The Iron Age 1929-05-23: Vol 123 Iss 21

THE IRON AGE New York, May 23, 1929 ESTABLISHED 1855 VOL. 123, No. Conveyors Add Working Radius Equipment Makes Feasible the Dispersion Departments, When Space Near-by Not Available FRED PRENTISS* ECENT installations conveying equipment the iator plating department, and gravity and overhead con- plant the Willys-Overland Co., Toledo, Ohio, in- veyors the radiator core assembly and testing depart- clude complete system overhead conveyors ments. The use conveyors eliminates the for handling automobile radiator shells through the rad- radiator shells and cores the floor. Both parts are kept motion the conveyors practically all the time *Resident editor, final assembly, except when they are removed for op- HREE Overhead Conveyors, All with One Drive, Carry the Radiator Shells Over Four Lines Polish- ing Machines, Which They Are Prepared for Chromium Plating. Each conveyor loops back the opposite direction, making all six parallel lines overhead conveyors the shell polishing department 1405 | | They are returned the conveyor when each operation finished. The shell after plating, and the core after assem- bly, are carried considerable distance overhead con- veyors. They meet point where the shells and cores are assembled together make complete radiator. The shell-plating and core-assembly departments and their conveying lines have capacity over 2000 radiators erations. day. Production has been materially increased the use the conveyors. Considerable floor space has been saved the efficient handling these parts process, and the entire avoidance storage the shells and cores the floor. Various problems material-handling and production growing out increases plant capacity necessitate re- arrangement. Production certain parts long dis- tance from sub final assembly lines has been permitted the installation conveyors for bringing parts from other buildings the assembly line. From One Operation the Next Chain Conveyor shells, brought from the press room trucks, are hung conveyor the grinding and polishing department. There are four lines machines, arranged back back two double rows, with aisle the center. the first line machines the shelis are rough polished. the succeeding lines they are given finer surface, finish polishing being done the fourth last row machines. Three loops overhead conveyors, all operated one drive, serve the polishing machines. machine operator the first line lifts shell from the conveyor above his head, polishes and hangs back the conveyor, which moves around the loop and back over the second row machines for the second polishing operation. Op- erators this line hang the shells, after the second pol- ishing, the center conveyor directly back them, and the shells move around the center loop the opposite side. 1406—May 23, 1929, The Iron Age There they are within easy reach the men working the third line machines. These also return the pieces the conveyor, which they are carried around the third loop the fourth line machines. Leaving the polishing department, the shells move the last conveyor line the copper and nickel-plating de- partment, which has automatic plating equipment. Two separate overhead conveyor systems serve respectively the copper and the nickel-plating units. After cleaning, the shells are suspended conveyor the copper-plating tank, which they make one revolution. Then they are rinsed water, after which they are hung the first overhead carrier, which carries them the copper buffers. Leaving the buffing machines they are put back the same conveyor, which takes them cleaning tanks and ACK Seat As- sembly The truck and as- sembly fixture are shown the curve. The conveyor edge type, with caterpillar the picture the drawbar hook detached from the chain, show the simplicity parts then the nickel-plating tank. After nickel plating the second overhead conveyor carries them the nickel buf- fers. Leaving the buffers they are suspended another conveyor, which carries them the chromium-plating de- partment, the opposite side the room. After chromium plating and rinsing, the shells are hung another conveyor, which takes them buffing machines for finish polishing. After brackets are assem- bled the shells they back the conveyor, which car- ries them spray booth, where one section the shell Then conveyor 325 ft. long carries them the radiator assembly department. While moving along this line the shells are taken from the conveyors benches beneath, where the name plates and stay-bar brackets are affixed. Then they are hung back the conveyor. Reaching the radiator assembly department, the shells are removed from the conveyor, cores are put and the finished radiators are loaded trailers the chassis assembly department. moving through the plat- ing and the radiator assembly department the shells are suspended conveyor hooks 30-in. centers. Two the conveyors the polishing department are 220 ft. long and the third 210 ft. long. The length the con- veyor the copper-plating department 140 ft. and the nickel-plating department, 110 ft. From the nickel 5, ~ 4 RODUCTION Been Increased and Floor Space Materially Reduced the Radiator Core Assembly Department the Use Roller Conveyors. Assemblers take the cores from the upper deck the roller conveyors shown the picture and after their operations push the cores back the lower deck this conveyor buffing machines the chrome-plating department the take the cores from the roller table, straighten them out conveyor carries the shells 440 ft. the benches and push them back the lower roller conveyor, the same plane their benches. The roller Using Double-Deck Roller Conveyor conveyor loops around the end the room, where the core the core-assembly department the radiator core given acid dip tank and then soldered. clamped metal form stationary table and set After soldering, the core placed another roller sheet-metal carrier. This pushed air lift, conveyor line. While this table the carrier and binding which raises the upper table double-deck roller plates are removed and shoved roller section conveyor, with work benches located alongside. Workmen mounted air hoist, which lifts them the level IFFERENTIALS Are Assembled Roller-Type Conveyor Oval Form. handled the