The Iron Age 1921-11-03: Vol 108 Iss 18

- ~ THEIRON AGE New York, November 3, 192] ESTABLISHED 1855 gy VOL. 198: No. 18 Making Dies for Forming Automobile Parts Design and Construction Explained for the Manufacture of Such Articles as Brake Drums and Step Brackets — BY RICHARD DALE HERE are three items that may be set down here 7" as being the very first with which the designer of dies should make himself familiar. They are namely: 1—The stroke of the press and the distance from the bolster plate to the plunger when 1M ~< 183 ~ od-> JES --+- - — re*:Jurn to sult Press AOIITZ J , A th“ V4 av £4 $+ } “lag~ioy ne c+ “r as ba KEEL ERAT et 7 6 (APSCrEWS - ROO | ENSNE y AS 7 ie a7 K , SSNS ARG AY ; % 2200 Wg x 2p » AXSY U. pay att Se Ned BSS ce ue STP == af > ere Force Fit Ss yp \ ah 4 ¥ 22 ; 6 re w AX " eq > 174 t< - TNS 11g =O Camp } ’ + ANY ®! + ft 5 at { i Jal _ iN 8 Capscrews --- Se . 1 NY 3% gt Yi Sy" SS Yas Y y ; wa ; I ~< 30 ~ Fig. 1—Brake Drum Blanking Die the plunger is at the lowest point. 2—The thickness of the metal in thousandths. Then from these he can estimate the best practicable die space or overall height of the punch and die with the punch entered into the die the required distance. 3—The approximate strain on the dies for the different operations. Having these down in his notebook, the designer is now ready to go ahead with the actual drawing up of the dies. In building brake drum dies, the first one consid- ered here will be the blanking die. Where the blank- ing diameter is already known this die is built first, but where it is not known the drawing dies are built first and the blanks turned on the lathe and run through Ce — “sO > a thhty <a ” A 4 Plates 114264 for centering blank K 30 - # ut m +-/7f4S > i ; iM MK ~~ 14-5359” Hig im rior + | oi as Air haya VBR \6-&Gpscrens |i did Rvar7 AN <a x VRS ; ; AS P ’ { —— Upp 4h. + iy é LLLL A Gee } AML, RR as —~ ~ Stripper Pin? WlaOS \....,Die Rings Grind 22" | lL. ee Casting Bores22+0002""——* —__ vad Fig. 2—Brake Drum Drawing Die the drawing dies, this operation being repeated till the proper size blank is arrived at. In this instance a 13-in. brake drum is to be made and the blank size is known to be 17% in. This leaves a little stock for the edging or trimming die to remove. The accompanying drawings are working drawings but the dimensions of the castings can be altered to suit the capacity of the press in which they are to be used. Referring to Fig. 1, an iron casting is made and turned up as shown. The tool steel punch should be a force fit in the counter-bore and care should be taken to have this fit not too tight or unnecessary strain will result. One can make a force fit that can be driven ” M- - IS --- ; SN syst to suit Press Mii > YY Sy» > it 7 ' | | «- Bore /3. 37 fs ae Fig. 3—Brake Drum Flattening Punch and Die home with a 5-lb, lead hammer and one can also make a force fit that would require 100 tons to force the parts together. The first mentioned is all that is re- quired here. It will be found convenient and profitable to use the best die steel obtainable for these dies, as the time saved (with the chances for broken dies being practi- cally eliminated) will more than pay the added cost of the better steel. The punch for this die is ground all over except in the counter bore, consequently allow- ance must be made for grinding. Here is one instance where the better grade of die steel affords a saving that means something in the hurried construction of a die. In using the cheaper grades of die steel, it is found necessary to make considerable of an allowance for shrinkage and warping, this extra stock necessitat- ing much high-priced time to remove on the grinder. It should not be necessary to allow more than 0.010 1127 a TR a Ree ee ee Sr nt nt EE te i ihe RS ae am ee > - NT a eee ea ria woe 1128 THE IRON. AGE ~< 30 > “ “Turn to suit ‘Press ort ooeamtiienial ( 7 —y - A \§ EI, My a Slidin rt }| SA® Siig... Nf, <<“ Mepsped- <A) rt AYA lh SA ARZ a 4 KK ott } + Cage — fit Y Beh ; j ee C Ne Pe SSE AAASESSSNGS " >|. ke La ogy ho mylik zi a “4 | Steiner « VUIde Fit7-y14 IPPe 7 6 V \Plate y | Drive Fit ~ x <<T ¢ + a > tA $ A iN : as 4 Ne cw eae t + NW f <— % tt te Rey « w Any - . 7 wt x \ © M x te gle t} » x > a SS Y LB? "i le 9 Fig. 4—Brake Drum Piercing Die in. on the outside diameter and more than 0.005 in. in thickness, as the better grades of die steel will not warp or lose shape to any appreciable extent in hard- ening. Considerable judgment must be shown, how- ever, in the heating and quenching of the steel, regard- less of what kind is used. No sharp corners should be left anywhere they are not necessary, as such have a tendency to increase the chances of cracking in harden- ing. All holes should be packed tight with asbestos packing before the die is placed in the furnace. This aids considerably in preventing the steel from warp- ing. In the punch six holes are drilled for %-in. diam- eter cap screws, the counterbore being deep enough to bury the screw heads. The outside diameter of this punch is 0.010 in, smaller than the diameter of the die ring. The diameter of the blank is governed by the eZ TTI FA ; “| turn = vsuit F Press : Sh —7 “s , y+ a ae MMETA At of fhe ¢ fh aff offs EG Kh as" | tak YE Eh TA RSAS ei JN} rs | "isp ~ > < , eet > OKO +e? fi fl Ty a ») SARIN Steed SPA CK AG SG AMMAN F C2 > SUN f Q LMAML AL AR hh hd hea. Ahh hk dg 4 Wy 4 9377, y AAALLLALRLT gNN h a ‘ & 3.93) nf WY ANN j-- §-F#l ot. ._39.9/0%------- SON | bo! mnie . ‘ “pig, ti, Jy Z a a SS Kid LE PLR eG ee ) \ BQ yr * te | X SEE SES Se NS Sa uJ ud we —_ | Y fep-aneninen «ng arsenal socal Fig. 5—Step-hanger Blanking Die diameter of the die ring. The clearance is left on the punch. The die ring is ground in the bore to % in. straight and then tapered off for clearance about 4 deg. The easting is bored straight but a trifle larger than the largest diameter of the die bore or at the bottom of the taper. This permits the blank to drop through readily. Provision is made in the casting of the bolster plate (not shown) for removing the blank as it drops. In hardening—this applies to all dies described, al- though of course the smaller pieces require less time to heat—the pieces are first heated