The Iron Age 1929-07-11: Vol 124 Iss 2

THE IRON ACE New York, July 11, 1929 ESTABLISHED 1855 VOL. 124, No. Handling Parts Skids Trucks Boxes Designed for Multiple Lifting Lift Trucks Carry Full Loads Established Routes FRED PRENTISS* RANSPORTATION problems small plant are often complex and more difficult solution than large factory, where, with mass production sim- ilar parts, long hauls and straight-line routing, the use electric trucks often regarded almost indispensable method economically handling materials process. While readily admitting their advantage for transporta- tion large-production plants, the manager small plant may assert that electrical trucking material would not practical economical his plant. While the Elwell-Parker Electric Co., Cleveland, has used trucks for many years its own plant, has re- cently evolved system which has improved its transpor- tation methods and solved its handling problems. These are character similar those many plants *Resident editor, THE IRON AGE, Cleveland. 4 pert like size, and which include handling material process and, from finished stockroom, numerous parts comparatively quantities. This plant with approximately 100,000 sq. ft. floor space, manufacturing being done for the most part one main four-story building. Not only does the plant arranged require considerable cross hauling, but the work has car- ried different floors. The company’s activities are confined making elec- tric industrial trucks some types. Large, standard- ized parts are handled large load skids, small stand- ardized parts small skid boxes, and nuts, bolts and similar small pieces nesting pans, that the number pieces may vary from 500. Transporting parts economically relatively small quantities with standard truck done this company the use small skid boxes and tote pans, designed Crane Truck Loads Truck Frames An- other Electric Truck for Trans- portation from the partment Assembly Depart- ment. the case such this, skids course are not needed. The crane truck can make de- liveries, but most serviceable own character Bin 77 KID Used for Transporting Small Parts and One the Tote Pans for Parts Smaller Than Those Handled the Skids (Right). Above are the three pieces sheet steel which the skid frame made that the truck can carry load near its capacity, made number different parts. Three these skids are usually transported one time. This method used conveying all work except some standard parts, usually moved large enough quantities make large single skid loads. addition, routing system provided for truck the production department, and card system for controlling the truck and material movements. Manner Obtaining Full Loads the use small skid boxes and handling three skids electric lift platform truck one time, each skid carrying different kind parts, good sized load can moved. Tote pans, set the skid boxes, are used for smaller parts than are carried loose the skid boxes. With the skids and pans, full load various parts can moved one time. The saving would not marked handling small loads the electric truck, except for the element speed. With the use skids for handling different parts the same time, there gain speed, the electric trucks moving three times fast the hand trucks, and also gain tonnage, this being ratio approximately nine one. Skids, designed the company, are in. long, in. wide and in. deep, their capacity being cu. ft., 1200 lb. each. They have clearance from the floor the bottom the box, permitting lift platform truck run beneath. They are made steel plates; instead having four legs, the ends are solid box construction. each corner mounted double-wheel caster, making the trucks convenient moved hand around the machines, well move the unloading stations. The truck serving the production department, which these skid boxes are handled, 4000 lb. capacity with 54-in. platform. This truck picks one, iwo three skids and can set down any one the skid boxes making the load. carrying three boxes, sets the three the floor, withdraws the platform and shoves out line the box left. Then the truck platform driven under the remaining boxes, deliver them another point. Tote pans are in. long, in. wide and in. deep, and hold lb. They have handles each end and are usually set the skids with handles resting the edge the skid, shown one illustration. The loads the skid boxes rule are not flush with the skid tops, that there room for the tote pans rest the skids without disturbing the material the skids. Each skid has hook-hole each end and the tote pans hook-hole each handle, for convenience dragging the floor hook-rod, from machine tool the department loading point. The plant uses 185 the skids and 500 tote pans. addition, there are large skids, in. long and in. wide, which are used for handling parts too large carried the box skids. Four electric trucks are service the plant. addition the one for handling the skids, second truck provided the production department for carrying By Truck. Three skids and several tote pans can car- ried one time, making full truckload numerous small parts. Material for certain assemblies may thus han- 4 dled all together, facilitating the work putting parts to- gether e © 4 ‘ | | | | — — - 78—July 11, 1929, The Iron Age frames from the fabricating department the assembly department, 5000-lb. non-lifting truck for handling raw stock and 10-ton tow tractor for moving the completed trucks before batteries are installed them for test shipment. Incoming material unloaded means over- head hoist from motor trucks lift truck skid. the stationary platform truck, which trailer attached when bar stock being handled. This truck takes the stock the rough stock inspection department, and then the rough stores department not needed immediately for production. This truck also takes. di- rectly the finished inspection department, parts like electric meters, bearings, horns and tires, which are completely finished when Trucks Follow Prescribed Route regular route laid out for the lift truck the pro- duction department and the operator covers this route least once hour. Usually the round trip does not take MATERIAL RECEIPT FIROM PT. Mo PLEASE RECEIPT THE FOLLOW INC TOVAI f iV rine ABOVE CRDFF DAILY PEPORT SIGNED