The Iron Age 1928-07-19: Vol 122 Iss 3

ESTABLISHED 1855 New York, July 19, 1928 Interconnected Conveying System Materials-Handling Methods Marmon Motor Car Co. been the pioneering spirit which has given impetus the development new manufacturing methods and the creation what, for lack better term, has the automobile industry has tion. Especially the past few years has the intense competition among automo- bile makers accentuated the need for finding new ways and means lowering pro- duction costs and the time attaining the highest possible efficiency. result, new achieve- ments this direction con- stantly attract the atten- tion industry general. Introduction new mod- often calling for the rear- rangement production lines that the available space can utilized the best advantage. Such was the problem the Marmon Motor Car Co., Indianapo- lis, when decided put the market its new “68” straight-eight car, was confronted with the necessity revamping its plant No. for pose. adopting certain methods previously used successfully, and instal- ling complete system ment, the company has been able turn out completed automobiles tory cost. Following its policy adopted several years ago, *Resident editor Cincin- nati for IRON AGE. Producing Cars from Parts—Several Types Equipment Used BURNHAM FINNEY* Coming Off the Body Upfit Conveyor, the Body Mounted the Chassis Means Overhead Crane Operating Monorail plan, page 138). The lifting frame has special clamps hold the body eliminating stock rooms, the company has made provi- sion plant No. for delivery materials points where they are needed the assembly lines. Wide aisles afford opportunity for motor trucks drive into the factory and unload parts convenient locations, while spur tracks from the main line the Pennsylvania Railroad extend into the building its southeastern end. The floor the freight cars level with the con- erete floor the factory, that loading and unload- ing are facilitated. means this arrangement, automobile frames, for ex- ample, can brought into the plant freight cars, removed and stored near the beginning the frame assembly line. However, frames are delivered motor truck, the trucks can driven along point immediately ad- jacent the frame assem- bly line. Adhering the policy instituted the Marmon plant No. the company has placed stock bins plant No. that workmen get what they want without going central- ized stockroom. in- stanee, along the body upfit assembly line are storage bins containing materials for local use. Four divisions the plant are served mechan- ical conveying equipment: the frame assembly line, the body upfit line, the machine shop and the chassis main VOL. 122, No. 135 assembly line. Supplementing these automatic contin- uous enameling which shields and small parts are enameled. Consisting oven fenders, side motor-driven belt conveyor approxi- mately 160 ft. length, the frame assembly line has several interesting features. Frames stored near the beginning the line are placed immediately adjoining the conveyor pile six seven frames high. They are lifted the conveyor means special carrier suspended from hand crane. The four hooks which fit under the frame and hold firmly while being moved carrier has the conveyor, the frame being placed crosswise posi- tion. Under normal conditions the conveyor operates minute for 100 cars day. The frame goes through spray booth while upside down, receiving coat lacquer. speed in. right angle the frame assembly line the chassis main assembly line. When the chassis reaches the latter upside down, but put the proper position the main assembly line means automatic turnover device designed the company. The main assembly line comprises two parallel belt conveyors arranged that the wheels the car rest them. The conveyors move in. minute for production schedule 100 cars daily. The conveyors, the speed which may adjusted meet production demands, make possible the progress the chassis without moving the wheels the cars. Each chassis starting down this line reaches the end, 480 ft. distant, finished automobile [480 ft. in. min- ute 145 min., hr. min.]. After the chassis leaves the turnover, the motor and the battery are set into posi- tion. short distance farther along the line the body, coming off the body upfit conveyor, mounted the chas- sis means overhead crane operating monorail. The monorail forms rectangle the length which runs for ft. parallel and directly over the main assembly line. Suspended from the crane lifting frame with spe- cial clamps hold the body. The body upfit conveyor feeding the main assembly line approximately 150 ft. long and consists two roller chain conveyors, paralleling each other, ft. apart. Bodies are placed metal holding devices, moving along the line Crankcase Conveyor Line (Below) Dividing into Two Parts Reach Two Milling Machines for First Machin- ing Operations (See plan) 4 136—July 19, 1928, The Iron Age production schedule planned make 100 cars Since the acid fumes from the battery room would tend rust the metal parts placed close proximity, that room located considerable distance from the main assem- bly line. Batteries move from this point the far side the assembly line, where they are installed the chassis means gravity roller conveyor. From the point where the body mounted the chas- sis, the car progresses steadily the final inspection pit, where leaves the conveyor. route the fenders, hood, rims, lamps, hub caps and step plates are added and the four-wheel brakes are adjusted. After the car has been thoroughly inspected, driven its own power from the pit, the left wheels passing over “trip” the track, which automatically lowers and raises screen for the purpose focusing the head lights. the machine shop, where the parts making the motor are machined, and where the motor assembled and tested ready for installation the chassis moves along the main assembly line, practically all materials are han- dled mechanically. Crankcases are delivered the (out- side) maker storage yard just outside the machine shop and adjoining the normalizing ovens. All-metal trucks are loaded with crankcases, are moved into the ovens, remain for stated period, and then are pushed into the machine shop. Here they are unloaded near