slowly to a blue and then removed from the furnace and allowed to cool. They are then placed back in the furnace and brought up to about 900 deg. during four hours. After this the temperature is raised a little faster till a tem- perature of 1450 deg. is reached, this requiring about three more hours. The temperature can be held sta- tionary at this point for an hour and then the dies are dipped flat till they have cooled to about 200 deg. when November 3, 192) they are placed in an oil bath which has been heate to 200 deg. After the ring is placed in the oil, the tem. perature is raised to'a degree which will draw the ten per to the desired hardness. It is a good practice allow the die to cool with the oil. The die ring shoul: stand a test on the scleroscope of about 85 or 90. Th. punch should be somewhat softer, about 75 scleroscopi: test. The Drawing Die The length of the casting to which the punch fo: the drawing die is attached is not given in the sketch for the reason that the maximum die space of th punch press on which the die is to be used and the length of the stroke govern this. In examining the brake drum used on the majority of automobiles, one SN eee — — SS a a ae Ff om ™ - = - enue (i sate — “7 > \ phtu, POLLS? LU DOLDIL TE tg t Y Ys = MD Sages 7 / Z Ge; SLRS "sg ee Lhhddidddddddiblilidididid — 7 27" yy a" IS R " “# ; Y mee — seiateild orn — - o VMs te. Le PEE a le a 7) > al 5 4 y Ehnnnhnhnnk&kh:nnkh&h&hh HH AHGGGSGAAS SSS SSS SS SS SSS SM Ys h ma -— 38 F >! fe---19”--3 wot yy Hs — ., RMS 3 FF ea <-- a Tr. “4 Fig. 6—Step-hanger Forming Die and Punch will find that the outside of the drum is smooth, as though it had been turned or ground. This finish is obtained in the drawing of the drum. For instance, it is desired to build a set of drawing dies for a 13-in. drum. The punch is turned, hardened and then ground to the exact size of the drum. The measurement of the drum is inside diameter and height. The metal or stock is 3/16 in. thick. This gives an overall diameter of 13% in. In the operation of draw- ing, the metal blank is forced through a set of draw rings, the inside diameter of which decreases in size till the bottom ring is reached. This ring gives the diameter to the drum. In the drawing of the drum, there is what is called the ironing out or squeezing of the blank to give the finish mentioned. This finish is desired only on the out- side of the drum. From 0.014 to 0.020 in. is the range of allowances for this ironing out, 0.016 in. being a good average. To get the diameter of the bottom or finishing die ring, from the overall diameter of 13% in. the 0.016 in. allowed for ironing the blank is sub- tracted which leaves 13.359 in. as the inside diameter of the bottom die ring. The punch and die rings should be rather hard, testing about 90. The die is made up in this instance of two rings, the top one being 5 in. thick. This ring can be finished to size on the lathe or boring mill and hardened. Instead of grinding, all that is necessary is to polish with emery or polishing cloth. If this ring is hard, it will not wear enough to be replaced till at least 25,000 drums have passed through it. Care must be ~ "ie, LIZ zzz. Machine to t 7 Y + Suit Press ‘4 > os TiTIS , ar >, SGyx, Sg’ y* PAO - 445-4 ~ <TR » x & % <= Ce Pm BAY) & QP j IA I \. LIL , iy 4 a 3 mr Xx x* > es Vii A 3 WG ~ ae GA wu x. hbk Fig. 7—Punch for Step-hanger Bending Die a ee a na oe te: Fs November 3, 1921 taken of course to paint the drum with a good lubricant as it is put in the die. The clamps shown on top of the drawing die serve two purposes. They act as clamps to hold the die rings ys z ; : heeederes Pram, SOy* fomehi Tr; | + J o> » 4 Lk y3 . ‘ tt i wis LLPs| Hee Tigh “= Cee AY © Setscrews-mmt i | SFG gy Poe | ly Va 5 | ou | os ———_ = ep rrr ee II seiearonnieanl la ieee Wf, Dip Sf, ee en eid tt hdd een eee nds 2 ss ae hha > 9 bg.--2--s2--= 32” > bee-anJf%a-~ > Fig. 8—Step-hanger Bending Die down (although there is hardly any upward motion) and they serve as gages to center the blank as it is placed over the ring. The degree of slope or angle of these draw rings is not given as one can use his own judgment just so long as the size is reduced gradually to the finished diameter. The radius at the top of the ring is about % in. and the blank extends over this about 4 in. About the same allowance is made for grinding on the bottom ring as was left on the blanking die. The drum is stripped from the punch by the strip- Fig. 9—The Blanking Casting Is Cored to Permit the Blank to Drop to the Sloping Surface and Thence to the Front of the Press pers which are four in number, permitting it to drop through the bolster plate. The Flattening Die When the drum leaves the drawing die, it is bowed considerable across the bottom. This is removed and the drum straightened by the flattening die. The die casting is bored out as shown in Fig. 3 and a tool steel disk ground to a sliding fit is placed in the bottom of the bore. The drum is forced down on this disk and when the punch comes up the drum comes with it and is stripped in the same way as shown in Fig. 4. A beam goes across beneath the press and to this is at- tached a steel pin turned slightly smaller than the hole in the center of the die casting at the bottom. This beam comes up with the plunger at the same time as the punch and carries the steel disk up with it, thus eliminating any possibility of the drum remaining in the die. Piercing Die The drums have a large center hole surrounded by smaller holes. These smaller holes vary in number according to the company for which the drums are be- ing made. Also the requirements vary as to the size of the holes. For that reason no dimensions are given for the small holes shown in Fig. 4. The punches, especially the smaller ones are of high speed steel, as this steel is especially good for punches of the kind when properly hardened. Step-hanger Blanking Die The outline of the blank for the step hanger to be made with this die is shown at the bottom of Fig. 5. The punch and die is made up of sections as shown by the dotted lines. The sections are held to the punch casting with dowel pins and fillister head screws and to the die casting with dowels and cap screws. The