RECEIVED RECEIVED IN GOOD CONDITION LOCATION ATERIAL Receipt Forms and Routing Tags Facilitate the Work the Delivery Trucks over min., and, unless his time taken special trips, the operator starts his next regular trip before the hour up. The routing this truck, starting with the raw materials inspection department, successively through the lathe and screw machine department, auto- matic machine and punch press department, milling ma- chine department, drill press department, inspection de- partment, finished stockroom, motor and controller depart- ment, assembly departments and then back the receiv- ing department. Two elevators are used for carrying the truck from floor floor. each department are conveniently located stations for incoming and outgoing stock. From the incoming sta- tions stock pushed short distance the caster- mounted skids the machines which operations are done, and when finished, the skid pushed back the outgoing station. However, the truck operator usually knows what machine the parts are going, frequently takes loaded skid directly the machine, instead leaving the station. The truck carries finished parts, either skids tote pans, from the finished stockroom the truck assembly motor assem- PREV Tots DELV bly departments, and delivers spare parts and pans the shipping department. Forms Used Controlling Material Dispatch The truck operator gets his instructions for moving parts means tags two colors, placed the work. Parts bearing manila tags from one depart- ment another; those bearing similar orange tag the finished stockroom, where the tag signed the in- spector, with the date inspection. This card stays with the work. these tags are spaces for listing the order number, number pieces, drawing number, name part and date. Another form used material which made out duplicate for each movement material. This receipt follows the work and shows the order number, the department from which the parts are sent, the department which they are received, the number pieces, the drawing number, name part, number previously deliv- ered, the total number delivered and whether partial final delivery being made. This material receipt signed the foreman the department from which the parts come and the foreman the department receiv- ing them. One copy goes the office and the other the head the department receiving the parts. When parts are issued from the finished store- rooms material list requisition issued the order department, usually covering number items. The head the finished stockroom copies each item sep- arate form, designating the pieces, the number and the drawing number. The pieces called for are put tote boxes and the truck delivers them the assembly floor. The assembly department counts the pieces check against the storeroom. After the requisition filled, the stockkeeper enters the material list the number pieces each item delivered, and sends the list the assembly department, which K.’s and returns the stockroom. case shortage some parts the stockroom, this indicated the requisition the difference be- tween the number parts called for and the number deliv- ered. The stockkeeper issues stock chaser shortage The Iron Age, July 11, ~ SIGNED DATE | | list, showing what required complete the order. Then the stockkeeper sends copy the material list, showing the shortage, the stock ledger department, where per- petual inventory kept. The stockkeeper retains the original material list with its record shortages. Parts supply these shortages come from the different depart- ments through the inspector, being accompanied with partial “turnout” signed the foreman. parts fill the shortages are received they are trucked the as- sembly department. Much Better Time Achieved This system has resulted speeding shipments spare parts. Formerly parts fill these orders were picked only once day standard skid box, having compartments each side and carried lift truck. Now, these orders are taken care once and parts are prepared for shipment immediately receipt. These or- ders often come telegraph, users this type equipment usually wait until actually requiring parts for replacement before ordering. Very few users stock any spare parts. Spare part orders, arriving the mail department, are sent through tube the order department, where the order written out manifold blanks. copy this dispatched aerial cableway from the second floor the office building the finished stockroom the third floor the factory. The order filled once and the electric truck takes the shipping room its next trip. This plan practically assures shipping all stand- ard part orders the day they are received. Since power trucks have been used for years this plant, and the present system has been gradually devel- oped, the principal saving has been smoothing out schedules that assure even flow materials match the speed the machine tools through which they pass. Marked European Progress Non-Ferrous Die Casting his paper “Die Casting,” before the Third Inter- national Foundrymen’s Congress London, June 14, Munday said that investigations, which had played important part, into the die casting copper- rich alloys confirmed his own personal experience ob- tained practice, namely, that when new die put into operation, there invariably period trial while small corrections are made, adjustments gates and vent ef- fected, before the most skillful workers are able pro- duce regularly and continuously satisfactory castings. satisfactory castings cannot produced under commer- cial manufacturing conditions 12-per cent silicon alloy, they cannot produced all, for general rule they are less liable “hot-shortness.” They are easier cast, have good tensile strength, generally greater elongation and impact values, and are more resistant corrosion. would appear that gravity die castings are pref- erable when the mechanical properties the finished castings are the chief consideration, and that pressure die castings are preferred when accuracy dimension and elimination machining are first importance. spite these conclusions, the marked success, achieved the author’s work the die castings air-pressure machines, makes one that when prepared under the best conditions. Much industrial research has been done overcome