The Iron Age 1922-05-11: Vol 109 Iss 19

STABLISHED 1855 Vliodern Methods of THE IROI New York, May II, 1922 | AGE VOL. 109, No 19 BE SP he RS OE Pa SS AE Making Leat Springs Continuous Process for Automobile Springs—Preparing the Plates—Automatic Hardening Forming and Quenching Machines BY E. F. LAKE” N the past ten years many radical changes have ] been developed in the methods and apparatus used for manufacturing leaf springs used on vehicles f all kinds. This is another instance where the auto- mobile has been the instigator of changes that have revolutionized old methods owing to its demand for large quantities of higher grade materials than were needed for other kinds of vehicles. The American Autoparts Co. recently built a new plant on a 30-acre plot in Detroit and made it the largest plant in the country devoted exclusively to the manufacture of leaf springs and automobile springs in particular. Under the guidance of its president, W. EK. Perrine, the continuous process was installed and the improved spring making machines, furnaces and ippliances that comprise this process would almost enable one to say that the entire plant is one large automatic machine. To fully appreciate the change it s necessary to compare this process with the methods general use less than 10 years ago and still found a few places. It is of the utmost importance in the manufacture *Mechanical engineer, Detroit. -Steel Stock Room of the American Autoparts Co., Detroit. Here the bars are cut into lengths for the various of any spring to have accurate and definite tempera- tures at which to harden and draw them, but this was impossible with former methods; the hardening and tempering was largely a matter of guesswork. Then the spring formers would heat the spring leaves or plates in oven furnaces that were held at tempera tures between 1700 and 1800 deg. Fahr., or from 200 to 300 deg. above the transformation point of the steel. I have frequently recorded fires that showed over 1900 deg. on the pyrometer. The formers con trolled their own furnaces and were always tempted to overheat the steel as the forming was piece work and the hotter the steel, the easier and quicker could it be bent to shape. From such furnaces the main plate was first pulled and bent over a form by two men who worked on opposite sides, started at the center and pinched it down to the form every few inches until the end was reached and then formed the other end in the same way. This plate was then quenched in oil and called hardened. After that this spring plate was taken from the oil and put back in the same high temperature furnace until the oil burned off and that was called tempering. It is to be regretted that such methods sized springs 1269 are still in existence but they are rapidly disappearing. : The other spring plates were built up on the main plate at “ . 5 and hardened and tempered in the same manner. The spring formers depended on their skill to re- move the plates from the furnace when they reached a temperature that would allow them to cool down to the transformation point during the forming opera- tions and thus be quenched in the oil at the correct heat. They also depended on their skill to burn the oil ; off in a furnace with a temperature above 1700 deg. and get a drawing temperature of some 750 deg. As the time consumed in forming spring plates varied a with different men and with different sizes of plates, their quenching temperature would have a wide varia- tion. Frequently this fell below the transformation point and resulted in soft springs. Under the best of conditions furnace temperatures had to be kept 200 deg. above the transformation point to allow for the cool e rm) . ” ‘ - 7. f Fig. 2 Small Portable Shears Are Used for Cutting Spring Plates. They are mounted on platform cars “ down during the forming operations and more often it was 300 deg. Every degree steel is heated above the transforma- tion point adds to the coarseness of the grain and 300 deg. might result in a crystallized grain that is very weak. Thus the fine grain that is obtained at the transformation point and that is needed for the fatigue resistance of springs could not be retained in the steel. In commercial work on a piece-work basis, it is im- possible to burn the oil off of steel in a furnace operat- ing at 1700 deg. or over and get a drawing temperature of 750 deg. Therefore, accurate heat treatment was an unknown quantity and many springs sagged from being too soft, while others broke from being too hard, brittle or crystalline. Scaling also went to the extreme in this method of spring making. By 1913 producers began to separate and make different operations of the forming, hardening and tempering. But this meant extra furnaces and a second heating of the steel for the hardening opera- tion. It also meant extra handling of the spring plates and additional skilled unskilled Then the plates would warp on this second heating for hardening some and labor. THE IRON AGE May 11, 19 and that meant extra work in peening them back to shape the formers left them in, so they would prop, fit the other leaves in the spring. Hardening and d; ing temperatures could be controlled more accura in this way and better springs were the result, but additional cost kept this method of spring making f; becoming very popular or desirable. Under the old method the spring plates would w some while being quenched in the oil and when }b. heated to the drawing temperature, but not as mu as when the cold plate was heated a second time to + hardening temperature. Both the spring formers a spring fitters that did this peening, were highly skil! men that had to be highly paid for this hand work. Benefits of New Method The continuous process installed by the America Autoparts Co., with the improved machinery, furna and other apparatus, has so completely changed th: above methods that skilled labor has been thrown 1p the discard and better springs are being made than the ‘highly skilled hand labor thought was possible The heat treating is accurately done at predetermined temperatures and on scientific principles. Warpage has been overcome to an extent that only about 15 per cent of the springs go to hand fitters to be