sections are fitted tight to the castings and the joints are square and fitted tight. The different pieces have THE IRON AGE 1129 allowances for grinding, and the hardening process is practically the same for these pieces as for the brake drum dies, the difference being that the brake drum punches and dies are dipped in a horizontal position and the pieces for the step hanger are dipped endwise. This position in quenching helps to prevent warping. After forming Die ax er ere f — eas a ere | Step-hanger Blank pita ebasungal z A ecenenneneneticinanani 2 Ih f 3) 4 \ After Bending Die 4 Fig. 10—1, Step-hanger Blank; 2, After Forming Die; 3, After Bending Die The pieces for the blanking die for the step hanger are drawn to a light straw color and the pieces for the punch are drawn a little softer. When one piece becomes chipped or otherwise dulled in use, only that piece needs to be taken out and ground. If considerable has to be ground from it, it is brought up to the level of the others by the use of shims. In Fig. 9 the blanking casting is shown cored out underneath to permit the blank to drop on the sloping surface and from there it slides out in front of the press. The forming die shown at Fig. 6 takes the blank and forms it to the shape shown by No. 2 of Fig. 10. The punch is held in place by set screws on one side only and the die by cap scfews on both sides. In the blanking die there are 0.010 in. clearance both ways but in the forming die only the exact thickness of the stock is allowed between the punch and die. The directions given in hardening the blanking die are followed, care being taken not to have the punch hard enough to chip. A hardness test of 75 is hard enough. The bending die shown in Figs. 7 and 8 bend the -Morse taper to fit ere ge & drill press used Ke Ket Slot Ore Tan! By 4g Square Too! Bi ; dl a . eee Coa =: ei Headless Screw Outside i= LLL LL a + Edging Tao! for flattening top ~ ce 4 Edging Tool-> , Hp a Tool for removing wien 3 - Inside Edging Tool burr from center a s 9 ——s = J t t 1 Lhd hh ELLA MN hhh hhh hdhedaclhddhhedhehed 42 TA Dowel Pin fithing Cast Iron Plate hole in drum Fig. 11—Brake Drum Edging Die. The brake drum edging die shown above is the last operation on the drums. The drum blank is left large so that any irregularities around the edge can be accurately remedied as the drum must be a specified depth. The cast iron base plate shown above is clamped firmly to the table of the drill press used in this operation piece as shown at No. 3 in Fig. 10. There must be gages or stops bolted to each of these dies to allow the quick, accurate placing of the piece in the die. As these stops are very simple to attach, space is not taken to describe them. The Stover Mfg. & Engine Co., Freeport, Ill., has issued a new price list to jobbers and’ dealers, carrying reductions on wind mills, feed mills, ensilage cutters, pump jacks, engines and hardware, nearly reaching the prewar level. This constitutes the fourth reduction made by the company since Nov. 1, 1920. sm ‘ sera titighc - 2 OEE NY ae Se nent ees es the aoe im sieieteni i diansesitiineahiariinatamamattitiies ew Oar ee | Pe ee ee ee ee ee ae Wingy) Ce ae pa’ 1130 HAMMER-WELDED STEEL PIPE A New Product of the National Tube Co., Which Has Developed the Methods of Manufacture Much larger in diameter than pipe made by the butt-weld and lap-weld processes, hammer-welded pipe is made by bending a steel plate into tubular form with edges overlapping, and then welding the overlapped edges after they have been heated, by hammer-forging THE IRON AGE November 3, 1921 force of the welding hammer will be most effective welding the edges together. The rough tube is then taken to the welding machine, where a short section of the overlapped edg: is heated to a welding temperature by water gas bur: ers, placed opposite—inside and outside tie pipe. Th: heated portion of the seam is hammer-forged on a: anvil supported by a long counterbalanced beam, afte: which the contiguous portion is heated and welded These alternate heating and hammer-forgings are con tinued until the entire length of pipe is welded. The Hammer-Welding Machines on Which the Overlapped Edges of the Rough Tubes Are Heated to Welding Temperature and Hammer them on an anvil block supported on a horn inside the pipe. In the manufacture of this pipe, plates of best quality open-hearth steel are used, of a grade to give the best results in welding and other manipulations. . Diagram Illustrating Principle of Hammer-Welding. At left, water gas burners are heating the over- lapped edges of the tube, inside and outside. The flame is directed on all surfaces of the portion to be welded, thus insuring uniform temperature After heating, the hammer, at right, forges the overlapped edges into a strong weld on the anvil block, which is supported by a long beam or horn The plates may either be bent cold, or heated and bent, depending upon their thickness. The tubular form is obtained by bending the plate on long horizontal rolls, in much the same manner as plates are bent for boiler shells and tank construc- tion. But they are bent competely around until the edges overlap to the required extent, and the proper diameter of the pipe is obtained. In certain sizes, two or more plates may be used with similar overlapped edges. Sufficient lap is allowed to make sure that the Forged welding machinery is developed to a point which allows the operator to direct every blow with the accuracy of the skilled smith with his sledge. The power hammer “an be operated at a high rate of speed, and can be regulated to hit with the varying degrees of force nec- essary to make a strong weld. After being welded, the pipe is placed in an anneal- ing furnace and heated, to remove strains and refine the grain. It is then placed on horizontal rolls to round 7 " MEF eh tly be an Ay ri qe. ro ' rT ee Microphotograph of a Cross Section of a Hammer Weld, Showing the Appearance of the Crystals After Annealing up the pipe, straighten it, and remove scale. After a preliminary inspection, the ends are trimmed to any desired angle or length. Each length of pipe is subjected to an internal hydrostatic pressure test, with pressure varying from 150 to 2000 lb. per