The Iron Age 1923-12-06: Vol 112 Iss 23

ESTABLISHED 1855 New Rod Mill for Wire and Cable Tonnage Unit of Combined Continuous and Looping Type Installed for Rolling Both Steel and Copper the Kinkora plant at Roebling, N. J., 11 miles down the Delaware River from the main plant of the John A. Roebling’s Sons Co. at Trenton, the equipment for turning out tonnage. Not the least of these is the labor situation, which is much easier to control in an industrial community, such as that at Roebling, than it is in the larger center. Again, the plant at Roebling contains the 12 open-hearth furnaces furnishing all of the steel for both the Kinkora works at that point and the main works in Trenton. It con- tains a blooming mill, a rod mill working on a high tonnage basis, and a full equipment of wire mills. The expansion has now added a new rod mill at that point, which is described in the following paragraphs. GS tte ii causes have cooperated in expanding at Because of the various products to be rolled on this new mill, including both steel and copper rods, flats and strips, many problems had to be solved in connec- tion with its design. The mill takes 4-in. billets, which have been reheated after leaving the blooming mill, and rolls them down into rods of 9/32 to % in. diameter or into flats or strips varying from 7/16 to 3 in. wide and from 1/16 to % in. thick. The mill has been de- signed for an annual output of about 40,000 tons. It had been under consideration for a long time, and about 18 months ago it was taken up in earnest with the idea of pushing it through to completion as soon as possible. It has now been in successful operation since the second week of August. Designed for either gas or oil fuel, the continuous yy Se - = ———— EEE — Under the Overhead Pipe Trestle Appears the Heating Furnace for the Rod Mill (in the Opening). located in the taller steel building in background and extending houses the Unaflow steam engine which runs the mill. The rolling stands are well to left of the steel stack. The brick section at left At extreme left appears the end of the loading shed Rolling Mill with High At Head of Page Is a General View of the New Rod Mill Building, with Loading Shed at Left, Monitor in Center, Engine Room and Furnace Room at Right 1505 mr =a teeta sea I di tiete Trcceaea ee een . _ eee ey ae ceeteeiaiediael ath othe te ore a ian avenger ase ae ete re, pon cs ta . a a ae Ie < a > pevine 9 Oe type gravity discharge furnace, 50 ft. long, is using oil at present. Arrangements may be made, however, for the use of producer gas if at any time it may seem desirable. Air for combustion is pre-heated in a cast iron stove located between the furnace and the stack, where the heat is supplied by the outgoing gases from the furnace. A fan handles this air at a pressure of Billets are shoved into and through the fur- nace from the loading skids by means of hydraulic pushers. All in all, the mill contains 12 stands of rolls. v9 to i OZ, One of these is a 3-high roughing mill, 18 in., operated at i Diagrammatic Representation of Hook Sus- pended from Loading Crane to Handle Hot Coils of Wire Rod or Other Similar Material a speed which reaches a maximum of 78 r.p.m. This takes the billets and reduces them in 7 passes to a size suitable for handling in the rod mill proper. From the roughing mill the elongated billet is fed continuously into an intermediate 14-in. mill consisting of three stands. From here it is fed again continuously through two stands of 12-in. rolls and thence to the finishing mills, consisting of six stands, varying from 10 in. to 11 in. in diameter. These six stands of the finishing mill constitute a looping mill, two of the passes being followed by auto- matic repeaters throwing the rod back in each case into the next pass. The six stands of this group are arranged in three lines, the first of which contains three sets of rolls with the same driving pulley, while there are two on the second and one on the third. Pinion housings of the finishing mill are of the inclosed continuous oiling type, built by the Treadwell Engineering Co., New York, and fitted with Falk her- ringbone pinions. Gravity lubrication is used on the mill pinions and the main drive bearing; this system consists of pump, filter and tanks. Otherwise, the equip- ment was built in the plant of the Roebling company, a oo Several Mill Drives Are Taken Off from This Broad Ro the Unaflow single-cylinder engine from view by it, is the drive for the roughing set, THE IRON AGE pe-Drive Pulley. and is directly-connected to the 14-in. December 6, 1923 where the entire layout was designed. The maximun speed of the finishing rolls is 450 r.p.m., which corre sponds with a rod speed of about 1250 ft. per min The finished rod, as it leaves the roll, is automatical); reeled on one of three reels provided side by side fo: this purpose. Scrap bundlers and shears and the othe: usual auxiliaries in a mill of this type are provided. Special attention has been given to quick roll chang- ing, both for changes in section and to replace rol! which become worn in service. Open top and straight side housings are provided, together with outside clamp: for holding the roll bearings in place. In addition to the general overhead traveling crane commanding the entire mill building a small special crane is run over the finishing stands to facilitate changing rolls in two or more stands simultaneously. Handling of the finished rods was one of the prob- lems which gave concern. Methods in vogue are very costly in labor, consequently a special arrangement was provided in this mill, including a buggy or receiving car and crane system. The bundle, discharged from the reels on which it is wound up, is carried by floor con- veyor system to an electrically operated buggy. When enough coils have accumulated in the buggy, each stacked on edge, an overhead crane (spanning the con- veyor position and the railroad track carrying the out- going cars) picks up a nest of bundles by means of a special boom or hook, and deposits them in the car in an orderly fashion. Unaflow Engine Drive Power for the mill is provided by a single-cylinder Unaflow engine built by the Mesta Machine Co., Pitts- burgh, and having