The Iron Age 1930-01-30: Vol 125 Iss 5

ACE New York, January 1930 ESTABLISHED 1855 Value Research Manufacture Specific Discussion Investigations Press and Die Design, Quality Sheet Metal and elding Technique Steel Auto Body Manufacture DR. GEORGE KELLEY ESTERDAY, looking 2. T hie improvement of old into the window products. notice printed upon box ESEARCH not only helps the methods manufacture absorbent cotton. read manufacturer keep his prod- old products order follows: “The cotton in this : to better the products or uct ahead competition, but package has been made thor- reduce costs. oughly absorbent process developed after years ex- haustive research.” opens new outlets for the main line its by-products Systematic ex- perimentation the materials process improves their adaptability rapid manufacturing, and the in- fluence, extending back through the Take, for case the lamp division General Co. Twenty knew that statement years ago tungsten filaments was true. were extremely brittle and prone break upon receiving the slightest jar. was, in- deed, serious problem for source supply, spreads the makers electric lamps out into general indus- and they placed great impor- tance upon its solution, Final- mechanical equipment worker discovered that the lightens the labor bur- breakage the filament was den, promotes safety How did know was true? Because the name the manufacturer was that firm which has long held high reputation for its med- ical supplies and because have more than inkling the necessary part that re- search plays the manufac- ture most the products —_ due the fact that cleav- civilization uses. res, much like those dia- safe say that al- and reduces the overall mond and other precious most great manufacturing stones, existed the filament company was ever established wire and ran, most cases, questionably such enormous organizations General tion cleavage and, hence. the fila- Electric Co., American Telephone Telegraph Co., Gen- ment wires and the failure the entire lamp. eral Foods Corporation, General Motors, various steel cor- The laboratory man went work remedy this situa- porations, and literally thousands other technical tion and, after numerous experiments, arrived very semi-scientific organizations. also true the Budd simple solution. introduced into the metal the wire company and every other progressive manufacturing con some finely divided base material, much like ordinary cern the automobile industry. earth, which, express unscientifically, set number partitions blank walls the wire and broke the Ductile Tungsten Important Example cleavages. The result was the tough, long-lived tungsten The laboratories practically all manufacturers are filament today, which will stand astonishing amount occupied chiefly with research devoted three aims, abuse. follows: Who can put into words the great benefit that this laboratory worker and the progressive organization be- hind him brought humanity? Financially, saved the millions users electric lights enormous sums money The development new products. Mfg. Co., Phila- *Metallurgical engineer, Edward Budd delphia. | | q VOL. 125, No. and made possible for his company manufacture litions which will produce the most favorable structure. has produced universal satisfaction and Tool steels must also selected produce low cost ser- isands stockholders and agent vice, and prepared manufacture that little Haphazard Experimentation Not Sufficient Use must made the newer methods producing Pre ar-resisting surfaces the use chromium plating, n I T} I A> A. } son, 11a Ir 1. } lj riale iburst hardening and nitriding wherever die materials her great inventions, Mr. treated appear promise cheaper and better service. All this with loss precision, for steel body stamp- ings must free from marks irregularities produced rgan research the effort reduce die maintenance cost have endeavored select those materials which would best re- wear when used dies. further reduce this cost have studied and developed drawing compounds which increase the life the dies and save the stampings from marks and scratches usually incidental the form- invent Not satisfied with existing safety devices our presses ons.” have developed new type our own which promises much more satisfactory than those previously use. Herbert Hoover, the engineer, expressing ter Much Study Given Sheet Metal Sheet steel carefully selected suit various special ntion here that the word research, purposes. Difficulties and failures which arise the pecially large manufacturers, includes such mat- manufacturing operation are investigated the labora- hat keeping workers hap} contented and tory and recommendations made with view eliminat- work, extensive and intensive investiga ing the trouble. Such investigations, carried out co- schedules, detailed study competi operation with the manufacturers sheet and strip steel, siderable number other things. have assisted the development products which are shall not have space talk this article. The research much more certain performance when subjected diffi- shall discu more technical nature. cult operations. The different steps the manufacture Technical Die sheet and strip steel have been investigated and the echnical Research ustrated Die Design influence these steps the performance the product nical research falls into two main divisions: (1) noted ecting (2) research has been found, for instance, that for certain stamp- Processes ings the metal must rolled and annealed definite ways Let see how these things are worked out the Budd and the grain size shown microscopic examination ny, employs maximum 10,000 men and, together with the physical properties determined rking capacity, produces approximately 1,000, test must measure predetermined standards, fail- teel automobile bodies per year. discuss only ire will follow attempt give deep drawing. production, take the matter