the shot blast booth, where the crankcases are cleaned preparatory starting their journey down the crankcase line. From the shot blast booth the crankcases are carried roller conveyor through all the machining operations En- gine (Above) Leav- ing the Assembly Line (the Parallel Bars Right Fore- ground) for Block Test (See plan). Numerous test stands appear the background. The motor moves the block test means over- head monorail con- veyor with special carrier attached the motor assembly line. After leaving the shot blast booth, they pass through small spray booth, where they are given sealing coat the inside the case. few feet farther along the line the conveyor track divides into two parts, that the can pass under two Inger- soll milling machines for the first machining operation. The division the track this point permits two time, delay the movement mate- rial down the conveyor line being thus avoided. After the crankcases have been milled, the two tracks are merged again into one for continued progress along the line. For some machining operations necessary remove the crankcases from the conveyor means overhead hoist, place them the proper position machined, The conveyor line paralleled other lines along which parts going into the motor are trans- chee ported. For instance, bearing caps, connecting rods, fly- wheels and pistons have separate roller conveyors along which they progress point where the connecting rods and pistons are assembled. right angle the crankcase line the motor assem- bly conveyor line. Approximately 175 ft. length, this line consists iron framework supporting two parallel iron bars located convenient working height. Small special holders, which are attached each the four cor- ners the motor, rest and slide the bars, thus permit- ting the motor suspended between the bars. this position the motor can easily moved hand down the assembly line. When the motor starts its journey down the line upside down; righted the proper place turnover fixture devised the company. Reaching the end the assembly line, the motor lifted Depressed Track (Above) Showing Ma- terial Being Unloaded Frame Assem- Floor freight car level with floor build- ing. (See plan) » Chassis Assembly Line Look- ing Toward the Spray Booth plan). Frame con- veyor operates speed in. minute for produc- tion schedule 100 cars day. Frames (upside down) are lifted the conveyor means special carrier suspended from hand crane special carrier depending from overhead monorail and moved the motor block test. This part the shop served extensive monorail system installed the Louden Machinery Co., Fairfield, Iowa. After the block test has been completed, the motor taken monorail the main assembly line, where lowered into position the chassis. Fenders, running boards, side shields and small parts are run through burn-off oven near the mechanical enam- eling oven, where they are thoroughly cleaned burning. They are removed stands and sanded and then delivered small dust-proof room, where they are dipped primer coat. conveyor carries them along, draining they go, through continuous oven, where the priming coat baked on. the end the oven the operation re- peated with coat enamel, after which the parts are The Iron Age, July 19, Assembling the Marmon Car Plant No. anda — Whee/ er ~ 3 Cutter ‘ AYOUT the Assembling Portion the Marmon Plant, Showing Flow Materials and Parts from Points Receipt into the Finished Car, Ready Drive Away Under Its Own Power. Letters refer photographs showing how the various items are handled. will noted that the engine assembled left and the chassis upper right. The body strikes across the center and all come together the main line running from top bottom drawing 138—July 19, 1928. The Iron Age a — Automatic ‘ { = or e Oven > > | = Here | / Nn Q | { } Q } \ \\ \ \ \ \ \ ( FANIKCa > - Delivering Shipping a Be Beginning Car Assembly Line, Showing the Chassis Turnover Fixture plan) the Left Foreground and the Flat Traveling Conveyors Which Make Possible for the Chassis Moved Along the Assembly Line With- out Moving the Wheels inspected and delivered the assembly line. After once being put the conveyor, the parts are untouched workmen until they are completely enameled and ready for use. The continuous enameling conveyor 195 ft. long and travels speed in. minute for production sched- ule 100 cars day. addition the various handling arrangements already described, the company uses electric lift trucks rather ex- tensively for moving stock about the plant. For example, lift platforms are taken electric trucks the doors freight cars which are unloaded. Here workmen remove the material from the cars hand and place the platforms. When the platforms are loaded capacity, they are carried electric truck the points the assem- bly lines where the material needed. The roller conveying system the machine shop was Bodies Con- veyor plan), Where Their Fit- ting Completed Before They Are Mounted Chas- sis. The body up- fit conveyor con- sists two roller paralleling each other, ft. apart. Bodies move along this line minute for pro- schedule 100 cars daily manufactured and installed the Mathews Conveyor Co., Ellwood City, Pa. However, much the mechanical han- dling equipment, especially along the assembly lines, was designed and installed the Marmon company. Study the plan the opposite page shows how well the entire series assembling operations has been dove- tailed into completed whole. One entire section—the left side drawing, and nearly half the total area—has been set aside for putting the engine together, and testing assembled unit. then passes the main assembly line almost the center the picture. Meantime two other operations, under way simultane- ously with the first, have prepared the chassis receive the engine and the body placed upon the chassis. both cases the movement from the right the plan toward the left, the chassis progressing along the top and the body } j 3 The Iron Age, July 19, 1928—139 —— squarely across the middle. Speeds conveyors are worked out synchronize the various movements such effect that there will waiting any point along the line. End Car Assembly Line Just Beyond the Inspec- tion Pit, Showing Ex- treme Left the “Trip” the Track, Which