a cylinder 56 in. in diameter by 48-in. stroke of piston. The rope sheave shaft of this engine is direct connected to the 14-in. inter- mediate mill. The drives for the other mills are ob- tained from the sheave by manila ropes on the British principle, including stands both sides of the direct drive; the breaking down mill is toward the cylinder end of the engine, while all the other mills are clear beyond the engine. Steam is supplied at a pressure of 160 lb. per sq. in., while the engine is connected to a central condensing system through which a vacuum of 25 to 26 in. is secured. The building, as shown in the general illustration of the mill, is of the usual steel frame construction, with corrugated steel sheets for roof and siding. A large amount of glass is used, however, on the sides, while ventilation is taken care of through the monitor roof. The main part of the building, housing the mill « as Et The shaft of the pulley is directly operated from intermediate mill. Beyond the pulley, and hidden its ropes appearing as the group at lef arer the observer are for the continuous an og the Sabian anh of ex Ga d looping stands constituting the finishing end of the rod mill aan December 6, 1923 Fl paly iD Arh THE IRON AGE 1507 —_ —s Continuous Type Gravity Furnace at A, Heated Billets Are Passed Successively Through the 3-High Breaking own Rolls, the Intermediate Set of Three Stands, the Two Preliminary Finishing Stands and the Six Looping Stands of the Finishing Train, Emerging as Wire Rod or as Flats or Strips. carried away by the conveyor chain shown. Rods are coiled on the reels in center foreground and At the left ig the pulpit from which reels and conveyor are controlled. At extreme right, behind the windows, are the Unaflow engine and the rope drive actuating all the stands of rolls proper, is 65 by 260 ft., and there is a lean-to on either side, that on one side containing the engine and fur- nace, while the one on the other side covers the con- veyor and loading system and extends considerably beyond the end of the main structure. The construc- tion of the entire mill, including the erection of the fabricated steel, which was purchased, was carried out by the company’s own organization, and most of the mill equipment was built in the company’s shops. DENOUNCES GREED Judge Gary Speaks at Civic Forum on Important Subjects—Opposes Bonus Judge Elbert H. Gary, chairman United States Steel Corporation, in an address before the Civic Forum and League for Political Education at the Town Hall, New York, Nov. 30, reaffirmed his position in regard to a number of important subjects. “In many lines of busi- ness, at the present day,” said Judge Gary, “if not to the extent which was formerly characteristic, there is, in conduct on the part of both the employer and em- ployee, unfairness, greed, reckless and brutal disregard for the proprieties and decencies of human contact. If money is acquired by reason of these delinquencies it would be appropriate to hand the amount to those who have unjustly suffered. “Prices just now in many respects and in many places are unconscionable, and they enter into the very high cost of living. If any one, producer, tradesman, or workman, after doing justice by those to whom he is responsible, can and will do anything to reduce the high cost of living, he will thereby give evidence of his gratitude for being permitted to live and work in this country of plenty and prosperity.” Judge Gary spoke strongly in opposition to the pro- posed soldiers’ bonus, but he was strongly in favor of liberal appropriations to care for the injured soldiers. Referring to the agitation in favor of cancelling or re- ducing the debts of foreign countries to the United States, Judge Gary declared the proposition to be irra- tional and preposterous. There are railroad tracks leading into the building at each end, for easy handling of material direct into the cars. The output of the mill is to go mostly to the Trenton plant, where it is to be finished into wire, cable, ete., for the market. Mill scale is dumped direct into scale cars, being handled by means of a clam shell bucket and overhead crane. There is also a general settling basin for scale outside the building. “It has been asserted by certain foreign nations,” said Judge Gary, “that they are willing to pay their debts when their debtors pay them and not before. Did any one ever before hear such a condition insisted upon by any self-respecting, solvent individual or nation? Does any one of these foreign nations, through its courts, allow individual debtors to other individuals to postpone payment until these debtors have collected their claims against third parties? What would a for- eign court say to such a defense to a suit brought upon a note given for borrowed money?” Republic Iron & Steel Co. Improvements Plant improvements under way at the Youngstown properties of the Republic Iron & Steel Co. include par- tial rebuilding of the Bessemer plant, changes to the billet and sheet bar mills, reconstruction of a blast furnace in the Haselton group and erection of an addi- tional battery of by-product coke ovens. The new by- product coke oven addition is now being completed. In the Bessemer department, a cupola is being dis- mantled and a mixer is being-built in, its place. The billet and sheet bar mills of the plant are being replaced in parts with modern equipment. Electric drive will be substituted for hydraulic operation of these units. Plans are being prepared for the addition of two buttweld tube mills at the Poland Avenue plant in Youngstown. The modernization of the Bessemer plant will enable the company to produce a larger tonnage of Bessemer iron, and supply semi-finished steel for the additional buttweld pipe capacity. Saemitinhdteieadien taints Sakae ee oa elma ga naps, 1508 NEW FIRE CLAY BRICK Uniformity in Size Claimed as Feature -Advan- tages for Blast Furnace Linings Engineers for a long time have desired a uniformity in size in refractory bricks for metallurgical use so that joints would reach smallest possible proportions. In blast furnace linings, in coke-ovens and in heating, heat-treating and other mill furnaces, the tighter the joint or the closer the