The Iron Age 1929-10-03: Vol 124 Iss 14

Ney ESTABLISHED 1855 VOL. 124, No. ober 1929 Huge Airship Factory and Dock Nearing ROPER conception the magnitude the Good- year-Zeppelin Corporation’s airship factory and dock now nearing completion Akron, Ohio, visit the site, because the structure set flat valley which has been graded exactly level for area about mile diameter. Consequently there nearby structure ordinary size which gives the scale the construction. The views show the skeleton about two-thirds com pleted; over-all dimensions are 1175 ft. long, 325 ft. wide, and 197.5 ft. high. The floor area large enough ten football gridirons. The main structure consists arches (with silicon steel main centers. unique method erection was devised the American Bridge Co.—haunches pair arches are erected, the inner ends resting temporary vertical bents, and all cross bracing attached. The central portion this double arch then erected low position, hoisted vertically position with the aid counterweights, and riveted fast. traveller roof then erects the intermediate members. About 5350 tons structural and silicon steel re- quired for the main shed. Four door leaves the ends (made the Detroit Steel Products Co.) require 1800 tons more. Physical properties are follows: en three -h nged ords) set ft. Lb. per Sq. Ih Lb. per Sq Minimum yield point... 30,000 Ultimate ‘strength Design Stress: Dead and snow load 18,000 Maximum from wind load 24,0 »,000 to 65.0 Completion Doors are shaped like segments huge orange peel; they are hinged the top 17-in. pin, ft. long, set spherical joint 30-in. diameter. the bottom, each door rests forged steel wheels, separately journaled and sprung, rolling standard gage rail- road track curved 187.7-ft. radius. Each door opened and closed rack and pinion drive constructed the Wellman-Seaver-Morgan Co. The rack consist 14-in. H-beam, bent proper radius and built into the door near the base; teeth are 4-in. pins set apart. Meshing into them bull gear with teeth, con- nected 125-hp. General Electric motor suitable worm gearing. Time limit relays, switches and controls arranged that single push-button will close the doors five minutes; deceleration the end automatically occurs the leaves creep together without bumping. Roof covering and siding Robertson protected metal, with large corrugations fastened with special clips resist tress all direction Huge though this building is, will house only one Zeppelin Corporation. ZRS-4 and ZRS-5 are each 134 ft. diameter and 785 ft. long. Ample room avail- able the sides the structure for row shops and offices ft. wide 640 ft. long—a considerable manu- facturing plant itself. Longitudinal I-beams are at- tached the lower chords the main arches for 6-ton electric trolleys, used for erecting material into the airship structure hoisting working platforms. Arti- ficial light will provided, all electrical equipment being carried special gas-tight conduits and boxes, and all circuit breakers and fuses located outside the building. 885 7 | | 7 | * LAE er TAL TEEL Work for Spheri- cal Doors Erected This End. Doors are rolled back past building, which has not yet been rugated metal airships will require about 6,500,000 cu. ft. gas each, railroad siding being installed alongside the gas handling plant, together with necessary piping, long enough for dozen tank cars, each containing about 600,000 cu. ft. helium under pressure. PAIR A Arches Has Been Hoisted Position, and < Inte Ratters N rat ind i ) t velle F ils to Ippo! nche next ircn + 24-11 teel pipe, closed ved |! elded on, and with welded itl in Since each rf the (Bi Iron and Steel Insti Great 2900 C., believing tal discovery honest preciou net Old poems legends mentioning the use iron, Mr. Rickard says, date from the author’s time, which would several centuries after the events recounts. After considering all the evidence, Mr. Rickard concludes that the melting iron from its ores was commenced the Hittites what now known Anatolia, Asia Minor, ome time after 1400 Previous that time the nly iron known was meteoric, which was very rare and 7 ‘ 4 = ie costly. Chrome-Nickel Stainless Alloys Chemical and Physical Properties and Applications Chemical the Real Corrosion Resistant Stainless Steels HOLLAND NELSON two previous articles, IRON AGE, April 25, are able establish definite ratios chromium nickel page 1139, and May 30, page 1478] the iron with carbon, produce material capable being stainless steel and chromium irons have each manufactured commercially practically all the variety contained reference the fact that intended shapes and sections which could called for the with the nickel-chromium alloys this field separate structural chemical engineer. topic. have done this attempt avoid confu and unfair comparisons. Situation Outlined Existing bibliographies are available for those through the various patents and technical papers range » nave be ena wed to overiatl that in il variety inventors and authors the subject. sha nowever, reier to two of the outstanding met: T lurgists, who were undoubtedly pioneers the develop nickel shows not only sound common sense ment these particular alloys. refer Dr. Bem but holds out also the hope wider development the Strauss, the Krupp Laboratories, Essen, Germany, and ous patents many alloy combinations value not owned their work and early patents the subject any one patentee and therefore the trade since been added both themselves and other workers The high alloys chromium and nickel with iron had been source difficulty and worry the metallurgist proportions nickel and chromium advocated unan capable being hot worked, although they were the cast form for heat-resisting purposes. Annealing presented quite problem and course machinabi Ratio Nickel Chromium depended substantially upon the success the operation the production alloy which did not hromium wa established, many of these alloy quire annealing produce machinability. were such type that they were martensitic, austenitic Continued metallurgical study these problems martensitic, entirely austenitic and, substantially finally enabled solve many them and today they existed through the hot working range, were they Widener Build not malleable, partially malleable