Op- erates Counter Device and Focuses the Screen for Headlights (See plan). This screen ap- pears right illustra- tion. From this point the car driven under its own power dock These speeds are task-setters for the men, whose motions fit with those the mechanical appliances forming completed car within appointed time. What Standards Industry Mean; Some Limitations May number the Annals the American Academy Political and Social Science given completely the subject standardization industry and what means manufacturer, distributer and consumer. There are articles, each from expert some particular line the work, and divided into four groups. Part covers standardization programs industry; part II, standardiza- tion programs specific industries; part III, standardiza- tion programs outside industry; part IV, standardization and the consumer. The latter includes the steps which are being taken the Government protect the consumer through certification standard specifications. foreword, Richard Lansburgh, professor indus- try the University Pennsylvania, says, among other things: “That the development standardization indus- try has been one the most significant phases the new industrial management has come known even those who have but passing knowledge modern industrial conditions. That there are limitations the extent standardization fully realized all who have been asso- ciated the work, and those articles which dwell this phase should serve ready reference check enthu- siams which carry good cause extremes.” One feature brought out discussion simplification and standardization Europe concerns British standardiza- tion. considerable sum money has been appropriated have existing British standards translated into foreign languages. This has for its object the possibility use these standards foreign purchasers, thus increasing the market for British goods. One the limitations standardization pointed out Condit, editor American Machinist. relates the 140—July 19, 1928, The Iron Age early development stages the automobile, years ago. “Most the designs were experimental and were subject radical changes each year, and sometimes oftener. Any effort standardize then would have resulted either fail- ure retarding development quite bad.” Later Mr. Condit says, regarding international stand- ardization: “Size standardization almost impossible be- cause variations measuring units. The great bulk the [world’s] manufacturing done Great Britain and the United States, English units, while the minor part done many other countries, metric units. little progress [toward standardization between the units] has been made with ball bearings and screw threads.” This standard size between measuring units brought out differently another article devoted filing equipment. Filing cards are now standardized inches: the early development this phase industrial control. Today the only metric cards use, with few exceptions, the United States are found libraries insti- tutions. This question filing equipment goes rather deeply into standards for steel filing cabinets and drawers. Standards are laid down for the various panels and dividing elements, both gage steel and grade sheets. sam- ple specification given, with considerable discussion reasons for the adoption each item. Cross indexing the rear this 282-page volume occu- pies less than pages. This should great value anyone consulting the volume, which primarily one reference, aA 4. Wear Testing Various Metals Steels and Bronzes Covered Methods Detailed Research Men Efforts Make Laboratory Simulate Service annual meeting the American Society for Testing Materials Atlantic City the last week June dealt with tests metals other materials, determine their resistance wear. Both steels and non-ferrous metals were included the four papers, hich abstracts appear below. papers presented before the thirty-first Wear Testing Various Types Steels this paper, which was presented Blake, engineer tests American Manganese Steel Co., Chicago Heights, apparatus was described which has been developed test the resistance metals abrasion under so-called wet grinding conditions. principle, the machine accurately controlled grinding machine which all conditions abrasive, pressure, speed, time and moisture other liquid content are under the opera- tor’s control. possible approximate any given set practical requirements. The wear measured the amount metal worn off approximately 15,000 ft. travel square inch used testing face approximately sq. in. The wear thus determined expressed the ratio wear loss compared with standard (commercially pure iron) 100. varying the abrasive used has been possible develop alloys specifically par- ticular field requirements. How the Abrasive Held Its Work Pressure between specimen and abrading service can adjusted from approximately 500 the square inch. The pressure can set read without stopping the machine. The specimen engages the abrasive coated copper surface angle about deg. This acute forward angle serves funnel the powdered abrasive between the gliding surfaces. The abrasive deeply indented into the soft copper ring which serves the bond for holding and forcing the particles abrasive across the surface the specimen. the equipment described, which has ring ft. diameter, over the periphery which the specimen run, the standard test 1200 revolutions. This gives ap- proximately 15,000 ft. travel, above. The amount metal worn off during such test may vary from gm. for some exceptionally hard steels 150 gm. more for alloys with high abrasion factor. This Fahrenwald abrasion factor against sand, for several well known materials together with several new very hard alloys, follows: Standard specimen (commercially pure iron).. 