all the difficulties the Doehler Die Casting Co. the United States, some firms the continent, and the author’s colleagues Fry’s Metal Foundries, Ltd., London. The last-named company recently acquired new process the manufacture die castings yellow metals, which promises revolutionize this section the industry. The improvements and modifications have passed far beyond the experimental stage, and the re- sults actual manufacturing conditions are quite satis- factory. How Size Section Affects Strength Gray Cast Iron suggest method which enables comparisons made between different irons melted under the same conditions, and the same irons melted under different con- ditions, the aim Pearce, British Cast Iron Re- search Association, his paper, “Influence Size Sec- tion the Strength Gray Cast Iron,” delivered before the Third International Foundrymen’s Congress Lon- don, June 14. The transverse test, course, only one mechanical test and may offer little guidance the ability the metal withstand fatigue, fluid pres- sure, abrasive wear, corrosion heat. series bars from cast tested tension the same-sized test piece, the values will not, under ordinary conditions, de- part far from the mean, and the same applies trans- verse tests. For the particular mixture and the sizes test bars chosen there will, therefore, definite ratio transverse tensile strength. For ordinary irons and the usual standard bars this ratio about 1.8 Through the courtesy Vickers-Armstrongs, Barrow-in-Furness, England, the author tested bars 1.2 in. and 2.2 in. cylinder iron transverse, averaging 80—July 11, 1929, The Aze three results each case. The broken bars were then turned tensile pieces different diameters, varying bars from in. and 2.2 in. bars from 1.9 0.2 in. was found that tensile strength falls off very rap- the machined diameter increases, but that the specified British Engineering Standard Association diam- eter for each size bar the tensile strength falls within the range represented transverse strength divided 1.8 2.0. The ratio transverse tensile depends the size the test piece, and tests other compositions will the influence composition determined. set bars four compositions provided Met- ropolitan Vickers, Ltd., 1.2-in. transverse bar was broken and one half turned the standard tensile diam- eter 0.564 in. and the other the standard tensile diameter 0.798 in. The transverse/tensile ratio varied between 1.59 and 2.18. Further examination needed. The strength cast iron determined its composi- tion and its structure, these factors being fixed part constitution the charge and part the melting conditions. | | Knowing Men Keystone Management Machine Will Known Quantity Work Known Time—a Man Will Such Work Willing and Capable ALFRED DVANCING waves other people’s progress sweep over the unchanging man and wash him out.” That statement, made Kettering the General Motors Corporation several years ago, true today was years ago when boy entered the shops the General Electric Co. Schenectady, But before dwell the present day situation, let’s project ourselves back the work day 1894 and there- abouts, when passed through the check-in gate seven the morning and out again six the evening, with one-half hour for lunch. Those were the days when the workman bought his own wooden wash pail, soap and towel, which kept under his bench, and hauled out few minutes before quitting time providing the foreman “super” wasn’t looking. luck was with you, you got home seven; you missed your car, telling when you reached home. There were compensations, you were tired and needed little nap, all you did was set your planer, shaper lathe cut the air, and your buddy tipped you off when the boss’s feet were heard. piece work, bonus premium. Some contract work rare cases, but mostly flat day rate, and not very much that. Quantity and high quality employee production, lowest possible unit cost, meant nothing the average employee then. knew little the customer’s side *Abstract address before the National Association Foremen Indianapolis, June the picture—seldom shared any the gains, conse- quently was interested only putting day’s work. The Buying Public the Boss And those early years had every often our nice little strikes because one the other didn’t want this that, and all sympathized with each other quit, sulked, lost our pay, and finally came back, all because the fellow that hired thought was boss and thought were boss—when all the time neither was boss—but hadn’t learned yet that “the buying public the boss all.” matter what position hold, workman, foreman, superintendent, manager, president, what not, let fail give make good products, then see how quick- called account for our work the buying course, the waves progress taught that mil- lions were wasted unnecessary strikes—we also learned that many losses were due neglect the part the manufacturers give the same consideration and atten- tion the human element their factory they gave their machinery. The employees learned also that the employer was their agent who found purchasers for the product their labor. between the two learned that many years labor were needed for worker recover his wasted savings, for the manufacturer replenish his loss. Treat ’em rough, and tell ’em nothing, was not very RESIDENT the Link-Belt Co., Chicago, Alfred Kauffmann has been associated with that organization since 1901. Born Esslingen, Germany, Aug. 20, 1879, came this country the age three. After attending the public schools New York and Rutherford, J., Mr. Kauffmann apprenticed himself the age -the General Electric Co., Schenectady, worked the tool room that plant until August, 1895, when entered the machine shop Robert Hoe Co., New York, manufacturers printing presses. While with the Hoe Company studied Cooper Union, New York, and 1898 cntered Pratt Institute, Brooklyn, from which was graduated 1901 with the degree mechanical engineer. Immediately afterward en- tered the service the Link-Belt Co. draftsman its Philadelphia branch. 