the cket on the bridge. the bins become empty, and there are no full lilable for filling them, the grab bucket picks ad, travels across the bridge and deposits it in While the bridge is able to dump into any ie bins, it is usually inadvisable to move so lass as this bridge any great distance, so a car of 30 tons capacity runs back and forth “ e track above the bins, thus saving the bridge leal of travel. ng on tracks below the bins are two elec- > operated larry cars of 75 cu. ft. capacity. ir is designed.-with a universal joint to en- ‘1 manager of operation, Shenango Furnace Co., v ling > ling, Pittsburgh. gage with mechanism for opening the bin gate, after which the gate is operated by a motor on the larry car. The larry hoppers are set, by the official in charge, to receive a certain weight of ore, coke and limestone. After receiving this load, the larry runs to a point opposite one of the furnaces, and dumps into a skip car of 110 cu. ft. capacity. This car is hoisted by a 100-hp. engine, and upon reaching the blast fur- nace top its load is discharged into the hopper. receiving The entire equipment cost around $300,000, when it was installed, in 1909. Since it is in good condition after twelve years’ operation, we are certainly safe in estimating its minimum life at fifteen years. Repairs to bins are not heavy, considering the amount of material handled and passed through. This does not exceed $2,500 a year. The hoisting apparatus and three larry cars (including one spare) require $1,000 worth of repairs a year per furnace. Repairs st) SN enue he ee This Ore Bridge Is in Operation Only 50 Per Cent of the Time, It Has Been Estimated That It Saves More the Previous Method of Handling the Same Material Manually and maintenance on the bridge do not exceed $2,500 a year. Including repairs to minor equipment, this makes the total annual repair cost about $8,500. The principal motors which consume large quan- tities of power are the 200-hp. bucket hoisting motor, which runs approximately 50 per cent of the time; and the 50-hp. motor which drives the cab back and forth across the bridge, and which operates approxi- mately one-third of the time. The bridge proper oper- ates only 12 hr. out of the 24, but the other equipment operates 24 hr. Each larry car has a 15-hp. motor, which is run- ning about 18 hr. out of the 24. The skip hoists re- quire 100 hp. and operate about 9 hr. a day. The total annual power consumption is approximately 587,650 kw. hr., which, at lc. per kw. hr., makes $5,876.50 a year. Our power rate is low, because of the fact that we use blast furnace gas for generating. The bridge requires one operator, who works 12 hr. a day at 50c. an hr., and an oiler at 40c. an hr. 935 —— a ee Ss aot . x, a a fougirt= 5 ern 936 THE IRON Each larry car requires an operator, and as there are two turns per 24 hr., this means a total of four oper- ators at 50c. an hr. Four men are also required to run the skip hoists. The transfer car is not used a great deal, so the charge for labor and power does not exceed $1,500 per year. Our total annual labor costs are $18,834. The to- tal cost for maintenance and repair is $8,500 a year. Adding average yearly interest, taxes and insurance, brings the total annual operating cost to $73,410.50. One furnace averages 550 tons per day, the other 400 tons per day, making a total of 346,750 tons per year. This makes the cost per ton 21.17 cents. This figure is low compared with the cost when this work was done by hand. With the hand system the materials were dumped from a trestle and loaded into buggies by hand. Each man ran his loaded buggy over a scale and then up into an elevator to a platform at the top of the fur- nace, where the load was dumped by hand. This old method required a number of men, who are expen- sive, hard to handle and sometimes difficult to get. We formerly employed 21 stock men per turn on each furnace. Since there are two furnaces and two turns every 24 hours, this meant 84 men for the two furnaces now fed and manipulated by machinery. At 40c. an hr., which is the present scale, this is a labor item of $147,168 per year. Deducting the annual cost of operating the Brown- hoist bridge, bins and scale cars, gives us a net an- nual saving of $73,757.50, or a net saving of 21.27c. per ton of pig iron produced. Therefore this system has cut our cost to practically one-half of what it for- merly was. The mechanical equipment has the additional ad- vantage of operating so much more rapidly that it in- creases production, and one furnace which used to produce 300 tons per day when fed by hand, now pro- innual Cost of Operation—Ore Bridge, Bins and Scale Cars Depreciation, $300,000 (over 15 yr.)