touched up and these need not be highly skilled, even though in- spection be more rigid than formerly. Scaling has been reduced to almost nothing and along with this great accuracy, the cost of production has been greatly reduced. First comes the 100 x 250 ft. steel room shown >; Fig. 1. The steel enters the plant through deor A, in railroad cars that run along that side of the building for its entire length. A 50-ton car of steel can be un loaded in from 20 to 30 min. by the 5-ton overhead crane that is shown carrying one bundle of steel bars at B. The different grades and sizes of steel are kept separate by steel posts which stand in iron socket flush with the floor and located every 12 in. Tw Toledo Machine & Tool Co., motor-driven punch presses Forming the Eyes by Means of a Single-Stroke Machine seen in the middle of the floor as they are rigged or cutting bars into spring plate lengths. They nade portable by the traveling crane and can be ved to the steel pile or have steel bundles moved them. The power current for such tools can be igged under covers C, which are spaced every 10 ft. When the steel is cut into spring plate lengths it es through doorway, E, to other departments. Plates, over a hot air duct that heats the building by ed draft and can be opened at any point. In Fig. 2 are shown two motor-driven shears that mounted on platform cars to make them portable. plug into the C holes shown in Fig. 1 and cut smaller stock than the punch presses. The cut plates are stacked, as at F, on platforms of Baker R & L elevating trucks, G. Several of these are moved in a train by electric floor trucks. This system of moving stock is used throughout the plant. At the other end of the plant the finished springs are loaded into freight cars in that way. Steel piles are marked on band, H, which runs all around the room. Main Building The main building starts at doorway E (Fig. 1), and is 250 x 360 ft. The first 30 ft. is partitioned off along this wall for a distance of 110 ft. for what Fig. 4—The Loading End of the Automatic Hardening Furnace * - S * area ee re -972 THE IRON AGE mecnanical work has to be done to spring plates before they are fitted together, heat treated and assembled. This includes eye forming, bolt hole punching, beveling and champering ends, nibbing, or any special operations that designers may specify. All departments in this main building are separated by 8-ft. wire fencing such as separates the assembling tables in Fig. 10. Beyond this 30 ft. are located four units of the continuous process which do the real important part of the work on springs. The shop was designed for eight units and the other four will be installed as soon as business conditions warrant. Through this remain- ing 220 ft., straigkt over from doorway, E, to the op- posite side of the building, the work travels, without a stop, through a hardening furnace, forming machine, oil quenching tank, conveyor, tempering furnace, over a conveyor assembling table and over the shipping plat- form into freight cars that run just inside this wall of the building. In Fig. 3 is shown one of the six units that form the eyes on the main plate. The hot plate is inserted in the machine as at I and lever K is pulled over. In May 11, 192» can be seen to the right. Four large lots of spri) can be worked through the shop at the same time these units. Small orders are handled in a differ; way and several lots ean be worked through at « time, but a more expensive method has to be used One unit was working on Ford rear springs a) these were chosen to illustrate the possibilities of { process, as the hump makes the plates more diffic to fit together than in springs of simpler shapes. Ty boys are kept busy loading this furnace by placing + spring plates on rails, J, Fig. 4, which are continua in motion. They raise to the position shown, tray forward a few inches, then lower into the slots unde them and travel back, leaving the work on the heart} of the furnace for a short time. The continual repet tion of this forward stroke gradually moves the wo to the far end of the furnace, where it gets the corr hardening temperature and is pulled out to be form: into shape and quenched in oil. The far end of this furnace is maintained at temperature just above the transformation point of th: steel, while the loading end is held at a lower tempera Fig. 5—The Forming and Quenching Machine Which Takes the Plates from the Hardening Furnaces at the Left a single stroke, this machine then forms the perfect eyes shown on the truck platform. They must be heated again to form the eye on the other end. Formerly it took three strokes of a machine to roll the eye to a perfect round and press the end into close contact with the plate and many such machines are still used. With this three-stroke machine 2500 eyes is about the best that can be turned in a 9-hr. day, but with this intproved machine 4000 eyes is considered a good day’s work. All the furnaces for minor operations are located along this wall, while the machines for drilling, bevel- ing, champering, nibbing, etc., are on the opposite side of the gangway. Continuous Units In Fig. 4 is shown the loading end of the intermit- tent type of automatic furnace, used for heating spring plates for the forming and hardening operations. It is here that the work is started through the continuous unit, and the most important part of modern spring making begins. The side of a furnace of another unit ture. Recording chart pyrometers and temperatur control instruments maintain a uniform temperatur: throughout the day so the plates will all have the sam: degree of hardness and the grain structure of the ste: will be held in its finest condition. On test runs this temperature does not vary 1! deg. The oven of this furnace is not high but it 6 ft. wide and 16 ft. long. To maintain a 10-deg. limit all day, the quantity of steel being heated must not vary; the air and oil pumps must keep up a give! number of r.p.m.’s; the fuel must hold to a definit number of heat units; nothing can clog the burners fo! an instant; etc. Thus so many factors have to be uni form all day that commercial work is never kept withi: this 10 deg. no matter how many assert that it is done. No