conveyor carrier having rotating carriage The differential case The Iron Age, May 23, — 4 =: $$ the table where they started their circuit. The core carried few feet another roller conveyor, which moves point where the outside rows are trimmed, final soldering done and the core inspected. then carried truck another room, where tanks and other parts are assembled. this department are several transverse roller con- veyors for handling the cores the testing tanks, where they are tested under 10-lb. air pressure. Here they are hung overhead conveyor and, while moving this, water blown out the cores, and steam forced in- side dry the outside the cores and clean out the acid. Then they are spray painted and placed trucks dry. The next and final operation testing tanks water. Thence they are hung another conveyor, which carries them the assembly department, where they meet the shells. Cores reaching the assembly department faster than they are needed remain the conveyor and make another circuit. Seat Backs Conveyor unique application conveyor for progressive as- found the use conveyor for as- sembling seat backs. This chain-type conveyor, oval form, 177 ft. long, and operating just above the floor. interesting feature that this conveyor chain runs its edges. The seat back assembled wooden fix- ture mounted truck, having especially designed casters that move track with rail one side. prevent the fixture from tipping sideways during as- sembling, the truck has angle iron grids both sides the caster brackets. For convenience assembling, the fixture may turned deg. from perpendicular either direction. Starting with the metal frame that forms the seat back, the springs, padding and upholstery are assem- bled. This work done entirely girls, the work- ing stations around the conveyor. Moving maximum speed ft. minute, the conveyor has capacity 300 seat back assemblies day. advantage found this method progressive seat back assembling that the operations are divided that each girl can quickly learn become adept her part the work, which she employed piece-rate basis. Before the adoption progressive assembling con- 4 q Assembled Roller Conveyor Are Transferred the Overhead Conveyor Shown, Which They Are Taken 1980 Ft. the Motor-Assembly Line 1408—May 23, 1929, The Iron Age veyor the work was not split present. disad- vantage the old assembly method, which has been elim- inated the new conveyor line, that, when sharp speeding production took place, frequently hap- pens automobile plant, took some time train girls all the various operations required assem- bling seat back. Seat backs would naturally assembled the side the body-assembly line, but space was not available that part the plant. However, providing suitable carry- ing conveyor the company was able place this depart- ment considerable distance from the body-assembly department. overhead conveyor 2340 ft. long, recently installed for this purpose, passes through three buildings and over two different floor levels. The seat backs are hung conveyor hooks 8-ft. centers and the conveyor moves speed ft. minute. There are two un- loading points, which the conveyor dips down about ft. from the floor, for convenience removing the seat backs, which are placed storage racks and trucked, needed, short distance the body-assembly lines. Motors Put Together Roller Conveyor INAL assembling Willys-Knight motors done gravity roller conveyor which the motors move toward the point where they are installed the chasses. While this conveyor the starter, motor transmission as- sembly, clutch and spark plugs are assembled the motor. The fan belt put on, oil and grease are put and the motor given its final inspection. The motor moves the conveyor structural steel carrier which the flanges the oil case rest. This conveyor 200 ft. long, 130 ft. being used for assembling purposes and ft. for storage. Differentials are assembled roller-type oval con- veyor ft. long, having ft. straight track each side. The most important operation this line plac- ing the gears the differential case. The case mounted heavy cast iron fixture carrier which has rotat- ing carriage. The carrier slides under steel angles each side the end the rollers, the angles preventing from tipping. Transmissions are assembled roller conveyor cir- cular form, which the hand-brake levers, shifting Motors Are Assembled Gravity Roller Conveyor, Which They Move During Progressive Assembling Point Near Which They Are Installed the Chassis levers, clutch and brake pedals and steering posts are as- sembled. overhead conveyor delivers the transmis- sions the roller table and from this, after assembly, they are suspended hooks 4-ft. centers conveyor 1980 ft. long, which carries them through two buildings the motor-assembly line. This conveyor line, which was put because there was room assemble transmis- sions near the motor-assembly lines, eliminates trucking from stock. Bodies Polished While Motion After lacquering, the outsides the bodies are pol- ished they move along conveyor, thus saving large amount trucking. The work done with elec- trically operated polishing machines having felt wheels driven through flexible shafts. There are these ma- chines, the outer side each the two parallel conveyor lines this point. Each machine suspended from trolley which may moved backward and for- ward ft. either direction. This permits the polisher move the machine along with the movement the body polishing. The bodies after polishing stay these conveyor lines, moving along points where they are touched up, striped and inspected, all which done while they are motion. Export Parts Handled Differently All unpainted metal parts for export the first floor the export department, where large parts are hung hooks and small parts are placed bas- kets. While this conveyor they are dipped heavy oil, prevent rusting, tank ft. long. Leaving the tank, the conveyor carries them over drain and the third floor for packing. Overhead conveyors the radiator shell plating and core-making departments were installed Mechanical Handling Systems, Inc., and Jarvis Webb Co., both Detroit. The former company supplied the conveyors used for assembling the seat backs and for handling transmis- sions, and the floor