sq. in., according to the size and November 3, 1921 wall-thickness of the pipe and the service for which it is intended. Then the pipe is given a thorough in- spection as to surface finish and dimensions, and a protective coating is applied if required by the cus- tomer. Hammer-weld pipe steel is inherently strong and ductile. The minimum tensile strength, taken in either direction to rolling, is 50,000 lb. per sq. in., and the elastic limit is equal to one-half the tensile strength. Strips cut from the plate will stand bending through 180 deg. on a diameter equal to the metal thickness. The strength and toughness of this pipe is the result of using a high quality steel, and the annealing of the whole pipe after welding. These characteristics are of great advantage in handling, before and during installation, as well as in resisting strains set up after BY WATER ROUTE Jones & Laughlin Steel Co. Inaugurates Plan for Avoiding High Freight Rates PITTSBURGH, Oct. 31.—The first organized effort by any of the Pittsburgh district steel companies to make regular use of the inland waterways of the country for the delivery of steel was inaugurated last Thursday when a towboat and fleet of seven steel barges loaded with 3500 tons of steel products left the Woodlawn, Pa., works of the Jones & Laughlin Steel Co. for St. Louis and intermediate points. The purpose of the trip, ac- cording to officials of the company, is to make use of the Ohio and Mississippi rivers and their tributaries to avoid the excessively high railroad freight rates, which have added so much to the delivered cost of steel prod- ucts at distant points. It is the intention of the com- pany to establish regular service by the water route. A. W. Herron, Jr., of the Pittsburgh office of the com- pany, and Edward Hughes of its Chicago office, are making the trip and will supervise the delivery of the steel, as well as investigate terminal facilities for future shipments. Included in the shipment are struc- tural steel, plates, pipe, bars, wire products, fencing material, spikes and practically everything manufac- tured by the Jones & Laughlin company, except tin plate. Stops for unloading will be made at Hunting- ton, W. Va.,*Louisville, Ky., Evansville, Ind., and St. Louis. No goods were consigned to customers in Cincinnati because that city was found to have no adequate wharf- age and unloading facilities. Several customers of the company in Cincinnati requested that shipments be made to them by the river. The fleet is expected to consume about 10 days getting to St. Louis. Prepara- tions for this trip have been going on for several weeks and, as a result, river interests all along the Mississippi watershed, other steel companies and the United States Army engineers in charge of river work are watching the results with unusual interest. Motion Pictures of Milling Machine Operations For use in 27 vocational schools in the United States 10,000 ft. of films have been produced of opera- tions of milling machines made by the Kempsmith ‘ifg. Co., Milwaukee. The motion picture photograph- ing was the result of an order to the Society for Visual! Education from the Government to take motion pictures of different machine ‘tools. The Kempsmith machinery was selected for the picture taking and the pictures portray the assembly of the units, the unit assembly to the machine, the complete assembly, simple milling operations showing close-ups of how the cutter re- volves and how the work is held rigid. The ultra-rapid pictures show how the teeth of the milling cutter per- ‘orms its functions in reaching into the metal and lift- ing the chip away, showing simple operations and the various jobs done with the dividing head, operations with the attachments, the cutting of gears and how THE IRON AGE 1131 installation, due to expansion and contraction from temperature changes, settling of supports and anchor- ages, carelessness in back-filling, or other causes. Engineers and other users of pipe consider the strength of the weld as synonymous with bursting strength. A chain can be no stronger than its weak- est link—a line of pipe no stronger than its weakest weld. Investigation has shown that the method of welding used for this pipe produces a weld of higher bursting strength than any other method. Hammer-weld pipe is made with a range of wall thicknesses from % to 1% in. Considering the tensile strength of the material, this range of wall thicknesses gives the engineer a wide working basis for computa- tions on those problems where large safety factors must be provided. Sizes from 24 to 96 in. are listed. the teeth are made; also many tool and production jobs The work was supervised by Sumter Calvert, man- ager industrial department, Society of Visual Educa- tion, Chicago, and W. Kavel, director Dunwoody In- stitute, Minneapolis. Merger of Western Car Companies The recent unconfirmed report of the merger of the Haskell Barker Car Co. with the Pullman Co., Chicago, is borne out by developments of the past week, The Pullman Co. is negotiating the amalgamation which, if effected, will result in the formation of one of the largest railway equipment companies in the country, with assets aggregating approximately $183,- 000.000. The plan will probably provide for the ex- change of Haskell & Barker stock at 75 for Pullman shares at par. Edward F. Carry, president Haskell & Barker Car Co., is mentioned for the presidency of the consolidated company. J. S. Runnells, president the Pullman Co., is proposed for chairmanship of the board. Southern Coal and Iron Corporation Enters Pennsylvania Anthracite Fields The Southern Coal & Iron Corporation, Philadel- phia, has taken over, under lease, with the option to purchase, the 600-ton electrically equipped Simpson breaker, the Ainsley anthracite mines, the Tipperary anthracite mines, with the 300-ton breaker, all located near Carbondale, Pa. These properties are estimated to contain at least 2,200,000 tons of anthracite coal and are equipped to ship 600 tons of prepared coal daily. The corporation intends to put these properties into immediate operation, under the direction of Murray B. Courtright, of Courtright, Dimick & Co., coal operators of Philadelphia and New