The Iron Age 1928-03-29: Vol 121 Iss 13

THE IRON New York, March 29, 1928 ESTABLISHED 1855 121, No. More ‘Tools Made With Fewer Men Elimination Manual Handling Has Speeded Production—Twice Much Output per Man FRED PRENTISS* RODUCTION has been increased and labor costs been sharply reduced the plan the Vichek Tool Co., Cleveland, the installation materials-handling equipment, through the use which hand lifting has been almost eliminated while the work moving through the various manufacturing oper- ations. complete cycle materials handling provided, from the unloading the stock from until ished tools reach the The handling equip- ment includes grav- ity-roller roller conveyors, belt conveyors, elevators, elevating buckets, monorails and cranes. stock process piled the floors, and the work kept moving almost con- tinuously from the time enters the machine shop until Two Rows, Between Which Apron-Type Conveyor Slightly Below the Floor Level, Which the Flashings Are Discharged. This carries them outside the building, and Forgings pass from the ma- chines through chutes bucket elevators, which carry them the storage floor above age department. In- confined some work process, mostly tools that re- quire polishing. One step the rearrangement for greater production and economy handling that now being made, but not yet fully completed, the elim- ination storage bins for finished products. The bulk the tools comprising the big production and fast moving items, instead being placed storage bins and taken out from bins for shipment, are stored the eventually into freight *Resident editor Cleveland for AGE. 857 standard shop boxes which they are carried through the machine shop and other departments for succeed- ing operations. These boxes finished stock are piled tiers the stock room. Storage bins, with the re- arrangement the stock room, will confined certain small and slowly moving tools. The company manufactures drop- forged tools, including hammers, automobile, open-end and other types wrenches, punches and screw drivers. portion the product as- sembled into auto- mobile tool kits. The forgings are deliv- ered the machine shop instandard shop boxes, which they travel stand- ard quantities through the various departments until they reach the stock room, where they are stored the same boxes. Plat- form scales are pro- vided various points the gravity conveyor lines for counting the pieces weight. These make count within per cent accu- racy, which garded close enough tor production purposes. When the tools reach the inspection department they are ac- curately counted weight computing scale located the gravity conveyor line. Stock the form steel bars unloaded from cars with monorail trolley that extends out over the receiving platform and through the raw stock room. d Lv which adj one end the forge shop. Stock used drivers and other products that are ror ¢ not forged drop hammers cut length the forge shop, and goes tripshammers and upsetters. All stock that goes the drop forging machines delivered the hammer men full length bars, which worked down until the stock used up. Bars are ded skids the stock room. electric lift truck takes the skids down aisles either side the forge shop and sets them front hammers located two rows near the center. The forging equipment drop hammers. Forgings drop from the hammers into corrugated AC H Coining Pre SS Is Equipped With Feeding Mechanism Op- erated Endless Chain. The operator lays the tools holder attached revolving steel belt carrier. The y are discharge d at the back the machine into bucket elevator which carries them age bins 7 used trimming forgings for tools that are made large quantities, are equipped with rotary trimming fixtures. Forgings fall from the through underground chutes and are delivered into bucket ele- vators. These carry them back the storage floor above, and dump them into shop boxes similar those used for bringing the work from the forging hammers the trimming department. The flashings fall steel apron-type conveyor which extends, just below the floor level, between the two rows trimming This carries them outside the building, where the conveyor rises few feet and discharges presses. Delivering the Forgings from the Trimming Department the Storage Floor Above. The work discharged from the buckets through chutes into shop which overhead crane carries the opposite side the room, dumping the contents through the floor into tumbling mills steel boxes which are in. in. deep. These boxes are picked hand-propelled overhead trol- ley, equipped with 2000-lb. electric hoist, which extends through the center the forge shop between the two rows hammers, and are carried adjoining trimming department. This located two-story structure, the upper floor which, used for the storage forgings, both before and after trimming, served electric traveling crane. Boxes forgings are raised through opening the floor one end the trimming department and are kept storage the boxes which they are received. Nine trimming presses are arranged two rows the first floor. The boxes stock are let down from storage through two openings the floor, one each side near the center the building, one opening for delivering forgings being provided for each line presses. Boxes emptied the trimming presses back the forge shop. Some the trimming presses, 858—March 29, 1928, The Iron Age them into large steel scrap box. overhead elec- trically operated monorail carries the box scrap elevated bin, into which the contents are dumped opening the bottom the box. The scrap bin located alongside railroad siding, and the flashings are chuted from the storage bin into car, upon open- ing the side the bin. Trimmed forgings, after being taken back the second storage floor, are carried the storage floor crane the opposite side the room. Here they are delivered tumbling mills located mezzanine floor between the storage room and trimming department. Steel plate sections form floor covering over the tumbling mills. One these sections may raised, providing opening the floor through which the work dumped the crane into the tumbling mill beneath. There are four tumbling mills, with 40- in. and 40-in. barrels. From the tumbling mills the forgings are discharged