conveyors for handling bodies trucks. The Logan Co., Louisville, Ky., furnished the roller conveyors the radiator core assembly department, and those used assembling differentials and Willys- Knight motors. Conditions Upper Section Blast Furnaces Studied SURPRISINGLY large portion the iron blast fur- for final reactions that take place the lower portion crucible the furnace. Efficiency operation depends great extent upon the conditions the upper portion the furnace. survey these conditions the upper section seven industrial furnaces has been made the North Central Experiment Station the United States Bureau Mines, Department Commerce, cooperation with the University Minnesota, Minneapolis. Furnaces operating Lake ores, Southern ores and Western ores were tested. The velocity, temperature and composition the gas varied from the edge the center the furnace, indi- cating that the ideal case true counter-current move- ment gas and solids not closely approached. concluded, result these investigations, that sinter- ing the finer sizes Mesabi ores, and crushing and sizing hard, coarser ores, such those used the South and West, would increase daily output, lower fuel con- sumption and dust losses, and decrease overhead charges. Investigations made the Bureau Mines the labora- tory and the field show that ideal iron ore from the standpoint physical structure one that contains large proportion intermediate sizes between 20-mesh and 2-in. pieces. The Iron Age, May 4 “ ~ oh 4 ; | New Pipe-Making Methods Outlined Fusion Welded Pipe Requires’ Small Percentage Heat Necessary for Butt Lap Principles Utilized and Development Rapid ROBERT KINKEAD* TEEL pipe manufacturers are beginning believe that they are not exempt from the troubles encoun- tered other industries which have been upset new engineering ideas. the case the ice manu- facturers, who have had compete with domestic re- frigeration, pipe manufacturers are faced with competi- tion from the new methods welding which threaten make obsolete millions dollars’ worth existing equip- ment. The matter was brought forcibly their attention outsider who was supposed merely manufac- turer automobile frames and rear axle housings. received great deal astonished attention when went | + | (G) Fig. 1—Sketch ered Welding Rod” Process out and took large tonnages steel pipe away from the recognized pipe makers with his new pipe-making method. The chorus has now died down the well modulated tones directors authorizing heavy expenditures for experi- mental work find out what all about. Making pipe tube any size specification largely matter heat cost and mechanical working cost. may true that heat cost and mechanical work- ing cost are locked together inseparable manner, but, since amateur pipe-making ideas have been the cause all the trouble, might well try separate the two for the moment order find out something about the implications the new pipe-making methods. Comparative Heat Requirements the old established lap welding butt welding processes, using 20-lb. plate, roughly 1200 lb. steel will have heated the welding temperature. may, for our pur- poses, neglect reheating during the welding and sizing op- erations. the other hand, the same pipe made one the electric gas welding processes, con- *Arc welding specialist and consulting engineer, 3030 Euclid Avenue, Cleveland. 1410—May 23, 1929, The Age siderably less than one inch metal either side the seam welded will have heated the welding temperature. For rough estimating purposes, may say that the new processes heat two inches the periph- ery the pipe, instead the whole periphery. The ratio heat required for 12-in. pipe the two methods being long lb. coal costs more than lb. coal, this element cost pipe making will probably have con- siderable significance, even after all the conversion losses between coal pile and welded seam are allowed for. brief statement summarizing the argument that the thermal advantage the newer welding processes lies the fact that the weld may made pipe without the necessity heating the whole pipe welding tem- perature. Cold Forming Versus Hot Bending But have put the cart before the horse, speak, neglecting consider the matter getting the plate skelp into cylindrical form preparatory weld- ing. That energy expenditure, and figures back the coal pile. The gentleman who could press automobile frames cold naturally assumed that could press pipe the same way. cost lot money for bending equip- ment, but after the figures were all in, probably found that did not require great deal more power cold press the pipe his plant than did pull the hot pipe through the dies and rolls the old process. Leaving out further details the adventure (and must admitted that both pros and cons are left out), the above outline the reasons for the wide interest among manufacturers the new welding processes for making pipe. may now pass the consumer’s view the matter. was found that the buyers pipe did not care how the pipe was made, long was reasonably round Fig. Head matic Metallic Arc Welding ‘ Fig. 3—Carbon Arc Fuses Fil- ler Strip and Abutting Edges Simultaneously Fig. Make Resistance Welded Tube and would, under test, burst anywhere but the weld. new process would mean saving $50,000 $100,000 long pipe line, the process which the pipe was made would look good enough almost any buyer pipe. The welding processes which the longitudinal seam pipe welded without heating all the metal are very simple principle. Fundamentally, they all revolve around the proposition producing large amount heat within very restricted area. The electric and the oxy-acetylene flame naturally occur one being sources such localized heat great intensity. How- ever, the resistance welding process also one the most important methods used the welding tubes and present holds promise great usefulness for welding larger pipe. The accompanying sketches show general way how the heat applied locally the vicinity the seam welded the newer processes. attempt will made more than discuss the general principle heat ap- plication. should mentioned that all these methods welding are covered many patents. Covered Electrodes Used Pioneering Pipe Maker Fig. shows the general arrangement for welding pipe