........... $20,000.00 Average yearly interest at 7 per cent, 16 $300,000 & 0.07 x —_——--— - wd eee ery re ne 11,200.00 15 2 Repairs and maintenance, estimated.......... 8,500.00 Power: Bridge motors, larry cars, transfer car and skip hoists, total 587,650 kw. hr. at lc. 5,876.50 Labor: 1 ore bridge operator, 12 (hr.) X 50c. 365 (days)...... es oy -. $2,190.00 1 bridge oiler, 12 (hr.) X 40c. X* 365 POD aca ais ban : or ; 1,752.00 t larry operators, 12 (hr.) XK 42% 365 (days)....... ; 7,446.00 { skip hoist operators, 12 (hr.) 12l%4c. X 365 (days)... icotss agape Total annual labor... si 18,834.00 faxes and insurance at 3 per cent 9,000.00 Total annual operating cost $73,410.50 Tons of pig iron produced, (550 100) xX 365 RUDD. Gir meatier ee te a ee ee 346,750 tons $73,410.50 Cost per ton, —— — $0.2117 346,750 Cost Comparison—Hand Labor for Charging Furnaces Hand labor per furnace per turn 21 men. Number of furnaces, 2; number of turns, 2. Total hand labor—21 (men) X 2 X 2 84 (men) X 12 (hr.) X 40c. * 365 (days)... $147,168.00 Total operating cost of Brownhoist bridge...... 73,410.50 fae a pe ce $73,757.50 Net saving per ton of pig iron produced...... : $0.21 duces 550 tons per day. Naturally, other factors have influenced this increase, but the fact remains that our two furnaces now produce as much as the three hand operated furnaces formerly produced. Locomotive Cranes in Blast Furnace Work There have been times when our locomotive cranes have saved us from shutting down our furnaces for lack of labor. At such times a locomotive crane has been worth almost any amount of money, but even in its daily work a crane is a profitable investment in work such as ours. In 1909 we purchased for our plant at Sharpsville a 15-ton Brownhoist locomotive crane. Its work proved so satisfactory that we bought a 40-ton crane AGE October 13, 192] of the same make in 1913. Our locomotive were bought for two reasons:—first, to cut down ating costs; second, to assure us a continual of raw material, regardless of labor conditions. both respects they have proved satisfactory. Using a magnet, the 15-ton crane loads ar loads pig iron from cars to storage, and adjust car weights. In normal times it handles 25,000 of pig iron a year, half of this amount being into cars and half unloaded from cars. Our crane handles an equal tonnage. We often equi; crane with a %-yd. grab bucket for handling coal gravel and fire clay. These two cranes together average five 40-to: of coal per week, unloading from the cars int boiler house. Each month they handle ten 40-ton wn ' nanny SODAS ANEADLOAEEDOANLLODAEVANOUEEOODOAUOAODEAAEEUAEAOSUOOUAUTEATODANNGHOESEDEBOLOAULDONSLONENON Annual Cost of Operation—15-Ton Locomotive Cra Depreciation, $8,500 (over 15 yr.)........ ai $5 Average yearly interest at 7 per cent, 16 $8,500 X 0.07 — xX TO TETT Cre Cee 15 2 Repairs and maintenance, estimated............ Coal, % (ton per day) X 180 (days) ae PP Sr ee eee $540.00 Labor: Operator, 180 (days) xX 12 6S ge Sear ere 1,036.80 Fireman, 180 (days) X 12 (hr.) PO. ucuneease Se VORs 0a ei weree oan 799.20 Total annual operating cost....... Tons handled: Pig iron.... 50,000 tons CAL. ape cas 10,400 tons Sand, etc... 4,800 tons 65,200 tons xX \% 32,600 MVOC COORD Bis 655 <i cae Coenen ae $4 Calculation of Saving Labor handling pig iron: 12 (men) X 12 (hr.) X 365 (days) X 37c. $19,447.20 Cost of spotting cars: 10 (cars per day) X 365 (days) X $2 xX \% 3,650.00 Total former cost (excluding coal and sand) $23,097.2 Cost of operating crane 8,260.01 Net annual saving. $14,837.26 oesepnevennnnycennoneonsnanensaeennneeieuiiereninniniT of sand, in addition to small quantities of fire clay and gravel for use in making concrete. They have also solved a very expensive and trouble- some problem by their ability to spot cars. The rail- road will spot a car once, but if any re-spotting is re- quired we have to pay for it. Since the charge is 52 a car, and we re-spot an average of 10 cars a da) our former cost for this work was $7,300 a year. Typical operating costs are best shown by the 1»- ton crane, which has been longest in regular servic’ This crane is doing one-half the work at our plant though it averages only 180 full working days year. The two cranes are necessary in order to t care of peak loads and insure uniform productio! Depreciation, repairs and maintenance are | upon our crane expense. The 15-ton crane consun approximately % ton of coal per day, at $4 a ton ing the annual power cost $540. The labor r includes an operator at 48c. an hr. and a fireman 87c., making the total labor cost $1,836. The for maintenance and repairs is $5,000 a ye