bricks, the longer, has been the general contention, is the life of the furnace or lining. In fireboxes under boilers a fire brick of dependable uniformity has been an essential long desired. At a meeting early this year of the Metropolitan section of Wall Laid Up with 13% in. x 6 in x 3 in. Stratgegnats (Right) To- gether with 9 in. x 6h: 3S Straights. The left half is brick of the same sizes not made by the new process Standard Blast Furnace Shapes (Below) of Fire Clay Brick Made by New Process the American Society of Mechanical Engineers in New York, Edwin B. Ricketts, assistant to chief operating engineer of the New York Edison Co., speaking as one who has made a special study of boiler wall construc- tion, emphasized “the major importance of uniform size, since lack of uniformity made thick joints neces- sary, these being the starting point for the destruction of the walls. The ideal was a brick-to-brick contact with only a thin wash of fire-clay to fill the pores.” It is clearly evident that in a blast furnace the use of brick so uniform in size that the lining made with them would approach in continuity a solid mass of fire clay should insure much less liability to disintegration and hence a longer life. A new fire clay brick, for metallurgical and other purposes, which, it is claimed, meets the ideals briefly outlined above, has been put on the market by the General Refractories Co. 117 South Sixteenth Street, Philadelphia. It is made by a new process, patented by the company and developed at its Olive Hill plant at Olive Hill, Ky. It is the result of extensive experi- ments conducted by the company over a period of years, the aim being to produce a brick so uniform ‘as to reduce joints all possible. The new process is claimed to turn out a brick ab- solutely uniform in size and with no sacrifice of quality. Essential features are described as regulation THE IRON AGE December 6, 1922 in the mixture, grind and density. Some of the brick made by the new process are shown by the illustrations. In one of these there is a comparison between a uniform brick made by the new process and a pile of brick of the same dimensions not made by this process. Sey eral piles of 3-in. thick brick made by this process, six high, showed a total variation of less than 1/16 in.. or less than an average of 1/96 in. for each brick. The other illustration represents a stack of standard blast furnace sizes made by the new process. Plans are under way to equip other plants of the company Already blast furnace records in the older form of brick have shown an output of 1,500,000 tons of pig iron on one lining. On the claim that the new brick can improve on this performance, there will be also the added advantage of the elimination of extra cost due to cutting of brick to fit and of the saving of the large amount of bonding material usually used to fill up joints. Pension Plan of British Empire Steel Corporation WASHINGTON, Dec. 3.—Providing payment to any male employee who has been 25 years in the service and has reached the age of 65 or more and who is retired either at his own request or that of his employing offi- cial, the British Empire Steel Corporation has insti- tuted a pension fund, according to a report received by the Department of Commerce from Consul Charles M. Freeman, Sydney, Nova Scotia. Pensions will be made monthly at the rate of 1 per cent of the average monthly pay received by retired employees during the past 10 years of their service, multiplied by the number of years of their entire employment. Benefits are also provided for female employees who have been 25 years in the service and have reached the age of 55 or more and have retired at their own request or that of em- ploying officials. Any employee who has been in the service 15 years and has become permanently incapacitated also is to be pensioned. The board of directors furthermore may direct the pension committee to include employees whose length of service has not reached the limits or employees of those ineligible for other reasons. Em- ployees who have been in the service 30 years and dur- ing the last 10 years received $83.33 monthly or $1,000 per year will get 1 per cent of the monthly wage, or 83c. multiplied by 30, or $24.90, but it is provided that no pension shall be more than $25. The plan differs from that of most other corporations by not providing for contributions from wages. Effective Dec. 3, it is the purpose of the corporation to apply it to remove 4 source of complaint, especially among miners. . The Ford Motor Co., having recently purchased a site of 45 acres at Norfolk, Va., has purchased an addi- tional 10 acres as the site for an assembling plant. Proposed buildings include a three-story main building 300 x 800 ft. and several other units necessary to the production of 300 cars per day. Molybdenum in Cast Steel and Tron Rolls Heat Treatment and Wearing Qualities of Low Carbon— Alloy Iron Rolls—General Properties BY W. NORMAN BRATTON increased remarkably within the past ten years. Alloying elements, commercially successful in rolls, were beyond the experimental stage in 1913. The wide usage of alloys in certain classes and com- positions of rolls was established some years there- after. Now alloys are generally recognized as prime factors in reducing rolling costs. One of the con- tributing causes for recent progress in this direction is the use of molybdenum, and the object of this article is to present some considerations bearing on the reasons why molybdenum is physically and commercially effi- cient. In forged steel rolls, alloys are used in all composi- tions. In cast steel rolls, the field for alloys was almost entirely in high carbon steel rolls, previous to the in- troduction of molybdenum. Chromium is one of the elements in all alloy cast steel rolls produced in the United States. In addition to chromium are nickel, vanadium, and high percentage of manganese. Mo- lybdenum is added to chromium either alone or in addi- tion to one of the other elements just mentiened. The combination of alloys best to serve a given pur- pose depends primarily upon the resistance to wear and breakage. Comparative tests take into account also the machining qualities and surface