y a ORGINGS Carried From the Presses Bucket Elevators Are Discharged the Two Belts Shown, Located Above Series Storage Bins One End the Machine Shop. The mov- able plow shown near left the picture set work into any desired bin. pieces from the bins indi- cated bottom page into chutes which converge into one main chute, through which they fall into shop box placed hand truck the trimming room floor. This arrange- ment for handling work through the tumbling mills gravity eliminates hand labor loading and unloading the mills. Only one man required for handling the forgings the second floor, which they make the two trips, before and after trimming. The man’s work includes also loading and tending the opera tion the tumbling mills. Boxes loaded with forgings delivered tumbling mills are pushed short distance coining presses, for straightening and sizing. The two coining presses are 400-ton and 600-ton capacity. Each press equipped with efficient feeding mechanism which was developed the plant. This consists work carrier attached endless chain. The oper- ator, standing front the press, places the forgings the carrier, which carries them through the press. After the coining operation the work falls off the car- rier incline and thence into bucket conveyor. The 600-ton press operated the rate strokes minute and the 400-ton machine strokes min- the Storage Bins, the Belt Con- veyors Being Back the Rail- ing Above, Which Incloses Aisle the Side the Conveyors. Tools are dumped from the hoppers into the standard shop boxes shown or, large tools, are removed from the hoppers hand and piled the boxes. From the gravity conveyor alongside the bins the boxes move other ture, lead the milling machines ute. Not only production increased the feeding mechanism, but the injury hazard entirely elimi- nated. The bucket elevators which handle the work from the coining presses deliver the forgings short belt booster conveyor. The latter discharges them through chutes long belt conveyor located above series wooden bins above one end the adjoining machin ing department. There are two these belt conveyors, each in. wide. The bins, about number, ft. high, ft. deep and various widths. sepa- rate bin provided for each kind forging. These are discharged from the belt into any desired bin means discharge plow. These conveyors are sim- ilar operation belt conveyors used deliver sand into hoppers above foundry floor. Each bin has slanting bottom leading hopper the front side. Smaller forgings are dumped from the hoppers into shop boxes gravity roller con- veyor extending alongside the bins. Some the larger forgings are taken out the hoppers hand and piled into the boxes. These boxes are the standard containers, which The Iron Age, March 29, 1928—859 the work carried through the plant for the various processes after leaving the storage bins for finished forgings, and finally for the storage the finished product. They are pressed steel, in. in. deep, and have maximum capacity 500 When loaded from the bin, the box moves along the gravity conveyor the side the bins and an- other series gravity conveyors which form Scale NSPECTION POLISHING AND GRINDING EXPERIMENTAL Roller Other Floor Con veyors ’ Section Roller Conve yor the elevator automatically set motion and the box automatically discharged overhead gravity conveyor which carries the tempering department. There spiral section the gravity conveyor carries the box down the working level. the tempering department there dividing point the movement the work. Forgings which SHOOK STORAGE MACHINE STORAGE ' Die HARDENING STORAGE HAMMER SHOP AYOUT the Plant, Showing Arrangement Conveyor and Monorail Systems and How They Serve the Several Manufacturing Departments network conveyors that feed the milling machines. After milling the operator throws the work into shop boxes opposite gravity conveyor. This one various feeder lines that lead from the milling machines live roller conveyor in. above the floor. The live conveyor carries the boxes electrically operated elevator one side the machine shop. soon the box the carriage 29, 1928, The Iron Age not require tempering move, leaving the spiral, straight line gravity roller conveyor located between cyanide tempering furnaces. Near the oppo- site end the tempering room this conveyor connects with automatic elevator, similar that the ma- chine department, except that air-operated. This hoist raises the boxes overhead gravity conveyor, which they are carried the cleaning department. —------------L_f a! | 7 MACHINING Conveyors / FORGE SHOP Machined They Are Put Back Shop Which Are Placed Other Gravity Convey- ors Feeding into the Live Roller Conveuor Center. They move this elevator back- ground. box moving the elevator auto- matically and discharged near gravity conveyor which takes the tempering de- partment Here second spiral conveyor carries the boxes down the working level. reaching the bottom the spiral the temper- ing department, boxes tools tempered are switched gravity conveyor line which extends front the furnaces. Here they are delivered bun- dling tables, where they are placed baskets wired bundles for immersion the cyanide bath. Levers suspended from overhead tracks are provided for han- dling the work and out the furnaces and into the quenching tanks. From the latter the hardened tools are dumped into shop boxes short section grav- ity conveyor provided each side the furnace. These conveyors feed back into the conveyor line re- ferred above, which extends between the rows furnaces and leads the cleaning department. the Cleaning Department Forgings Pass Along Gravity Conveyor the Side the Room (Not Shown) and Are Pushed Short Section Portable Con- veyor. This the mechan- ical loading hop- per the ma- chine. The end this hopper raised dis- charge the work into the tumbling mill, which the first unit the cleaning machine the cleaning department the forgings pass along gravity conveyor the side the room and from this are switched short section portable con- veyor mounted wheels. box work pushed off the main conveyor line the portable roller con- veyor, and the truck which this mounted moved ft. the loading end cleaning machine. The box shoved into mechanically operated hopper