1906 was made superintendent construction and 1909 was appointed sales engineer charge the West Virginia territory. January, 1913, was made assistant the president, Chicago, and July that year was appointed the Philadelphia plant charge operations the company’s Eastern division. October, 1914, was transferred Indianapolis and February, 1915, was chosen vice-president and general manager, the position held until his election president few years ago. KAUFFMANN The Iron Age, July 11, q i | 2 4 | “a \ | 0 = i i ¥ — = —s 4 ¥ 5 q { : far from the true relationship between management and employees manufacturing plants the early days. Today, just the opposite views are held executives whose function the handling employees. Men today want know what it’s all about. They are intelligent enough comprehend the facts, and use them con- structively, and it’s good business give them the in- formation. Keeping Down Customer Turnover Old customers are the backbone any business. keep them satisfied with price and quality and delivery will have less customer turnover. When these facts are brought home employees, will stimulate them appreciate that their performance has direct bearing upon the marketability the product. Losses and wastes invariably are reduced the arousal interest. say again, consider the factory employees part the sales force, and tell them everything. Modern business organized such large units today that ever-increasing number cases men who years ago would have been business for them- selves are today important factors large corporations. Men with high qualifications devote their talents mar- keting, production, accounting some other phase the company’s business, but irrespective its many ramifica- tions, the fundamental principles underlying business suc- cess are few number and simple character. start with, the object being business make profits, and the index success the ratio the profits actually earned the real profit-making possibili- ties the business. Having determined what these profit-making possibili- ties are, the next step ascertain what the causes are that contribute failure realize these potential profits. must find out what extent this failure due manufacturing inefficiencies—to excessive sales costs—to short-sighted incorrect company policies—to defective accounting methods—to ineffective inadequate advertis- ing, still other conditions. Mergers Substitute for Good Management Bear this small companies into one large company provide substitute for competent management. After they are set and operating unit, their earnings, any other form business, de- pend entirely the sound judgment and foresight the management. But with big business and mergers entirely new condition was created. Industry, instead belonging the privileged few, passing into the hands the many. Today there army employee-owners every large organization. Does not this put added responsibility the management? The passing dividend becomes serious matter, the action hits the pocketbooks the workmen, foreman, superintendent and company officers. Also workers who are now part owners their companies are beginning have better understanding the duties and difficulties management. Now what part play this picture? Most this room are interested the manufacturing end. What proportion the failure get the best out our plants can pinned us? all know that indus- trial plant only mass junk unless some one around see that the bricks, mortar and machinery be- come tools production. And that takes human beings. There may all kinds trends industry— mergers, consolidations and what are sometimes called vertical trusts; history may bring about the cutting the big units into small ones again, but what will always needed will men things. Men are not such certain quantities money, materials and machinery. machine will known quantity work known time. man will such work willing and capable doing. Men, then, are the most important factors the con- duct any business. And what difference does make whether mention this before gathering foremen, salesmen executives, when the cry always the same. Forget the title tacked our names, and look from the big opportunity standpoint. Men grow hav- ing responsibility laid upon them. You may fore- man today and superintendent manager tomorrow. The same applies the workman under you. sense you are his manager. Encourage him, let him know that has chance get ahead, and that his chance lies himself, and you will get further than through any scheme profit sharing, bonus, welfare work, though they all may very helpful. Employees Need Encouragement The chance say “Yes” the question, “Am get- ting on?” what appeals most men. You men here who are foremen— You know better than the many petty things that come during the day week, the burden which must borne you. You know the most important factor maintaining high quality and low cost. Why tell you anything about the direct loss due spoiled work, that rush jobs are always more expensive than regular jobs? Some you may, but all you should, have practical knowledge manufacturing economies and have clear insight into such overhead items equipment depreciation—tool cost—scrap charges—supply costs— supervision and inspection charges and the like—in their relation direct charges and total costs. But more important than all working knowledge human beings. Unreduced Oxides Pig Iron STUDY the origin non-metallic matter pig iron and its behavior steel-making processes, being con- ducted the Pittsburgh experiment station the United States Bureau Mines, cooperation with the open- hearth committee the American Institute Mining and Metallurgical Engineers and the Bourne-Fuller Co., Cleveland, has shown that always present any grade pig iron, but that present fairly small amounts unless the blast furnace working irregularly. The average percentage samples basic pig iron was 0.0272, samples Bessemer iron, 0.0223, and samples foundry iron, 0.0078. The oxide content the metal increased during transfer from one vessel another, such from the blast furnace the 11, 1929, The Iron Age from the mixer the open-hearth, due oxidation the metalloids the iron. When the blast furnace operating irregularly the proportion non-metallic mat- ter may high 0.15 0.20 per cent. These non-metallics are composed silica, and iron and manganese silicates, and analyze approximately per cent silica, per cent iron oxide, per cent manga- nese oxide and per cent alumina. When pig