properties of the rolls. Unless there are peculiar circumstances, the type and class of roll which reduces rolling costs, by less wear and breakage, is the roll which is used. The actual machining time in dressing a roll is usually a small percentage of the final cost of the roll. Whether it machines hard or soft is often overbalanced by the number of times it must be taken out and put into the mill, transported to and from the roll shop, ete. The surface properties of rolls are adjusted by analyses and heat treatment with the exception of surface cracks, (fire cracks). These are difficult to control and seem to vary with the composition of alloys employed. _ After the raw material and processes used in mak- ing rolls are as good as is commercially possible, alloys are the last means to increase the economic efficiency of rolls. Molybdenum was first tested in rolls during 1920. Since then compositions of varying analyses and uses have been developed. Molybdenum is now used in all the four classes of rolls; namely: Low-carbon steel, r \HE consumption of alloys in carbon steel rolls has *Sales metallurgist, Climax Molybdenum Co., New York. 1509 greed rolling mill rolls, both iron and steel, have 4 become an important part of the regular equip- ment. Alloy rolls are not a new development; several types of cast steel and forged alloy rolls have been on the market for some time under various trade names. This article discusses one of the more recent develop- The author has devoted much study to the alloy roll industry. ments in alloy roll metallurgy. high-carbon steel, iron cast in sand molds (sand rolls), and iron cast in metal molds (chilled rolls). Low-Carbon Steel Rolls For the severe service in blooming mills and rough- ing mills, the low-carbon steel molybdenum roll was developed, yielding a high degree of strength, tough- ness, and wear. Before the molybdenum rolls were placed in service there was no preliminary way to de- termine the resistance to wear. On the basis of hard- ness and carbon contents comparable to other alloy steels, the density and grain size of the molybdenum castings proved favorable and were accepted as an index of the wearing properties in service, taking into account also the previous performance of molybdenum steels for tough-hardness and hot wear. The manufacture of molybdenum steel is extremely simple. The molybdenum is added to the molten metal in the furnace before the slag comes to the top and remains in the steel without passing into the slag. Accordingly the molybdenum diffuses thoroughly through the molten metal for such a long time that there is no doubt about the intimate and uniform mix- ture of the alloy with the steel. Heat Treatment After the rolls are cast a plain anneal may be given, or for special requirements the rolls are cooled in air. This last treatment is a recent advance in the metal- lurgical practice of roll foundries. A complete treat- ment follows which is used in whole or in part or modi- fied as preferred. Starting with the rolls as cast, an anneal is given at high temperature to break up the casting structure, then an anneal from a temperature slightly above the critical point for grain refinement. The rolls are next machined and after this they are heated to a temperature about 200 to 250 deg. Fahr. above the critical point and cooled in air, being allowed to cool until the temperature is equalized throughout the mass below a red heat. The last and final step is the drawing temperature to lower the hardness as de- sired and increase the toughness. The air treatment for cast steel rolls has an effect ip to a depth of six inches depending upon the size of the roll. Following this departure from annealing only, future refinements will be more drastic cooling means ane . hae Ore mn Maven tiaat bedmerencanitmevet racer “< wee - ss ~ a . “ “ — ete Rares ony tytnersnn Bs - a eo NN , — ; ees - - _— ee ee ee ee ete ee ee es 1510 THE and media so that small sizes of cast steel rolls may eventually be given liquid quenching and drawing treat- ments. The wearing qualities are now definitely known. The figures in some cases are surprising, showing com- parative ratios that are three and four to one. Extra- ordinary results in some instances are those, where the service was as much as 12 times the maximum pre- viously obtained. The records below were obtained under five different classes of rolling conditions. Item six is a molybdenum cast steel roll versus a forged steel roll. 1.—12 days versus 4 days; dressing same. 2.—18,000 tons versus 7000 tons; dressing 7s in. versus 4 in. 3.—4 weeks versus 1 week; dressing same. 4.—Over 200 per cent better; no fire cracks. 5.—572,000 tons versus 180,000 tons; life of roll. 6.—500 tons versus 300 tons; dressing % in. versus \% in. Results such as these are positive evidence of in- creased service and consequent reduction in actuai roll- ing costs. An example of the strength and toughness of molyb- denum steel rolls is found in the illustration where it was necessary to roll 9 in. x 9 in. ingots to 5 in. x 5 in. billets on a 16-in. mill. The 2-ft. rule shows the actual size and gives an idea of the small cross sectional area at the bottom of the pass which resists the heavy re- peated working stresses and impacts. Molybdenum has established itself as one of the alloys in high carbon steel rolls. Figures have been given to the writer on relative service of molybdenum to other high-carbon alloy compositions, but not for publication. Molybdenum is being used with economic success and satisfaction. Alloy Iron Rolls With cast iron rolls the toughness is negligible and the strength is much less than with steel rolls. The wear, smoothness, and hardness of surface of the roll are all important. Without toughness any undue treat- ment or other abnormal condition will cause breakage. The alloy which will effect an economic improvement in iron rolls in wearing and finishing properties has a promising future. Molybdenum chilled rolls produce a better finish on sheets, and are especially useful to pro- ducers of high finished sheets. The variables in roll foundry practice more seriously affect chilled iron rolls than steel rolls. Alloys which affect the depth of chill