the “paste-covered welding rod” process (the process used the outset and which made necessary for the in- dustry reconsider the established methods welding pipe). The electrode connected the positive side generator and held holder which may manually lowered compensate for the consumption the electrode, may moved electrically operated feeding mechanism. The paste covering the welding rod protects the metal being placed the joint from the action the atmosphere during the welding operation and assures ductile metal the weld. The mandrel confines the metal being added the seam and prevents its running through the inside the pipe. The edges the pipe are originally scarfed give opening ap- proximately semi-circular cross section. One more trips across the pipe seam are made put the required amount filler material the seam. The arc welding process illustrated Fig. feeds the metal electrode through automatic head, the nozzle which shown The automatic head maintains the proper length are and feeds the electrode from the coil required. One such automatic head may make several trips along the seam supply sufficient metal fill the kerf between the edges joined, several heads may operated sequence the complete weld made one trip the whole mechanism lengthwise the pipe. Fig. shows the general plan operation the ma- chine-driven carbon arc process. this process the filler material laid the seam the form strip rod and the carbon arc used fuse the edges and the strip into homogeneous mass. The mandrel stops the molten metal the inner surface the pipe. gas en- velope furnished burning paper twine against the hot carbon the electrode, and this manner ductile metal the weld obtained. The carbon arc stabilized strong magnetic field produced which con- centric with the vertical axis the carbon electrode. The general plan the resistance welding process now used the manufacture welded thin-walled steel tubing shown Fig. This continuous process which Fig. 5—Flash-Welding Also Process Great Promise Fig. Uses Multiple Flames Above Below the Joint The Iron Age, May 23, the curled strip passed through rolls R-R, which squeezes the edges together. Rolls W-W are connected the low-voltage side transformer the current passing from through the seam, thereby producing heat which, combination with the squeezing action the rolls R-R, produces weld. The weld made this process quite ductile. Fig. shows proposed application the flash weld- ing process. Clamps C-C force the edges the seam to- gether while heavy welding currents are supplied through the brushes Fig. shows the general plan making tubes pipe with the oxy-acetylene flame. Pressure applied the pipe the rolls R-R and heat applied the seam the torch While the sketch shows only one torch, common use from three six tips, one close behind another, for high speed operation.* Heat Generated the Metal will seen from the above notes the new weld- ing processes that they are all designed produce the heat only the point which required make the weld. resistance welding all the heat produced within the metal welded. the carbon process *Details of the n described by J. L. Anderson in ethod and machinery used were THE IRON AGE, Feb. 2 approximately per cent the heat produced within the metal welded. the metallic are processes ap- proximately per cent the total heat produced the pipe and the filler rod. All the heat the oxy- acetylene flame produced externally the metal. Research men and engineers who are traveling about the country, looking the various pipe welding methods, see, course, only those processes which were developed years gone by. The engineers and development men connected with the welding industry have filed large num- bers patent applications covering improvements the electric arc, resistance and gas welding processes, and these developments will appear the normal course events working processes within months two years. Some manufacturers are now being penalized for neglect study the implications the new welding proc- esses, the inability catch with developments this direction, even find out what direction new eries will made. all probability much money will wasted developing processes which either are covered patent application, which have been found imprac- tical. The bright spot the situation from the pipe-makers’ point view that reduced costs will undoubtedly widen the use pipe, and much larger tonnage will re- quired than has been made the industry heretofore. Time Graphitization Cut Down Malleable Iron Annealed New Electric Furnace Three-Day Cycle—Controlled Analysis and Observance Laws Governing Graphitizing Are Essential HAT there well-defined market for what known the trade malleable cast iron gen- erally recognized. However, most producers, well most users, also realize that the potential market can greatly increased when commercially prac- tical produce this material methods comparable with those used the steel industry, effecting consistent, uniform and arbitrary physical and acteristics. While there still much desired melting con- trol and molding practice the production malleable iron, the graphitizing equipment and practice offer the greatest opportunity for improvement. Only too fre- quently malleable castings satisfactory composition, properly molded, have proved unsatisfactory the user because improper graphitization. fact, proper graphitizing will, surprising extent, discount errors melting control. properties char- Research Graphitizing Exact knowledge the relation the analysis “white iron” the physical properties and characteris- tics malleable iron has been limited, least its application. Equally serious the lack comprehensive and exact knowledge the laws graphitization, influenced composition, time and temperature, arities heat cycles, and gas balances, producing malleable iron desired physical characteristics. Several months ago the Industrial Furnace Corpora- tion, Buffalo, undertook, with the cooperation re- *President, Industrial Furnace Corporation, Buffalo. 1412—May 23, 1929, The Iron Age search organization (recently incorporated the Hayes Malleable Iron Co., Chicago), accomplish the following: 1.