iron con- verted into steel some these unreduced oxides remain the steel and has been shown that high temperatures, high residual manganese and fluid slags are favorable for their elimination. certain cases, the quality the steel could related directly the amount unreduced oxides the iron used making the steel. | | | 7 q Fine Springs Need Close Tolerances Small Errors Size and Shape Result Large Variation Load-Carrying Ability—Heat Treatment Affects Elasticity and Fatigue COOK* things which spring maker can and cannot do, and how variations sizes (which may seem quite negligible the uninitiated) have large influence the work which the spring will able perform. For some reason spring manufacture has commonly been looked upon art rather than applied science, and there has always been atmosphere mystery sur- rounding the so-called “art tempering.” Many people are under the impression that the spring maker, through some uncanny power, can spring stronger weaker some change the heat treatment. dispel these errors will demonstrated, first, that spring support predetermined loads the result good en- gineering design and not heat treatment; and, second, that spring made annealed wire would support much load one the same shape and size that was heat treated cold drawn provided the elas- tic limit the soft ma- terial not exceeded. Metal the form springs has the same physical characteristics though were used for other engineering parts. For instance, obeys Hook’s law, which states that stress pro- the elastic limit the material. other words, spring deflects in. when supporting 100 will take 200 de- flect in. The physical proper- ties used for designing laying out springs are the same the engineer would use designing bridge, gear au- tomobile axle—the ma- jor difference being that, instead designing the bridge sustain certain loads with little de- flection possible, plans them deflect definite distance under definite load, return exactly the same posi- tion when the load re- paper will endeavor indicate some the the others *Vice-president and fac- tory manager, Wallace Barnes Co., Bristol, Conn. PRINGS Wide Variety Shapes and for Many Diverse Purposes. Each presents design problem different from moved, and repeat this exacting operation indefinitely. Some materials are fine for springs and some are good all. For instance, cast iron useless for spring purposes; piece stick sulphur would take deflection whatsoever before breaking; piece rubber, which might capable being stretched great distance and return its original length, would make poor spring because moves too far for small load. spring steels not only have high elastic limit, but have high resistance stress (or These two are the important characteristics; the total usefulness piece metal, far the manufacture springs con- cerned, expressed combination its stiffness and its elastic limit. Stiffness Measured Young’s Modulus This matter stiffness expressed standard terms, that one material can another, means Young’s modulus elas- ticity. Young first dis- covered that the stiffness material and the amount that could deflected were two entirely tors. lus mentally dividing the load test piece the amount stretches. expressed, therefore, pounds per square inch. are talking Young’s modulus tension, number pounds which would require the material measured in., assuming that this could done without passing the elas- tic limit. The peculiar part this physical property that Young’s modulus for mately the same number. The slight variations noted mental determinations are not brought about heat treatment but other factors, such The Iron Age, July 11, 4 ‘ < j | 7 t f wy" f chemical analysis and size test piece. spring can treat the modulus con- stant; for steel tension use 30,000,000 per sq. in., and 12,000,000 per sq. in. for steel torsion. course, bronze some other metal used, then have substitute the modulus for that metal the formula. therefore find that formulas for unit loads springs contain constant factors physical dimensions. Consequently design alone, and not heat treatment, con- trols the unit load. Controlled Elastic Limit The other physical property metals used spring engineering the elastic limit, which controls the distance that spring can deflected without permanent set. Flat Spring Deflected One End. 0.0005 in. varia- tion thickness 0.010-in. strip makes error per cent load-deflection test Elastic limit directly dependent the quality the material and its heat treatment, enters into the formula for total capacity spring, but the limiting factor only when springs are used maximum capacity. Needless say, this condition should avoided when pos- sible, but encountered some important spring work, such clock springs. Either the elastic limit the ultimate strength the metal also connected with the endurance springs repeated loadings. Not nearly enough yet known about this important subject. Since heat treatment can affect the elastic limit and the ultimate strength, also must have some indirect relationship the endurance. Some authorities who have studied metal straight test pieces claim that the endurance limit (that is, the load which can repeatedly placed the metal without ulti- mately breaking it) raised the tensile strength goes up, either alloying heat treating. This appears contrary the old, old rule thumb the spring indus- try: “for fatigue conditions use the lowest temper* that will the work without taking set.” Test Results Affect Manufacturing Conditions Another method testing used the laboratory Wallace Barnes Co. deflect springs under definite operating conditions until they break, and continue vary the manufacturing conditions one time until the com- bination found which gives best results. One definite finding may noted: overheating, especially steels con- taining more than 0.90 per cent carbon, prolific cause erratic performance. have also been able prove that the rule thumb mentioned above has basis fact, namely, that low tempered spring will actually far more work than high tempered spring. Therefore, most important result heat treatment found producing uniformly good fatigue proper- ties, and this field research yet only its infancy. Probably will eventually find that certain micro- structure and hardness will deliver more work than any other. conclude this portion the discussion, springs should designed that their work well within not *“Low temper” here means low carbon low hardness, rather than low drawing temperature. 