The Iron Age 1928-12-27: Vol 122 Iss 26

THE IRON New York, December 27, 1928 1855 VOL. 122, No. 7500 All-Steel Toys Day Production Saves Auto-Body Scrap and Occupies Parts Man- ufacturer During Slack Season for Automobiles for grown-ups and for kindergartners these products, but the company’s business this side line form combination that has solved two problems has grown such extent that considerable auto body the plant Murray Ohio Mfg. Co., Cleveland. seconds now has purchased for toy manufacture. One was find some way keep the plant busy during sea- present salvaged scrap represents about per cent the sonal lulls demand for automobile stampings. The other amount sheet steel consumed the toy plant. was find some use for the large quantity high-grade From the standpoint seasonal demand the two lines sheet scrap that was being bundled and sold low together admirably. rising demand for automobile Pressed steel juvenile vehicles, manufactured side stampings usually starts January but off line, seemed solution these two problems. During the following month toy manufacturing be- the start, five years ago, only scrap metal was used for gins its seasonal activity, reaches its prime during August times ed for autome bile Pp 1 Bigge st mpings are na th this battery small machines used minor toy doors panels; this 1623 Spray Machine for Cleaning. Parts have same color are sub-assembled, then cleaned, enameled and baked continuous machinery adopted from best auto-body practice and ends with November. Nearly all toys must leave the factory not later than Dec. reach retail stores for day the past few years the public has been buying better and more lasting toys, toys that will stand under hard usage. This tendency has favored American makers, who have face the competition inferior imported toys. American pressed steel toys also occupy distinct field, the German toy makers, who the past have been the strongest competitors, center their efforts largely what are known mechanical toys. Santa Claus’s Assistants. 97 1624—December 1928, The Iron Age Another favorable factor the American mass produc- tion pressed steel toys, exemplified the Murray Ohio plant, which results marked decrease the cost making high-grade article. Thus the manufacturers have kept pace with the demands the youngsters for toys that are equipped with most the extras they see grown-ups’ vehicles. Some the higher grade juvenile automobiles and trucks have such refinements ball bear- ings the rear axles, roller bearing front wheels and carbon steel springs, well the numerous accessories found modern types passenger cars. Youngsters, rather than gray beards, having good time building motorized “hook-and- = 7 Starting make juvenile vehicles five years ago side line, the Murray Ohio Co. has increased production These range from sturdy coaster wagon juvenile automobile down tiny red cart baby finds delight pulling around the living room floor, and include all-steel juvenile trucks, airplanes, scooters, wheelbarrows and steam shovels. The company’s maximum daily output 7500 toys and shipments reach carloads per The used the toy department largely 22-gage auto-body stock, although thick gage finds its way into front axles. Thus the toy automobile made considerable part good quality steel high-priced passenger car. Scrap from automobile stampings goes from the blanking presses shear, where the pieces sufficient size sal- vage are cut off and the remainder goes the baling press. Some the.scrap left form diffi- cult handle and has comparatively small sections that can used, that not worth the time required sal- vage it. However, from per cent the sheet material that was formerly scrapped salvaged for the manufacture toys. The heavier stampings, such frames, hoods and body parts for juvenile vehicles and tops for coaster wagons, are formed the same large presses that are used making automobile stampings, thus keeping the equipment busy when automobile manufacturing slack. This supple- mented number small presses for blanking and forming minor parts. Stamped parts for toys all from the presses stockroom clearing house, and from there they are deliv- ered the department. Usually there are two more colors toy vehicle, and the parts are sub-assembled according the finish they are have, order that each portion may enameled unit. Both Fatigue Strength STUDY turbine blading has been made Moore, Lyon and Alleman, University Illinois Engineering Experiment Station, for Allis-Chalmers Mfg. Co. (Bulletin 183.) Short lengths the blades were mounted chucks and rotated under load failure developed from the alternating bending stresses. Failure started the tips, usually the thicker one, where the highest stress bending occurred. Owing the unsymmetrical shape the cross sectional area, there were certain effects evaluated; furthermore, the ordinary beam for- mulas required modification. After such corrections had been applied, the endurance limits the blades were found nearly high that larger bars, machined the standard round specimen. This nclusion verified experience with steam turbines. Blades tested were (80:20), monel metal, and cyclops metal No. carbon steel per cent Ni, per cent Cr, and per cent Since there fairly close relationship between hardness fatigue resistance, this ratio was uted for made tests materials this analysis. Fatigue strength puted means such ratios hardness tests taken harmonic inertia spot welding and riveting sed indivi and r.veting are used joining the individual parts, welding being preferred. Power riveting machines the tubular type are used. sub-assembly units are washed machine where they are first sprayed with caustic solution, then cleaned dried. Work carried through this machine woven wire belt. After cleaning they the enameling depart- where the parts are dip painted enamel and hung ment, racks that carry then through continuous baking ven. This double chamber oven having one chamber for black work and the other for red, green and blue. The black enamel baked for two hours temperature 450 deg. Fahr. Other lower temperature and somewhat slower rate. through The oven equipped with automatic temperature control, and was built Young Brothers Co. further finishing colors, strip- hand. The