quite malleable. AGE April 25, Mr. Nelson discussed the first article referred homogeneous ture heing the ideal for tance corrosion and, OIL (Right) Made from Chrome-Iron Alloy (Courtesy Enduro and dished heads (left) for tank boiler construction. These can readily made from either chrome-iron chrome-nickel alloys. (Courtesy Lukens Steel Co.) The Iron Age, October 1929—887 ~ the eh Ne lay ‘ . ‘ the chrome-nickel alloys are concerned, homo- tance but also reasonable malleability for hot-working eration ich rging, rolling, and general bricat n. Generally speaking naterial containing say from cnromiu res l ) Ai t rey eY t entirel\ ius nit then nickel content from per cent would chromium content would ] fact that vould unstable ] nd nisned produ aimeult . Four Different Products I aum ul inderstant ] ? which has taken place with the 1] } ntially with «Ai et ‘ » Lic not too evidence this have taken four popular brands and quote the manufacturer’s analysis each cidentally amusing note that each them operating under different patent: Per Cent Per Cent Per Cent Per Cent 0.12 0.10 to 0.2 max. 0.20 max. 0.12 ~ 7 1 to max. 0.50 0.40 to 0.66 7to 19 17 to 2 to 7 ] tov might assumed that because the chromium-irons, previously dealt with the other articles, have been adapted readily the chemical field there might little demand for similar material containing nickel, which obviously also increases the price. However, experience with the stainless steels and chromium-irons the building chemical equipment brought light many difficulties which were not easily surmounted. for instance, due the difficulty ex- perienced welding chromium-iron, large heating coils which called for tubes pipe one single length were extremely difficult obtain. Many difficult bends and joi hat could have been readily welded had to be modified simpler design before they could executed straight chrome-iron. Let glance the physical properties typical one these alloys and review some the outstanding features that such analysis modification brings about and then perhaps shall more fully realize why the nickel-chrome alloys are regarded decidedly advantageous addition the existing and irons. He ‘ api cal Properties o Ch y e-Nickel Alloys Analy Per Cent unde 0.75 M ese ..under 0.50 | 0.0 | 0.0 N trom S00 to 10 ustenitic material ar ed by quenching) \ a] per q. in 30.000 to 40,000 ngatior - In., per cent to 60 Reduct per cent B 130 to 140 MM tol stallation Showing Hydrochloric Acid Tank, Nitric Acid Tank Tank for Washing Off with Water. (Courtesy Lukens Steel Co.) stated above, just because many installations have been successfully built from chrome-iron, does not necessarily follow that the chrome-irons were everything that could desired. date know not one single installation which has failed due corrosive attack, but the fabrication was due entirely close cooperation between the manufacturer the material, the designing engineer and the fabricator and many modifications design were necessary account the high physical properties the material (particularly induced work hardening) restricted heating ranges, the difficulty welding, ete. Such modifications times im- paired general efficiency but were necessary, due the material itself. Therefore any material little more more ductile, with wider hot working ranges, either the steel works the fabricating shops, becomes immediately welcome addition. The nickel-chromium alloys offer many these improvements which turn means that the designer can more nearly approach his true design. The wider temperature range makes possible for both steel manu- facturer and fabricator form more complicated shapes the more readily and the absence the serious grain growth which develops the straight chromium-iron | 4 Where the Demand for Chrome-Nickel Alloys? high temperatures, such when welding, opens the possibility welded structures where welds for other reasons are not considered detrimental. The Range embrittlement chromium-iron, due prolonged heating temperature range between 850 and 1050 deg. Fahr., which caused considerable trouble the oil industry, for while, was responsible for the manu- facturers seamless tubes welcoming the advent the chromium-nickel alloys, which far apparently have shown tendency develop this ous reasons have been offered explanation ac- count for this brittleness, all which, the author’s mind, are still inconclusive. Nor satisfied that similar condition will not develop some the chrome- nickel alloys under certain atmospheric conditions though may less dangerous range and over much longer time cycle. Some these alloys are yet close unstable compound that elevated temperatures are apt show striking results. These remarks are not made pes- simist but because the author, handling these stainless Castings, Typical the Kind Produced from Chrome and Nickel-Chrome Alloys alloys since their birth, has seen childish and unwarranted optimism lead disappointing and serious results. Com- ing from the original school stainless steel, and follow- ing through the development chromium-iron and ing been associated some capacity with practically all the large installations the country has naturally brought attention many limitations the straight chromium-alloys. would unhesitatingly state, how- ever, that, while welcoming the development the chrome-nickel alloys, they cannot regarded cure- all and every care should used their selection. very popular combination before the moment that known the “18 and type,” signifying per cent chromium with per cent nickel. The typical an- alysis and physical properties this material are found the preceding table. The low elastic limit, together with such high ductility exhibited the elongation, reduction area, impact and Brinell, clearly explain how readily this metal can cold worked. Articles extremely intricate design can formed and fashioned from this alloy which would impos- sible produce straight chrome material. Like all other metals these alloys become harder with continued cold work, which course reflected increase the tensile strength and elastic limit, with corresponding reduction the elongation and reduc- tion area. simple heat treatment, i.e., rapidly heat- ing 1900-2000 deg. Fahr. and either air cooling