11, 1929, The Iron Age For all ordinary Torque only the elastic limit but the predetermined endurance limit for that particular metal. All which substantiates what has been indicated many times practice, that springs have suitable hardness and still not perform, the design should changed rather than hardness in- creased. The latter results erratic fatigue resistance. Close Tolerances Frequently Necessary Having indicated the limitations heat treatment relates the performance springs, the matter tol- erances may now considered briefly. taking few examples great amount light can shed spring design general, and new idea acquired the degree accuracy required the manufacturing small springs. Take the insignificant lever spring the distributer automobile engine. gets scant attention, but must return the circuit breaker lever its original position with correct tension within two ounces, plus minus. will this 250,000,000 times while eight-cylinder car runs 25,000 miles. might consider the control which ad- vances retards the spark the throttle opened shut; actuated spring which will not vary length over 0.005 in. under given loading. Such exam- ples could multiplied indefinitely. Such limitations mean the accurate control more dimensions than are met with most machine parts. Causes Variations Wire Size One these dimensional tolerance the material itself. Without discussing this detail interesting note few causes variation cold rolling strip steel, such variation size and quality the hot rolled bars, change temperature the rolls, bending the rolls during cold rolling; “give” the roll necks and bearings; eccentric grinding the rolls; and extreme difficulty gaging strip while traveling 100 ft. per min. Sim- ilar causes variation might found wire drawing, and while these variations might amount only 0.001 in., even quarter much, they affect vitally the action the spring, will demonstrated later. Then come Clock Spring, Normally 0.020-In. Thick, 0.001 In. Undersize Would Lose Per Cent Total Energy and 1/3 Per Cent Running Time the difficulties fabricating the spring itself, not only forming the correct shape, but the much more dif- ficult task heat treating without deformation. Thickness Flat Wire Most Important Dimension For the first example show how these slight varia- tions affect the test performance the spring, as- sume sample flat spring, such many illustrated the group the first page this article. fixed one end, like cantilever beam. has in. effective length, in. wide and 0.065 in. thick. will deflect = approximately in. lb. hung the free end, ac- cording the formula— Ebh* this, equals the deflection, the load, the length, the modulus elasticity tension, the width the stock, and the thickness. will noted that the de- flection varies directly the first power load and the cube the length, and varies inversely the modulus (which constant), the width, and the cube the thick- such spring all these factors can easily con- trolled except the thickness. subject variation due the conditions the roliing mill previously mentioned. Helical Spring, Where Fabrication Tolerances May Cancel Each Other Note that the thickness has very important effect the load (or the deflection, the case may be), since enters into the formula the third power. Suppose the spring bought under specification which says that the minus per cent. That means that the thickness nom- inally 0.065-in. strip can vary only plus minus 0.0015 in. This less than the commercial tolerance for rolling this thickness material. Variations thickness become more important the spring gets thinner. Thus, assume tolerance plus minus 0.0005 in. for 0.010-in. strip (which would considered excellent accuracy rolling). That alone would cause variation plus minus per cent the load required give standard deflection. Another good illustration clock phonograph driving spring, such shown the bottom the illus- tration the first page. The formula Here also the load varies the cube the thickness. the thickness ordinary phonograph spring de- creased from say 0.020 in. 0.019 in., other factors being equal, the maximum torque would drop from lb. loss maximum torque and total energy per cent. such spring 0.020 in. would give effective turns its arbor under the working condition, and the were 0.001 in. undersize, one total turn would lost. This means per cent the running time the spring- driven motor. Errors Helical Springs May Mutually Counterbalance Variations size have even more noticeable effect helical springs, such valve springs, but fortunately there are several variables entering into that formula. Some these variables will run over and some under, with the net result falling within the specified tolerance for length compressibility. For instance, actual specification calls for valve spring 7/16 in. long, 7/16 in. mean diameter, with coils 0.162-in. wire. required in. long under 30.25 plus minus and 7/16 in. long when loaded 61.5 lb. plus minus 1.5 lb. The formula for the unit load such spring The unit load varies directly the fourth power the wire diameter and the modulus torsion, and indirectly the number coils and the cube the mean radius. order within the tolerance allowed the load test, the wire diameter must correct 0.001 in., other dimensions being exact. may take 0.010 in. tolerance the diameter the spring, allow one- seventh coil the number coils, 0.015 in. the length. Each these figures taken separately too close limit for mass production. The ordinarily accepted tolerances such spring would plus minus 0.002 in. the wire size, plus minus 1/32 in. the diam- eter, plus minus 3/32 in. the length the spring, and plus minus one-half coil the number coils. Fortunately some these errors production will the high side while others fall the low side, and thus partly counterbalance each other. Otherwise would matter great good fortune find spring which would fall within the specified acceptance limits. While spring makers who take pride their product like work close