100 Merchant bar iron, Stellite (welded wearing Amsco alloy No. 459 (welded wearing face)... Amsco alloy No. 459 (as Wearing Qualities Tire Chains study the wear-resisting properties steel for auto- motive tire chains wear test developed was described paper Parker, research engineer American Chain Co., Bridgeport, Conn. Specimens may al- most any shape, including chain links already formed. They are held constant pressure against rotating alundum grinding wheel which the surface kept con- tinually dressed. Automatic record obtained the number revolutions required produce given depth wear. the service which tire chains are subjected in- volves the relation between impact and wear resistance, somewhat theoretical discussion given this relation applied the links tire cross chain. Some results wear tests were reported. Comparison with service tests indicates that the laboratory test rates various ma- terials practically the same order road tests, while giving much greater distinction between them. The laboratory test furnishes relatively quick means for comparing different materials and different heat treat- ments. Relating Laboratory Tests Road Tests Making comparison between machine test and service wear test which the different materials were treated alike each case, one material showed loss weight per cent service and 14.4 per cent the machine. second material showed losses 7.7 per cent and 19.6 per cent service and machine. third mate- rial showed 8.4 per cent and per cent; fourth, 8.6 per cent and 23.7 per cent; fifth, 9.1 per cent and per cent. Only the cases the third and fourth was the order resistance varied between the two kinds tests. the relatively ideal conditions under which labo- ratory determinations are made not obtain service, somewhat difficult check the results the one with the other. For some materials certain other factors may have influence upon the life the cross chain, such liability failure under repeated impact tendency certain sections the link develop cracks under heat treatment. general, however, has been found that the correlated results the laboratory tests give reliable index the service qualities cross chains. Wearing Tests Manganese Steel EVELOPMENT test for the wearing properties per cent manganese steel was described paper John Howe Hall, metallurgical engineer Taylor- Wharton Iron Steel Co., High Bridge, was endeavored find test which would give results com- parable with service experience. crude methods were abandoned after trial, usually because they were too slow too clumsy did not give true indica- tion the wearing properties. Finally was concluded adopt the method crush- ing known amounts hard stone small laboratory stone crusher, which the jaws were made the steels The Iron Age, July 19, | 7 7 | | | | 4 3 7 3 ea q tested. tained The loss weight the jaws was ascer- regular intervals. More recently wear tests have been made the Ansler and the Brinell abrasion machines. But was found that these machines not simulate the particular kind wear which manganese steel successfully withstands service: that is, abrasion associated with severe cold working, such obtains with the pressure exerted the crushing hard material. Hence the tests went back the tedious but reliable jaw crusher. the paper details are given tests such crusher manganese steel, plain carbon steel, nickel steel, chromium steel and nickel-chrome steel. was found that manganese outwore carbon steel about Chromium decreased the wear the pearlitic steels very little, all, but nickel decreased that wear marked extent. Considerable Work Needed for Dependable Results Two types crushers were used, one with fixed jaws and the other with moving jaws. They did not give exact- the same line-up materials, far resistance wear was concerned, but both showed the per cent man- ganese steel far superior any the others tested. was found that when the jaws were first put work the wear was much more rapid than later period. This attributed all the specimens surface de- carburization the steel. the case the manganese steel, and perhaps some the others, attributed also the fact that the surface later becomes work- hardened the pressure the stone being crushed, and then gives greater resistance. For this reason test considered any value whatever which only few hundred pounds stone are crushed. can easily happen that steel which would give excellent results extended tests wears rapid- first account decarburized skin. Another and the surface, might first appear better than the good steel whose surface was decarburized. has been the practice these tests weigh the jaws after each 4000 lb. stone crushed. The loss weight grams recorded and the loss grams per square inch jaw surface each 1000 lb. stone crushed. high degree accuracy claimed for the results, but they are regarded reliable indication. Tests Railroad Bearing Bronzes tests copper-tin-lead alloys, both chill- cast and sand-cast, were reported paper French, senior metallurgist United States Bureau Standards, Washington. These tests were made for wear and the alloys were tested under friction without lubrica- tion temperatures from 300 deg. Fahr., under friction with lubricant deg. and under tension with single-blow impact and repeated pounding tem- peratures from 600 deg. Generally speaking, chill-cast bronzes were ant wear and notched-bar impact than sand-cast bronzes. They were, however, more resistant pounding and tension. Increase the proportion lead, particularly the range between and per cent, improved the wearing properties but lowered the resistance pounding, impact and tension. Increase the tin component was found improve all these properties. Increase the temperature which the test was run generally decreased resistance tension, impact, pounding and wear. The changes from this cause were most marked between 350 and 600 deg. High-Lead Bronzes Without practical applications there are decided advantages the high-lead bronzes for service where lubrication can- Lubrication 142—July 19, 1928, The Iron Age not maintained. These bronzes containing about per cent lead did not wear rapidly the low- lead bronzes, nor assume rough surface, tests with- out lubricant. wear the chief factor considered, and approximately constant ratio maintained between copper and tin, variations lead within the range per cent seem unimportant. Where important also have high resistance pounding and high static strength both atmospheric and elevated temperatures, lead may advantageously kept near the low limit the range mentioned. Its strength and toughness notched tests decrease the proportion lead increases. These differences, however, are relatively small, and for many purposes bronzes with changeable. When mechanical properties