one would think of raising an objection if hardening temperatures were kept within a 25-deg limit, just above the critical range, and ordinary shop regulation will do that in this furnace. The dischargé end is inclosed by the furnace wall, except for smal! 12x18 openings (Fig. 5) on each side, through which to pull the work. There being no end doors to open THE IRON AGE 1273 i aoe 6—The Forming Machines Are So Constructed That Two Plates for Smal! Springs Can Be Formed at the Same Time and close and lower the heat in the furnace, the greatest ause of variable temperatures is removed. This makes easy to maintain an accurate and uniform tempera ture and also prevent scale. The conveyor is timed so plates consume 25 min. ep n traveling through the 16 ft. of this furnace. Thus 20 min. of this can be used for slowly heating hem up to the transformation point and 5 or 10 min. a soaking at that heat; if the furnace. is kept at the hardening temperature at the discharge end this idually dies down to a low heat at the entrance. This accomplishes preheating in a scientific manner i the only addition to cost is a few feet more in gth of furnace. The benefits derived from preheat- have been common knowledge for a long time but ng makers could not use it with old methods of | ifacture as it added another operation and furnace | increased costs already too high. Forming and Quenching Fig. 5 is shown how the plates are taken from ardening furnace to be pressed into shape in the ming machine and quenched in the oil tank that ns its base. Another forming machine is located 0 the left of this one and its side can just be seen of the furnace. It is fed from the opposite side ‘—Where the Clamps Made Ready for the ing Machine. The eight * which make up a Ford & are in the foreground of this same furnace. Conveyors pull the plates from both quenching tanks and convey them to ons tempering furnace that can be seen in the background to the right. A continuous conveyor assembling table is beyond this furnace. The complete unit, from hard ening furnace to assembling table, inelusive, occupies a floor space 25 ft. wide and 155 ft. long. Beyond that is the shipping platform and freight car track Two men work together in operating this forming machine. It is of the revolving type with six sides for plates and capacity enough for an 8-plate spring, with a main plate over 7 ft. long. The machine stands in the position shown until the first man has located the main plate and stepped on pedal K, Fig. 5. This causes the machine to clamp the plate, as shown, and revolve enough to lower it into the oil quench, and stop with the second plate form in this same position While that is being done, the second man has pulled the second plate from furnace opening, L, with tongs, bent it to shape, M, by a pull up between projecting bars, O O, and is ready to place it in the next forming clamp and step on pedal K. In the mean time, the first man has come back for the third plate. Thus they work in circles as long as the furnace feeds them plates. As the upper plates get shorter, two can be located ——= — woe e with > ee ne = eum — Se ale agg re ot ANE A ts Te \ at alone Merveectemmeienh i thiilinalien orem) sehapiaieicailaaae tatiana cabins: camp ipeedipatthcmpelimn die: 8 sce A EN ee se Rettae es gps leveareetenlta ates ig Aa sin thi snag aes aD -— — ~ Sree he 5 Ry ene Re AER Sp I My Ie ee ee Fs ot RAE T jm Sines vio Roe = 1274 THE IRON AGE in one section of the machine, as shown at N N in Fig. 6. When the clamps close on these plates they will be shaped like formers P P. Sometimes the bottom of the clamp is a solid iron casting that can only be used on one particular plate. Sometimes it is a thin flat steel bar that is held in shape by bolts and can be changed to shapes that fit other plates. The top of the clamp is always of the latter kind as that will give enough to prevent the machine from breaking if one plate should happen to be a little thicker than others. If both top and bottom were solid, allowance would have to be made for a varia- tion in thickness of plates and they could not be made to fit together so well. With the methods used, this hump spring is assembled just as plates come from this machine and about 85 per cent pass a rigid inspection for fit. Only 15 per cent have warped enough to need a re-fitting by hand peening. Sometimes the plates only need turning end for end to make them fit. It takes less than half a minute to get each plate from the furnace, into the clamps and into the oil quench. Thus the steel hardly has time to cool down STANDARD FREIGHT CARS Recommendations to Be Made by Joint Congres- sional Commission WASHINGTON, May 9.—In its forthcoming report to Congress, the Joint Commission of Agricultural In- quiry, will recommend complete standardization of ’ freight cars and central control of distribution of all classes of rolling stock. Another set of recommenda- tions will have reference to the railroad labor situation. The recommendation as to standardization of cars is to be made as one of the suggested remedies for the constantly recurring shortage evil. Chairman Sydney Anderson, in outlining this part of the report, said that the commission has found that the number of locomo- tives operating and owned by some railroads is inade- quate to meet the need during business activity and it should be augmented; that the supply of box cars, coal cars, stock cars, and refrigerator cars is inadequate to meet the demand during normal periods of activity and should be rapidly augmented. Pointing out that failure to supply cars in adequate numbers during any considerable period usually results in an inflation of prices, Mr. Anderson says: “The commission has therefore concluded to recom- mend to Congress complete standardization of all freight car equipment except with respect to cubical and weight carrying capacity in order to reduce initial cost, reduce the number of necessary repair parts, facilitate the repair of cars, to make possible economies in maintenance of freight equipment and to reduce unnecessary empty car mileage.” The report will show that the number of freight cars owned and operated by the railroads has in- creased 6.7 per cent over 1911. The