Fireplace Made from Chrome-Nickel Alloy quenching according section, will restore the original ductility the annealed material. Personal View Regarding Nickel Content author can perhaps make his own view still more clear (and incidentally leave himself open serious criticism) stating frankly that, practically all these alloys, the chromium which gives the metal its corrosion-resistant properties. Undeniably the nickel additions are valuable more particularly regard their bearing upon the physical properties, which are course reflected easy fabrication. view regarding the chromium incorrect, then show one the commercial chrome-nickel alloys which does not contain more than the minimum chromium content stipulated Brearley* being required produce stainless corrosion-resistant alloy. Further would refer the work Pilling and Ackerman excellent paper the subject iron-nickel-chromium alloys wherein they state: The solubility n nitric acid of ufficient dilution t afford rapid rates corrosion may affected change ntent nickel, chromium iron, yet the point which substantial passivity reached depends practically wholly the chromium content independent nickel iron Inasmuch have made very definite claims re- garding the value chromium and its effect the re- *Mining and Metallurgy, Feb 1929 Dinner Ware Made from Chrome-Nickel Alloy The Iron Age, October 1929—889 | | sistance corrosion, should clearly understood iwa high-nickel-silicon alloys with and small quantities chromium; also niori These are bevond the this and ent different field from that the author, for which claims have re¢ ra to re tal to } al whlori and I il iturs il thev t W ] he Vel enginee! Genera! H orkine Instruct ons ») ] approximate 00 deg + Fey ae rant l aimeulty y pera ail ut and nas a } } + burs naterial T 1500 deg. Fal then Tem- eg i i a ey t ni \" +} + IN‘ i n? ha tior he { ns 1 ca 1 in [he 1 ‘ ind sting not pal Lat ind re idily neral practic place ( i I ) a cniork ( ac ( l to ema + n 4 Valel | eT perature ol i ba Cal ) ed n advantage 200 deg. the material now mew! nit irtace tne ling installation \ CASTINGS ( all ( ne possi- 4 4 riect asting \ Lit ! n the ast iron. ihe ra} n t e difficult or con that cannot get casting +} Wy orht bd tea ere » ng the ft t that he 7 hromiut 4 +) t} O! nad today Wwe re iD tall 1 . 4 1 1 trot ol rame nozzles, etc., ict i are llu rated. icing I neets plates ( Ss one Unit produce finished article the orm Problems Today 1929, The lron Age engineer l, he will exX- pect obtain that same material throughout his job, even the cast parts. The result that alloy foundries receive orders from time time for castings from such and such brand material, which ad- vertised chemical specification practically impossible produce the cast form. foundry has its own problems deal with and the wise buyer will have his castings made reliable house from material substantially the same analysis that the rest the equipment built from, but leaving the foundry make such modifications may necessary produce sound clean castings capable being machined. Because there are different trade names for materials with but slight variance chemical an- alysis, there reason why there should the same number casting analyses, which has led many castings which one hand were sound machinable, and the other, material which was ma- chinable but not sound. the chrome-nickel alloy range, the foundryman needs his latitude, working margin safety, you care call such. that you bar specification foundry for castings not surprised the intelligent foundryman declines not easy produce perfectly satisfactory surface casting. Pickling resorted just the wrought but the surface inundations and imperfection such rough surface have tendency hold small article foreign matter. the early stages small imperfections inclusions will rust quite considerable area, but, they are soluble, service under corrosive conditions they are gradually eliminated. almost impossible obtain finished kled casting which will not show some oO? if Some Concluding Thoughts concluding this article may again say that development the chrome-nickel alloys extremely welcome manufacturer, fabricator and user alike, in- asmuch they have opened wider field appli- ation for corrosion-resistant alloys, due their fabricating qualities. May however, again reiterate that due regard should paid the chromium content any alloy which used combat corrosion and sulphuric acids excepted) for firmly convinced that chromiun the weapon with which fight corrosion, friend that comes our rescue when certain alloys not the physical properties which a Finally, have been asked repeatedly—is “18 and the last word this type alloy? frank say that believe nearer the first word and that the iture will see using straight chrome and series hrome-nickel and nickel with silicon chromium her alloys, each dealing with separate problems. Principle Established Brearley firmly believe that Brearley established vhich will carry for all time. That principle was this, certain percentage chromium iron renders combination insoluble under certain conditions.” shall find other alloy combinations and shall probably again modify and adjust them meet the demands the fabricator, for this true progress. next article will heat resistant alloys, which regard question corrosion atmospheres by- products elevated temperatures, which chrome-nickel and nickel-chrome alloys entirely different ratios play important part. ™ | VN nt n la VS avaliable oday » quote. problems before the present-day alloy foundry ] 1x lay he } are largely due the fact that, picks material build his equipment - eeps Production Costs Down Closely Regulating Movement Stock Through Manufacturing Departments, Studebaker Corporation Lowers Expenses the statements most frequently heard nowa- days that “in buying automobile one gets one’s money’s opinion has developed determined within the automobile industry, and most cases re- every ductions have been made possible the inauguration manufacturing economies. keep costs minimum figure plant capable turning out 600 cars day the task which faced the management the Stude- baker Corporation South Bend, Ind. How this done described the following paragraphs. Appropriations for manufacturing