become primary im- portance, and lubrication can maintained that wear secondary importance, there are advantages low lead and high tin. Both these features favor high strength and resistance pounding. Tests Indicative, When Not Fully Conclusive one selected laboratory test yielded information adequate itself for general comparisons. Each test, however, contributed valuable information developing the characteristics the different bronzes. alloys, with practically constant ratio copper lead, in- crease tin from 0.7 about per cent resulted marked improvement wearing properties tests with- out lubricant. Further increase the tin, however, per cent did not materially modify the wearing prop- erties, but resulted improved tensile strength and re- sistance pounding. has been shown that reproducible wear tests can obtained the laboratory. When combined with suitable mechanical tests, the results give comparisons consistent with practical experience. Accuracy Analysis for Oxygen and Hydrogen Steel recent years much work has been done both here and abroad the accurate determination gas metal. order compare the methods used different steel-pro- ducing countries, the United States Bureau Standards prepared uniform sample ingot iron, and distributed portions various investigators. The iron contained 0.04 carbon, 0.03 manganese, 0.02 sulphur and 0.006 silicon. Anal- ysis for gases gave the following results: Cent————_y Hydrogen United States Bureau of Standards..... 0.058 0.0006 Institut fiir 0.059 0.0008 The first two laboratories use vacuum fusion method, melting graphite crucible contained high frequency furnace. The American method weighs the evolved gases, while the German method measures their volume. Hydro- gen reduction solid sample (to which added anti- mony-tin alloy) used Sheffield. may concluded that the three methods are the same order accuracy, and give comparable results when carefully performed skilled analysts. Industrial Standards No. 206 and 212 the Bureau Foreign and Domestic Commerce have been prepared Portuguese text, and are sale the Superintendent Documents, Washington, for 5c. each. These are respec- tively translations American Society for Testing Mate- rials standard specifications for carbon steel locomotive forgings, and for carbon steel and alloy steel forgings for general purposes. — ‘ Building Industrial Stock Values Prices Which the Return Only That Good Bond Need Insures Continued Success STERLING BUNNELL* the present time, the common stocks large, well-managed industrials reach prices such that the rate return the investment more than bond interest, commonly said that the prices these stocks are too high. This may so, the sense that when such belief generally held, slackening demand easily possible, and prices consequently may fall. The feeling general among old and experienced investors, who gained their knowledge owning and trad- Government and public utility securities, that industrial stocks are peculiarly hazardous investments, and that com- mon stocks particular should bought only specu- lators and then only basis large dividend return. Stocks and Bonds Hang Together reasoning based the idea that bonds and such preferred stocks are secured fixed assets can some- how considered safe any event against interruption interest and loss principal value, that the rate in- come paid, though low, permanently assured. Bonds are frequently backed mortgages real estate, and the reg- ular payment interest the first charge against earn- ings. But important remember that, when busi- ness ceases earn profit, the payment interest must necessarily suspended, and that not easy liquidate the shrinking assets unprofitable concern protect the bondholders’ principal. such event, stock- holders and bondholders alike lose their income, and the latter are only degree less likely than the former find their principal also lacking. Only the case indispensable industries, like main- line railroads, generally possible for bondholders exert their rights foreclosure without fatal consequences wiping out much the value the property. Indus- trials are combinations plant, inventory and operating organization which can survive only kept complete and working order. The owners class securities guar- combination hold Shylock’s bond, which collected would destroy the whole organization. Wise and upright judges have often intervened prevent foreclosures likely *Consulting engineer, New York. little advantage the bondholder and disastrous the other interests concerned. Every Form Security Should Yield Good Return successful operation the corporation, that liberal percentage profit earned the entire invested capital, the only real assurance security for the bonds, well for the stock. the business earns just enough for bond interest and more, the bonds cannot given high rating. earnings just cover bond interest and stock dividends, neither bonds nor stock have assured future; for well-equipped, successful industrials frequently are “depleting assets,” just like mines, and pro- ductive efficiency and marketing methods are allowed deteriorate with time, until only idle factory adapted for making unwanted product left liquidated its scrap value. Depreciation tends decrease the productive efficiency plant and equipment, and obsolescence may even destroy the value organization, product and business well. industrials are not have, like mines, limited term useful existence, their life and energy must continu- ally renewed methods progressive development. Well- managed industrials ought not therefore expected pay out substantially the whole their earnings, granting their common stocks dividend rates two three times the rate income customarily paid bonds. Right Handling Surplus ROM the policy paying moderate regular dividend the common stock and reserving considerable part the total net profit undistributed there results account- ing surplus which, properly employed, will provide tive security for stocks and bonds alike. The scope and degree security afforded depends, however, the way which the accumulated surplus utilized; for surplus profits are not usually held the form cash cash equivalents. This surplus may invested increases the stock materials hand work