aggregate ca- pacity has increased 18.2 per cent and the net ton mileage for 1920 showed an increase of 62.4 per cent over 1911, the traffic handled during 1920 being greater than any previous year. The commission, according to the chairman, will recommend to Congress as a further remedy for car shortage, prompt consideration and adoption of a com- prehensive plan for central control and distribution of freight cars: (a) To meet currently and in full the requirements of shippers in each and every section of the country, (b) To eliminate all empty-car mileage except that made necessary to protect originating territory, (c) To meet demands in originating territory by balancing movement of loaded and empty cars. The report will state that it is clearly apparent that with respect to freight car control and distribu- tion, and the co-ordination and unification of terminal facilities, the carriers have not progressed, and it is declared that as to adequate car supply, all lines of May 11, 1922 through the critical range. This quick work allows heat in the furnace to be held at a temperature will just heat the steel past the upper critical p, Then all instruments and valves can be set so the | nace temperature will not rise more than 25 deg. a! this transformation point, as that will allow for variation during a day’s run. With such a system o heating becomes a thing of the past and long sp: plates can be hardened, in commercial quantities, a: accurate predetermined temperatures as can gears any other steel part. In Fig. 7 can be seen the shape of the eight plat. that make up this Ford spring, just after they | passed through the furnace, forming machine and quench. On the floor are clamps that are used in t machine on other springs, while at Q is one that being adjusted to shape a spring plate on the next job Rods, which are threaded their whole length, are us: for bolts. To get the correct shape for a spring plat: it is only necessary to screw these in the right dista: and lock them with a top and bottom nut. (To be concluded) transpoitat.on must be placed upon the same basis a the provlem treated in its nation-wide applicatio: Some plan, it is stated, should be devised, which wi aid the weaker lines by enabling them to purchase and properly maintain sufficient equipment to supply the present needs of shippers, together with a margin to meet a normal development of business activity. It is declared that the commission has found that the American Railway Association, whose car service divi- sion is empowered to relocate equipment between rail- roads, is not fitted to prevent emergency conditions and that any plan which may be adopted for the handling of equipment must contemplate current relo- cation of empty cars. Further recommendations to Congress will be made as follows: That the railroads and shippers co-operate to secur+ the full utilization of the carrying capacity of cars whereve possible ; that permanent joint railroad and shippers’ commit tees be organized to carry on a nation-wide campaign | reduce loss and damage to goods in transit; that freight revenue divisions should be promptly revised to the basis two-figure percentages; that regional clearing houses bb established for the current settlement of debits and credi! growing out of rate divisions; that the railroads should ado)! universal through waybilling of interline freight; that th: railroads maintain complete cost data covering each item 0! expense with particular reference to the maintenance of equ!) ment; that the railroads adopt better systems for checking the extent and value of repairs to equipment when made lines other than the line owning the car. The commission has found that the number of ca's in bad order exceeds all previous records and unless bad order cars are promptly repaired the supply w: be materially impaired; also that a large proportion o! the cars being used in interline movement are box cars and should be made fit for bulk grain loading; and all other classes of freight equipment should promptly made suitable for all requirements, inclu’ ing general interchange throughout the country. Labor Situation In dealing with the railroad labor situation, the report expresses the belief that in the settlement ordinary disputes as to wages or working conditions, the carriers and their employees stand upon an equa footing and their disagreements should be settled ) the ordinary process of adjustment applying in othe! industries. This statement is made following a discussion | compensation paid to railroad employees and the cos! which railroads pay for labor material and equipment It is stated that compensation paid to railroaé employees increased 151 per cent in 1920 over 1916 and to 105 per cent in 1921 over 1916; that the numbe! of employees increased in 1920 over 1916 by 384,59! and that in most cases the hours of work increased !! much lower ratio. How Some Manufacturers Putting Idle Equipment to Use Are Keeping Their Plants Busy—Two or More Separate Outlets Prevent Shutdowns BY STERLING HEN a manufacturer is forced to admit to W himself that business depression is upon him and expenditures must be cut, the step that nost dreads is reducing his working force. It is erally easy enough to put new names on the pay- when business revives; but it is not easy to get ack the trained men who have hustled for other jobs nd become settled in new surroundings. The idea of ving to board up the windows every once in seven ten years, let dirt and cobwebs accumulate, and then fter a while turn to and train another force of work- ; in the established habits of the concern, has directed minds of many manufacturers to the desirability of ng on some new line of production, first, to provide rk to keep the wheels turning, and second, to open business in two or more sales H. BUNNELL equipment for producing the radio devices is now being made as required, including the design and construc- tion of such machines as presses for forming the sheet metal parts. At present, the machine tool organization is largely occupied in fitting up the electrical shop, and the production of electric specialties is being rapidly increased. The fortunate possession of all the essentials for producing