York. Its property at Rittemhouse Gap, in the heart of the eastern Pennsylvania furnace district, is now ship- ping iron concentrates, and the company is at pres- ent augmenting its plant and expects to ultimately put it on a basis of shipping 500 tons of iron ore concen- trates and 600 tons of sand daily from this property. Belief that the new Hudson River vehicular tunnel can be adequately ventilated was strengthened by re- cent tests at Pittsburgh, conducted by the Bureau of Mines and witnessed by engineers and tunnel commis- sioners from New York and New Jersey. Eight auto- mobiles, 40 ft. apart, were driven back and forth through the 400-ft. experimental tunnel at speeds of 10 to 15 miles per hr., ventilating apparatus being used to hold the proportion of carbon monoxide below 4 parts in 10,000. Those in the tunnel are reported to have suffered no discomfort. To fill orders received from the Pittsburgh & Lake Erie and the Erie railroads, the Standard Steel Car Co., New Castle, Pa., has expanded its productive capacity to near normal. Se : . * ee ae Pe eee Ga oo ‘ ey 1132 Plunger Press for Multiple Operation A special plunger press for doing multiple oper- ation work similar to that of an eyelet machine, but capable of heavier stamping and drawing, has been recently developed by the Waterbury Farrel Foundry & Machine Co., Waterbury, Conn. It is shown in the accompanying illustration and is said to be, as far as known, the only machine having separate plungers for each operation that will do heavier work than an eye- let machine excepting the multiple plunger presses of the knuckle-joint type, which because of their con- struction are relatively expensive. The machine is built for taking the work already cupped, as in many cases it is preferable to cup and draw the work and then anneal it, as by this method, it is said, the metal can be worked more than without an intermediate annealing. A four-motion feed makes it possible to pierce holes during successive operations A Four-Motion Feed Enables Piercing of Holes During Successive Operations Which Must Register with Each Other. A system of upper and lower knockouts keeps con- trol of the work which must register with each other. In connection with the four-motion feed there is a system of upper and lower knockouts that keep control of the work from the first operation until it is dropped out of the machine. A friction dial feed, mounted on the outside of the right hand upright, delivers the work to the tools through an opening in the upright. The runway on this dial is kept filled with shells while the press is in operation. The shells pass out of the runway and are carried down an incline through an opening in the frame by positive means, to a position in line with the tools, where the main transfer mechanism serving the tools can reach it. A pair of bars parallel to the tools, and having pairs of fingers shaped at their ends to fit the work, is given a motion such that at the beginning of the forward movement of the bars the pair of fingers at the feed-in end of the machine grips a shell and carries it to the first working position under the tools. From this point on, at each advancing move- ment of the transfer fingers, the shell advances suc- cessively to each set of tools and having passed the last set it falls into a chute which conducts it away from the machine. For each finished piece that falls into the chute a shell is carried into the machine; thus all THE IRON AGE November 3, 192) the tools are kept at work continuously and simu) taneously. The gate connections are of the eccentric adjus ment type, an eccentric bronze crankpin bushing bein so fixed in the connection that a reasonable shortenin or lengthening of the connection can be obtained | loosening the clamping screws on the connection ca and rotating the bushing with a pin wrench. Eac transfer finger is independently adjustable. The dix bed blocks have a limited amount of adjustment sid: ways and endways, sufficient to insure the dies lining up with the punches. The strippers and knockout have independent external adjustments, so that their positions relating to the tools can be changed without disturbing the tools. The tool spaces and means of holding the tools are generous, considering the work that would be done on the machine. The principle of using independent gate: for each set of tools shows to advantage here, it i claimed, in the marked accessibility of the tools, th action of which may at all times be readily observed from every side. The die-bed block, along with the working end of the knockout, can be readily removed by taking out two screws and sliding it out under the carry bars, the working end of the knockout having a slip joint in line with the bottom of the die-bed block so that as the block is pulled out the knockout dis- connects itself. The punch holder is also removable by taking out the two screws holding it to the bottom of the gate. The machine illustrated has a capacity for shells 2% in. in diameter by 1% in. long. The weight is 21,100 lb. and the floor space occupied 71 x 100 in. Safety devices are provided to prevent damage in case the various mechanisms fail to function properly. isi ak yy “The Nature of Brass” was the subject of a paper presented by A. E. White, director, Colleges of Engi- neering and Architecture, University of Michigan, at the regular monthly meeting of the Engineers’ Society of Western Pennsylvania, at the William Penn Hotel, Pittsburgh, Tuesday evening, Oct. 18. The Traf-O-Lite Sales Co., Newark, N. J., recently ’ incorporated to manufacture mechanical devices for ¥ automobile service, is having its manufacturing done by the Hygrade Engineering Co., Newark, N. J. Buffalo Companies Ask Lower Freight Rates Claim Made That Recent Reduction in Irom Ore Rates Has Brought Some Radical Change in the Competitive Situation, Which Means Disaster ~ BY L. W. WASHINGTON, Nov. 1.