sub-as- semblies the final assembly room after painting, and when completed the toys are boxed and moved the ship- ping department. Some special equipment has been installed. The most interesting special welding machine for affixing tires. These tires, solid rubber cut length, have wire run- ning through the center and extending slightly beyond the ends. one operation the tire pulled tightly around disk wheel and the protruding wire ends are welded their lapped position. While this being done the ends the rubber are held back inch two from the joint. When the weld completed and the wheel leaves the machine the two ends the rubber tire spring together. Toy airplanes are made separate department equipped with spot welding and riveting machines, power hammer for driving the wheels, and special baking oven for drying the parts after they are dip painted light gray enamel. This enameling done before assem- bling. Steam Turbine Blades (The blades were too produce round are given the adjoin- the blades. specimens. ing table. Fatigue Strength of Steam Turbine Blades Ratio Computed Actual durance Endurance Endurance Brinell to of Blade Metal Hardness Hardness Material Cupro-nickel 117 166 19,400 Monel metal. 212 190 Cyclops metal 171 250 Graft Selling and Purchasing Boycott the hest remedy which can found cure that commercial bribery which yet exists between pulous selling organizations and purchasing agents (or those who specify purchases), the opinion Mac- donald, writing Purchasor. honest purchasing (which means out 100) would refuse any busi- ness any price basis with concerns offering bribes them, and cut off all commercial relations with concerns which have been publicly exposed admit such practices, the selling graft would rapidly lose popularity because would cost too much lost and unapproachable business. Iron Age, December 27, “~~ ‘ = 7 | Progress Iron and Steel Wor Engineering Features Receiving Most Present Attention PEAKING for the executive committee the Iron and Steel Division the American Society Engineers, George Snyder, chief engineer National Tube Co., Lorain, Ohio, and chairman the committee, presented Dec. the annual convention, his report the year’s progress. was part follows: Open-Hearth Furnaces Development open-hearth practice has not shown any radical departure general design furnaces equip- ment. rather along the line refinements, such preheating air, insulating walls chambers, sloping back- walls, greater recovery from waste heat gases, and, course, continued efforts improve quality. one writer puts it, “future trends will toward larger furnaces aim- ing greater tonnages and lower costs, efforts secure more refractory linings, better utilization present sources heat, and better control atmospheric condi- tions.” There also the question mixing and coke-oven gas secure enormous volumes gas sufficiently rich serve the open-hearth well other metallurgical furnaces. Multiple pouring ingots being used greater extent, and advantages are claimed. The equipment for multiple pouring requires careful mechanical designing, safe and effective. sometimes difficult accomplish existing plants, for lack headroom other clearances. Tilting open-hearth furnaces are preferred many cases and are being advocated for the well-known advan- tages slag control, tapping, steel quality, and ability patch bottoms. The mechanical equipment con- trolling the tilting these furnaces seems entirely satisfactory. Insulation checker chamber walls has been much dis- cussed, and there are many advocates. hoped that, where applied old furnaces, these will analyzed all cases careful tests prior and subsequent the in- stallation. The use fans each end the furnace secure better combustion being tried, and satis- factory results are claimed. England the Merchant Iron Works Co., Middles- brough-on-Tees, Benjamin Talbot installed auxiliary hearth open-hearth furnace. This device used preheat the metal, scrap hot iron, before dis- charged into the main hearth. claimed that material increase the output the open-hearth furnace thereby obtained. Bessemer Many mechanical improvements are possible new Bessemer plant, such electric tipping, scrap charging, provision for double pouring, delayed teeming, and cental equipment needed reduce loss. small amount study and attention might increase the proportion made converters. That there are many uses for this kind steel well known, and improvements the practice might readily extend these uses. Duplex Plants While satisfactory steels are being made duplex plants there does not seem much development the way additional plants. The large tonnages possible make this manner making steel attractive, although there are 1626—December 1928. The Iron Age numerous difficulties encountered and great care taken the selection metal, fuel, and preliminary blowing. Sheet Mills and Sheet Bar Mills Continued interest shown the new mills which have been built during the past two three years. Biggert, Jr., says: “If present indications are borne out experience, may expect see sheet steel selling prices sufficiently reduced make possible its use for mul- titude new purposes. should noted, however, that this has not yet been accomplished. The new mills repre- sent large investments and require large tonnages and large individual orders make their operation profitable.” From operating standpoint they are still ex- perimental stage, and doubtful any them has yet shown costs lower than can made established methods. The following pertinent statement has been made: “An- other phase interest this portion the steel industry that most the inventions and discoveries necessary for the successful operation the new method have been cov- ered patents, possibly greater extent than any single industry save perhaps that wire. The rolling process and machinery and the subsequent processing, an- nealing, pickling, etc., all come within the scope this pro- tection. would unfortunate indeed the situation were handled any but the broadest, fairest manner, for which the leaders the American steel industry are emi- nently fitted.” passing interest the rolling one the American Sheet Tin Plate Co. plants 48-gage tin plate which torn easily between thumb and