which, when raised, lifts the forgings and discharges them into the machine. the discharge end this machine they pass into boxes another gravity-roller conveyor. With this tie-up the cleaning machine with the roller conveyors, both its loading and dis- charge ends, hand lifting work going through this machine avoided. The cleaning machine consists two connected The Age, March 29, SARA 4 ‘ = - yg rt \ 44 — units. The first includes tumbling mill with large- diameter drum which the work, 1500 2000 load, tumbled hot cleaning solution for min. Then the rotation the barrel reversed and the forgings are carried into smaller perforated drum, which the solution drained off. From this they are dumped into washing unit consisting large metal drum, which they are washed water containing rust-proofing solution. through wire screen drum for drying and from the latter are discharged, both clean and dry, into shop box gravity conveyor. The cleaning machine was built the Ideal Concrete Machine Co. Leaving the cleaning department, tools move the gravity conveyor the inspection department, they are japanned are switched through the japanning department. short motor-driven booster section provided the conveyor line this depart- ment, raise the work few feet that can con- tinue its movement gravity. From this unit the tools pass the inspection department the tools are inspected ind weigh-counted. The boxes, except those contain- ing tools which are packed loose, are picked traveling crane equipped with electric hoist ng. From here they are sent over short roller con- veyors the assembling department, where tool kits ire assembled and packed into boxes. Tools which are loose-packed go, their shop boxes, gravity conveyor from the inspection department the loose-packing store room, where they are stocked four boxes high. From these boxes they are transferred packing boxes. roller conveyor extends the length the shipping room. This used for conveying the packed shipping oxes scale for weighing, the covers being nailed WELDED CONDUIT PIPE Thin-Wall Steel Conduits, Electrically Welded, Offered Place Heavier, Standard Pipe conduit pipe for carrying electric wires buildings has been developed Steel Tubes, Inc., Cleveland, which will place the new product the market shortly. This thin-wall ‘onduit which will known “Steeltubes” metallic tubing. will fabricated from cold-rolled open- hearth strip steel and welded under process used the company the manufacture electrically- welded tubing for the automotive and other industries. The process and product will covered patents the company. continuous process used both forming and welding the tubing. Additional operations required for making the tub- ing for conduits will include galvanizing the exterior ind enameling the interior, provide smooth race- way for the wires well resist corrosion. After being formed and welded, the tube will run through continuous automatic machine which will ‘leaned and dried and then galvanized and enameled. Experimental work developing the tubing has been inder way for several years. The conduit will made %-in., and diameters, 17, and 19-gage strip steel, which stated provides wall more than the required strength for electric tubing. expected that per cent the product will one size, stock. With production mainly one size, and standard lengths, large output can obtained from one manu- facturing unit. Since the introduction steel conduit pipe for electric wires, standard steel pipe has been used for this purpose. This pipe, contended, heavier than required and its use results needless waste steel. However, the comparatively heavy wall necessary carry the threads and allow the use 29, The Iron Age them the conveyor from which they are trans- ferred truck for shipment. used also for bringing empty shipping boxes points which they are packed, and for taking empty shop boxes out the shipping room. These are loaded electric trucks and are taken back their starting point be- neath the discharge hoppers the bins the side the machining department. Other cranes, and mono- rails and hand trucks also, serve the store room and the assembly and packing departments. The gravity and live-rolled conveyors, belt conveyors and elevators operating conjunction with the roller conveyors were supplied the Mathews Conveyor Co. 1918 the Vichek company had drop hammers and employed 480 men. 1927 had increased its drop hammers and reduced its working force 280 men; and with the reduced labor force had in- creased its output per cent. The increased production not attributed entirely the installation materials-handling equipment, various other changes have been made increase the plant efficiency. Improved materials-handling facilities have created demand for more rapid production tools the machin- ing department, and speedier tools have called for the faster moving material. Consequently the two fac- tors, the use more rapid machine tools and the bet- ter materials-handling facilities, have gone hand hand. work longer piles process, marked re- duction has been made the time takes through the plant. Formerly routing took open-end wrench from three four days from the time the blank reached the forging hammers until the finished tool reached the stock room. Now stated that that tool, finished, can reach the stock room hr. after forging. standard fittings. asserted, also, that the develop- ment electrical conduit the lighter and cheaper form will result more general use steel electrical conduits than present. One advantage claimed for the welded steel conduit its economy installation. The ends will joined slip coupling, eliminating threaded joints, and the only tools required for installa- tion will hacksaw and wrench. The electrical committee the National Fire Pro- tective Association, compiler the National Electrical Code, its recent annual meeting decided change the code allow the use electrical metallic tubing, and will provide installation rules covering its use. expected that this tubing will listed shortly standard the Underwriters’ Laboratories, Inc. Steel Tubes, Inc., will begin the manufacture the metallic tubing shortly its Brooklyn, Y., plant and later will add departments for its manufacture some its other plants. Study