—Blast furnace and steel in- terests in the Buffalo district are seeking lower freight rates on coal and coke. It is urged that they be estab- lished to the basis existing prior to June 25, 1918. Making a comparison with ex-lake ore rates to interior furnaces, it is maintained that the rates on coal and oke to the plants of these consumers are dispropor- tionate to those applying on ore to interior consumers and that the spread has been further accentuated by the recent reduction of 28 per cent made on ore shipments from Lake Erie ports to official classifica- tion territory through which no benefit is derived by lake front furnaces. In an effort to arrive at an informal solution of the complaint, Attorney Francis B. James, speaking for the blast furnace and steel interests in the Buffalo district, has addressed a letter to the Interstate Com- merce Commission, the Association of Railway Execu- tives and to railroad presidents, proposing a joint con- ference on Friday of this week or Monday of next. Accompanying the communication from Mr. James is a letter addressed to him by President G. F. Downs of the Lackawanna Steel Co., Vice-President and Treasurer Floyd K. Smith of the Donner Steel Co.; President T. H. Wickwire of the Wickwire- Spencer Steel Corporation; President William A. Rogers of the Rogers-Brown Iron Co., and Vice-Presi- dent C. A. Collins of the Hanna Furnace Co. They point out the alleged inequities in rates on coal and coke applying to the Buffalo district and ask Mr. James to call them to the attention of those whom he has addressed and “take such steps and institute such proceedings and make such interventions as may be necessary to secure for us the relief to which we are entitled.” Relative Ore and Fuel Rates It is stated in the letter directed to Mr. James that prior to the late war and down to Federal control, and particularly prior to the general increase of 25 per cent in rates, effective June 25, 1918, the rates as between ore and fuel were fairly well balanced. The effect of that advance, it is stated, was to increase the rate on Superior or Northwestern ore to the head of the lakes oUc. per net ton, equivalent to 33.6c. per gross ton, and equivalent to an average increase of 57 per cent, with no increase in the rates from Lake Erie ports to interior points. The result of this increase is described as throwing an undue proportion of the burden of the increase upon lake front plants. The rate on coal from the Pittsburgh district to Buffalo, it is pointed out, was increased from $1.40 per net ton to $1.70 per net ton, increased on Aug. 15, 1919, to $1.75, while the rate of $2 per net ton on coke from Connellsville, Pa., to Buffalo became $2.60, effective June 25, 1918. A number of competitors, it is stated, at interior points are located close to their fuel supply and their rates were increased much less in the aggre- gate, while the lake front plants, despite their natural advantage, received no benefit in the way of lowering ‘re rates. Under the so-called 40 per cent general rate \dvance of last August, it is set forth, the rate on coal ‘rom Pittsburgh to Buffalo and vicinity became $2.51 per net ton and the rate on coke from Connellsville ecame $3.64 per net ton and the rate on iron ore from Lake Erie ports to Pittsburgh 91c. per gross or 81.3c. per net ton was increased to $1.275 per gross or $1.14 per net ton and the rate of 92c. per gross ton on iron ore from Lake Erie ports to industries in the Connells- if Not Relieved MOFFETT ville district was increased to $1.44 per gross or $1.29 per net ton and the coal rate from the Reynoldsville district to Buffalo was increased from $1.60 per net ton to $2.36 per net ton, while the ore rate from Buf- falo to DuBois and Punxsutawney, in the Reynolds- ville coal district, was increased from 70c. per gross ton to 98c. per gross ton, or from 62.5c. per net ton to 87.5c. per net ton. The Buffalo consumers then make a comparison of the recently reduced ore rates with coal rates to Pittsburgh and Buffalo and other points and also show increases they have to pay on Connellsville coke shipments. Ore and Coal Rates Compared “Comparing the present rates on iron ore (the recently reduced rates) per net ton with the present per net ton rates on coal, the ore rate from Buffalo to DuBois and Punxsutawney is 26.65 per cent of the coal rate in the reverse direction, the ore rate from Lake Erie ports to Pittsburgh is 39.95 per cent of the coal rate in the reverse direction and the ore rate from Lake Erie ports to the Connellsville district is 43.69 per cent of the coal rate in the reverse direction,” it is declared. It is pointed out that this situation obtains despite the fact that the cost of transporting coal and ore is substantially the same and that the present price of ore at Lake Erie ports is practically double the present price of coal at mines. “The recent reduction of iron ore rates of our competitors at interior points by restoring the iron ore rates to what they were prior to June 25, 1918, without making a corresponding restoration of the rates on our fuel has brought about such a radical change in the competitive situation that same means disaster to our industries,” the Buffalo interests declare. In conclusion they say: “While the prices of our products have been rapidly declining and are approaching pre-war prices, the rates on our raw materials are at their peak and out of proper adjustment with that of our interior competi- tors. Competition was never more severe and promises to continue to be severe, and therefore delay in secur- ing the relief to which we are clearly entitled will be a severe blow to our industries and to the city of Buf- falo and its vicinity.” In his letter, Mr. James says the 40 per cent in- crease in rates greatly widened the competitive spreads on fuel, raw materials and finished products between producers who are near from those who are more dis- tant from the sources of fuel and raw materials and the markets for finished products. He declares that the “present exaggerated spread between the long and short hauls is unjust and unreasonable and a reduc- tion of this competitive spread will tend to restore competitive relationships between producers and inure to the benefit of the consumers and the carriers.” Rates Must Come Down Mr. James quotes Commissioner Potter in connec- tion with the recent decision lowering rates on agri- cultural products wherein the commissioner, referring to rates generally, says they must be gotten back to the proper