forefinger.” The field for the use this very thin material said lim- ited, but its availability may develop additional uses. The importance progress the art rolling sheets shown the progressive development made Weirton Steel Co. the three periods, 1916-1920, 1920-1925, and 1925- 1927, which horsepowers progressed 4900 hp., 6300 hp., and 8500 hp., respectively, and monthly tonnages, also re- spectively, 8365 tons, 11,386 tons, and 13,658 tons, rolling Coke Plants Dry-quenching coke has not made much headway this country during 1928. The claim saving per cent over 2,000,000 tons coke per year should encour- age further investigation and, established, promote this project cooling continuous passage inert gases through the coke and reclaiming the heat absorbed producing steam. Rolling Mills Additional items interest regard the new mills the Homestead works the Carnegie Steel Co. are avail- able. has been pointed out that the construction these large and modern mills sites occupied old mills that continued operate called for what may termed “emer- gency engineering” and for great resourcefulness upon the part all who had anything with this project. There dual set mills running parallel, with motor room between and soaking pits the end, arranged that ingots can, when required, fed either mill. The build- ings covering these mills are said weigh nearly 27,000 tons and cover more than 1,000,000 sq. ft. The square foot floor space covered seems figure out over which denotes very substantial construction for build ings this type. While this group mills was designed for 000 tons month, expected this will greatly exceeded, which not surprising, since designed tonnages all kinds rolling mills seem always exceeded, and sometimes soon after they are placed ignt per Seamless and Welded Tube Mills Development this branch the iron and industry bas been rapid, and competition keen. Whether build pilger mills some other kind seems still question, and advocates both types can undoubtedly point fin- ished production that satisfies customers. The combination piercing and expanding mills followed the usual equip- ment points still larger diameters than are now being made. The enticing features pilger mills, while calling for some elaboration the open-hearth plants, will con- tinue attract attention and probably promote more mills this type. By-passing soaking pits, blooming mill, and bar mill for rolling rounds attractive idea that will continue alluring. Mr. Stiefel, however, who should au- thority the whole field seamless-tube making, says: (1) Output tons with plug mill two three times greater; (2) cost installation about the same; (3) tool cost pilger mills two three times greater; (4) rolls and mandrels for the pilger mills call for special steels; (5) maintenance and tool equipment less costly for plug mills; (6) plug-mill product better quality; (7) pilger mills can roll longer lengths; and finally, (8) plug mills will probably built that can produce tubes 24-in. diam- ate "he enntrav nae eter. The controversy, there one, must resolve itself int the — into the question of cost to produce from start to finish. Blast Furnaces The large furnace about ft. diameter hearth considered good practice, and satisfactory operation stacks, large nearly large this, about 850 900 tons iron day (average), not unusual. important improvements stack, skip, stoves have been noted, the changes, any, being details. Considerable attention has been given blast-furnace operators and de- the matter gas cleaning. This matter and the ever-present problem flue-dust production and disposi- tion are sufficient occupy the minds furnace operators between casts and deserve much thought and study. Blast furnace practice must improve, according va- rious authorities, through the use better burdens, large furnaces secure low costs, better gas cleaning secure good results consuming units, and the recovery the iron content now lost wasted flue dust. Improvements equipment for the recovery the iron content blast- furnace flue dust, either sintering some other method, point the possibility large blast-furnace oper- ators facing penalty, addition the yield loss, for all dust wasted beyond the amount known recoverable. Attention was called early the year the German achievement operating blast furnace 1000 tons day, largely through selected burdens. They have used sintered fines from the ores, practice which may show re- sults this country far beyond present conjecture. Quot- ing from article printed February this year: “Large American furnaces, supplied with rich sintered ores, would produce far more than anything yet achieved here abroad.” Management Engineering Small Plants Problems Production Control and Grouping and Classification Equipment; Importance the Operating Personnel DYKSTRA* POWER industry can directed its highest state efficiency only proper guidance and proper planning. Production methods have received more attention from management engineers than have methods selling and distribution and design. Stand- ardization design may well given some consideration plant managers, especially plants where the product greatly diversified and quantities are limited. stand- ardization parts given the attention deserves, will once have tendency bringing parts through the plant greater quantities. Certain factors which make for efficient operation, the order their usefulness establishing workable system not entailing too great cost the average small industry, are: Production control; Grouping equipment and its cla sibilities modern equipment; The personnel man operation possible. ssification and pos- wer that makes successful Production Control rat such main Production control can separated into items proper scheduling, routing, stores control, and purchasing. Many obstacles are frequently encoun- ofle h abstract paper read Dec. Engineers. York, the American Society tered the smaller shops due the limited quantities and the dissimilarity parts that must often produced the same machinery, but machine-tool builders have demonstrated that many standard machines have built into them the possibility caring for greatly diversified prod- ucts, simply equipping the machines with suitable fix- tures and jigs. Proper