and selling electric specialties has thus made it possible for Mr. Bilton to develop a small business into a large one, at the opportune moment when his previously large business had become small. The ma- chine shop has become the support and feeder of the electrical factory, and will thus be enabled to carry over until the demand for machine tools again becomes active. By shifting workers to Hg ds wh ich will not be subject en CEOOPEERDODOHEAN THER FERED L TT CC eRRERRERCeRHT DETERS the new organization as far as exactly the same causes and : Tus is the second of a series of possible the Bilton organization es of depression. : five articles by Mr. Bunnell; the is maintained. The two corpo- For causes well known and : ily understood, in the metal : ides, those shops which make etal-working machinery have been the most severely affected the general attempt to re- we expenditures in all indus- es. The demand simply was there, and most of them, cognizing the fact, cut down heir sales efforts and expense til a turn should take place the better. But with men nd equipment available, more than one manufacturer is now efusing to continue his forced vacation until better nes, and instead is embarking on a venture in some held where existing facilities can be utilized to produce ods and return a profit. markable, but not veepReUN nO NseanOnCanONSoesecunnaany enneE articles are: tories. Broadening the Making the Lesser Carry the Greater (he Bilton Machine Co., Bridgeport, Conn., was ganized by C. E. Bilton to manufacture milling ma- nes and cutters. Mr. Bilton had been engaged in production of machinery, tools and fixtures for a ge manufacturing plant, and his knowledge rapidly up the new business and filled the shop with or- rs. His earlier years, however, had been spent in manufacture and sale of telephone equipment and tric supplies, giving him a wide acquaintance in the trical trade. He had kept up his interest in this s of work through a connection with a concern pro- icing electric specialties. This corporation had little is attention until the demand for machine tools sed and left the large organization flat. "he slump came just before the successful develop- of the wireless telephone caused a sudden de- nd for radio equipment for amateur use. Mr. Bil- immediately reorganized his electrical manufactur- concern as the Elwood Electric Co., and began to roduce parts for wireless telephone apparatus. As ‘ business expanded, idle space in the machine shop ‘S put to use, and the necessary tools and fixtures for work were produced by the Bilton Machine Co. All nsulting engineer, New York. first appeared May 4. have been prepared from an investi- gation, at the instance of THE IRON AGE, to learn what the metal-working industries are doing to improve the business position. bility to conditions on the part of wide-awake manufacturers. — ; The titles of the remaining three = Progress in Readjusting Manufac- turing and Sales Costs. Progress in Conversion of War Fac- MI 1275 These articles rations supplement each other by operation in entirely differ- ent sales fields, so that future depression in the one is not likely to be coincident with de- pression in the other. They show u *e- unexpected, adapta- ' New Uses for an Alloy i The situation has been simi- larly met by the Baush Machine Tool Co., Springfield, Mass. This corporation, through its metals division, has for some time produced the lightweight alloy duralumin, having the general properties of mild steel as to strength and duc- tility. As the machine tool demand fell off, attention was diverted to developing new uses for the alloy, and to producing new shapes and forms for component parts of machines, particularly automobiles. Having a ten- sile strength of 60,000 to 65,000 lb. per sq. in., duralu- min in rods and sheets is a desirable substitute for steel in forming stamped or drawn parts, rolled and forged shapes. The manufacturers have produced disk auto- mobile wheels and detachable rims, hub caps, and other rolled or drawn parts; also worm gears for motor-truck rear axles, which gears are as strong and durable as bronze, and being much lighter in weight, relieve the rear axle frame of a great part of the shock and strain on rough roads. The Baush Machine Tool Co. is of course in position to produce all necessary machinery for working duralu- min into shapes as required. New parts and uses are being developed as rapidly as possible. The increasing demand for such light and strong alloys will undoubt- edly enable the organization to devote its principal effort to the production of duralumin parts for distri- bution to a wide variety of interests, and leave the original business of manufacturing machine tools to take a permanent second place. Sales Field. Abrasive Becomes Safety Tread To enter a new field of use with a new product usually requires the development of a new sales organi- zation and system, even though the manufacturing a 1276 THE IRON AGE equipment may need little if any change. If there is any one field which at this time must show activity above all others, it is that of the building trades. The orderly increase in houses, apartments and office build- ings necessary to take care of the steadily increasing population of the United States suffered a check for two years of war and three more years of excessively high cost of materials and labor, and all of the lost time must shortly be made up. The Norton Co., Worcester, Mass., has taken advantage of this condition to put to work a largely increased productive capacity originally intended for the manufacture of grinding wheels and abrasives generally. Several years ago the Norton company brought out a nonslipping tile composed of alundum and a ceramic binder, burned in a kiln. The same properties that make the material useful in cutting metals serve to maintain the sharpness of the cutting fragments which hold the shoe-soles of the passers-by from slipping on steps and pavements of alundum tile, and also to main- tain the surface of tile itself under the heaviest traffic. Naturally, a pavement virtually composed of grinding wheels would be expected to be costly as well as effec- tive, and so the tiles were at first offered as