purposes originate the finance committee, which composed offi and members the board directors. After appro- priation has been made, the sales department makes schedule for the next three months, staying, course, within the limits the appropriation. The car schedule, when transmitted from the sales department the manufacturing division, constitutes the latter’s au- thority purchase materials and make sufficient parts supply the assembly lines for days. While some parts going into Studebaker automobiles are bought from outside sources, most the major parts are manufactured the company. this connection the fact obvious that there must method scheduling production parts conform the needs the assembly lines. This done adher- ing the following plan. has its own “bank,” reserve stock, assembly lines. The size the bank number shop schedule clerks who ations and set the proper protection against sudden material, six-days’ supply each part Between Various Production Depart ments and the Final Assembly Lines phone Typewriter System Shown the Diagram (Left). indicates “receiving only” instrument, sending instrument and S+R sending and receiving machine. The photograph below shows a depart ment head receiving message trom the final assembly department The Iron Age, October shortage FISSEM BLY Li VE BOO, eer Fl 2208 VN ENO | 94-5 } “ASS floor . 4 Typewrite the Master Ma- chine the Pro- duction Super Office, Which Sending Messages the the messages 1 m the poay ade- partment. The cards the are orders | re il ne Sal urrent 1G yin the a Ul I remal! i I na | } rk ento? Protec a rotection Against Sud- den Shortage Material, Days’ Part Kept Stock, Where Is Not Used Ex- cept Emer- gency not used except emergency. ains daily tab stocks, and into the reserve supply for production needs, immediately report the purchasing that the amount stock has ger When fresh material the storekeeper brings the part again the proper level Tor current use. ctically eliminated possibility supply any part and thereby assembly lines. also serves reserve stock. applied not only parts bought from outside sources, but also those made the company. either case vidual shortage notice equivalent rush order for part required the production division. The purchasing department responsible for getting prices from and placing orders with vendors and for delivery materials the specified time. this re- spect just important prevent surplus stock from accumulating assure proper supply. When material delivered vendors, checked and weighed the receiving department and report made the production records department. partment Each de- manufacturing parts maintains accurate check its output having all finished parts pass The Iron Ace ia 3 —, — through clearing house station final inspection be- fore they leave the department. they are counted clerk and the production records department sup- plied with the information. this manner the produc- tion records department has its possession all times data upon which base shop operations. Every Department Has Stockroom Each department has stockroom charge store- keeper, who has before him copy the dai'y for assembly lines. Material released from the stock room according this schedule. the foreman department along the assembly lines finds that must have additional stock, the storekeeper gives him the extra amount, but charges against him loss stock. The precaution exercised releasing stock waste the part production departments acted guard against shortage. Once year inventory raw and finished stock count the stock storage, and clearing house clerks departments producing parts tabulate the stock the floor. Throughout the year the production records department compares its stock records with actual stock conditions reported storekeepers. too great discrepancy exists, special inventory the part question ordered. superseded new part, the production records depart ment ascertains from its files the number parts hand. attempt made make the change point when the supply the old part exhausted, but this not always possible. the change such de- cided improvement that the management thinks ad- visable substitute the new part soon possible, the cost the old part and the quantity hand are considered, and decision made regard scrapping the old part immediately. When new model automobile put the market, invariably material for the old model left over. list this stock made and given the servic department, which takes the quantity wants. The re- mainder sent the salvage department, where kept until the new model actually then sold scrap. Foreman Furnished Production Sheet Monthly Every month foremen are furnished with production schedule sheet showing the number parts needed that month and the daily there are usually multitude parts going through department, sometimes difficult for foreman keep date. This simplified system helps the foreman track his standing. Consequently the production re- cords department draws the parts production schedule sheet red line the date which the quota for each part for that month has been manufactured. the red line for any part has fallen behind the current date, the foreman knows that short his quota and must concentrate bringing his production that part visualize moment the position his department relation production needs. has already been stated that clearing house clerk count the number parts going out from operating de- partments. This information recorded transfer tickets, which are sent the end each day production records department. Night clerks are employed ; + transfer the accumulated data shop schedul Accurate Check Fin ished Clearing House Station Final spection They Leave the Department Which They Have Been Manu factured record, copy which put the hands every fore man when reports for duty seven o’clock the follow ing morning. Thus has before him the beginning the day the results the previous day’s activitie what work immediately ahead him. the executives the company receive daily from the production records department car tion and shipment which lists the various Stude baker models and sets forth parallel chedule, production and shipments for the previous day and for the month date. separate column corded the number automobiles