scheduling can frequently en- hanced, however, noting the requirements the sales department over few months. determine the production capacity various de- partments essential study considerable detail the suitability well the grouping the equipment produce the desired part. most cases similar equip- ment can grouped together profitabiy for lighter ma- chining operations. our present age specialization, better supervision obtainable lathes, turret lathes, screw machines, milling machines, are grouped their respective classes. the heavier classes work best arrange the necessary equipment the same sequence the operations performed; this manner the operations can usually completed the smallest space, with elimination unnecessary moves. Proper Routing Proper routing parts through the factory obtain- able only keeping mind the fact that material, when once has left the stockroom, should travel the gen- The Iron Age, December 27, 1928—1627 | eral direction the assembly finished-stores department, accompanied identification tag showing the sequence operations well the departments that are perform the work. This can most easily accomplished placing the production-department’s office set master route cards which show the sequence operation and the various operations themselves. aid the department foreman much possible highly desirable furnish the departments with proper descriptions all operations performed any one piece. These operations, readily designated their num- bers, should appear the operation card logical se- quence. full description the operations per- formed should this card and the tool numbers the fixtures and tools needed should given. Proper Costing Almost every factory manager will agree that proper costing prime necessity all departments his plant. The mainstay proper costing the establishment time study determine (1) best possible tooling require- ments obtainable with production requirements, (2) meth- ods determining the time required perform the vari- ous operations with the equipment available, and (3) accounting all time spent any job. Minimum costs are obtainable only through system which accounts for every minute the day that spent the employee the shop. The psychological effect knowing that every minute recorded generally con- ducive the best effort. simple job ticket giving the symbol the part, together with lot and shop order number, can made out the office the time the ma- terial ordered. then necessary for the department foreman only fill the name the employee and the number the machine used for the operation. This ticket, stamped the beginning and completion the work the employee himself, can then used for both progress report and costing purposes. considering the tooling possibilities always nec- essary consider the tools available and the time required with these tools. With this factor known becomes com- paratively easy determine the possible savings with more elaborate While the more elaborate fixtures are invariably considered from cost-reducing standpoint, well also bear mind the increased accuracy which such fixtures usually bring about, thereby frequently reducing the assembling cost the product. Grouping and Classification Equipment With any well-thought-out scheme production control always necessary provide for such emergencies “breakdowns” equipment. Almost every machine tool any plant carries designation number and these machine numbers should carried the departmental operation sheet well the time-study sheets. This once guides the department foreman distributing his work hand departments. grouping the machines similar ca- pacity and adaptability certain work provides once means for him, case necessity, shift the work hand other machines that fall under the same classi- fication. This gives desired flexibility operation not otherwise obtainable. The possibilities modern equipment are usually not well enough known many factory executives. dif- ficult for the department head factory where quantities are small show sufficient saving any one product justify the expenditure required for the purchase mod- ern equipment. Many pieces equipment the average smaller indus- trial plant would replaced modern tools the ex- ecutive but knew their production possibilities. Many tools would discarded readily the car model year two ago modern equipment were considered terms 1628—December 27, 1928, The Iron Age saving man-hours, instead saving dollars cents per unit produced, most generally the new up-to-date machine tool will usually save erable amount time, compared with machine years old, and the accuracy obtainable with the more ern machine tool always reflected considerable gree the erection assembly costs. spite common knowledge regarding modern machine tools, shops have entirely too much equipment which, while ful, not profitable when compared with the produc possibilities the new machine. While the saving possible labor cost product may not loom large, the fact remains that ever new machine per cent more efficient tha the old one, the operator’s effectiveness increased tha: extent. If, therefore, the average machine tool shop per cent less efficient than the new tools, follows that per cent reduction payroll could effected the use the new tool. Executives many smaller plants fail realize the fact that the best modern equipment pays well, even difficult show beforehand dollars the resulting savings, not only the machining, but also the subse- quent assembling operations. Facts bear out the assertion that general new equipment materially reduces the de- partmental overhead, through the absence repair costs and shutdowns, but also usually decreases the general unit overhead increasing sales that the better product often makes possible. Man Power Engineers should remember that the human element not subject the rule cold figures. While the analysis possibilities the human element involved should and one the mainstays our planning manage- ment engineers, should ever bear mind the fact that those directed can taken over many obstacles properly led. Industry the whole and engineers well have been slow recognize the value competent leader- ship. While there are, doubt, many men who work neither for money nor fame, but