the last extreme of perfection for subway stairs and railway Vortable Cylinder Reamer, Which Is Clamped to Engine Casting station ramps and walkways, where high price was a secondary consideration because all other materials were unsatisfactory. From a condition of being six months behind on delivery of orders for grinding wheels, the Norton Co. was almost instantly left by cancellations with an un- sold stock, and at a time when a large increase in kiln capacity had just been completed. The possibility of developing a business in floor tiling, sufficient to em- ploy this surplus capacity, suggested itself. Manifestly there is only a narrow field for a plain unornamental tile at a price considerably higher than other material, even though the latter were less durable and gave a less secure foothold. It was therefore decided to engage men skilled in the use and sale of ornamental tiling, and to develop a material of fine appearance, in varied designs suitable for all conditions, always with the desirable non-slip quality, and at prices which would make it salable in competition. This has been done with great success. The Norton non-slipping floor tile is now offered in various sizes, and in several colors; also in terrazzo, or in patterns, or with various inserts of black or col- ored marble or other stone. It is made in shapes suit- able for stair-treads, thresholds, steps and ramp pave- ments. Being largely composed of alundum, its dura- bility is far in excess of any other floor material. It May 11, 1999 -—— is priced very little in excess of ordinary tiling and terrazzo. Its durability under the heaviest traffic make it the cheapest possible pavement. A very moderate development of the tile business would seem likely to utilize fully an equipment suff cient for making an enormous quantity of abrasives for shop use. Having opened sales offices in several] cities in the course of starting a national sales campaign, it seems probable that the Norton Co. will soon be ducing a tonnage of alundum tiling far in excess former tonnage of grinding wheels. Portable Cylinder Reamer Many new tool-making shops were organized to meet the excessive demand for special cutters and ot tools for war production, and later by the activity i: automobile manufacture. Most of these concerns have been left with very little work, a condition intensified by the lack of railroad purchasing due to reduced traf fic earnings and to the high wages of railroad shop employees. Some of these shops must find new lines of production or give up business. The Bridgeport Cutter Works, Bridgeport, Conn, is saving its own situation by putting on the market a new porta machine for reaming worn automobile engine cylinders, which costs much less than a cylinder grinding machine and does a thoroughly satisfactory job in very quick time. The machine is adapted to clamp directly on the upper flange of the cylinder block, as illustrated. Ad- justments are provided for centering the cutter spindle in each cylinder in succession, dividing the inequalities due to scoring and wear, so as to remove the minimum amount of metal necessary to produce a perfect sur- face. On all but one or two of the smallest cars there is room to set up the machine on the engine as it stands in place, instead of being obliged to remove it from its position. The machine is provided with reamers for over- size reaming, five, ten and fifteen thousandths larger than the standard bore, so as to suit the oversize pistons regularly supplied on order by the manufacturers. It is driven by a suitable electric motor mounted in place on the cutter-bar mechanism. Besides costing but a fraction of the price of a cylinder grinding machine, it produces a surface better adapted to retain the film of lubricating oil. This cylinder reaming machine is suitable for use by a large number of owners of repair shops, and by operators of fleets of trucks, taxicabs and buses, and has therefore a wide field of sale. It is of the type of machinery that is in demand for the repair work that must go on alike in good or bad times, It is particu larly suitable as a product for the plant of the Bridge port Cutter Co., because a supply of reamers is needed with each reaming machine, giving use for all the ex- isting cutter-forming and heat-treating equipment. Washing Metal Parts In some cases special machinery built for the service of an industrial plant can be adapted for other plants and made into a regular line of production. The Colt shop in Hartford has developed washing apparatus that is salable in two important fields of use. One is for the removing of oil and chips from machined pieces, 45 required for screw machine products, hardware and many other articles of bright metal. The desirable out- side field of sale is also provided by the suitability of the machine for dish washing in restaurants, hotels and institutions. The washing machine for use in machine shops, a5 recently described and illustrated in THE IRON AGE,” has a traveling bed on which the articles to be washed are placed and automatically carried into, through and out of a spray chamber. The spraying system is oper- ated by a motor-driven pump which forms part of the *Page 1080, issue of April 20. May 11, 1922 ,achine. The apparatus as offered for washing dishes : large numbers is made also in a round type of newhat less capacity, easily used by one operator, o puts in the soiled dishes and removes them at the point, after they have made one or more complete utions on the revolving table of the machine. Every one of the cases cited above is an example of Electric Tron and Steel from the Same THE IRON AGE 1277 the advantage of having two strings to the bow, so that one is always ready for an emergency. It is, of course, good economy to standardize on one product and stick to it; but when hard times come all rules have to be set aside, and business must be gone after where it can be obtained, if the wheels are to be kept turning. Furnace Castings from Scrap Only—Melting and Foundry - ) a ; Practice in Intermittent Operations T'MHE Alaska Treadwell Gold Mining Co. has been | manufacturing electric furnace iron castings since tober, 1918. The factors that entered into the adop- of the electric furnace were many, and the results as to warrant the discontinuing of cupola melting. For a period of about seven months in the year the rreadwell company has a surplus of electric power enerated by its hydroelectric plants. During shortage wer may be obtained from another local company at very reasonable rate. Hence the factor of power sup- ply which is most important is very favorably taken ire of. We are charged nominally at the rate of le. «r kwhr. Connellsville coke costing $8 per ton on the able I—Analyses of Electric Cast Iron from AU-Scrap Cupola-Melted Charges Mangan- Phos Graphitice Silicon, ese, Sulphur, phorus, Carbon, Carbon, t PerCent PerCent PerCent Per Cent Per Cent Per Cent 2.15 0.44 0.030 0.334 2.96 2.02 0.47 0.056 0.49 2.90 1.83 0.57 0.020 0.41 2.95 2.19 0.64 0.048 0.44 2.96 1.93 1.28 0.054 0.50 3.01! 