—To develop commercial graphitizing equipment and process capable producing, consistently, uniform malleable castings predeterminable physical properties and characteristics. make such product less than present aver- age production costs. effect material reduction the time “in process” normally required producing malleable iron. The measure success that eventually attended these efforts will apparent from the results which are now possible consistent duplication any producer malleable iron. There must available, however, the proper equipment and the necessary metallurgical edge the commercial application the graphitization. laws More than five years intensive academic research work Dr. Anson Hayes and his associates developed the fundamental information which made possible the practical commercial heat cycles necessary graphitization large tonnage loads white iron castings. Electric Elevator Type Annealing Furnace obtain the desired results special design the elevator-type electric annealing furnace used. (Patents and patent applications controlled the Industrial Fur- nace Corporation.) The first commercial unit, tons net capacity, has now been continuous operation for year the plant the Acme Steel Malleable Iron Works, Inc., Buffalo. During this time test heats practically all compositions white iron, ranging from high-carbon cupola iron air furnace iron less than per cent carbon, have been properly graphitized short heat cycles and commercial basis. Equipment has now been developed, together with the operating tech- nique, make possible the handling charges net tons, with output about 3000 tons per unit per year. Results Already Obtained The results this development work may briefly summarized follows: Establishing the necessary technique for producing arbitrarily, uniformly and consistently (a)—Castings having physical structure per- patterns, not record test, but matter service. By-Product Right Analysis and Correct Laws However, short cycles are really only “by-product” controlled analysis and the commercial application the laws graphitization. The possibility producing consistently much more uniform casting desired physical properties and characteristics would appear first importance. That this can done more rapidly and lower cost merely added gain. The value the development work referred may further indicated stating that the translation academic formulae for commercial application, and the > — Special Electric Graphitization Furnace for Reducing the Time for Heat Treating Malleable mitting unusually high machining while still retaining physical properties 35,000 yield point, 50,000 Ib. per mate and per cent (b)—Castings having normal physical proper- ties, indicated 40,000 yield point, 60,000 Ib. per sq. in. ultimate and per cent elongation, with normal machinability (c)—Castings having abnormal physical prop- erties indicated 55,000 Ib. yield point, 75,000 Ib. per sq. in. ultimate and per cent elongation, with only fair machinability having completely graphitized core, with pearlitic wearing surface very poor machinability. 2.—Developing commercial graphitizing equipment and formulated technique for accurate and complete graph- itization white iron total cycle three days less. speeds, ulti- indicated sq. in. 3.—Obtaining material reduction the total cost producing malleable castings where the foundry has elec- trical energy available normal average cost. The importance successful, commercial, short-cycle graphitization quite apparent, not only making possible better service users, but increasing the scope the market. rush order for castings was recently delivered four and one-half days after receipt designing satisfactory commercial graphitizing equip- ment, have been possible only through the actual experi- ence gained from the graphitization hundreds tons white iron the widest range chemical analyses and under practical foundry conditions. The statements made this brief summary are limited appraisal results research work that has been completed, and believed that further de- velopments will complementary rather than over- lapping conflicting. Hadfield’s cast manganese steel (12 per cent man- ganese) after heat treatment cannot cut the usual machine tools. sufficiently hard tool may slightly “touch” the surface, but the layers just below automat- ically harden and resist the tool. Industrial uses have therefore been limited shapes which can cast with any subsequent finishing done grinding. Drills have recently been made both America and England which can bore this material commercial speed, and Arts Metiers recounts similar success France. tool special high-speed analysis hardened glass-hard, yet tough enough take the pressure several tons necessary penetrate cast high-manganese steel. The Iron Age, | | Tungsten-Carbide Cutting Tools Precautions Necessary Preparing Alloy and Mounting Limitations Use HENRY LONG AND PAUL EDDY, JR.* not the purpose this paper discuss the gen- eral properties tungsten-carbide tool materials; these have been adequately described others previous writings. is, therefore, more order this time present the results experience the fabrication these tools and both successful and unsuccessful at- tempts apply them various types work, assist the readjustment manufacturing practices which must necessarily take place, are allocate tungsten carbide its true place industry. Design and Fabrication Tools The brittleness tungsten-carbide alloys prop- erty which encourages the use large, and especially thick, tip relation the size the cut taken. The factors limiting the tip size may the cost the material, the necessity for ample support the cutting tip stronger and tougher material, and the space available for the operation the whole tool. also necessary, designing tool, consider chip space, especially the case multiple-edged tool, that there liability chips becoming packed the tool face the extent that chipping the edge results. The comparative weakness this material demands sharp cutting angle possible, reduce the chip pressure. are use large rake angle, however, without crumbling the edge, absolute rigidity es- sential. more rugged machines are built, and fluctuations power application are lessened, will become possible use steeper cutting angles. The angles are not the same, course, for all jobs, but