Annealing Crane Chain committee the National Safety Council has arranged with the Carnegie Institute Technology, Pittsburgh, conduct series tests chain. The proposed investigation will cover the following items: (1) Analysis chain (2) tension-proof load and tension test destruction chain received; (3) impact test chain stock; (4) chain received subjected repeated stress test; (5) tension-proof load and tension test destruction chain after test (6) impact test chain stock after being subjected repeated stress test; (7) anneal chain various temperatures; (8) cooling chain air and furnace after being heated for (9) tension-proof load and tension test destruction chain after each annealing and cooling operation has been completed; (10) impact test chain stock after each an- nealing and cooling operation has been completed; (11) study the effect low-temperature heating, following the same procedure given above; (12) metallographic studies chain under the various conditions outlined above. | Scales Used for Production Control and Inspection all sorts, but especially automobile leaf springs and gas engine valve springs, are tested measuring the weight required compress them completely. The Packard Motor Car Co. has devised simple attachment platform scale whereby the force required compress each motor valve spring definite distance can tested ‘ gers 7 4% overhead monorail scale enables the Jones Co., Toledo, Ohio, keep close check all drill rods, either coming from plant warehouse from warehouse railroad car. Since weight and number units are interchangeable ali items mass production, small parts may most readily counted weighing the unknown quantity against known number placed counterpoise pan. the cupola. easily accomplished means weighing molten pig iron charging into bull !adles were taken for the Tole- Ohio. The Iron Age, March 29, 1928—863 \= = ow-Manganese Steels Gain May Heat Treated Properties Comparable with More Expensive Alloy Steels and Consequently Favor Are Finding Increasing Application JEROME STRAUSS* ECENT years have witnessed increasing in- terest alloy steels containing the low-cost ele- ments silicon and manganese, particularly such compositions secure high hardness and good ductility. The largest tonnage has contained manga- nese the principal alloying element; 0.9 per cent manganese may regarded the amount separating common steel from alloy steel. Most the com- mercial production has been steels containing 0.3 per cent carbon and per cent manganese. Steels containing lower carbons and manganese per cent have been the subject much study. How- ever, this paper concerned with steels the former range. For all these carbon-manganese steels, the foremost American proponent has been John Howe Hall (THE IRON AGE, Sept. 28, 1922, page 786), particularly for use castings. Recently, however, several American producers rolled steel bars have manufac- tured manganese steels quantity, and their use for forgings articles machined directly from the bars has spread rapidly. Lower-carbon steels per cent manganese are being applied both for carburized their *Material engineer, United States Naval Gun Factory, parts and for pressings forgings, but they will omitted from this discussion. Critical Points Displaced Air-Hardening May Result Published data critical points yield approximate information tabulated below: deg. Fahr. for each per Fahr. per cent Mn; lowered Acs drops 110 deg. change. cent manganese. thereafter little Ar, is lowered 90 deg. Fahr. or more for each per cent manganese. lowered 125 deg. Fahr. for each per cent manganese. Since lowered more rapidly than with either carbon manganese, the two overlap steel con- taining 0.40 per cent carbon and 2.0 per cent manga- nese, another containing 0.20 per cent carbon and 3.0 per cent manganese. Obviously the above involves lowering the eutectoid carbon content, which appears about 0.78 carbon for 1.0 per cent manganese, 0.50 carbon for 3.5 per cent manganese. One very important feature the lowered trans- formations the ability harden temperatures below the usual quenching point, after furnace cool- ing from the latter. %-in. sections, for instance, This abstracted version paper read 0.45 1.09 steel heated 1550 deg. Fahr., slow- before the Montreal meeting the Americ: Society 130 | ot a 100 Typical Carbon Steels, Manganese and Alloy the left dia- were heat treated sq. in. ultimate the 135,000 lb. per sq. in.; 000 Ib. per sq. in. strength; next to . and the dia- gram the ex- treme right all steels broke 225,000 sq. in. DS Sr os S 864—March 29, 1928, The Iron Age PER JUCTION OF AREA CE L -LB ) IMPACT FT ~ wo > OUT though quenched from 1550. That the tension and im- pact properties not suffer from this method heat treatment indicated the following data for 1-in. sections 0.51 1.17 steel: Heated 1500 deg. Quenched from 1350 deg. Fahr. Quenched from 1500 deg. Fahr. 144,100 Ib. 142,800 Ib. per sq. in. Proportional limit 101,900 109.500 Ib. per sq. in. in. 17.5 per cent 17.1 per cent area 53.2 per cent 52.6 per cent Izod impact..... 62.5 62.6 Properties Heat-Treated One-Inch Bars order compare the properties manganese steel with those the more conventional analyses, series tests were made which are summarized the four diagrams the bottom the page. Values plotted are the results interpolations between aver- ages two tension and four impact tests for each heat treatment. Bars heat treated moderate strength were an- nealed 1450 1500 deg. Fahr., then quenched and tempered develop 110,000 135,000 per sq. in. ultimate strength; then machined size. Tension bars were in. diameter; in. gage length, with threaded ends. Izod impact bars were mm. square, in. long. Each had two Mesnager notches (drilled hole, mm. in. diameter, with center mm. below the surface). When heat treated for 200,000 lb. over, the tempering temperatures were below 900 deg. Fahr. this instance the tension and impact bars were nor- malized and annealed, then rough-machined 0.035 in. oversize and the impact bars drilled, then all were heat treated and finally finish-ground. This method gives better indication the properties steels which are used for gears, springs and other parts similarly processed. Although comparisons rarely