so that it cannot be uniformly taken care of in foundry practice are not suitable for chilled rolls. Molybdenum is free from this objection. The molybdenum is in the iron throughout its manufacture and the chill is read from tests before tapping. When molybdenum is pres- ent the graphite is in the form of nodules instead of flakes. The strength of the iron is consequently in- creased. General Properties of Rolls The relative properties of the different classes of roll compositions may be given in the following order from characteristics which are most prominent in each class. Physical properties are based on tensile tests. First Second Third Low-carbon steel... Toughness Strength Wear High-carbon steel... Strength Wear Toughness PAG POM. <vces s Wear Finish Strength Chilled rolls....... Finish Wear Strength For example, comparing the four classes, low-carbon steel rolls have the most toughness, less strength than high-carbon steel rolls, more strength than the iron rolls, and the least resistance to wear, etc., noting how- ever, in continuing this general system of comparison in the other classes of roll compositions, that chilled rolls resist wear better than high-carbon steel rolls and better than sand rolls. As an arbitrary means of classification, the dividing line between low-carbon and high-carbon steel is taken at 0.25 per cent carbon below the eutectoid. The arrangement above is to be taken only in a general way since there are specific instances where high-carbon steel] molybdenum rolls are used as semi- finishing rolls intermediate between sand and chilled rolls, and high-carbon steel molybdenum rolls that show IRON AGE December 6, 192 better wearing properties than sand rolls. The tab). will serve, however, to bring out the necessary proper ties that a combination of alloys must economically i), crease in each class of rolls, and the reasonable ce, tainty that a major alloying element that has thi accomplishment throughout the entire category properties, will have the largest tonnage use. A source of weakness in hot rolls made of stee! ar: surface cracks, called fire cracks. These may be caused either by contraction and expansion of the surface laye: of the steel roll or by compression and tension on th roll surface in working hot steel. Where sections ar large and are given a heavy reduction of area in the rolling process surface cracks develop most rapidly. When the cracks deepen so the strength is affected it is necessary to cut more metal off the roll than is re- quired to true up the worn surface. The alloy which will minimize this defect will have a favorable recep- tion in the roll industry. Molybdenum decreases fire cracking. Some Properties of Molybdenum Alloys such as chromium, nickel, vanadium and molybdenum produce strength, toughness and resist- ance to wear. Nickel is a ferrite element, chromium and vanadium are carbide elements. Molybdenum is both a ferrite and carbide element. Molybdenum has a direct effect upon the ferrite as a toughening alloy and a direct effect upon the carbides as a strengthening and wear-resisting alloy. The comparative efficiency of alloys in steel depends upon their intensity and commercial applicability. The intensity is defined as the cost of the quantity necessary to produce the desired effect. The commercial appli- cability is determined by the ease in manufacture and heat treatment, and the ease in fabrication. The intensity of molybdenum is almost directly proportional to the molybdenum content up to 0.50 per cent. The effect of molybdenum is pronounced in per- centage contents from 0.15 to 0.25 per cent. This is the range of molybdenum content in molybdenum auto- motive steels. On the other hand types of molybdenum steel are in commercial production wherein 0.70 to 0.90 per cent molybdenum is specified. The dual effect of molybdenum upon both the ferrite and carbide is espe- cially valuable in combination with chromium alone or in combination with chromium and nickel, or chromium and vanadium. Molybdenum has its own individual effect and serves to accentuate the desirable properties of the other alloys with which it is combined. The fractional percentages which are required to produce results can leave no doubt as to the intensity of molybdenum. A metallurgical digest of results in the numerous technical papers on molybdenum steels testifies to the advantages of molybdenum steel in ease of manufacture, heat treatment, and fabrication. Selection of Alloys The final alloy or alloys in rolls will be those that function best to increase economically the desired prop- erties and give the least amount of trouble in manu- facture and heat treatment. Alloys will never be a cure-all. However, when the conditions are right metallurgically and otherwise from start to finish of the roll a judicious selection of alloys and alloy com- positions effects a reduction in rolling costs. Analyses and treatments of alloy steel and alloy rolls have received a new impetus. It is true that molybdenum is a contribution in this progress backed by sound reasoning and splendid service. The data so far gathered from hundreds of molybdenum steel and iron rolls and repeat orders from many steel mills are definite evidence of the merit of molybdenum as an alloying element in rolls. With the experience that has been gained during the past three years it is only logical to expect further advances and a solution of problems which will benefit the industry as a whole. Domestic production of the Ford Motor Co., for the week ended Nov. 20, was 40,226 cars and trucks while 1713 Fordson tractors were produced during the same period. Production at the Lincoln division totaled 134 cars. December 6, 1923 THE Double-Spindle Threading Machine The 1%-in. double-spindle thgeading machine jj- lustrated is a recent addition to the line of the Geo- metric Tool Co., New Haven. In general design it is similar to the %-in. machine described in THE Iron AcE of March 3, 1921, and is intended also for work in which the threading time for both pieces is sufficient to permit the operator to chuck and start a second piece while the first is being threaded. For this class of work the double spindle units are rapid producers and are said