for the joy the working, Kip- ling put it, facts amply testify that general all human endeavor directed toward the reward that brings. cost-reducing plan, therefore, which does not bring its re- wards and its encouragements those who carry out, will never attain its full possibilities. Improvements Possible Most Plants Many opportunities for improvement operating con- ditions plants are neglected because inertia the management, according George Hagemann, associate editor Manufacturing Industries, New York, who led the discussion Mr. Dykstra’s paper. Evidently, best re- sults are obtained, delegation authority essen- tial. company employing 300 400 men was cited, which each foreman has capable assistant who can run his department any time necessary. This not only provides for accident, both physical and otherwise, but permits the foreman out, when occasion arises, in- spect machinery appliances and other equipment which are order for the plant, and shortly will have used that foreman’s department. Improvements production control, while perhaps more expected the small plant than the large, are means confined. The large plant has great oppor- tunities for improvement, almost every instance. Another speaker stated that engineers charge design have not yet reached that peak efficiency their designs which needed progressive management. Espe- cially this true with regard the standardization parts, such can used for variety purposes concern doing what essentially jobbing business. f Adds Cold-Rolled Strip Department Sharon Steel Hoop Co., Part Its Modernization Program, Completes Cold-Rolling Plant BOUT year ago the Sharon Hoop Co. ac- quired approximately acres ground adjacent its Sharon, Pa., plant. This area now largely occupied modern mill buildings housing new pickling and galvanizing departments and cold-rolled strip plant. The new construction marks the first major step complete modernization the Sharon plant, and when, short time ago, the first cold-rolled strip steel came off the new mills. the company entered the ranks manufacturers that product. its name suggests, the company first was en- gaged the manufacture hoop and the days the wooden barrel was large factor the production the narrow flat bands used the cooperage industry. When the Southern cotton grower depended largely upon Northern mills for ties for baling, the company was one the important sources supply. The plant, since its construction 1900, has been de- voted exclusively the rolling flat light-gage steel. With the rise the motor vehicle industry, with its numer- ous and increasing uses light-gage flat steel, the decline the use similar steel for cooperage purposes, and, account foreign competition, the passing profitable forward looking management that the company several years ago stopped making cotton ties and went more strongly into the production the steel called for the automotive industry. Out the effort distinguish the requirements the motor car builders from those other consumers devel- oped the term “strips.” The company still producer hoops and bands, but with its new productive facilities, reckoned essentially maker strips. Its entry into the field cold-rolled strip steel has the backing record years the rolling hot-rolled flat steel. Under construction present part the moderniza- Cluster Mills, Together With Reel and Coiler program continuous, electrically driven, hot strip mill, which expected operation next March. Electrification the plant has been another important de- velopment. One the impressive features the new plant its skillful tie-up with the older sections the works and the remarkable ease with which steel coming from the hot mills transferred either railroad cars for ship- ment the pickling department preliminary further finishing. The new structures are notably solid construction, the columns being almost wholly heavy single piece beams. account the closeness the plant the Shenango River, there was soil condition which had met in- sure solid foundations. Besides the use concrete piles, there 4-ft. bed tamped slag topped concrete which have been laid creosoted wood block floors. There air solidity and permanence the new structure, and lighting and ventilation are the character which helps make the working place attractive. The efficiency the plant has gained appreciably, the records the plant since completion the new section show that larger ton- nage being turned out with one less working turn per week. The 8-in., 9-in., 10-in. and hot strip mills, which have been operation for number years, parallel each other, shown the accompanying plan. These mills discharge their strip, either cut lengths coils, into the No. loading building. From this building the strip either loaded directly into the cars taken the No. load- ing building the pickle shop storage building, roller bearing trucks and tractors. From the pickle shop storage, the coils sizes in. wide are fed through continuous pickling tanks, washers, dryers, and then multiple head coilers. The wide coils and the cut strip are put special Monel racks The December 27, 1629 | 7 | 7 and handled cranes into pickle and wash tanks, then dryer roller levelers and oiling machines. There are two sets continuous pickling tanks. The first set will handle eight rows strip widths in. This set consists one long pickle tank, water, muri- atic acid and lime tanks. There also pull-up machine for and galvanizing pot, which fired with natural gas. From the galvanizing pot the strip fed eight- coiler. Each head provided with small roller leveler, which takes out any corrugations that may have developed the strip the hot mills during the pickling. The heads this coiler are driven with individual motors, which have variable speed and there also The strip pulled through the tanks this coiler constant speed means automatic control wh:ch slows the motors down the coils increase diameter. The second set continuous pickling tanks are about the same the first except that they are wider and will handle pieces strip. There galvanizing pot this set. The coiler has heads. Every other head will coil strip in. wide and the alternate heads in. wide. The coils are loaded trucks cranes the coilers and then taken either the cutting