depend upon character material being cut, type tool used, speed, feed and condition machine. example, are using lathe tools for malleable cast iron front rake deg. and side rake deg. have hopes increasing these angles for steel approach freedom from vibra- tion operation. Inasmuch heat generated the tool relatively un- important, find possible use broader-nosed tools tungsten carbide than high-speed steel, thus dis- tributing the cut over wider areas and lengthening the life the tools. Partly the interests economy, the company with which the writers are associated studying methods and technique making tools tipped with tungsten-carbide alloy. This is, perhaps, field itself; yet one with which believe every user these tools should familiar. With money tied such expensive mate- rial, imperative that the investor position use efficiently possible and eliminate losses resulting from delays procuring, regrinding, repairing re- modeling tools. *Chief experimental engineer and assistant metallurgist, re- spectively, Brown-Lipe-Chapin Co., Syracuse, The paper was read the Rochester meeting the American Society Mechanical Engineers, 1414—May 23, 1929, The Iron Age tungsten-carbide alloy nearly the size required tool, the first problem encountered that removing from small bar stick the alloy piece the desired size and shape, with minimum effort and the least possible loss. the first place, the bar alloy should purchased with its application mind, that two dimensions the proposed tip will have been fulfilled. Then would appear merely necessary cut the length desired means thin grinding wheel, the special composition recommended for grinding tungsten-carbide alloy. Bar Fractures Before Fully Cut not simple, however. have never been able cut completely through even thin piece this alloy with grinding wheel; the piece always fractures before the job finished. feeding the disk carefully not heat the alloy excessively, and turning the piece grind into two opposite sides perhaps into all four sides, may possible cut away two- thirds the section before the piece cracks. The discour- aging feature that, even with these deep notches care- fully ground, the fracture more likely occur be- tween the notches than anywhere else, with the limita- tion, course, that always starts one the notches. have found, after many trials, that grind one side only (one the broader sides, the section not square) directly into the piece until cracks sure any method resulting flat fracture the desired plane. With this method the feed the wheel into the work, within reasonable limits, appears have little in- fluence the result. The fracture, the way, with any method, usually does not begin the lowest point notch, but rather the side its rounded bottom, line with one wall the notch. The notching should not attempted hand, but should done small sur- face grinder. are using 7-in. wheel, not less than in. thick, the circumference which has been dressed rim approximately 1/16 in. thick and in. wide, with fillets the shoulders and with rounded edge. Mounting Requires Firm Support The next step mounting the tips the holders. Firm support paramount importance. The tip must fit the seat closely, and should have contact over not less than three sides. Blades multiple-edged tools, such reamers and facers, may made thin, flat pieces alloy, which should mounted slots sawed angles points. This method results locking the blades against the pressure the chip, which would otherwise pull out the blades during operation. Brazing may done heating the holder and tip furnace having atmosphere nitrogen hydrogen. using copper the brazing material. Good results can obtained, however, without such furnace, heat- | ing the flame blow-torch, provided brass alloy substituted for copper. The strength well brazed joint brass may not great that equally good copper joint. But, owing the fact that the brass flows more freely, complete filling the joint can made much more easily under the blow-torch with brass than with copper. The tip blade may ground its final shape after mounting. the past have occasionally encountered tips which their crumbling defied all our efforts grind good edge. Various methods impregnating sev- eral materials with fine abrasive for use laps, well many ideas lapping processes, were investigated overcome this difficulty. developed machine lapping with aluminum disk which was brushed fine sili- con-carbide paste. This served the purpose fairly well, although there were still some edges which required fin- ishing with hand lap brass. late, however, both grinding wheels and our tech- nique seem have improved. find that fixed posi- tion surface grinder results rounding crum- bling the point; consequently grind hand, moving the tool across the side the wheel. Good results roughing are obtained with certain Czechoslovakian silicon-carbide wheel and with 60-I 80-I Crystolon wheels. For finishing 100-I Crystolon wheel satisfactory. Wheel speeds are approximately 3400 r.p.m. now rarely find necessary resort lap- ping the finishing operation. feel, however, tnat further improvement possible, possibly through the use still finer finishing wheel. Cutting Malleable Cast Iron well known, the properties tungsten-carbide alloy point the low-tensile materials the field greatest service. have found number operations malleable iron castings which these tools are ap- plicable. One these the breaking down chamfering the flanges differential case castings. The operation the first performed the rough casting. One typical case requires chamfer about in. flange 9-in. diameter. Best previous results were obtained with Stellite, cutting speed r.p.m. and with feed 0.014 in.; the production per grind averaged 200 pieces. simply replacing the tool with tungsten-carbide alloy, the average production jumped over 7000 pieces per grind. the same lathe set-up, the flange rough-faced. Stellite was formerly used, making cut 1/16 in. deep, with feed 0.014 in. the same speed above, 170 ft. minute; the tool life was about 150 pieces per grind. Tungsten-carbide tools are averaging 700 pieces per grind. The speed these operations are present limited other tools, notably reamer, the set-up. Finish-facing the same flange then performed