relation to other things, and “they must come down, and whatever is necessary to bring them down must be done.” Mr. James also quotes from a sworn statement of R. N. Collyer, chairman of the Trunk Line Association, made to the commission in connection with the recent application to lower ore 1133 ilies aR a el neo te omni ral SOOO EO SES ote ie ee Sta Bes oan eth ae IE a. 2) ee et ae otter . OPS 2. Ee ee Pa rates in which Mr. Collyer said that “The iron and steel industry has gone through a period, of severe price reduction (comparable, perhaps, to that of agri- cultural) and its prices are substantially on pre-war ” basis,” and it was added that if the ore is to be moved at rates which recognize the deflated prices obtainable for its products so as to seasonably assist the industry New Line of Automatic Tapping Machines A line of automatic tapping machines of the type illustrated, and including also bench and belted motor drive designs, has been developed recently by the Cin- cinnati Hy-Speed Machine OCo., Cincinnati. They are being mar- keted under the name of Hy- Speed and are built with from 1 to 3 spindles in two sizes, the maximum capac- ities being % an % in., respective- ly, in steel. Among the features are the patented spindle lead and auto- matic reversing mechanism. With the use of the spindle lead de- vice the _ tap is said te be brought forward and returned in a positive way en- tirely free of the operator, tapping holes accurately When Set at Full Automatic the Spindle and without dan- Automatically Reverses at Each End ger of stripping of Travel the thread or breaking the tap. A half turn of the stop plunger at side of the control handle changes the machine from semi to full auto- matic. When set at semi-automatic the spindle travels forward, reverses automatically and ‘stops at the end of the return stroke. To start forward again, the operator pulls down on the control lever. When set at full automatic the stop plunger is withdrawn, the spindle then automatically reversing at each end of its travel. The spindle can be stopped at any point, re- versed and again brought forward by the use of the control lever. The machines are regularly furnished for right hand tapping, although an attachment can be supplied for left hand tapping. Adjustable trip dogs with limit stops on the trip rod regulate depth of tapping. The chuck is driven by a clutched end on the spindle and is locked in position. S. K. F. ball bearings are used throughout. Tables are furnished with a No. 28 B. & S. T-slot, and pump and tank are attached to the base. Ore Loading and Unloading Record Loading 1000 tons of iron ore at the rate of 1.3 minutes, the Great Lakes steel freighter D. G. Kerr broke all loading records one day last month. The former record, which stood for 10 years, was 1000 tons in 2.7 minutes, made by the steamer Corey. The D. G. Kerr made the recent record by loading 12,382 gross tons in 16% minutes at the Two Harbors, Minn., docks of the Duluth & Iron Range Railroad. She was at the dock only 19 minutes. The ore cargo was poured into the Kerr through 35 hatches. The steamer is 600 ft. t ) , | ESSE ee é is 1134 THE IRON AGE November 3, 192 in its efforts toward recovery the rates must be ma: effective as quickly as possible. “The reasons given for the restoration of the rat on ore to the interior iron and steel producers a precisely the same that require a restoration of ¢} rates on coal and coke to the producers of iron ar steel at Buffalo and vicinity.” long, 60 ft. wide and belongs to the Pittsburgh Steam ship. Co., a subsidiary of the United States Steel Co: poration. When the cargo reached the company dock at Conneaut, another record was broken in unloadin; the 12,382 gross tons having been removed in thr hours and five minutes, at the rate of 1000 tons every 14.9 minutes, as compared with the previous record o/ the P. A. B. Widener in 1912, when the unloading rat: was 1000 tons every 16 minutes. Clean, Cold Producer Gas from Bituminous Coal Following an inspection of the Atha works of the Crucible Steel Co. of America, at Harrison, N. J., mem- bers of the metropolitan section of the American So- ciety of Mechanical Engineers met at dinner at the Downtown Club, Newark, N. J., and then heard a paper, under the above title, read by C. F. Kaufman, gas engineer of the Atha works. The speaker laid great stress upon the necessity for thorough removal of tar from the gas, tracing the development of the suc- cessful gas producer from its inception, 60 years ago, through the stages of bituminous gas cleansing through tar removal, 20 years ago, and the more recent produc- tion of a cold gas from soft coal. Bench Type Power Broaching Press A power broach press of the bench type as shown in the accompanying illustration has been recently placed on the market by the American Broach & Ma- chine Co., Ann Arbor, Mich. The machine is in- tended for operating push broaches, for pressing man- drels in and out, for pressing bushings and for many operations usually per- formed by hand. Operation is by a 2% in. belt on a 10 in. pulley which revolves in one direction con- tinuously. The power is. trans- mitted through a 6 pitch worm and worm gear of 30 to 1 ratio, and thence through a steel pinion and rack. The ram is 2 in. in diameter and has the rack teeth cut on the back of it. The stroke is adjustable, the worm being ar- ranged to disengage automatically at the end of a pre- determined stroke by setting a collar on the top of the ram. The return of the ram is automatic and is accom- plished by means of a weight and cord, the cord being wound in a groove in the hand wheel. The machine has a stroke of 14 in. The bore in the table is 2% in. and is central with the ram. The Stroke Is Adjustable by Setting the Collar on Top of the Ram Steel bars imported into France for manufacture into springs now are dutiable at the pre-war rate, pro- vided the conversion is made within a period of six months from the date of importation. Electrical Development in Steel Mills Report of Progress During Past Year— Extension of Electric Drive the Main Feature—Advance in Control Equipment is to be said in regard to new installations of main drive equipment. At the various meetings