progress, which may signify either its useful employment increased busi- ness earn additional profit, its useless locking idle excess goods which better management would able BUNNELL elaborates idea that has had more and more attention financial circles, and one that giving new investment standing common stocks industrial companies. points out that well-equipped industrials may “depleting assets,” mines are and cites with approval examples the policy treating common stocks like preferred, maintaining moderate regular dividends with the highest assurance being able continue them because the wise use surplus profits development itt 4 The Iron Age, July 19, 1928—143 ~ move and turn into cash. Again, surplus may invested additions plant and equipment, capable (or incapable) earning profit proportion the investment. money cannot “tagged” locate the particular destination each particular dollar, the accumulated surplus past undivided profits, however invested the business, may considered just as, and more, efficiently used earning profits the rest the invested funds. investing the intangible asset industrial devel- opment work, surplus may even more effective pro- moting the continuance can permanently successful only through unceasing process growth. steady earnings. Better methods and results, the discov- ery adaptation new products, and most all, ever- increasing effectiveness personnel, are required cope with new conditions and when they occur. Every func- tion industrial engineering required the constant endeavor maintain and improve the operating efficiency the large industrials. Research and invention are con- stantly employed anticipate future marketing require- ments and prepare supply them. Selecting, training, retaining, insuring and satisfactorily paying the workers, superintendents and managing heads the plants involve the maintenance personnel department organization liberal scale expenditure. All this development work looks toward insuring future success, and properly provided for appropriations from the undivided surplus profit previous years; but treated element present cost, the net amount for dividends would remain the same. Function Depreciation Reserves EPRECIATION reserves also, set aside factory ac- included cost accounting figures, can and should util- ized strengthen the future position the securities. the depreciation charges not represent actual expenditure, depreciation reserves, like surplus, usually offset invest- ments operating assets inventory accounts receiv- able, additions plant equipment which are not regarded replacements mere betterments. modern, progres- sive industrials, plant and equipment are constantly being improved, that the depreciation that which use continually balanced the addition entirely new equipment. following this practice, these industrials always have plants date that new money could not possibly construct more efficient ones. would, course, possible treat industrial depleting asset, and invest the depreciation reserve securities form sinking fund reimburse the owners the plant and wind the business fixed date. But self-extinc- tion not the contemplated purpose industrials gener- ally. There need fixed span corporation existence, life and activity are constantly renewed intelligent use portion the earnings development. The Right Building Security Values the last twenty years great corporation, which started with hugely watered stock, has steadily built its effec- tive investment until its securities represent value far above par, although the rate return the market value little more than current interest. Its plants, with respect productive efficiency, are equal the best. Another corporation, with output once classified luxury, with few thousand possible purchasers wealthy small fraction the population, has constantly developed product and methods construction until the wildest assumptions former enthusiasts have been sur- passed the cold facts its operations. Another, holding fast the rarely adopted principle one unchanged design through many years, was all the time preparing unadver- tised development and the accumulation huge reserves that when the market for the standard design should be- come surfeited, complete new design should ready for 144—July 19, 1928, The Iron Age prompt production. This was done the proper moment without the slightest disturbance the financial security the corporation, and production and distribution the new product proceeded the previous enormous schedule. Many other American industrials might also cited examples the success the policy treating common stocks like preferred securities, maintaining moderate regular dividends with the highest assurance continued ability pay them, because the wise use surplus profits development. Surplus held reserve investment current assets income-paying securities available for maintaining dividends periods earnings below average; and when such reserve provided for this purpose, common stock may expected pay income quite steady pre- ferred stock bonds. But reserve cannot inex- haustible, the important thing maintain average rate income sufficient for progressive renewal the life and usefulness the industrial, addition reasonable rate return the invested capital used the business. Stock Values and Purchasing Power Money should remembered that great changes the pur- chasing power money have taken place over long period years, and the average the movement has gone long way the direction reducing the value the money unit. Owners bonds and debentures have found that principal and fixed income alike have become less valuable purchasing power, while standards living have increased the demands personal income. The owner common stock possesses fractional share the value the business, while the owner bonds debentures possesses only the equivalent certain number dol- lars. The holder common shares may reasonably expect that the prices the securities will rise affected general decrease the purchasing power money, and may well prefer that accumulated surplus used develop further earning power, rather than held fund interest and nothing else. The policy forward development, adopted large proportion our industrials, has resulted large increases