1.88 0.61 0.064 0.37 3.17 219 0.67 0.044 0.45 3.23 4 1.64 0.63 0.031 0.40 23 t 0.69 0.54 0.071 0.23 »0 GOA 0.69 0.49 0.086 0.190 2.43 Hol 1.78 0.55 0.032 0.195 2.42% 0.65 0.62 0.049 0.29 50* 2.18 0.58 0.031 0.36 2.55 2.54 2.00 0.54 0.027 0.38 2.80 2.81 1.56 0.58 0.023 0.195 3.27 o 1.79 0.56 0.049 0.52 2.81 2.62 1.56 0.47 0.069 0.33 2.72 2.71 1.77 0.55 0.054 0.40 2.77 2.50 1.73 0.57 0.063 0.53 2.58 2.57 1.74 0.45 0.055 0.53 3.16 2.78 \fter first tap 160 lb. manganese steel was added Hard iron. Before last tap of 166-A 12 Ib. ferrosilicon was added to t rush order of castings These castings machined ely Add to analysis—Cr 0.61. Chrome ore was used in charge h gray iron to make hard iron. \tlantie Coast costs $48 per ton delivered to the foun- iry. Foundry pig iron costs from $45 to $50 delivered. lhe conditions above mentioned make it possible to ‘roduce electric furnace iron castings cheaper than be done with the cupola, not to mention the great lifference in quality. Duplexing With the Cupola lt was soon found that pig iron was unnecessary. \n all-serap charge of machinery scrap melted and re- ned on a basic hearth resulted in a superior quality metal. The melting is done in an 800-kw., 3-phase, --ton Heroult furnace in a neutral or reducing atmos- ere under a reducing slag. For medium weight castings no additions are made; small castings and thin sections the silicon can be reased as desired by addition of the ferroalloy. The nalyses in Table I are mostly from all-scrap cupola- nelted iron that has been through the electric furnace. high percentage of sulphur in commercial scrap be easily eliminated through the medium of the ectrie furnace. Phosphorus can be controlled by the ‘t steel scrap; silicon and manganese can be con- ft ‘From a paper “Electric Furnace Iron and Steel; Inter- nt and Alternating Operations,” presented at the spring g of the American Electrochemical Society at Balti- ‘©, Md., April 27 to 29. The author, W. E. Cahill, is metal- eist and foundry superintendent Alaska Treadwell Gold ng Co., Treadwell, Alaska. trolled by the addition of the ferroalloys to the bath. For economic melting of cold scrap iron in the elec- tric furnace the nature of the charge is very important. The charge must not be too dense, otherwise the elec- trodes will not penetrate it, but do most of the melting from the top. This will cause early heating of the upper part of the furnace with subsequent losses by radiation. The melt will be dead, and will require con- siderable unpleasant manual labor of poking to free the bottom of metal. Sprues and gates make the best charge for the bottom, clean scrap for the top is de- sirable for electrical conditions, as insulation is very common when melting cast iron. In starting very low current is used until a good circuit is established. If insulation develops, the best remedy is to shovel crushed electrodes, about walnut size, around the electrode that is giving trouble. This electrode material will afterward unite with the lime to form a carbide slag. As soon as full current is on the lime is shoveled in. The lime requirements are about 2 per cent of the charge, with sufficient fluorspar or silica sand added to make it active; coke is added with the lime. The resultant slag is strongly carbide and will analyze up to nearly 1 per cent sulphur. If the slag is kept right, very little hearth repair is neces- sary, usually 10 to 20 lb. of magnesite will suffice. The danger of burning the bottom is slight, as cast iron melts at a much lower temperature than steel. The temperature of the metal is under control of the operator. Electric furnace iron is necessarily poured hotter than cupola iron, due to the absence of fluid forming impurities. By running hot iron it is possible to reduce the size of gates and risers. Foundry procedure when using an electric furnace is different from the cupola. The time-honored custom of molding until the cupola blast is on is discontinued. The pouring does not interfere with the molding, the pouring being done by a few men. The rush to keep the metal away from the cupola no longer exists. The confusion of dull heats has gone. Iron from the electric furnace may be tapped in any amount from a few pounds to the whole charge and at any interval, the remainder in the furnace being held at the required temperature until called for, raised or lowered if de- sired. The floor can be cleaned up almost immediately, as low sulphur iron is noticeably not so tender, and may be pulled out while still hot without injury. The most distinguishing characteristic of electric furnace gray iron is its uniformly fine-grained nature. It is claimed by some to be due to low phosphorus, which prevents grain growth. As the same texture is found when the phosphorus is fairly high, low sulphur must have some influence, but probably the greatest factor is the thoroughly deoxidized condition of the metal and the absence of occluded gases. Power Consumption Power consumption varies greatly with both iron and steel, depending upon whether or not the charge is melted in a cold furnace or after a previous heat. While the range is not very great, the results are in- teresting: Kwhr. Per Ton Iron, Steel Single voltage ... iWie tees ceeke ee 893 Dene CORNS oe oad Wie de ne i én ae 851 The averages were taken for 25 consecutive heats i278 THE IRON AGE May 11, 1922 each of iron and steel after new lining. With steel the higher voltage is used for melting and the lower for Lake Iron Ore Shipments in April = — : : fining; with iron the change is made to lower voltage Shipments of iron ore from Lake Superior ti when the scrap is nearly all in. If the higher voltage in April, this year, as compared with April, | PE is left on after the scrap is all in the furnace heats up Were as follows in gross tons: : ico much. The above figures are for intermittent opera- April, Apt 4 tion and may seem high, but melting cold scrap in a aie ice - 4 cold furnace is necessarily high, us considerable energy Marquette Sos ea ; is absorbed in heating the furnace. ioe vee 130 aan 246 e + Intermittent operation of the electric furnace shows Duluth ._ . 