to handle practically as much work as two single spindle machines. The 1%-in. machine cuts threads of %, %, 1, 1%, 1%, 1% and 1%-in. diameter. The greatest cutting Two-Spindle Threading Machine for Use Where Thread- ing Time Is Sufficient for Operator to Chuck and Start Second Piece While First Piece Is Being Finished length at which the swinging gage can be set at one time is 9 in., but with resettings a length of 14 in. may be obtained. With a countershaft speed of 296 r.p.m. and the change-speed lever set at % in., spindle speeds are 74 r.p.m.; when set at 1% in., the spindle speed is 38 r.p.m, The machine may be equipped with a 6 hp. motor drive. The net weight is 2165 lb., and the floor space required is 48 x 65 in. The countershaft driving pulley is 18% x 5% in., and the weight of the countershaft is 150 lb. A New Abrasive Cut-off Wheel Cut-off wheels having Redmanol, a phenol resin of the same family as Bakelite, as a bonding agent, have been placed upon the market by the Carborundum Co., Niagara Falls, N. Y. The Redmanol is said to give a wheel that combines strength, porosity, hardness, and resistance to heat; it does not soften or melt and the wheel is free cutting. For cutting high-speed steel, Stellite and general steel alloys, an Aloxite Redmanol wheel is said to be used to advantage. In cut-off work it is general prac- tice to use wheels 12 in. in diameter, and these wheels can be made as thin as x in. Wheels 12 x ss or 12 x % are popular sizes. : Carborundum Redmanol wheels are also available, these being used for general cut-off work on materials of low tensile strength and for cutting carbons and brushes of graphite and copper. For these a wheel in 50 C grit, 4 grade is recommended. In both types, wheels of 8, 10, 12 and 14 in. diameter are available. Performance records of the Aloxite Redmanol wheel have been compiled by the company. With a wheel 12 in. in diameter, sy in thick, in 50K grit, 8 grade, running at 4000 r.p.m. five cuts were made on a piece of Chesterfield metal % in. square. The wheel loss is claimed to have been ys in. and the average time per cut 8 sec. Diamond alloy tool steel % in. square was cut in 10 sec. per cut and the wheel loss after two cuts was ys in. ‘Three cuts of Mohawk tool steel 1% IRON AGE 1511 x % in. were said to average 9 sec. per cut, with a wheel loss of but zs: in. A piece of Stellite 4% x 2 in. is said to have been cut at the rate of 12 sec. per cut, with a wheel loss of x in. after two cuts. Old Firms in St. Louis St. Louis, Dec. 4.—The St. Louis Chamber of Com- merce has been compiling a list of names of firms which have been doing business in St. Louis 50 years or more. The list has grown to more than 200. After the list is completed the firms will be honored at a banquet, when executives and leading citizens will gather to pay tribute to them. The list, as compiled, with the year the firm was established, includes the following: American Car & Foundry Co., 1862; Beck & Corbitt Iron Co., 1852; Bridge & Beach Mfg. Co., 1837, stoves; Buck Stove & Range Co., 1846; Campbell Iron Co., 1867; Charter Oak Stove & Range Co., 1847; Curtis & Co., Mfg. Co., 1854; Fulton Iron Works Co., 1852; Hemp & Co. Corporation (sheet metal); More-Jones Brass & Metal Co., 1874; Pauly Jail Building Co., 1856; Stupp Brothers Bridge & Iron Co., 1858; Joseph Wangler Bros. Boiler Works, Wrought Iron Range Co., 1864. Device for Demagnetizing Chucks The Thorn demagnetizer, a device recently placed on the market for use in shops and tool rooms, is operated directly from a electric light socket and a motor is not employed. It is built for 110 or 220 volt alternating current circuits. Portability and the small space occupied are features of the device. A. J. Little- john, Syracuse, N. Y., is the distributor. Automobile Hubs Machined Automatically An automatic machine for finishing automobile hub forgings and adaptable also for machining second operation work on arbors, such as bevel gears, bevel Automatic Machine for Finishing Automobile Hub Forgings. The arrangement of work and cutters is shown above gear housings, pinion gear shafts and transmission gears, has been placed on the market by the Cleveland Automatic Machine Co., Cleveland. The machine is similar in action to the automatic piston machine manufactured by this company. The hub is mounted on an arbor as illustrated, one end of which is chucked by means of a hand- operated air chucking mechanism. The other end of at ee ee ee eee Ee ee) nen ae 0 a , , rs . o - . - m . —— ~ ner ernenrase waren A Serrnuen at Cael te Pee ee cetenetnel a alone tek norte ee renin Meet vate tel ete ae nt - « oy wa 1512 the arbor is supported by a roller bearing in the tool- stock spindle and is driven by a boss on the spindle hood engaging in the lug on the arbor. The tool operations follow rapidly, working simultaneously. The overhanging arm, mounted on the tool stock pindle and supported rigidly in the rear, carries three cutters, one of which turns the flange diameter and the other two rough turn the small diameter and face one end. The overhead turning attachment mounted securely on the spindle head and operated longitudinal- ly from a cam on the camshaft carries two cutters for rough turning the other small end. There are three cutters in blocks mounted on the rear cross slide which BALANCING HIGH-SPEED FANS Importance of Correct Dynamic Balance Stressed Static Balance Is Not Enough BY ARTHUR L. GREENE () ‘CASIONAL troubles experienced with fan wheels, supposedly balanced perfectly, develop operating difficulties due to vibration. Although not always seri- ous, this may become so, and can be removed only by rebalancing the fan in position, which at best is a diffi- cult task for without special experience. It is needless to dwell on the expense and loss of time com- resulting from unbalanced fan wheels, to make one ] moniy . BALancine | CHART Cera tin lnint »y - . foe (0 04 Baavce ~~ i 4 Ff ~ 2.4 wan + Tas eTolelinl liz * T aoe ae o te ‘c ae > dwvemie Tete tas | ale: le) eT wT rat rrr pe Leh 5h ls Bisa sa , * Cod j ; +-4 7 ri i iA \ \ vy lw s + Me! 5 a rt Tel, - Toe | I ae ee 2 om t a! aches nttntinn ~entteaccl anertniasencenintinegiittinioess | Aore —__— By Means of This