over under the production schedule date. the extreme right the sheet the number finished automobiles hand for shipment dealers. Telephone Typewriter System Installed Communication between various production department and final assembly lines maintained means telephone typewriter system, which the largest instal lation its kind the United States. consists machines installed cost approximately $18,000 and has been operation since March There are two groups machines, one group comprising three machine the body department, which send and also make copy what being transmitted, connected with one receiving machine the office the production superintendent. case one the machines operation, red light show the other two, indicating that the circuit use. white light the “go ahead” signal. This part the system keeps the final assembly lines informed bodies inder construction and ready for delivery. The other group consists sending and receiving machine (this machine also makes copy what being The Iron Age, October 1929—893 x — A n nan In ¢ ) j ne m ( nad \ to +} \ t } ! I n rece ) n ; One n t) } mit ra L ryt ed of fin al as- located at emergency delivered messengers, instructions now are typed ending machines. Messages are received typewritten form page-size paper, and four copies can made. Installation conference telephone system sta- ons was completed recently. Although not direct part the telephone typewriter service, supplement it. The system provides for hooking the entire group without the necessity department heads leaving their offices. case anything should wrong with the typewriters (and, with two emergency call, such situation not probable), the telephone conference system could brought into use } The telephone typewriter system has proved great benefit and vital factor program increased production brought about the concentration all Studebaker production South Bend. Casting Practice Insure Uniformity High Carbon Steel ‘ i rt ~ a ~ | | ‘ nad St ey a} When — | - ( i ( rt n nr | ead n ) rn? l + n ited ire 11Ca Cl sla + ene ilso De the direct ) } — cy i ly ene? low ll ? Lo ! is ¢ t ror LOp he n y i f+ tine t + + + + i (ap at tirn? nad no i i qaut was oscillated back and forth through short each reversal being suaden. This produced ingot with columnar shell about in. thick with normal carbon, and very sharp transition small random crystals; this plane the carbon analyzed 1.36 per cent. Analysis Exuded Drops nalysis of exuded drops showed the degree of “seg- sof He This measure the differences analysis the the dendrites and the mother liquor trapped their branches (much this segregation later diffused). Arrow-headed and segregation “on large From theoretical considerations, the ingot contour il- lustrated was developed which practically these “segregations large very prominent slightly tapered ingots. The tendency for segregation mainly function the difference temperature be- tween beginning and end and conse- quently each grade steel should cast mold taper for that grade. Discussion Dr. Hatfield discussion Dr. Hatfield said there was nothing the paper which was contrary the findings the Institute’s Ingot Committee. would appear that the had not given sufficient weight that evidence. Hatfield challenged the statement which was some- imes made, although not Mr. Hultgren, that the ingot commitee had largely confined its publications the statement what was observed current practice, and had not contributed substantially complete solu- tion the troubles the manufacturer. The author seemed deal only with small ingots. Prof. Andrew suggested that the author wished study segregation known Great Britain must obtain his ingots from country other than his own, for seemed have very little segregation his ingots high carbon steel. harge erate In Case any foreman’ All the lve age tron | on, i ssembly of ommunica ot ‘ nes or orders formerly for 1.10 bon steels was Hultgren ved n, to the fall (British) Institute. lb. and less, cast and with hot ned etched ned ingot showed 0.35 ente? oT larg i it i scale” thought Mr. Hultgren represent channels through which such enriched mother liquor has been sucked feed shrinkage. larger than mucn iargel nan a single ection; erlock Main stems bent and the markings. large crys etched plan approxi- llel the etching al, the direction isothermal imnar crystals rystal austenite; the primat may suppressed e and temperature, teeming per cent steel all cent carbon) and ent the ingot mold lidification the mold aking Machine Tools Safe Adequate Protection Should Given the Cutting Point, the Most Dangerous and the Most Difficult All Guard LUTHER BURLINGAMI seven seals safety mark the vital steps will disengaged not revolve when the which the safeguarding machine tools has pro- feed engaged. gressed, seal after seal barring the way When cone pulleys are used and belt shifting thu having already been broken. required, has not yet become usual, except heavy Looking back the days when machine tools types machines, make belt shifting devices built without guards and with- the regular equipment, the out any provisions for safety, till being considered extra see the first seal broken are also controlled guards were applied pro- hines. The trend the time tection against gears, belts make the operation machine however, toward the adop- and other moving parts. The tools safe pointed out this article tion such features, not only second seal was broken when makers supplied the complete guards with the machines placed the market. The third, when through rede- Luther Burlingame, who has because utility saving vices, but also for been prominently identified with the machine tool industry for many years. More attention being emphasizes, however, that much given providing chain hoi signing the machines, gears remains done, especially along and other accessories part and danger points were placed inside the machine out reach, where guarding was the educating workmen the regular equipment use safe methods carrying their necessary. The fourth, when aptly say not moved with physical mechanical controls for shift- that we should guard machines less, tion and with greater safety. ing belts, operating chucks, but that should educate for safety Where chain