the market values their shares. The common stocks corporations managed, paying steady, low rates dividends from comparatively large surplus earnings, some- times become known “rich men’s stocks,” because they are bought and held the wise and far-seeing investors who are generally found the wealthy class, wherever they may have started the process accumulation their savings. these men, the steady increase principal value preferable the receipt high dividends which are uncertain continuation, the event any severe disturbance the accustomed routine the business the corporation. Stock prices the basis returns little greater than for good bonds are not necessarily too high; certainly they are not regarded the shares represent partici- pation the assets corporations which are managed intelligently that permanently successful operation virtually certain. Notes Molding Sand Bulletin 266 the Bureau Mines (“Tech- nology and Uses Silica and Sand,” Weigel), includes brief account the properties molding sand, list its principal sources, and description the quar- rying, grading and washing methods used. Numerous foot- notes referring special writings different phases the subject are.included. Other varieties quartz used the metal industries for furnace fettling, flux, grinding and polishing are given similar treatment. The bulletin may secured from the Superintendent Documents, Washing- ton, for | | | Multiple Spot Welder for Making Fireproof Doors CORRUGATED reinforcing cover sheet number places. This machine has pairs weld- ing electrodes and nine transform- ers, ensure adequate current weld each spot. Sheets are gripped feed rollers and driven forward steps Geneva drive; each halt the electrodes are lowered cam motion, current switched on, and row spots welded simul- taneously. second set driven rollers discharges work. Capacity, operations per minute, each making welds, 1088 welds per minute. (Agnew Electric Welder Co., Mil- ford, Mich.) Welder for Side Seams Steel Barrels ENT sheets, No. gage and in. long, are placed the lower horn and held down magnetic clamps. traveling roller die then moves over the seam ft. per min. Uniform current, notwithstanding the variable location the roller die, secured automat- ically patented secondary lead con- struction and auxiliary choke. Heat varied conform different thick- nesses metal and surface condi- tions five transformer taps, change roller speed (driven rack and speed drive), and change tension the pressure spring. Lower weld- ing die %-in. hard drawn copper bar, which can filed and adjusted without removal. Roller die can removed for dressing loosening six cap screws. Dressing necessary once day, after 3000 ft. welds. (Thomson Electric Welding Co., Lynn, Mass.) * Machine for Making Railroad Ties Out Scrap Rails plates are adjusted exact position jig and pneumatic clamp, and angle bars are held ends with spring toggle clamps. En- tire jig rotated deg. forward, and the far edges the tie plates are welded the rail tops the two au- tomatic heads; they are then rotated backward and the near edges are welded. The angle bars are welded hand-operated arc. Capacity, one tie every min., using two workmen, 1500-amp. motor-generator set with four welding circuits, and approach and delivery conveyors. (General Electric Co., Schenectady, Y.) * The Iron Age, July 19, 1928—145 Passes for Hot-Metal Rolling Calculations for Reduction Height and Area, Combined with Increase Width, Section Produced SLATTENGREN* the purpose hot rolling, generally, reduce the cross-sectional area the ingot billet, and also most cases the same time break the crystalline structure the ingot billet and refine the grain—in other words, “to make the metal.” This can accom- plished means various forms passes, the choice depending upon how fast the metal can worked. This consideration includes the size the ingot billet and the characteristics the particular metal, and also upon what shape product desired. shall here discuss mainly the shapes and sizes the various grooves which make the passes used hot roll- ing, and what relation they bear each other. The ratio reduction height, and resulting reduction area, certain measure the efficiency pass, and this shall use. Material, size and speed the rolls have certain and definite influences upon the behavior the metal the various forms passes, and must taken into considera- _tion for accurate results. The larger roll forms the metal more gradually and with less shock, other things being equal, but tends increase the spread (sideways), while increase speed increases the stretch (forward), which However, the above effects are generally small enough within the limits the adjustment provided the space between the rolls, which should always made small possible, consistent with the economical life the pass. This life depends upon the amount metal that can passed through before the grooves are worn much that the rolls touch “ride,” and cause the product be- come oversize for subsequent passes. course, the temperature the ingot billet gen- *erally determines the softness the metal, and this the main point consideration designing grooves. The com- parative plasticity the metals the rolling tempera- tures, and not their hardness other physical properties when cold, determines the relative sizes the passes. For instance, high-cobalt magnet steel 2100 deg. Fahr. may just soft pure iron 1000 deg. Fahr., and would accordingly behave similarly identical passes Shapes Grooves Rectangle into Rectangle—Plain Rolls 1-in. square some metal the right rolling tem- perature passed between plain rolls set give re- duction height per cent, the height the produced rectangle with rounded ends will 0.5 in. The displaced area will be, course, the same; some this will spread sideways and some will stretch forward and disappear from the cross-sectional this disappearance area will equal the difference between the area the original square and that the product, can more less readily determined experiment, about which more later. The percentage reduction area found from the area which stretches forward, divided the original area. *315 Herrick Road, Riverside, Ill, 146—July 19, 1928, The Age Let equal the ratio reduction height; Ra, the