another lathe. High-speed steel tools formerly used pro- duced average 400 pieces per grind. Tungsten-car- bide tools operating speed 300 ft. minute, with 0.013 in. feed, average 12,000 pieces grind. These tools not give quite smooth finish the work did high-speed steel, but their big advantage, aside from increased production, the elimination size variation. was necessary for the operator readjust the set-up several times during the life steel tool. With the tungsten carbide adjustment required throughout day’s run, and difference size between the first and last piece can detected. Another malleable cast iron application that line- reaming pinion bores differential carriers. double reamer in. diameter, each section having six blades, run one such job, r.p.m., removing about 0.015 in. with feed 0.052 in. High-speed steel reamers pro- duced average about 1500 pieces per grind, and each reamer had total life about 6000 pieces. The tungsten-carbide reamers average 9500 pieces per grind, and the life reamer approximately 28,500 pieces. this application better finish well less size variation obtained with tungsten carbide. The rate production, furthermore, has been increased approximately per cent, the high-speed reamers were run half the above speed, with little greater feed. all the above applications may say that, though improvements may still expected, the use tungsten- carbide tools has progressed beyond the experimental stage. These tools have been definitely adopted stand- ard these jobs, simply because they have proved advan- tageous, either from economic from quality-of- product standpoint. Use Gray Cast Iron Certain pinion spacers are now made malleable cast iron. obtain greater crushing strength and effect savings material costs, desired replace malleable with gray iron for these parts. Such move, however, has not been found practicable when using steel tools, ac- count difficulties facing and boring which have in- variably been encountered whenever the substitution has been attempted. The method performing these op- erations the malleable spaces use two boring bars—one for the two bore diameters, another with two blades for facing both ends length simultaneously—on lathe, all cuts being about 3/32 in. The advent tungsten-carbide tools, however, mak- ing the desired move possible. Experimental work this job has not yet been completed, but indicated that these operations will soon carried out gray iron spacers drill press, using two double counterboring tools, each which will face one end and bore the adja- cent diameter. Each tool has six boring and six facing blades. The rate production expected double that the present method. Not allowing for possible increased tool cost, the saving will probably labor and 2%c. material, per piece; and, addi- tion, the part will superior its predecessor. Cutting Alloy Steel have been cautious applying tungsten carbide the machining steel. Nevertheless, there pres- ent one important job which saving being made its use. Bevel-drive gear forgings, usually per cent nickel steel, were formerly made with minimum machining allowances 1/16 in. backs and 1/16 in. faces. The initial operation was take fairly heavy facing out from the backs the forgings heavy machines with high-speed steel tools. Owing the powerful chucking required, occasional forging was distorted that, when was removed from the machine after the cut, the back would not quite flat. This condition caused trouble subsequent operations. The present method specify 0.070 in. allowance for machining the face and merely clean the forge shop excess 1/32 in. 1/16 in. from the back with tungsten-carbide facing tool, lathe. This means that comparatively thin cut taken surface abrasive and speed high that high-speed steel tool will not finish one piece. The remaining operations the gear blank—turning, boring and facing—are han- two set-ups large vertical automatics. The speed the initial facing cut typical forg- 267 314 ft. minute. The feed 0.020 in. tungsten- carbide tool will face 150 175 pieces per grind and will have total life 3000 4000 pieces. Ignoring the former cost high-speed tools, find that tungsten- carbide tool, costing $24 and facing 3600 pieces, does the The Iron Age, May 23, 1929—1415 | work for per piece. Against this place actual saving 3c. material each forging, increase production finished gear blanks least per cent (on man-hour basis) and the elimination warp- ing troubles; the answer obvious. should mentioned that some difficulty was ex- perienced obtaining lathe which would stand under the high speeds required make this facing operation economical, and that before such lathe was used the tungsten-carbide tools gave much trouble chipping, result lack rigidity. Unsuccessful Applications natural that, seeking for applications which tungsten-carbide tools will improve the product lower the costs, some failures will occur. fully impor- tant, interests all concerned, believe, record operations which these tools seem un- the adapted broadcast their successes. have been unable make cutting-off tool for automatic which every tool chips very quickly. have not been able make tungsten-carbide tool work satisfactorily Multaumatics; the large overhang permits sufficient vibration chip the tool. This alloy has also proved ineffective rough-turn- ing the outside diameter the flange certain differ- screw machines operates successfully; ential case malleable cast iron, owing the irregu- larity depth cut. are still having some difficulty either purchasing manufacturing multiple-edged facing tools from which the tungsten-carbide blades will not pull out during opera- tion. are attempting face the backs differential side gears; though have some hope ultimate suc- cess, our efforts have thus far produced but erratic re- sults. flat-faced tool in. the work 0.0017 in. wide, feeding forward into each revolution under speed 100 ft. minute, has not performed one case, for example, 4700 pieces were faced this manner before the tool needed regrinding; another time the tool broke badly that was ruined when less than 2000 pieces were faced. general may say that the heavy pressures en- countered facing with flat-nosed tool, end- milling, have made these