machines, the cars for shipping, the cold-roll plant. There loading dock along the east side the pickle and cold-roll plants over 1000 ft. long. Part this loading building has crane runway for open car loading. Between the pickle and cold-roll plants there covered runway that the pickled strip never exposed the weather. The cold-rolling plant about 250 ft. north the pickle shop. This intervening space reserved for extensions either the plants. The rolling equipment consists three sets tandem roughing mills with reels and coilers and complete handling equipment for material and rolls. There are seven sets finishing mills with auxiliary equip- ment the same the roughing mills. Other finishing equipment consists slitters, roller levelers, edging mills, 1630—December 27, 1928, The Iron Age rewinders, polishing machines, oiling machines and shears. The first roughing mill consists four stands in. and 26-in. cluster mills set tandem, about ft. center center stands. These mills are driven 200-hp. variable speed motors, each pass, and the ery speed ranges from 125 375 f.p.m. possible control the complete mill from any stand, means push buttons. The reel and coiler are driven variable speed motors and are synchronized with the mill. The reel the cluster mills mentioned can adjusted for maximum pull 4600 lb. The other reels have maximum pulls propor- tion the sizes the mills. The coilers are the five-roller type, with special guide rollers for holding the coil place, during the coiling opera- tion. The second roughing includes three stands in. and 16%-in. 18-in. cluster mills, set tandem about 10% 18- In. Finishing Mill With Ac- companying Reel ft. center center stands, and with reel and coiler. fourth stand about ft. from the third, with and 16%-in. 26-in. rolls, set tandem, that can used with the other three stands can used single mill. also has reel and This mill driven with 150-hp. motor each stand. The third roughing mill three-stand tandem, two- high, mill with 10% in. rolls. This mill has set driven edging rolls before the second and third stands for the purpose producing square edge material. This mill has reel and coiler, the same the other mills. The finishing mills comprise two stands 18-in. rolls, two stands 10% 18-in. rolls, two stands 10-in. rolls and one stand 26-in. rolls. These mills are all equipped with variable speed motors. The reels are also driven with variable speed motors with adjustments for variable tension the coils. Six these mills are equipped with edgers which are driven from the mill motor. All the mills are equipped with roller bearings. The cluster mill bearings are Timken and the two-high mills are Rollway. The cluster mills and the 26-in. finish- ing mills have motor driven screwdowns, with motor 4 each screw, and magnetic clutch between the drives, that the screws can operated separately together, desired, system push button control. The auxiliary equipment consists slitters, portable coilers, polishers, roller levelers, portable shears, oiling ma- chines and scrap bundling machine. this equipment, which, with the mills, was built the Bliss Co., has capacity for making cold-rolled strip any gage in. thick and any width in. roll grinder, furnished the Norton Co., has equip- ment for grinding the the rolls either straight, concave convex. There are three shears, built the Hallden Ma- chine Co., which will straighten and cut the finished strip The annealing department equipment consists four double, box annealing furnaces, which are hand fired. There are cast annealing boxes and bottoms, and the neces- sary equipment for drying and handling the gas the boxes. 50-ton crane serves annealing bottom with the charge and cover complete. the Right the Chargin the annealing furnace building there are two Leif Lee heaters, which furnish the heat for the cold-rolling plant. These are located that the coal and ash handling equip- ment can serve them the same way does the anneal- ing furnaces. This equipment includes track hopper and coal elevator, which discharges into boxes ashes from bin into standard car truck. The coal boxes are moved overhead crane the different furnaces and the ashes are taken from the furnaces this same crane bin adjacent the coal elevator. Another addition our rapidly growing list tech- handbooks 383-page volume just issued the American Burner Association, Avenue, New York. was edited Harry Tapp the association. intended supply those interested authoritative in- formation concerning problems combustion and needed the practical application oil-heating equip- ment. The volume, which priced $3, flexible bind- ing and thin paper that will fit the pocket. End the Continuous Pickling Tank, While the Foreground Shows Part the Pickling Shop Storage The Iron Age, December 27, Multiple Head Coiler Used Connection With the Continnous Pickling i Reheating Furnaces for Alloy Blooms Soaking Chamber Forms Part Furnaces Timken Company—Hearth Has Three Zones —Refractory Recuperator Feature EHEATING high-quality alloy blooms quantity production basis has been provided for the new mill the Timken Steel Tube Co., Canton, Ohio, the installation two large continuous reheating fur- naces, especially designed for the work. The furnaces are the triple-fired, recuperative type, using natural gas for fuel and having capacity tons per hr. each. Blooms are brought directly the charging end the furnaces live roll table running from the main trans- fer table and are pushed through the furnaces means motor-driven pusher mechanism. Due the quality the steel, extreme care must taken the heating these blooms, which accounts for some the features the design and construction the furnaces. Upon enter- ing the furnaces, the blooms are gradually warmed 10-ft. dead end, next passing through the channel and main heating chamber, and last receiving their final soak- ing temperature approximately 2200 deg. Fahr. brick hearth. From this hearth the blooms are discharged gravity directly second run-out table that carries them the 28-in. mill which serves roughing stand for subsequent rolling operations. These furnaces are the first their kind ever built and put operation, and incorporate number interest- ing features construction and design. they