27,431 19.0) its most severe effect on electrodes and roof. Alter- Two Harbors 27,783 f ‘ BOON execs kin eee aes 176,211 136,1¢ ey t Table Il fnalyses of Steel Made in a Furnace Following Decrease us — F 10,1 ; peony: The Great Northern ore dock is credited with 1 2%) atin osiai dinate rere ers ees hy sire 0.24 per cent of the total this year as compared with 4 i Manganese, per cent 0.68 0.87 0.57 0.58 per cent last year. The Duluth proportion this ; Z ' ene ee nl EL ag rm geet 0.065 0 040 0 O48 ° $47 was 13.95 per cent against 15.57 per cent last y: oP } Carbon, per cont 0.41 0.50 0.31 0.37 sini atin % Second heat of steel after iron ‘i m : Silicon. per cent.-.... 0.21 0.32 0.34 0.31 Large Automobile Production 2 Phospherus per cent. 0.038 0) O41 0.041 0.018 According to Automotive Industries, the prod ‘ Catton. bar vam ee ot ig sae tion of passenger cars and trucks in April, by : : manufacturers in the United States, is estimated « nating heating and cooling of the roof, with its corre- 213,000. This is very oe the record production sponding expansion and contraction, causes spalling of @7Y one month, and it is thought that when fi the silica brick. Sheet asbestos seems to be the best "ures are available a new record may have be : expansion medium. We have been able to get over 200 made. In any case the production for May will, ei: heats to a roof. anticipated, be a new record. ’ . It has been estimated that the probable 1922 p: ii. Alternating Iron and Steel Heats duction of automobiles in the United States will amount Phe When alternating heats of iron and steel great care to 1,800,000 cars. This compares with an estimat: ‘ must be taken in furnace operation. Of prime im- of 1,680,000 in 1921, with 2,200,000 produced in 1920, : portance is a good spout so that the furnace will com- 1,875,000 in 1919, 1,150,000 in 1918, 1,870,000 in 1917, 2 pletely drain. The effect of residual iron is very notice- and 1,583,000 in 1916. No year previous to 191' able on steel. The slag must be fluid enough to run reached 900,000 cars. ‘ out with the iron, otherwise it will mean additional ; sulphur to be removed from the next heat of steel. If New Cutter Holder for Turret Lathes a heat of steel is desired after iron, the furnace should e charged with low carbon steel scrap so the melt will An adjustable angle cutter holder for turret lathes, be fairly low. The carbon may be lowered by adding intended to eliminate guess work when adjusting the iron ore, but there is a limit to this reaction. If car- cutter to close limits, has been placed on the market ® ried too far it will begin to show its effect on the by the Warner & Swasey Co., Cleveland. : furnace. The removal of sulphur is not dependent upon In turning to accurate size with a cutter head at carbon in the steel, but upon the length of time the steel least two cuts must be taken over the surface of the is held under a carbide slag. If the sulphur is high the work. The roughing cut can be held to a limit of heat will necessarily be prolonged, which is objectionable 0.004 with the usual holder by tapping the cutter lightly for furnace reasons. with a hammer. When using the common holder fot . The analyses for steel directly after iron are shown in Table II. After the first heat of steel there is no noticeable effect of iron, and the procedure may continue : as in ordinary practice. Y Pittsburgh Steel Co. Acquires Ore ‘ The Pittsburgh Steel Co., Pittsburgh, has acquired “Hy? an interest in the Plymouth Mining Co., controlled i by Pickands, Mather & Co., Cleveland, operating an 2 : ore property located in the Menominee range, Gogebic - County, Mich., section 18, township 47, range 45. This mine, which is an open pit operation, was first opened in 1916. It yields soft red non-Bessemer hematite ore and is capable of 750,000 gross tons annually. This The Screw Adjusts the Cutter Accurately A limit of acquisition gives the Pittsburgh Steel Co. a new supply less than 0.001 can be held of ore to take the place of the Rowe mine, operation of which was discontinued at the close of the 1920 — | finishing cut, however, considerable skill is required | season because of the marked decrease in the available ae ca ia = adiustabl reserves of merchantable ore, and because of the high = ees See the curser — far. The a se cost of extracting the low grade ore which remained. angle holder illustrated was designed to eliminat x guesswork in the matter. The American Industrial Engineering Co., Chicago, A graduated adjusting screw operates a small but rigid cutter slide. The screw adjusts the cutter so that a limit of less than 0.001 can be held. The head is of hardened steel throughout and a series of severe tests proved it to be rigid. When in use the lock screw is drawn up tight! has recently taken an order from the Tennessee Coal, iron & Railroad Co. for the installation of complete low pressure pulverized coal burning plant for utilizing : pulverized coal as fuel under one of the boilers in that : . company’s new power plant at Ensley, Ala. The boiler : a ‘ 1 ; under which this installation is to be placed is a Ster- and kept in that position so that adjustment can e ing 834-hp., designed to operate at 200 per cent of ™ade without changing the tension of the screw. r ; rating. A particularly interesting feature of this in- adjustment as small as 0.0005 re ae sald to be — stallation is in the system of control whereby the In addition to obtaining the original setting eas!) op