hoists changing feeds, became the question safety test the standard practice; the fifth the links the chain when individual motor drives comes item for attention. largely replaced the use ex- Where power hoists are used, posed belts and eliminated other features danger. The “kink” have the hand-pulls arrow-headed, with the sixth, giving attention the location and lighting one that lifts pointing and the one that lowers pointing machines and proper instruction their use, including down. also matters clothing, goggles, etc. The breaking convenience placing heavy work between this sixth seal for safety still progress, the use which the work can rest that breaking the seventh, giving protection the cutting when the footstock center advanced the work raised point, the most dangerous well the most difficult from the rest sufficiently clear. After the operation all guard. performed, the withdrawal the center allows the connection with provision for the control feeds, work again rest the “cradle” ready for removal speeds and direction conveniently located levers and This method especially useful for heavy work grind push buttons the outside the machine, within easy ing and polishing machines well some classes reach and away from danger points, the feature heavy lathe work. convenient and safe dual controls from different station that the workman does not have step around Operation Reduces Accident Hazard reach over the machine. Modern equipment often The more completely stock operated can includes automatic oiling and automatic control the automatically power, the the redu coolant. important that levers and other hand- tion the accident hazard example the mag: operated parts shall have sufficient clearance that the zine feed for automatic screw machines which hand will not pinched the knuckles “barked” wher piece stock automatically fed into the machine upon the extremes movement. feature pro- the exhaustion the previous tection from accidents as well a safety to the work and The fifth seal to be broken for safety is in elimir tools have the levers always operate the direction ing the drive ubstituting constant-speed of the traverse or feed. Where hand-wheels, crank t drive, or better still by using a motor drive i 4 ger other hand-controlled elements are used, and where they erally conceded that the use motor drive increa may times operated comparatively high speed, the safety operating machine, although im- the mechanism should interlocked such manner that portant that electric equipment should talled and carefully inspected avoid lurking danger The October 1929—895 | represents a decided step forward in measures for safety. When machine being repaired oiled, the ff. Many insist having the starting device locked that the machine cannot started until repairs adjustments are completed. Such meas- es, although some may think them extreme, help pnt na rtil light, aisles, distance from ls, lumns, and other machines. Keeping the ma- repair also important means pre- enting accidents. The human element must always ‘ten greater factor than guard- ng a ents The safety progran along intangibl nd tneretore doe sn ttent tnat t in rtance Val Fool-Proof Guarding Necessary operatives have never machir hop are put that because modern equipment wer mentality well less akes the need “fool-proof instruction safe methods work more essential nt ( be i ded i. ning workmen to be - I xt t t! na s sometime dvisabl generally king, the use gloves ] nes This is ten rench being read that ni t ring caps perator of machin rement inate painful and dis- y a istrated not niv y th ust ot vhen the fety dogs required nerhanp secreted for the purpose modern ithe dog with safety the old and more dan Most Machinery Accidents Occur Cutting Point Lt eventh eal, which, when broken, will still fur- ead guarding the cutting t h re imed is the pon of rhaps that more itisfactory results have owed. Cannot equal ive like results for ning ols ? 1 he fl, I chip fron latne vork the revolving cutters and drills, the danger from nch presses and grinding wheels will llustrate. machine tool factory, with over 6000 em- ployees, less than one-fourth the cost compensation for accidents was for cases involving machinery, but more than three-fourths the cost which came this classifi- cation was for accidents occurring the point cutting showing the importance finding means for breaking 3 this seventh seal obstructing the way safety. 896—October 1929, The Iron Age lathe chip guard, with glass opening, that the work may safely observed, widely used, but has limitations for many kinds work, fact where its universal adoption cannot present recom- mended. The same can said about milling cutter guards. Many designs have been brought out and some are satisfactory for use certain jobs; but far known guard universally applicable for this purpose has yet been devised. The simple expedient pro- viding brush wipe away the chips that the con- ditions cutting can seen and strict rules that the fingers shall not used for this purpose eliminate one the greatest hazards milling machines. Another ex- pedient used advantage have stream coolant under pressure that with hand-operated valve stream sufficient force can thrown against the cutter clear away the chips. These expedients, however, are palliatives, not cures. Guarding the grinding wheels quite general, but hazard exists for internal grinding for does not seem practicable provide guard which can remain place. The particular hazard here that when the wheel run back out the work and gage used for testing the hole, there danger its releasing suddenly and the hand being cut against the revolving wheel. There are designs guards protect against this danger the guard being automatically swung into place front the wheel when the latter withdrawn from the work, thus protecting the workman case his hand should slip. Important Guard Against Fying Chips Questions guarding against flying chips, where guarding the past may have been doubtful expedi- ency, may, when machine tools are designed for the record- breaking speeds now being experimented with, become paramount importance. also case where the human element must given full consideration order that safety may insured, these