tolerances (and like collect the premium which precision always warrants), the above explanation indicates that the limits should chosen with judgment. Accuracy should asked for where accu- racy actually needed, and latitude allowed where lati- tude possible. designer who used dimension- ing machine parts plus minus 0.002 in. should this out mere force habit when ordering springs, may inadvertently place conditions upon their manufacture which will cause exasperating delay and unwarranted ex- pense. Nitrogen Content Steel Harmful There has for long time been controversy the effect nitrogen steel, many claiming that harm- ful. Norwegian, Hjalmar Braune, discusses various problems connected with this subject Norwegian technical paper, according the London and Trades Review. When iron made charcoal blast furnaces, nitro- gen usually present the iron quantities about 0.002 0.003 per cent, the furnace worked mod- erate speed and without excessive preheating the blast. However, with hot-blast and high-speed working, the nitrogen content will considerably higher—often 0.020 0.025 per cent, owing the increased formation cyanogen compounds the furnace. has long been known manufacturers and consumers high-grade pig iron that furnace working conditions have great ence the quality the iron, even the ordinary analy- ses are identical with exceedingly low contents sulphur and phosphorus. According the author, has always been almost impossible make first-grade steel from hot-blast iron fact recognized function the nitrogen content, which causes excessive brittleness the hardened steel. Buyers Swedish pig iron, therefore, often used stipu- late that the iron should produced under fixed working conditions, such cold blast (not above 150 deg. C.), mod- erate speed, etc.—conditions which cannot easily con- trolled the consumer. recommended, therefore, such cases adopt the determination the nitrogen con- tent the standard test, since this oan easily deter- mined, and will give clear evidence furnace working conditions. The Iron Age, July 11, 1929—85 : 7 . A { 4 q 7 va 4 4 Automobile Hardware Forged Transition from Castings and Stampings Suggested—Methods Production and Heat Treatment Versatile Plant MANKER* ETTERING the quality materials and workman- ship, trend craftsmanship the times our forefathers, also dominates the present age mass production. Probably the outstanding example this today the trend the automobile industry to- ward better performance, greater endurance, longer life and greater beauty lines. This applies the individual parts just forcibly does the completely assembled car. Among the parts that make car the automobile hardware includes such items crankshafts, steering knuckles, clutches, brakes and accelerating pedals, shift levers, yoke end assemblies, brake band assemblies, disk clutch plates, etc. Organized 1881 for the manufacture vehicle hardware, the Cleveland Hardware Co., Cleveland, today the largest maker vehicle hardware the world and the only one the United States that produces full line. During its early years made hardware for buggies, sleighs, farm wagons, etc.; with the advent the automobile this line was added. This company made the hardware for the first commercial automobile—the Winton. present per cent its output goes into automobiles and tractors, but still making hardware *Assistant the president the Great Lakes Steel Cor- poration, Detroit, but, when article was written, vice-president of the Surface Combustion Co., Toledo, Ohio. for farm wagons. Every American car today carries some parts made the plant this company. Originally the metal parts buggies and farm wagons were castings, but this company saw the gradual transi- tion wrought iron and steel. This same transition just starting the automobile industry and, while castings and stampings are still largely vogue, there little doubt that the automobile hardware tomorrow will completely forged parts. least per cent the line manufactured the Cleveland Hardware includes some part which drop forged. While this company makes and stocks thousands parts different types, approximately per cent its output special work made contract, and accord- ing the blueprints and specifications its customers. This firm operates its own rolling mill, where rolls special shapes. Much this steel later put through the upsetting forging processes. There are two plants, five miles apart, each duplicate the other, except that the rolling mill No. for both. the rolling mill are six stands one train, and independent mill; all are three-high. Two sizes billets are used, These are heated two regenerative billet furnaces which are fired with gas, temperature 2200 deg. Fahr. being maintained. The hearths are ft. and ft. Each furnace has two gas burners each side, and the standard reversing Gas-Fired Carburizing Furnaces Row, 86—July 11, 1929, The Iron Age Used Making Hardware Items A Corner De- partment, with Two Rows Gas-Fired Furnaces Mechani- cal Handling Parts and from Heat- Treating Fur- naces vided for the Hand Oper- ated Overhead Crane. Pyromet- ric control these furnaces tive results “a. Carries the Parts Tumbling Barrels for Cleaning — The Iron Age, July 11, mechanism. Natural draft supplied through 175-ft. chimney. The independent mill used roll ruptured bar stock, which saves certain operations forging. row board drop hammers, tons capacity, well bulldozers, presses, etc., are used work the steel. Hot- trim presses are placed alongside the hammers, while the cold-trim presses are adjoining department. These latter are arranged long line, supplied traveling belt conveyor. The forgings are placed this the hammer room and are carried along just back the presses. The operators the different presses pick off the parts which their particular press equipped trim, trim off the flash and drop the parts short conveyor running right angles the supply conveyor. These short conveyors dump the parts another long conveyor running parallel the first conveyor, which delivers them the tumbling barrels another section. When full, these barrels are put stands and revolved. This ganging system, belt conveyors bring work and remove from the operators and machines, used throughout the plant wherever applicable, thus