ratio reduction area; Wo, the width the original; and Wp, the width the product. Then the general formu- las for rectangle into rectangle, through plain rolls, are: can readily seen that increases with and Rh, but course decreases increases. Similarly, increases with and Rh, but decreases increases. per cent and that equal in. Then, substituting equation (1), have: get: 2.4 1—0.8 0.2 per cent This holds good very closely for any rectangle through plain rolls, after making small allowance for the convex sides the product, which comparatively easy mat- ter do. Square Into Oval (Ellipse) Pass 1-in. square into oval pass 0.5 in. high, which makes equal per cent. The displaced area this case will somewhat more than 0.5 square inch. Because the shape ellipse, the stretch will more than for plain rolls, the other factors are equal. well note that the oval groove always cut into the roll with round tool which makes its outline are circle, but negligible for our purpose. The area ellipse equal 3.1416 times the product its half-axes. again let equal the width the oval, the other symbols remaining the same, get: (1—Ra) Wp- 0.7854 (3) and Oval into Square Diamond (Rhombus), with Major Axis Oval Coinciding with Diagonal Square Diamond ta 1— 1.5708 Wo (6) Side square equals 0.70711 Wp; and the area dia- mond rhombus equals one-half the product its di- agonals. Square into Diamond—Side Square Parallel Diagonal Diamond (1—Ra) (1—Rh) (8) — | | Diamond into Diamond—Diagonals Coinciding (1—Ra) (1—Rh) (10) Oval into Round (1—Ra) 0.7854 (1—Rh) 0.7854 above Essential Information HEN designing pass first all necessary decide upon the amount desired. This gov- erned (1) the strength the rolls; (2) the gripping angle, which usually about deg. from the vertical axis the roll; and also (3) the amount reduction which particular metal will endure without damage. Metal the ingot form generally requires careful and easy roll- ing until its structure sufficiently refined for the higher reductions. After this, reductions height per cent may used with safety. the interest efficiency and economy, course, “hit the work” just hard will stand, because, shown above equations, always increases with other things are equal. may decide use the same throughout. But desire keep the ratio width thickness the oval more less uniform, will necessary decrease the billet gets smaller and cooler—in other words, when the spread sideways increases. seems invariable rule that the harder the metal is, time rolling, the more spreads sideways, and vice-versa. For convenience illustrating, let assume per cent throughout. Theoretically, does not vary with the size billet under the same and shape pass. But does practice, due differences rate cooling and the fact that the size rolls not changed propor- tionately. Determining and proceed, get sample lengths the metal rolled the following sizes squares: 0.25 in., 0.5 in., in., in., in., in. and many more required, depending upon the sizes rolled. These are passed per cent (as decided upon above) between plain rolls material, size and speed corresponding what the actual rolling conditions will be. From the round-ended rectangles produced, easy compute the amount for the different sizes. They may plotted suitable cross-section paper, that the for intermediate sizes may found from the curve. This done, may computed also for any size rectan- gle into rectangle, and curve again plotted for convenience, desired, which may checked scaling the width the rectangles rolled above. know now the and for any size, within the range, rectangle into rectangle for the metal ques- tion. Let compare the equations from above: (1—Ra) Rectangle into Rectangle. (1—Ra) Square into Oval. Wp= (1—Rh) and Ra = 1 — Oval into Square Diamond. 1.5708 (1—Ra) 2Wo (8) Square into Diamond (10) Diamond into Diamond. 1—Ra) 1—Rh) Oval into Round. Taking equation (1) basis for comparisons, seen that the for equation (3) 1.273 times the size for equation (1). Similarly, (5) 1.5708 times the (1); the (7) twice that (1). The both (9) and (11) are the same (1). The above true only when Rh, and are the same all cases, unlikely condition, the com- parison cited only for general information. However, with the possible draw consid- erably more definite relation between the different shapes passes. For instance, plain that the equation (4) larger than (2) for the same and Wo. How- ever, the numerical relation not simple arrive at. For instance, divide (4) (2), get: 0.2146 (1—Wp) (1—0.7854) (1—Wp) This for our practical purpose does not mean much. But possible arrive comparative value means direct example, follows: Let equal per cent, equal and equal 1.5 equation (2). Substituting, get: 0.25 per cent. For the same values equation (4): —0.5) 1.5 0.7854 0.589 0.411 41.1 per cent. both interesting and instructive draw compari- sons between and for the different equations. But when try arrive direct relation, tind them cumbersome that they have little practical value roll pass designers. Several attempts have been made make graphical comparisons and evolve formulas, and with some success. The following equation which sup- posed apply only steel, but will hold good for any metal with the same softness and characteristics the rolling temperature. European origin, believe: where equals the width the oval; equals the side square and equals the height the oval, which must assumed according the amount reduction desired. formula not necessary get the dimensions the new square, these can determined the ratio reduction. There little danger that the square will become over- filled, but the smallest possible square used, safer make the angles the square grooves from deg. deg., prevent forming seam along the bar. process manufacturing chromium plate has been placed commercial basis the Apollo Metal Works, Salle, offered Apollo Chrome, “in sheets avail- able for immediate fabrication without plating.” The Iron Age, July 19, 1928—147 i Cupola Operations Are Changing Cooling Reduction Zone Expected Improve Thermal Economy— Desulphurizing Alkaline Slags MPROVEMENTS cupola practice, principally thermotechnical nature, are attained replacing coke with other fuels, chiefly liquid powdered form, cutting down the formation