more hazardous operations requiring workmen with steady nerves and superior in- telligence, the demand being great greater, than the case the old-time mechanic, who, while could produce marvelous results that handicraft skill required, night not sufficiently versatile fit himself the equally exacting, although modern, conditions. When definite steps break the seals safety were taken quarter century ago, the general impression was that the remedy for accidents was for employees guard gears and other moving parts machines and that when these first and second seals were broken, the work would completed. analysis accidents soon showed that far the greater number were not caused lack physical guarding equipment machines, but were due other causes, involving carelessness the part workmen laxity general shop instruc- tions and practices; that, while but per cent accidents could prevented guarding, the most important effort was needed along the lines educating workmen and foremen use safe methods carrying their work. Accidents Reduced Per Cent Foremen’s Cooperation Over and over again has been shown that when the foremen’s cooperation can fully enlisted, accidents, even well-ordered and well-guarded shop, can cut half. not that should guard machines less, but that should educate for safety more, that the future may see this sixth seal safety fully broken and the seventh, having with the still greater hazard the point cutting, made matter intensive study order that it, too, may yield the skill the safety engineer. 4 - odern Tools Cut Production Time Centrifugal Compressor Machining and Assembling Reduced from Three Four Weeks Three 8-Hr. Days New Manufacturing Layout ONFRONTED with the problem manufacturing centrifugal compressors heretofore made an- other company for its Centrifugal System, used for cooling theaters and other public build- ings, the Carrier Engineering Co., Newark, has developed method that reduces machining and assem- bling time from three four weeks three 8-hr. days. Although the problem involved manufacture the impellers, impeller shaft and other parts the compressor gas pump, de- chining the will serve show the thoroughness with which proposition was handled. Also, this part the manu- facturing problem was, perhaps, the most troublesome, and the selec- tion and adapta- tion machine fixtures, tools and gages, traditional were garded. previously made, the pump casing consisted separate that necessitated some machining operations. Being the “neck the bottle” the manufacturing process, this casing was closely studied and way found cast all parts each half integral, which permitted machining the two halves one set-up, thus combining the operations. The redesign also resulted reducing the number parts the labyrinth from 216 22. There but one other machining operation the casing, final reaming, which done machine using special “combined” reaming tools, after the two halves are bolted together. The casings are close-grained gray iron castings. Machining operations consist milling the joints, boring six, seven eight stages, boring and facing the im- peller bearings and the joints—all which done one set-up the 72-in., 18-ft. bed, planer- type milling machine illustrated, which was built liam Sellers Co., Inc., Philadelphia. This machine has one rail milling head, one right-hand side-milling head, grinding head the rail, and boring head that car- ried extended apron integral with the left-hand end the cross-rail. Being standard units, the two Redesigning with Reference Manufacture, the Number Parts the Compressor Casing Was Reduced from and Those the Labyrinth from 216 milling heads permit use the machine for other work when the pump casings are not being machined. Each half casing set and locked separate fix ture, which means tongue and groove located positively the table, with relation the boring head and the corresponding table locks. The castings are placed joint upward the fixtures and the first operation milling this joint. This done standard planer- type miller job, using 16-in. inserted blade cutter the rail head. One rough and one finish cut taken, 3/16 in. metal be- ing removed in all. The next oper- ation, boring out the centrifugal pump stages, unusual For this special Davis boring bar bolted ing head faceplate and supported outboard bearings fastened the cross-rail, shown. This bar, which ft. long and weighs more than 2000 ber integral ing the number pump. These disks and the bar proper contain the cutters necessary bore and face the pump stages the exact diameters and thicknesses. The cutters, all, are removable and are accurately set micrometer gages, being possible remove and grind any cutter without disturbing the others. idea the accuracy this work may gained from the fact that this casting, which weighs about 3000 there are dimen- sions calling for limit plus minus 0.001 in., four calling for limit 0.002 in., dimensions calling for limit plus minus 0.0025 in., two requiring limit plus minus 0.004 in., and requiring limit plus minus 0.005 in. When the boring bar place, the table traversed the fixed stop opposite one the castings fixture and locked position. The boring head, driven the rail milling head, then set for the proper speed and the boring bar set motion. The crosshead, ad- justed unusually large screws, then fed down slowly and steadily, carrying the rotating boring bar with it. When the cutters have been fed into the casting The Iron Age, October y f 4 the stance, the irious pump stages, and the in. previously allowed for finish. Length travel and end and ntern bearings for the impeller shaft reversal the table controlled planer, ex- have been finish bored and limits required. cept that the speed both directions the same. The the are down point which grinding head arranged with screw feed across the rail. Reamer Bar Ft. Long, In. Diameter ted herewith being’ used in tnis nection, finished, the cross-rail raised and the The casings are then removed from their fixtures, inlocked and traversed bring the other half bolted together and then the bore for the impeller shaft ising into position, which bored out exactly After the cases are taken from the machine, firs the two extreme surfaces which are used support