Logarithmic Chart the Determine Quickly the Fan Amount 30th Statice and Dynamic THE IRON Pur Sema on Migner Hew Sioa or | Chrerem Lowe Nanny $010 0% 24 on SN Morn Marresing rtm ivratacerion \ Man Doing the Balancing Is Enabled to and Position of Weights Necessary to Give the Balance AGE December 6, 192° rough face the flange and rough form and face 0; end. Both ends gre finish formed and the front the flange is finiMed faced by four cutters mount: on the front cross slide. A hub is produced at ea cycle of the camshaft. The machine is driven from a single pulley wi: a clutch which automatically stops the machine wh, each hub is completed. The lever for starting as y as the air control lever are within easy reach of operator. The machine is arranged either for ly or for motor drive. It is stated that one man c¢ easily operate three machines and that each machi: will produce twelve hubs per hour from forgings. no mention of the cost incurred in repairing damag parts such as dislocated fan blades, worn-out bearing etc. Efficient results are now reported by the Buffa! Forge Co., Buffalo, in getting, so far as possible, bot! static and dynamic balance in high-speed, high effi ciency fans. What Are Static and Dynamic Balance? Static balance is merely balancing an object in stationary position by placement on a knife-edge 0: roller-bearing support. If it shows no tendency t roll, the body is in static balance. Dynamic balanciny however, is the adjusting of those forces which tend to take the body out of equilibrium when running, « differentiated from those forces acting on a body when at rest Now the “running balance” as ordinarily obtained consists 4 of nothing more scientific than arbitrary addition and subtrac- tion of weights to counter- balance irregularities in the | blades or hubs, making for un- even distribution of weight in the fan and thereby causing vibrations. While this method is far from scientific and is not based on formula or rules, it is possible to attain as true a bal- ance by this system as with the use of the most complicated bal- ancing machine. The difficulty 4 =. arises, however, as might be sus- .- es pected, in that the method is , purely arbitrary and depends : e—* for its success, in just about ms | equal proportions, on cut and mee’ iF try methods, and on possession by the operator of a “sixth sense,” This slow and laborious method depends too greatly on the human equation and always leaves the ultimate outcome of ‘ the test an unknown quantity. a | True dynamic balancing, how- ever, represents utilization of a device to obtain a scientifically HH | true running balance. Having a perfect static balance does not insure a perfect dynamic bal- ance. And if the fan is not in dynamic balance a couple will be set up tending to cause the end of the shaft to travel around in circles, with consequent vibra tions just as serious as if the fan were statically unbalanced. \ At the Buffalo plant it has \ been the custom for many years \ to give all the P. M. X. fans (planing mill exhausters) “B” volume, and steel pressure blow- ers, a running balance in their own bearings. This operation is comparatively easy, because os Le ee ae poe - oe! ot ~~ -~ - December 6, 1923 hese fans are self-contained, having no eparate pedestals to erect and line up. The speed is fairly moderate and the blast wheels have already been given tatic balance as assembled. Something in the nature of a “bogey nan” arose for the fan manufacturer, ywever, when high-speed fans for motor ind turbine drive came into use. For various reasons it was found impractica- le to perform the running balance in heir own bearings, chief objections being that a great deal of power was required ) run these outfits at full speed, that the ndependent bearings would require con- siderable time and expense to set up and that the many types and sizes of motors required would necessitate a large and varied testing installation. Hence the Buffalo Forge Co. has in- talled two dynamic balancing machines. The object to be balanced is rotated at ‘omparatively slow speed while vibrating supports allow the rotating object, when out of balance, to indicate this unbalance by exaggerated vibrations. By means of idjustments made in both the angular position and radial displacement of a known weight, attached to the shaft or mandrel and rotating with the object, a new centrifugal force is set up which exactly compensates for the force or forces tending to unbalance the rotating object, and brings the object into a state )f rotating equilibrium. By an adjustment of the balancing machine, the whole machine may be made to vibrate to the rotation of a statically unbalanced object. On the other hand, another adjustment of the machine will THE IRON AGE 1513 Balancing Machine for Obtaining Dynamie Balance. Exaggerated vibra- cause only one of the two bearings sup- tion produced by unbalanced rotors is corrected by adjustment of the porting the rotor to vibrate and will thus angular position and amount of rotating weight attached to the shaft, indicate the dynamic unbalance of the as shown at right above. This gives data for permanent correction to the rotor, the operator reading from the chart, as shown on page 1512, the rotating object. Static unbalance can be detected much more accurately by a bal- ancing machine than on the most care- fully made knife-edge ways. Having brought the object to a state of rotating equilibrium, either for static or dynamic unbalance, it is easy to determine the amount and position of weights which wil] permanently compensate for either unbal- anced condition. Static unbalance is always corrected ‘rst, as a prerequisite to putting an object in correct dynamic balance. A simple logarithmic chart allows the workman who operates the machine to calculate the permanent weight or weights required as quickly as he could caliper and measure the diameter of a shaft. History of Electric Light In an interesting booklet of 110 pages the Smith- sonian Institution of Washington has issued a compen- dium of information regarding the development of in- candescent, are and vapor electric lighting, carrying the reader back to the time when a Greek philosopher -o centuries ago discovered