show superiority all properties, becomes immediately apparent from the diagrams that manganese steels, and especially those higher this added element, are more closely allied the other structural alloy steels than carbon steel. also interest that neither moderately high phosphorus (0.078 per cent) nor moderately high sulphur (0.103 per cent) adversely affect the strength and toughness. Overheating Not Especially Damaging result the efforts Hall and others, the association “brittleness” with steels manganese containing more than per cent has almost vanished. One additional item evidence may cited. Steels showing undue sensitiveness when quenched rapidly enough produce high hardness might expected show deterioration ductility impact resistance, crack when quenched after overheating. deter- mine this point, number tension and impact test bars were quenched from temperature 200 deg. Fahr. higher than that usually employed. Comparing these data with those the diagrams showed that the de- terioration elongation impact greater than the other alloy steels (in many cases both de- crease was noted). The losses cracking were greater for manganese steels quenched water than for the chrome-nickel steels quenched oil and far less than for the chrome steel quenched water. will noted from the graphs that Izod impact values the manganese steels the higher hardness ranges are below some the other alloy steels. Other and more complex heat treatments were tried without improving this result. Temper Brittleness Depends Method Manufacture Jones the research department, Woolwich Arsenal, England, Report No. “The Properties Medium-Carbon Steel with High-Manganese Con- tent” expresses the opinion that such steels have in- creased likelihood temper brittleness, very marked per cent manganese. The same author suggests method determining the degree susceptibility this defect. This test consists tempering the hard- ened specimens 10°0 deg. Fahr., cooling half them = a oY & vo a SS ct Ss eas tan ~ in 2 trey Mm WD LIMIT PER THOUSANDS PROPORTIONAL PER CENT ELONGATION REDUCTION OF AREA PER CENT OD IMPACT FT.-LB 17 ~ a S cP ~ ~ & The Iron Age, March 29, iV 40 20 S per min. 29. The Iron nese steels compare very favorably with other struc- tural alloy steels ductility and impact resistance, when heat treated heavy sections. Disadvantage respect elastic ratio appears grow rapidly with increase cross-section above in. Maximum hardness and depth penetration are not good for manganese steels for some the more expensive alloys. Machining Qualities manufacturer the high-sulphur se sitahi pitting ighe eel contends suitable for cutting speeds higher than heart} L ‘ rnoparliv ac high for open-hearth screw stock, and nearly high for Bessemer screw stock. determine this point, ests were made in the manner described and the author Transactions the American S ciety ior Steel reating, Ol. <, Page 17 O° > } + Results are shown the chart printed ntains data secured similar eel with rmal sulphur (0.023 per cent), car witn UV » per ent manganese, na a Stee steeis | it treated successively t tw r more 20 - shown the figure that, rough-turning, Ir steel eY i¢ttine th ant ‘ } ur steel wnen cutting tne per cent nicKe! > } | | , steel, T parison bdelng asea Oo! equal ensli In lik sanner th nr eng a ilxe manner the rougn-turning e! es Ur iower-manganese Steel and tne piain Cal I steel are com} and both produce more rapid nttine than do the first two steels men- ] tne cutting too! than ado tne nr CW veeis me Miscellaneous Properties generally recognized that pearlitic manganese steels are more resistant sea water and most natural steels. This has re sul ted j in the steel about 0.35 per cent and waters than are for cast steel anch manganese itor cast steel ancnor chain ~ vice because the com- bination resistance, high strength and ability sustain suddenly applied loads. White and Clark have commented upon the ability 1.5 per cent manganese steels reta their strength properties slightly elevated tempera- this has led their employment for bolts steam lines. Exact data are still — ah! 7 > ; hi acking enable one predict performance this service usually encountered carbon and many alloy steels, and degree comparable with that occurring properly poured ingots. higher-manganese made in th made the same plants, however, inverse segregation has been encountered, extremely pronounced one lot the high-sulphur product. Heavier sections cast steels containing 1.5 per ent manganese more may show segrega- tion and coarse dendritic formation. The latter are particula persistent, and present some magnitude the manufacture and treatment a@iivys hearing the sale the property the Hy- draulic Steel Co., Cleveland, will conducted Marc! the United States District Court that city Following the bid $1,000,000 for the plant the Truscon Steel Co., Youngstown, bid $1,525,000 was Lewis Levitt and Theodore Friedberg American Oil Burner Association, Inc., 350 Madison Avenue, New York, will hold its annual con- vention the Hotel Stevens, Chicago, April 3-5 =" > < +} . in the cnoser! juenching medium (water) and tne otnel half the desired slow rate (0.5 deg. These same pleces are then all reneated to the same tempering temperature, Dut which were cooiea t t Was t the author was hardened in was than anticipated. steels Iten s Ww tnes elrects, and, wnen tested Dy thé 4 + + + + 4 \ \ ~ \ \ » JO \ Ve A AAO \ \ > + hac renneay AYLON OPEEL ER Cutting That High-Sulphu Steel Less Damaging Rough- + } } Dire } nave been reported as high as 5U. But since tnese steels are eing pr luceaq continuousiy Witn ratios OT ie€ss than 1.5, methods manufacture can aa- temper-brittleness. possible that the brittleness the manganese studied Jones due manufacturing maladjustments Hardening Larger Sections Rolled forged rounds, in. diameter and in. were held heat min. and quenched water They were then reheated 900 deg. Fahr., held nd furnace-cooled Phvsical tests are summarizé i i Rockwell hardness shown. New York. Whirlwind Engine Parts Require Many Call for Expert Care Crankshaft FAY LEONE FAUROTE f ng and Facing Operations Crankcase Main Section RODUCTION the crankcase, pistons, piston sump section. These crankcase parts, like the cylinder pins, valves, valve