bear- The foregoing ring and facing operations were con- ings are accurately scraped half-circle gage, which lativel nall diameter second assures the casing being split the center. They are t ; 7 d Addition the Rail and Right-Hand Side Milling Heads, the Sellers Planer-Type Miller Has Grinding Head, the Rail, and Boring Head That Carried Extended Apron Integral the Left-Hand End the Cross-Rail. Heads buttons and 1S completely interlocked similar design rger than bu ) ( ed slowe1 Casing Joints Ground Same Set-Up now being completed, the casings are then repared nal operation laner-type mill grinding. The fixtu lamps relieve the castings strain, the ring the grinding head brought into operating ition. Then traversing the rail and adjusting the nding head slide, the wheel set grind off the 0.005 1929, The lron Age have individual motor drive. Control push then joined, with plug each end, and the dowel holes reamed; this assures proper alinement the two outside The 7-in. diameter 7-ft. long reamer bar shown here- with then placed the case special which replace the standard bearings used later. revolved and fed forward distance in., when all the surfaces the machine are accurately alined and sized; the casing then ready for assembly. Planer-Miller Heads Have Individual Motor Drive The Sellers planer-type miller slight modification the standard machine described length THE IRON AGE Nov. 1928. Heads have individual motor drive, pe | | holes. Boring the Pump Stages Special Davis Boring Bar Em- ployed. This bar, which ft. long, weighs more than 2000 and con- tains accurate set cutters, bolted the boring head faceplate and sup- ported bearings fastened the cross-rail, show n we Halves of the Casing Are Ma chined One Set Up, Final Reaming After the Are Bolted To gether. Operations consist of milling the joints, boring the st iges, boring and facing the bearings, and i] pel grinding the joints er machine ployed modification the standard type William Sellers Co., Philadelphia = the Reaming That Follows the Planer-Type Miller Operations, Special Reamer Bar That In. Diameter and Ft. Long Used connection with the standard machine, and lifferent speeds, ranging from 300 r.p.m., tainable through sliding gears and clutches. boring head, driven through coupling rail milling head, utilizes ground worm and revolve the horizontal boring spindle. nge speeds from r.p.m., obtained through changes the milling head. The grinding head ntal spindle and driven 5-hp. motor through drive. Both the motor and the grinding spindle unted slide for fine adjustment. back type cross-rail, the deep box table one flat and one double-vee way, the table and bed construction are the same the stand- hine. change gear box and rheostat provide essary feed range and rapid traverse, this type Fo +9 tion of Bar Holds Gage onWork ——7-2----- } \ 0.003% Bar 7 \ \ J \ | \ | / / / 4 4 AGE Used the Boring Operation. The boring bar fed down until the gage rests the casing—the indicator read- ing zero—which leaves 0.005 in. for grinding located both sides the table, which arrangement makes unnecessary for the operator move from one side the machine the other start, stop re- verse the motors. Control the machine completely interlocked; feed motors cannot started advance the cutter motors; overload the cutter motors will slow down stop the feed occasion demands. Safety clutches are added precaution against abuse. Impeller parts are die formed, the material being stainless steel special quality. When the impellers are assembled their shaft, the entire assembly mounted the massive special Norton grinder illus- trated, which finishes all revolving surfaces. this the impeller unit dynamically balanced. The grinder, designed for unusually large diameter work, similar the standard 28-in. Norton machine, except that the wheel-slide hydraulically operated and Following being said assure the steady feed essential controlled one lever the front the machine. and accurate finish separate motor used for driving the hydraulic mechan- are ntrolled push buttons from ism, and another motor for the lubricant pump. Impellers 4 aa Surfaces. The unit then dy- anced 900—October 1929, The Iron Age 4 ‘ a ~ ~ | ~ \ i } | | | — “Courageous Spending Needed Industry” Charles Abbott American Institute Steel Construction money largely, but rather wasteful penurious, declared Charles Abbott, executive director, American Institute Steel Construc- tion, address before the Na- tional Industrial Advertisers’ Associ- ation, which meeting this week Cincinnati. Industrial and commercial success, Mr. Abbott said, has been predicated upon courageous expenditure funds and willingness gener- ous all worthy efforts. Mr. Abbott went say: “Today successful businesses are conducted entirely different plan from that which prevailed the pre-war days. “To manage business successful- requires much courage that possessed the soldier who goes war. Business courage the more natural because all the benefits which the public has material wealth come from it. “The problem sales management far more important than ever was. must not only teach our salesmen how sell, but, what greater importance, must teach the public how consume. “In the past, business operated what may call the economy principle, the principle paring down and saving; and has wonderful and worthy back- ground. America would never what without it. Creative Spending Policy Needed “But this policy has had pass; now understand that the hold- tight, spend-as-little-as-you-can prin- ciple must give way new more constructive and aggressive outlook— business now beginning em- phasize the principle creative spending rather than that pinching economy. feel our family, our business, and our national attitude. “We not need the old quality caution today nearly much need the new, the courage plan and panics were just around the corner naturally needed great deal caution and watch-dogging, but the business are gone. now have bigger things than merely guarding what already have. have vast creative ahead raise the standards living the millions people who still exist below the minimum comfort level. now know that are sell- ing industrial equipment our market limited the sales our custom- ers the public. the