are pre- cisely alike all details, description one will serve for both. over all dimensions they are ft. long, ft. wide and ft. high one end and ft. in. the other, Cross Section Continuous Furnace, Showing Arrange ment Heating Compartments and Recuperator above foundations. The hearth ft. long and ft. wide with roof height that varies from ft. The furnaces extend maximum ft. below ground level. The section shown one illustration gives idea the construction and general arrangement the furnace interior. The main furnace chamber divided into three zones—the first for gradual warming, the second which the main heating done, and the third, which consists soaking chamber for equalizing heat throughout the bloom before discharging. The latter compartment, the soaking chamber, one the features the design. this chamber, only sufficient fuel fired supply radia- tion losses and maintain the entire soaking hearth, side- walls and roof constant discharge tically heating done here, this chamber being used equalize the temperature throughout the steel and soak the entire bloom the same heat condition. The soaking chamber accomplishes two important things. First, serves heating blooms, removing dark spots caused contact with water-cooled skids the heating chamber; and second, makes independent each other the temperature condition the steel and the ton- nage output. Due the soaking chamber, tonnage output can changed will adjusting the burners located back the soaking hearth without any way affecting the quality heating found the discharged blooms. The roofs all three chambers are flat arch con- This type roof struction, supported from overhead girders. AIR 27, 1928, The Iron Age t for wide furnaces such these found make for uni- form flame distribution and heating throughout the 20-ft. width the furnace. The entire length the furnace chamber liberally provided with working and inspection doors located both side walls, care having been taken, however, that the doors thickly lined and tightly fitted, eliminate heat losses from the furnace interior. Hearth Construction Three Sections The construction the hearth proper also somewhat unusual. Taken whole, may considered divided into three sections, according construction. The first section, which extends from the charging door point ft. into the interior, standard firebrick construction. Extending along its length are four firebrick piers, which are mounted the skids which the blooms slide. These skids are water-cooled, the skid proper consisting two concentric steel pipes. The inner carries cooling water Motor Driven Pusher Mechan- ism for the Two Furnaces. The centralized con- trol shown upper left General View the Two 40-Ton Reheating Continuous Furnaces for Alloy Steel Blooms the extreme end, the return being made through the outer. The pipes are all connected common header, that there continual circulation water through the system. the second section the hearth, can seen from the drawing, the brick supporting piers are dropped away from under the skids, which are supported cross pipes bent rectangular form. These pipes are the same construction the skid pipes, and are supplied with water from the same header, forming part the general closed system. This hearth construction has been adopted provide combustion space for the burners firing beneath the blooms and permit ready circulation the heat below the steel, that the cooling effect the skid pipes will minimized and the soaking period reduced when the blooms reach the soaking chamber. The hearth the third section solid firebrick con- struction, steel bars set almost flush with the firebrick taking the place the water-cooled skids. The lintel The Iron Age, December 27, % the discharge door also water cooled, front wall support across the 20-ft. the hinged doors. form rigid span well carry The discharge doors consist number hinged steel plates that are swung outward the impact the blooms against them. Three Tiers Burners Provided the triple-fired name implies, there are three tiers burners incorporated the heating system this fur- nace. One tier located the discharge end for main- taining the soaking chamber the desired temperature. The other two tiers are located behind the soaking hearth, blooms near the roof the heat- ing chamber and one one firing above two latter tiers the tonnage output the furnace, the intensity the heat from this point back the charging door being controlled give the proper temperature for any desired tonnage output. iring beneath the blooms. These Between the two roof lowered forn from the the flat arch restriction the flow gases soaking chamber into the main heating chamber. This restriction very important point the design these furnaces since makes possible the maintenance slight pressure the soaking chamber prevent the in- filtration cold air the discharge slope through the flap type discharge doors. extremely important that scale losses kept low, due the cost and quality alloy steel. The infiltration air and resulting oxidation noticeable the ordinary type end-discharge fur- nace reduced minimum means the lowered roof between the soaking and heating chambers. ating na compa Control Made Automatic The control the main heating system manual the present time, but changed over the near future automatic fuel-air proportioning system work- ing conjunction with automatic draft regulator. The highest flame temperature obtained this type furnace found the main heating chamber back the hearth, where the steel being rapidly heated and where the tonnage output controlled. The main heating cham- ber ports are arranged use highly preheated ai: with the natural gas fuel. Since the steel colder thi point the furnace than the usual design end-dis- charge furnace, possible adjust the temperature bring about extremely rapid heat transfer the blooms, thus increasing the heating efficiency the furnace without detracting from the high quality the heated product. Refractory Tile Recuperator Under the Furnace The pre-heated air delivered both the main heating chamber tiers burners under positive pressure the refractory tile recuperator, which situated beneath the furnace proper and arranged three units. The central recuperator unit furnishes its