springs, and crankshaft heads and pistons, are made the Wright company’s Wright Whirlwind J-5 series airplane engine calls foundry. The alloy, however, differs slightly, the com- for the same careful handling, testing and position being: Copper, per cent; nickel, per cent; that characterized the manufacture the cylinder and magnesium, 1.5 per cent; silicon, 1.5 per cent; iron, cylinder head the engine, described THE IRON 0.75 per cent, and aluminum, 84.25 per cent. AGE March page 590. The crankcase made five sections: Front section; intermediate section; main the complicated character these cast- Castings Made Foundry ings Necia ‘ore ic -equire ir) rrenari the m section; rear section; and the intake-manifold and oil- ings, special care required preparing the mold and placing the cores and chills. The sprues are very engineer. New York. and former editor series the Wright Whirlwind geneity the casting and prevent blowholes Crankcase Main Sec- tion, Left, the Larg- est Part the Engine. intricate casting and Crankcase Made Five Aluminum- Alloy Castings, Three Which, the Front, Main and Sections, Are Shown Below, Right and Lower Right Respectively for expert care pre- paring the mold and placing Cores and chills The Iron Age, March 29, 1928—867 } 4 giving the gas plenty chance get out. Air chisels and power bandsaw are used clean the castings afterward. They are also thoroughly sandblasted, given inspection and series tests determine their fitness. Since portion the interior the crankcase utilized intake header for the car- buretion system, these passages are carefully cleaned and tested applying air pressure lb. per sq. in. submerging the castings water and looking for in- dications bubbles. the case cylinder head the castings are next subjected specified heat treat- ment relieve internal strains and refine the grain. They are also submerged hydrochloric acid solu- tion for about min. order that cracks, seams other defects may readily spotted. Bullard vertical boring mill equipped with stand- ird tools used bore and face the ends the main tion. The bronze bearing ring then in- serted, and addition having shrink fit an- chored with pin. The bearing ring bored and the open end faced vertical boring machine. Next, the nine cylinder flange holes, which are equally spaced crankcase sec around the circumference, are bored and faced horizontal boring machine, the work being held indexing fixture. Combination facing and boring heads are used. Then the nine intake-pipe bosses are bored and faced and tapped. Other small holes are drilled ORING Piston Pin Holes Engine Lathe. During transit be- tween machining operations the pistons are kept individual containers 868—March 29, 1928, The Age ISTON Pins, Special Steel Tubing, Are Ground Centerless Grinders, Which Make Five Passes, Removing Less Stock Each Pass YRANKCASE Main and Intermediate Section Assembled Rods and Valve Tappets With Master and Articulated and tapped, with the exception the cylinder stud hole the nine cylinder pads. The eight holes each pad are drilled upright drill equipped with multiple drill head. After several more minor operations are performed the crank- case receives the usual final inspec- tion and then enamelled. The other parts the crankcase are treated similar way, and addition the usual turning and boring operations, they undergo number milling operations. The rear section has number oil passages it; therefore, has carefully machined and pressure- tested. The rocker boxes, nine exhaust and nine intake, are also cast the Wright company’s foundry from aluminum alloy, No. 30. This alloy contains from 8.5 per cent copper. These small parts are, course, very thin section and require great care machin- => ing prevent distortion. There are number drill- ing and milling operations high-speed sensitive drill presses. Multiple-cutting and continuous-milling methods are also employed later processes. Disk grinders finish the cover face. The parts are subjected the same enamelling and baking process larger parts. The rocker box covers are punched and formed complete from sheet aluminum punch press. The oil and the fuel pump parts, bearing retainers, and other small aluminum castings are also cast the company’s aluminum foundry. this depart- ment many the problems weight reduction have been solved. careful physical check and laboratory test determine molecular structure, combined with rigid inspection and exhaustive pressure tests, insure good quality all times; and uniform run good material free from the high percentage defects many times found such foundries. Pistons Seasoned Special Heat Treatment The pistons the Whirlwind engine are aluminum-alloy the following composition: Copper, per cent; nickel, per cent; magnesium, 1.5 per cent; iron, 0.75 per cent; silicon, 0.5 per cent, and aluminum, 91.25 per cent. the case the cylinder head they are seasoned special heat treatment; excess amount metal used insure clean interior. was informed that some difficulty had been experienced getting cutting tools which would operate satisfac- torily the pistons. After considerable research cutting steels, satisfactory method was found. Before the “Y” alloy was used, the wristpin holes were bored with boring bar carrying diamond cut- ting point. This gave good results. But the new metal this tool will not give smooth, true holes. Vari- ous high-speed and carbon steels were tried but with- out success. Finally, was found that chromium- plated tool gave the best results. have been informed that the company has been broaching the wristpin hole and this method has greatly increased their pro- duction. ordinary round broach fitted with detach- able chromium-plated burnishing buttons the end now used. machining the piston the excess metal first removed and the part subjected heat treatment refine the interior structure. Boring the skirt open end close dimension the second machine opera- Rocker Arm Housing, Valve Rock- Arm and Valve Operations Are Required Complete the Crankshaft. The balance weights are at- tached and turned lathe, exacting balance requirements being met tion, after which the piston held special chuck locating the inside diameter the piston. The skirt opening bored concentric with