that amber when rubbed will attract light objects. There are many illustrations, especially of the early forms of lights and some of the — apparatus, culminating with the 1923 pat- erns. Particularly interesting is the story of the develop- ment of the incandescent light from Edison’s first °x- perimental lamp of 1878 and his first commercially suc- cessful carbon lamp of Oct. 21, 1879. It is estimated that in the. United States today there are about 350,- 000,000 incandescent. lamps, the number of which is Increasing at the rate of about 10 per cent per year. The annual demand for new lamps and renewals is approximately 200,000,000 per year, exclusive of minia- ture lamps. The use of incandescent lamps in all the other countries of the world combined is about equiv- alent to that in the United States. The average candle necessary adjustment to be made power has increased from 16, which prevailed about 1905, to over 60. The average number of watts con- sumed, however, has remained practically stationary al about 55. This shows that the present lamp has about four times the efficiency of that of 18 years ago. The work was prepared by Henry Schroeder of Harrison, Powdered Coal for Malleable Iron Melting Furnaces The Dayton Malleable Iron Co. has decided to em- ploy powdered coal in connection with its melting fur- naces, of which are 14 at its plants at Buffalo, Dayton, Ohio, and Ironton, Ohio. The Fuller-Lehigh Co., Ful- lerton, Pa., is to provide the equipment and apparatus, and three complete plants will of course be required, including the usual distributing machinery, appliances and furnaces. The use of the powdered coal may be extended to the 84 annealing furnaces in the three plants, but attention will first be given to expediting the installation for the melting furnaces. Steel Furniture Shipments WASHINGTON, Nov. 27.—The Department of Com- merce announces October shipments of steel-furniture stock goods, based on reports received from 22 manu- facturers. Shipments amounted to $1,365,600 in Octo- ber, as against $1,273,259 in September, and $1,227,447 in October, 1922. Stresses in welded and riveted steel tanks under hydraulic pressure have been investigated by the Bureau of Standards and the results are available in Technologic Paper No. 243 for sale by the Superintend- ent of Documents, Washington, at 5 cents a copy. eee ; Hi aS 1 4 i a a Fone wor 1514 Automatically Controlled Spot Welder A spot welding machine equipped with automatic control, permitting of high-speed operation, is being marketed by the American Electric Fusion Corporation, Chicago. The range of the machine, which is illustrated herewith, includes production welding operations from the welding of fine wire to the joining of comparatively heavy sheet steel. With the automatic control provided, the current is tu.ned on and off, and the pressure applied, by the controlling mechanism. The current is applied to a certain definite spot only and in just the quantity and for the length of time necessary. Because of the in- tense heat and the rapidity with which it can be gen- Spot Welder Equipped with Automatic Con- trol. One or a obtained by series of spots may be foot treadle, or operation may be continuous erated, it is claimed that thousands of welds an hour can be made on small, light stock. The welder is driven by a Westinghouse type A. R. S. repulsion-induction type motor operating at a speed of approximately 1100 r.p.m. Mounted on the motor shaft is a quadruple thread worm, meshed with a worm gear, giving a primary reduction between the motor and the lower drive shaft of the gear housing of 1 to 10, which, with equal gears, drives the welder at the rate of 110 spots a minute. Two other gears of the lathe change type are provided, which permit a min- imum speed of 80 spots and a maximum speed of 140 spots a minute. Other combinations of gears to suit the work in hand may be used. By substituing a double or a single thread worm and gear in place of the quadruple, a reduction down to 13 spots a minute may be obtained. If a quick change drive is desired, a quick shift attachment with nine steps may be used, giving a range of welding speeds from 20 to 120 spots a minute. The foot treadle control for starting and stopping the welder is arranged so that one or a series of spots, depending on the kind of work, may be obtained. When the control is fully engaged, the operation is continuous. Prospectus of World Power Conference Prospectus of the world power conference to be held at the British Empire Exhibition, Wembley, Lon- don, June 30 to July 12, 1924, the first gathering of this kind ever held, has been issued by O. C. Merrill, Federal Power Commission, Washington, general chairman of the American committee. The conference is promoted by the Council of the British Electric and Allied Manufacturers’ Association in cooperation with the technical and scientific institutions and indus- THE IRON AGE Dezember 6, 1922 trial organizations of Great Britain and other coy; tries. The purpose of the conference and the person: of the American committee were given in THE [ko AcE of Aug. 16, page 408. The outline of the progran ealls for five divisions under the following classific, tions: Power resources, power production, power trans mission and distribution, utilization of power, and general division, embracing a number of subjects whi are likely to be of primary interest at the conferenc but which do not lend themselves to classification the other divisions. Papers for submission to the conference will printed and distributed by the British committee the members of the several national committees suffi ciently early to allow examination and study prior to the opening of the conference. These papers will no: be read, but the sessions will be devoted to oral dis cussions of the subjects with which they deal. Smoke Abatement Experimental work by the Bureau of Mines in the elimination of smoke from railroad, industrial, and do- mestic fuel consumption has shown that it is perfectly feasible to get rid of the greater part of the nuisance. A 32-page pamphlet just issued by the bureau shows by comparative photographs conditions before and after certain campaigns operated and, by dia