of our association sections, however, much valuable discussion and data have been submitted with respect 9 main drive equipments now in operation, which will ; undoubtedly lead to further application of the electric main roll drive, as conditions warrant the building of additional mill equipment. The paper on review of costs of rolling steel, with Di: to the present business depression very little i: discussions,} gives us actual data showing the benefits E to be derived by electric reversing mill drive over steam : irive, and this undoubtedly shows that the electric ; drive is the one for most economical operation. Coupled a vith the savings as indicated in this paper are the possibilities of a saving in labor for operating the electric driven mill, made possible by the easier manipu- lation with electric control. It is entirely possible and perfectly feasible to operate an electric driven blooming mill with two men 7. in the pulpit, against a minimum of three required by steam operation. This has been tried out on the Spar- rows Point 40-in. blooming mill and operated success- fully since last April, without slowing up the operation of the mill in any respect whatever. Carrying this idea further, in the case of the 60-in. reversing universal plate mill at Sparrows Point, two operators handle this mill in place of a minimum of four required at other plants with steam operation. Since last year the following new main roll drive ; equipments have been put into operation or placed on order: Direct Current Motors with Ward Leonard Control [—28-in. combination rail and structural mill. Tata Iron & Steel Co., Jamshedpour, India Double unit motor rated 6,300 hp., 80 r.p.m. continuously ; 500 hp. 75 rp.m. maximum. Maximum speed 120 r.p.m \C power—3000 volt, 50 cycles; direct current voltage, per a rmature, 600. Induction motor driving the flywheel set is b. t.d 16 pole, 6500 hp., 375 r.p.m., 3000 volts, 50 cycles. bs [I—28-in. rail and structural finishing mill, Tata Iron « Steel Co., Jamshedpour, India. Single unit motor, 1400 hp. continuous capacity, at 50 m, with speed control to 115 r.p.m. Maximum capacity hp, at 80 r.p.m. AC power supply, 3 phase, 50 cycle, » voit. Induction Motors with Speed Regulating Set (All at Illinois Steel Co., Gary, Ind.) I—20-in. hot strip mill. 5500, 4400, 3400 hp., 170, 136, 105 rp.m., 6600 volt, 25 cycles. ll—20-in. hot strip mill. 2070, 1650, 1205 hp., 235, 7 137 r.p.m., 6600 volt, 25 cycles Il1I—12-in. hot strip mill 2750, 2240, 1750 hp., 262, 14, 167 r.p.m., 6600 volt, 25 cycles IV—12-in. hot strip mill. 750, 625, 450 hp., 360, 300 20 r.p.m., 6600 volt, 25 cycles. V—12-in. hot strip mill. 750, 600, 440 hp., 473, 375, 278 p.m., 6600 volt, 25 cycles. _VI—12-in. hot strip mill 300, 225, 165 hp., 335, 225, > r.p.m., 6600 volt, 25 cycles. t Current Motor Drives for Continuous Hot Strip Mills, Trumbull Steel Co., Warren, Ohio Stands Hp. (Continuous) Speed (R.P.M.) 2,3, 4 1250 175 to 350 6 1250 175 to 350 ] 800 200 to 400 s S08 231 to 462 49 800 256 to 512 10 800 275 to 550 This 14-in. mill will consist of 10 stands, all driven adjustable speed direct current motors as listed ibove. Power is derived from two 2200-kw. synchron- is motor generators. The control requirements for *Electrical superintendent Bethlehem Steel Co., Sparrows 1 Md. This is the report, substantially in full, sub- tted by Mr. Gerhardt’s committee on electrical develop- nt to the Association of Iron and Steel Electrical Engi- heers, in convention at Chicago. *THE IRON AGE, Oct. 20, page 998. ________ BY R. B. GERHARDT* ——— ausasines this mill are most exacting. The several stands of the mill are located close together and the steel is rolled at an unusually high speed, making it necessary to provide for very close adjustment of the speeds and Additional Mill Drives Volt- Fre- Jie Plant HP. R.P.M. age quency Kansas City Bolt & Nut Co... 450 440 2200 60 National Pressed Steel Co..... 1000 705 2200 60 Knoxville [ron Cet eeues -.-. 800 880/490 2200 60* National Enameling & Stamp- : Sa. dc eewn sa 2000 235 22 5 ns BAU HOC Re eseceeseceres 2 235 2200 60 oe nch Co. Nee née weous . 300 365 500 50 on Pet na vdele dun ehnie de 300 365 500 50 ~ aa ome et Homecourt, France. 5750 500 3000 50 Marine et Homecourt, France. 3200 500 3000 50 ( ae Metallurgica Bra- Bees. BED csvacecsicacscs BOO 500 i 5, Se Metallurgica Bra- : — 2s Sileira, Brazil 500 500 5 i ; ete eeeee aa f 6000 § American PP SNS os vce ews cs 500 450 2200 $9 American Brass Co......... . 400 360 2200 60 American OS Se 400 360 2200 60 American Ts a ee 400 600 2200 60 American Brass Co........... 600 600 2200 60 American Tube & Stamping Co. 400 360 440 60 American Tube & Stamping Co. 300 360 440 60 Harrison Radiator Corporation 350 250 440 25 Cyclops Steel Co.......... - 400 720 2200 60 Interstate Iron & Steel Co... | 2000 250 2200 60 2000 150 Simmons Mfg. Co... eee a 360 440 60 oo > = 350 240 Simmons Mfg. Co... ‘ ee 225 440 60 : 750 68 Weirton Steel Co. Pde orn 1500 ; 14 6600 60 : ; 1500 237 Weirton Steel Co 600 720 6600 60 ~ ) 600 360 *Rotary converter speed test. 108 for maintaining these speeds with wide fluctuations in load to prevent the development of loops or stretching of the steel between the stands. Replacement of Engines by Motors The installation of the blooming mill motor in place of the engine at Steelton, Pa., is an epoch making event for this country. In 23 days from the time the engine was taken out of service, the electric drive was put into operation. On the third day of electric operation the mill rolled 1006 tons on a turn, which was within 40 tons of being the record for the engine, and since re- finements and adjustments have been made to the — equipment, the turn record now stands at 1520 ons. A most important event was the replacement of the twin tandem reversing engine, which drove the first finishing stand of the Lackawanna rail mill, by a re- versing motor equipment. This equipment was the first main roll electric reversing drive sold in this country to replace an engine. It was sold in 1917 and delivered in 1918, but conditions at the Lackawanna plant were such as to make it inexpedient to instal] the equipment until this year. This motor unit has the highest continuou