preheated air the under- fired burners; the two outside recuperators deliver pre- heated air the overhead firing ports means two steel ducts which are insulated and brick lined. The waste gases travel through the furnace the down- takes ft. from the charging door where they are led beneath the hearth the three recuperators. The heated gases travel horizontally through the recuperators, making three passes, each successive pass being lower level until the gases are discharged from the recuperator the stack flue temperature approximately 700 deg. Fahr. The heat given the waste gases passing through the recuperator heats the hollow refractory tile through which air for combustion passing vertically upward. collecting chamber situated the top each re- cuperator unit, where the air collected from all the ducts each recuperator and thence led the main heating chamber firing ports. Blooms are charged the furnace directly from the runout table double rack type pusher. general view the pusher shown another illustration. The motive power supplied 120-hp., 220-volt, direct current, mill type motor, which directly connected reduction unit common both rams. The total reduction speed giving ram speed 17.4 ft. per min. The capacity each ram 82,000 lb. horizontal push. The shafts all pinions, gears, and idler gears throughout the drive includ- ing the rack pinion, are mounted Timken bearings. Diffusion Solid Carbon Carburizes Steel ARBURIZATION iron and steel occurs when the metal heated contact with solid carbonaceous ma- terials, with carbon monoxide methane gas melted cyanide. Two theories have been advanced explain this action. One that gas, such carbon monoxide the carbon carrier; diffuses into the steel and reacts with the iron form cementite according the reversible reaction. The other theory that the gas decomposed contact with the surface the metal, depositing carbon soot which then diffuses atom atom into the hot iron, entering the solid solution austenite. Experiments Support Decomposition Theory The latter theory supported recent experiments Takahashi, published Science Reports, Imperial University, Sendai, Japan, July, 1928. finds that pure iron tube with mm. wall evacuated inside and stoppered, and then bathed outside atmospheric pressure, earburized throughout about 1.5 per cent carbon hr. 1000 deg. C., but the gas pressure inside has crept meanwhile only mm. decarburization was effected similar fashion with CO, but the interior pressure rose only mm. Other ex- periments showed that hydrogen diffuses through the hot tube walls readily, but CO, CO. and hardly all. If, Almost complete 1634—December 27, 1928, The Iren Age seated carburization readily occurs while gas penetrating but slowly, the effect must due most part diffusion solid carbon. This conclusion also line with x-ray studies austenite, which indicate that carbon dispersed within the interspaces the iron lattice carbon atoms and not the compound Eye Accidents and Industrial Eye Strain Increasing “Safety first” has brought down the number accidents industry gratifying extent, but the most distressing kind—preventable eye comprises the most serious industrial hazard, according Lewis Carris, speaking before the Safety Congress, Syracuse, Y., Dec. Furthermore, the number the increase. esti- mates that American industry pays $10,000,000 yearly com- pensation blinded workmen, and the loss them and their families much greater. Eyestrain from dark work- ing places from glare more prevalent, and represents loss, although does not figure com- pensation statistics. The remedy constant use ap- proved goggles, helmets, and scientific lighting, and in- formed cooperative attitude between employers, workmen and the medical profession. Causes Failure Coiled Springs Corrections Determined for Design Tables—Rough, Decarbonized Surfaces Detrimental—Mild Corrosion Avoided SPECIAL research committee the American Society Mechanical Engineers, under the chairmanship Wood, has fostered number researches into the properties springs. Definite results have been obtained some lines, and were reported the general meeting early December. common experience that heavy, closely coiled heli- cal springs—such used railroad rolling quently fail even though working under loads well within the supposed safe limit. The common type failure detail fracture starting the inside the coil; usually attributed faulty heat treatment. Wahl, research laboratory Westinghouse Electric Mfg. Co., East Pitts- burgh, analyzed the stresses approximate methods, then performed tests loaded springs and spring segments Stress Multiplication Factor Ratio Mean Diameter Wire Correction Curve for Spring Tables Divide coil diameter wire diameter, run cor- responding ordinate curve, then across left read factor. Multiply stress given spring table this factor get maximum stress actually existing spring which verified the theoretical results. Agreement was also close the results much more rigorous mathematical analysis the problem published years ago Ger- many, but generally neglected designers, probably be- cause there has been experimental verification until Mr. Wahl’s work. now finds that the stresses the outer diameter the springs are materially less than the accepted spring tables, while those the inside the coil may much 2.5 times large the outer diameter. Hence concludes that failures ser- vice are ordinarily caused overloading this region. also suggests factors taken from the curve convert the tables given handbooks into safe de- sign data. several commentators who the Mr. Wahl’s work, Eaton, Molybdenum Co. America, Pittsburgh, said that the problem spring age will not solved until more the steel manufacture and the spring fabrication. his opinion many avoidable defects originate poor ingot surface (due splashes, surface segregates stresses), persisting through the round rod from which the spring was made. even greater danger the fin- ished spring the thin decarbonized surface left after roll- ing, coiling and heat treatment. The gross result that the most highly stressed fiber spring least able withstand its load because faulty mechanical and chemical conditions, Corrosion Reduces Endurance Limit Jr., metallurgist United States Engineering Ex