the inside diameter within 1/64 inch. The sequence operations then is: Drilling the wristpin hole drill press; turning the outside diameter; facing and centering the boss the head; and rough cutting the ring grooves, which done semi-automatic machine. The wristpin hole then redrilled and the outside diameters are finish turned, leaving enough stock for grinding. The ring grooves are finish turned and burnished rolling, after which the wristpin hole HE Piston Is Y-Metal. Wristpin holes are broached with ordinary tool ium-plated nishing the end rough bored horizontal machine. The pistons are then tested for leaks using hydraulic pres- sure. Following this the wristpin hole broached and the outside diameters are ground. After finish facing the head and removing the working boss the pistons are inspected and weighed carefully. Wright require- ments are met within close limits reboring the skirt- Kerosene used cutting lubricant for all finishing operations. The pistons are carefully kept individual containers between operations and during transit. Pins Quenched Vertical Position Prevent Warping Piston pins are special steel tubing bored and cut length automatic machines. They are heat treated, rebored semi-automatic machines and then hardened. After the heat treatment electrically-controlled gas furnaces the parts are quenched vertical position prevent warping. Finally they are submerged for min. per cent hydrochloric acid solution enable the inspectors spot unsound sections and defects. The pins are ground centerlesss five passes, each pass making smaller cut. The open ends are ground internal grinder receive the wristpin plug. Afterwards both ends are squared surface grinder. Finally they are lapped the outside diameter within limits 0.0002 in., production-lapping machine. Each pin individually wrapped waxed paper preparation for final as- sembly. The Wright valves are purchased outside specifi- ‘a The Iron Age, March 29, 1928—869 cations supplied the company and the product metallurgical tests the additional treatment undergone the ex- haust valves interesting. checked chemical and They are cleaned dip- ping gasoline and boiling caustic then immersed head down bath chemically pure potassium nitrate kept temperature from 700 900 deg. Fahr. until bubbling ceases. They are then raised above the liquid and diameter ejector rod, which has been preheated the temperature the bath, pushed down until strikes the bottom the hole the valve. The ejector rod then removed and the valves taken from the bath and permitted cool. The valve stem plugs are driven into the valve stem with arbor press. The whole assembly then washed and placed the furnace where heated 700 750 deg. Fahr. for After cooling they ire inspected for leaks, dipped into the per cent acid solution 180 deg. Fahr. and finally and inspected and placed assembly cartons. min. hydrocl washed Valve springs, also made outside specialists, re- ive careful inspection means electrical testing The intake valve guide made special bronze alloy bar stock automatic machine. The uide made from tungsten steel bar washers are made from bar stock machines and are ‘xhaust valve g stock. Valve hardened yanide process. The valve tappet guides are steel forgings; the tappets are turned from bar stock drilled and cut off complete automatic turret lathe. Slotting accomplished horizontal milling Loading and Unloading Pipe East Ohio Gas Co., Cleveland, rough the use magnet instead hook block for pipe handling with truck crane. greater unloading speed reported the Unloading, stacking, rehandling and loading pipe all handled this company means Uni- versal Crane Co. crane mounted 5-ton White truck. Formerly this crane was used with hook block and slings for such work, but recently this was changed the installation the crane 22-in. diameter, 230- volt pipe type magnet, resulting per cent sav- ing time. The photograph shows the truck crane unit loading pipe into trailers from stock piles. claimed that the following unloading speeds from railroad cars are averages for the crane and magnet unit: gat z= - 870—March 29, 1928, The Iron Age machine which cuts several parts one time. The ball socket and push-rod balls are special steel and are formed completely automatic machines. These parts are hardened cyanide process and tested for hard- ness Rockwell machine using diamond cone. The hardness range from minimum maximum. Next they are immersed nitric acid solution and examined for defects. Before hardening these parts, the ball ends are ground plain grinder using special ball grinding device. Crankshaft Requires Operations According the operation sheet operations are required finish the crankshaft. received forging special steel and test piece cut off and checked for physical characteristics. The shaft first rough machined all over, placed per cent hydro- acid bath for min., inspected for defects and then finally finished, machined and ground all over. During the progress the operations turning, milling, gun-drilling and grinding, two shafts are gen- erally worked upon the same time. Great care exercised the manufacture this part one the most important components the whole mecha- nism. Much depends upon its perfect balance and the balance weights which are attached and turned lathe are checked high-speed balancing machine until the exact balancing requirements have been satis- fied. The balance weights are made bronze and steel and are attached the shaft means special and screws. Magnet Truck Crane 65 to 2 in. pipe, 3 hr. per car in. pipe, hr. per car in. pipe, hr. per car 10 in. and over, l hr. per car Total savings were greater than represented just this unloading speed. After the magnet was attached there were two less men needed handling 4-in. pipe and four less men 18-in. pipe. An- other item savings was less spoilage pipe from ruining the threads warping. The magnet this unit excited generator mounted the rear the crane cab and driven the crane gasoline motor. This makes the entire outfit com- pletely contained and does not detract any way from the mobility the motor truck. With mobile unit this type the company has been able serve several yards scattered throughout the city. For emergency jobs the crane can sent full