elimi- nating much trucking, hauling, etc., possible. The forge shop equipped with overhead traveling crane 120-ft. span, while the other shops and machine divi- sions are served with overhead monorail systems and elec- tric hoists. The company makes its own tools, dies, jigs, etc., completely equipped and modern tool room. The vari- ous forged and cast parts are finished the machine division, which fully equipped with milling machines, drill presses, reamers, thread cutters, etc. Several types special machines are provided for special operations. Exceptionally modern and up-to-date equipment, arranged for the most effective and efficient operation found the heat-treating room. There are gas-fired furnaces this room, row nine each side with quenches between, and traveling overhead crane assist handling the work. These furnaces are ft. wide, ft. deep and ft. high and are all alike. They are used interchangeably for all kinds heat treating, annealing, etc. Each has automatic pyrometric control and both overfired and underfired, with two burners located the crown and two alongside the hearth. These are provided with Surface Combustion Co. (Toledo, Ohio) inspirators and combustion equipment, through which gas supplied lb. pressure. battery six recording pyrometers set the wall the metallurgist’s room, together with switch- board which wired the thermocouple each furnace. this way exact maintained over the oper- ation each unit. For hardening die blocks the practice heat them from 1400 1600 deg. Fahr. and soak them for from hr., according size and physical require- ments. They are then drawn temperatures ranging from 800 900 deg., after being quenched oil. These quenches are cooled recirculation. This gives hard face and tough matrix. The drawing accomplished cast iron plates set brick and underfired with four burners. Great improvement performance modern over obsolete equipment shown these furnaces, dis- closed tests with the old combustion system and the new equipment. heat treating forgings, when the temperature was maintained constant, and the cold work was regularly charged into hot furnace, saving fuel consumption per cent has been effected, to- gether with per cent increase production. And there material reduction furnace maintenance and scale loss. These economies were effected through the use inspirators, gas-air proportioners, which the gas- air ratio regulated give either reducing oxidizing furnace atmosphere. The desired ratio once attained then maintained automatically, regardless the flow gas. Shipping Automobile Bodies Utilize All the Space NTERIOR Freight Available Box Car 88—July 11, 1929, The Iron Age ‘ranged Accommo- Cars (Left) Ar- date Three Tiers Touring with Bodies Car. Sedan bodies (right), being taller, are loaded freight cars, two high, for shipment Detroit, from Graham Paige Corporation, Evansville, Ind. ain Europe’s Industrial and Political Future Pivots Coal and Iron Ore HIS study the coal iron ore supplies the different European countries not primarily geo- logic, nor concerned with very hypothetical future ex- haustion coal and ore re- serves. the contrary concerned with the immediate cal, also with the bearing that future these coal and iron resources and their development. For am, will appear, advocate the very unpopular theory that are not now living new age economic miracles, but still cold, prosaic world where effects are produced causes. Today, after speculative mania such has never before been seen, every security market the world hopelessly unsound position. Under normal conditions the inevitable remedy for this would speculative col- lapse, which might cause great individual suffering but not necessarily any great general economic loss. But the present case the situation irretrievably compromised the colossal mass inter-governmental obligations arising from the war—obligations which must the long run paid for the export goods most tremen- dous And may noted that whatever paper agreement may be.reached the German reparations matter the economic dislocation will more severe than anything the industrial world has yet seen. [As Mr. Eckel wrote, the reparations conferees Paris were still disagreement.—EDITOR. There are several countries which must secure reparations full order avoid bankruptcy. There are other countries whose furnaces and mills might well shut down for the years during which such payments are progress. obvious that the and iron industries, which are after all the only real bases for German earning power, are the ones most keenly interested the whole matter. And that gives certain point and timeliness the present study. Europe’s Coal Percentage Half That Ore Before considering actual and probable future develop- ments Europe itself, will well note very briefly the status the European continent whole, with regard coal and iron ore reserves and output. dealing with unmined reserves never necessary waste energy any attempt precision, since such factors grades, depths and workability are subject wide range individual judgment. the present case will deal with the subject very round tonnages and percentages, feeling that this will bring out all the really important points with sufficient definiteness. With regard coal, may then note that, any possible basis comparison, Europe ranks third, and rather bad third, North America and Asia holder unmined coal reserves. The total high-grade coal Europe, reasonable depths, may run some 750 thou- sand million tons. This equal between per cent and per cent the total world coal reserve, figured *Mr. Eckel spending several months France and Germany, the interest American clients. Four Countries Hold the Key the Reparations Must In- crease Greatly Their Production for Export—Some Economic Disloca- tion Ahead EDWIN ECKEL* the same basis. Low compared with the two other continents named, the Euro- pean reserves are still enor- mous compared with those the three remaining conti- nents, and probably three four times great those South America, Africa and Australia combined. against this reserve tonnage, all Europe combined will mine this year not much over 800,000,000 tons coal and lignite all grades. With regard iron ore, the European situation even more favorable.