operations very difficult per- form with tungsten-carbide tools. The locking the tips blades seems present the only solution. Conclusions evident, from our experience, that tungsten-car- bide alloys are have important place the fabrica- tion ferrous metals. The occupying this place will come, however, only after careful investigation all likely applications. And progress this direction will necessarily gradual and slow, especially view the very high price which must present paid for the alloy. Although further evident that the next move the continuous battle between machines and tools now the machine builders, nevertheless firmly believe that the future these alloys factors effi- cient manufacturing the hands, not the makers the tool materials nor the builders the machines, but the users machine tools. wonder, also, the fate the present tung- sten-carbide alloys when they shall required work machines which have begun grow bit old ser- vice. Will possible construct machines that will remain sufficiently rigid and vibrationless, throughout lives reasonable length, permit these tool materials operate without chipping? will hecome necessary develop new alloys, possibly with tungsten carbide the base, but containing larger amounts cobalt other metal, which will stronger and tougher than the present alloys even some sacrifice hardness? These are questions which must soon answered. Selection Steel for Springs the spring steels commonly used Great Britain have been studied the National Physical Labora- tory, and the results reported the Iron and Steel Insti- tute from 1926 1929, which the adjoining table gives summary. Fatigue tests were made small polished specimens cut from %-in. flat bars, and the endurance consid- erably higher than can expected from commercial spring leafs, with roughened and frequently decarbonized sur- faces. The results are comparative, however. fatigue limit necessary for long-lived spring. high proportional limit necessary prevent “settling down” use. High Izod toughness should indicate resistance the growth surface cracks. will noted that several steels show good tough- ness when tempered 350 Brinell, particularly the high chromium and the chromium-vanadium steel; the me- dium hard condition the latter superior all others; the hardest condition the steels are all comparatively brittle, but the water-quenched silico-manganese steel nearly tough the more expensive chromium-vana- dium. The 0.46-per cent carbon steel appears definitely inferior quality. All the steels have elastic modulus close 30,000,000 per sq. in. Physical Properties Quenched and Tempered Spring Steels Cher al Analy $6 carbor 1.46 0.51 0.09 810 W 6 carbon 0.77 0.21 S00 W O 0.8 carbon O82 O.26 900 O Low chromium 0.60 0.62 0.26 ... 0.56 High chromium 0.45 0.69 0.12 Chromium-vanadium 0.68 ... 1.16 0.27 Nickel-chromium 0.36 0.50 0.29 3.42 0.60 ... 820 (a) O means 1416—May 23, 1929, The Age Tempered Tempered Tempered 350 Brinell Brinell 470 Brinell Endur- Propor- Endur- Propor- Endur- Propor- Limit Limit Izod Limit Limit Izod Limit amit Izod 81,000 90,000 17 81,000 100,000 85,000 120,000 19 92,000 130,000 13 108,000 150,000 2 85,000 108,000 23 94,000 150,000 14 105,000 170,000 5 §5,000 108,000 50 $2,000 140,000 17 112,000 155,000 12 92,000 112,000 96,000 140,000 99,000 155,000 87,000 115,000 17 103,000 135,000 12 108,000 150,000 9 j Mechanical Engineers Rochester Discussions Include Tungsten Carbide, Diamond Tools, Industrial Training, Materials Handling, Manage- ment and Other Topics Program OTABLE among the sessions the Rochester, Y., meet- ing the E., held the Sagamore Hotel May 13-16, were those devoted machine shop practice. The society’s committee education and training for the indus- tries also arranged program un- usual interest. all papers were presented the sessions. These included ma- terials handling, management, wood industries, mechanical springs, applied mechanics, boiler furnace refractories, boiler feed water studies, heat trans- mission and economizers and preheat- ers. More than technical commit- tees held meetings. Entertainment features included informal get-together the home Miss Kate Gleason, life member the society, and dinner which Dr. Mees, director re- search laboratory, Eastman Kodak Co., was the principal speaker. Plant visits, made each afternoon, included the Bausch Lomb Optical Co., Gleason Works, Taylor Instru- ment Co., Garlock Packing Co., Kodak Park works the Eastman Kodak Co., General Railway Signal Co., Todd Co., Telephone Mfg. Co., General Railway Signal Co. and the Bastian Brothers Co. Reports Use Tungsten- Carbide Tools NUSUAL interest was evidenced carbide cutting tools, which were pre- sented the first the two machine- shop practice sessions. These were “The Status Tungsten Carbide Cutting the Subcom- Special Research Committee Spencer, Western Electric Co., Kear- ny, J., chairman, and “Tungsten Carbide Cutting Tools,” joint report Paul Eddy, Jr., assistant metal- lurgist, and Long, chief experi- mental engineer, Brown-Lipe-Chapin Co., Syracuse, Active interest was also shown the contribution and engineering, Bausch Lomb Optical Co., “Diamonds Metal Cutting One came away from these discus- sions with definite feeling that 16, page 1349. page 1344. “new things are the making.” For instance, the committee’s report cited the following instances increased life tool means tungsten-car- bide tools: machining bronze valve disk automatic chucking machine, the life the tungsten-carbide tools 27,000 pieces per grind, compared 600 800 pieces with steel tools. malleable iron part having brass inserts, also machined auto- matic, the life the carbide more operation per grind with steel tools. drilling bakelite with 9/16-in. drill, tools tipped with tungsten grind, compared with 155 with steel drills. drilling and counterboring bakelite-asbestos clutch production 50,000 holes per grind, compared with 1000 with high- speed steel. The Brown-Lipe-Chapin Co. has adopted the tungsten-carbide tools standard for number operations malleable iron castings. one piece the production per grind jumped from 200 7000 pieces. an- other, line reaming pinion bores differential carriers, the steel ream- ers produced about 1500 pieces per grind, with to