truck speed. TSING the Time Saved from Railroad Car 7 rs Testing Society Committees Confer Large Attendance Annual Group Meeting—Work Stainless Iron and Alloy Steel Castings Inaugurated —Advances Research and Specifications group meetings various committees the American Society for Testing Materials have now become virtually fixed policy the society. The seventh meeting this nature was held last week, March and 23, the Mayflower Hotel, Washington, and was one the most successful and best attended the series. Close 450 members and visitors registered for attendance the numerous gatherings over committees. Sessions main and subcommittees were held morning, afternoon and evening each day, the conferences being preliminary the annual convention Atlantic City, June 29. These group meetings were initiated the spring 1924 Pittsburgh. The second one met Wash- ington the fall the same year. the spring 1925 Philadelphia entertained the third meeting, while the fourth occurred Cleveland the fall that year. Annual meetings were inaugurated March, 1926, with gathering Providence, The 1927 sessions were held Philadelphia last March. The features most these group meetings have been described THE IRON AGE, and some those the sessions last week are here presented. Metal and allied committees which were active last week were the following: A-1 steel, A-2 wrought iron, A-3 cast iron, A-5 corrosion iron and steel, A-6 magnetic properties, magnetic analysis, B-3 corrosion non-ferrous metals and alloys, joint committee phosphorus and sulphur steel, and joint research committee the effect temperature the properties metals, well few other minor groups. There was also meeting the cast iron research committee the American Foun- drymen’s Association. Progress Steel Specifications Attendance the meeting committee A-1 stee! Friday afternoon, March 23, was not large pre vious occasions, and the session was brief. Minor revisions several standards and tenta tive specifications were favorably acted upon. note regarding the permissible overweight plates ordered thickness was approved for inclusion standard specifications for structural steel for bridges, nickel steel, structural for buildings, and struc- tural silicon steel. This note the same that which appears the American Railway Engineering Asso- ciation’s general specifications for steel railroad bridges. The specifications for locomotives and cars were re- vised the inclusion the same note embraced the four standards just mentioned. Specifications for Alloy Steel Castings The specifications for carbon steel castings for valves were revised the adoption several revisions agreed last year, but which were referred back the com- mittee the annual meeting result controversy over other revisions proposed that time. The ques- tions which were controversy have been temporarily dealt with another manner for settlement later. result replies questionnaires sent out users high-temperature and high-pressure equipment, the committee finds that there not sufficient demand, nor are the practices sufficiently standardized, warrant the preparation specifications for materials for use 1000 1200 deg. Fahr. The subcommittee steel castings, through one its subcommittees, engaged determining the limits physical requirements for alloy steel castings, which expected will lead specifications. Defi- nite requirements have not yet been fully agreed upon. Progress also being made the preparation two new specifications for alloy steel forgings, one for annealed and normalized forgings and the second for quenched and tempered forgings. Interest Cast Two important meetings were held the subject cast iron, one that committee A-3 the and the other the research committee the American Foundrymen’s Association. New Light Fatigue Cast Iron Attendance the meeting committee A-3 cast iron was quite large. Considerable interest was mani- fested the announcement paper fatigue tests for the program the annual meeting the society June, presented Kommers, associate pro- fessor mechanics, University Wisconsin, Madison, Wis.. This paper will cover results testing nine sets cast iron test bars received from varieus sections the country. The complete results ten- sion, transverse, impact and fatigue tests, well chemical analyses and casting conditions, will in- cluded. Under the auspices the committee there has been conducted during the last year elaborate series tests determine the relation between the properties specimens cut from iron castings and the proper- ties separately cast test bars from the same heat. These results, prepared Jesse Jones the West- inghouse Electric Mfg. Co., Pittsburgh, will in- cluded the committee’s annual report. There was considerable discussion the arbitration test bar and the tension test bar for cast iron, and progress was made toward advancing the specifications covering these further stage development. Research Gray Iron Under the chairmanship MacKenzie, chief chemist American Cast Iron Pipe Co., Birmingham, Ala., well attended meeting the research committee the American Foundrymen’s Association was held Thursday morning, March 22. Some the progress made members this committee studying the fluidity and viscosity gray iron was discussed. Work which contemplated studying the machinability and wear cast iron was gone into quite extensively. Plans are also under way investigate certain phases the shrinkage cast iron. Vew Work Magnetic Research the field magnetic studies two important com- mittees held meetings. session committee magnetic analysis, reports were received several investigations now under way, the present studies which will outlined the committee’s next annual report, while subsequent report more detailed summary will given. new investigation was an- nounced which will involve material other than that use the present investigations high-speed tool steel. the field magnetic properties committee A-6 its meeting organized new committee tests high magnetizing force, under the chairmanship Howard. The scope and proposed activities this committee were given very careful consideration. Last year the committee submitted extensive list The Iron Age, March 29, 1928—871 SRMASAASS ASAD 7 ' terms relating magnetic tests materials. T