characteristic and inherent defect sheet metal rious bod stamped, shaped and known stretching strains. These appear slight de- welded together into complete pressions the otherwise smooth metal surface. Former which must fitted wit! rolling, but this caused sacrifice ductility. Another pecially designe dies, shaped produce certain device was that roller leveling, but that failed work arge part body. Our largest dies with uniform success. Happily have developed me- four-door sedan, with two door opening stretcher strain formation and does without reducing ning, raised molding, depressed the workability the metal. This permits better finish at lower cost. wheel the chassis operate in, and the largest steel sheet ever rolled for automobil Large Sheets and Welding Reduces Number Parts rom the first press not completed The stampings themselves must designed that the limit the pressing strain which blank when laid out the sheet will give the maximum sneet teel will stand, and the piece, after useful areas the parts cut away. suitable welding first operation, must further shaped, clinching these pieces must utilized other parts trimmed other the body. constant effort made our plant main- are made material, labor and tain the most economical ratio waste usable material Before the dies are made investigations are con every sheet. Those parts which are too small for use ted hich determine that combination materia major automobile body parts are worked over special greatest servi the lowest first and main department recover such areas are useful making This requires that cast irons specia mall metal brackets and reinforcements. ised and that castings nder The methods joining pieces metal tagether have 292—The Iron Age. January 23, 1930 mit course, when this immense stamping. been brought high state perfection the Budd very small part the research conducted the manufac- plant. ture Budd automobile bodies. This research follows the For irregularly shaped blanks,two sheets may welded product through all the various processes, from the design, together, that way avoiding the purchase analysis and specifications raw material the com- sheet with its attendant waste. The process used here plete body after has been placed upon the chassis and flash welding and, perfecting the methods finishing. out the road. the welds become almost invisible and are Much experimental work deciding the number equal that the original metal. Flash welding and function the dies, the most efficient applica- plied formed pieces well flat sheets, resulting tion the conveyor principle assembly are all part the production units consisting single the work; the research not actually the laboratory, Thus cowls are made one piece and even then special investigating groups. The Budd com- two sides and back panel car are joined that pany 1929, for example, installed over three miles body consists single piece metal from the new conveyors which, despite their cost, have already front post, around the back the front post the othe: proved themselves worthwhile economy. Tests side. showing the longevity all-steel bodies, their safety, bal- progressive called for the creation Spot, flash, are and gas welding are also employed special machine giving most rigid tests simu- join several small pieces into unit, spot welding lating actual road our steel bodies and their extensively used the final assembly. have studied ndividual parts that have been able discover and its design and operation, standardizing replacement part remedy weakness before the bodies into actual manu- and modifications design increased the output the facture. machine appreciably. the same time have studied only fair say that because the Budd company those conditions which contribute the uncertainty has maintained the most scientific and continuous manu- spot welding and which are responsible for the bad repute facturing research, upon which constantly spending which the operation has been held and have reduced much time and money, that there are approximately 6,000,- one which the welds that are produced are all 000 its all-steel bodies now use the United States cases perfect. and receiving ever increasing acceptance from car the foregoing paragraphs have covered only makers and from the public. Too Liberal Spacing Group Patterns for Small Castings equipment,” continued, “should not common characteristic find pattern makers saving who have been accustomed work with heavy sections continue have their castings produced too liberal with the space which they allow between designed wornout patterns that waste large part small patterns, says Judge, works engineer, Hamilton the savings made from their other modern production Foundry Machine Co., Hamilton, Ohio. Spacing, ar- tools. This condition may have been brought about rangement, gating, molding, size, etc., are all factors af- the fact that casting production equipment something fecting the ultimate cost castings. They are all equally which the important and one should disregarded. offers the photograph, here reproduced, clear example inefficient spacing and arrangement. gates patterns, properly spaced, are arranged each side for comparison. From these illustrations, wastefulness the design for the central equipment, adds, must apparent. The facts are this equipment was never used, the casting buyer was convinced that re- gating worth the extra cost. Good pattern equipment, urges Mr. Judge, offers larger opportuni- ties for saving production costs than many other types equip- ment. “Manufac- turing establish- ments that take pride their new and modern machine tools, and other infrequently. also probably true the part the owner the Two property encourages similar state foundrymen.” the The establishment that worki \ 4 " the Group Pattern with Undue Spacing; Those Flanking the Center Are Regarded Satisfactory equipment and consulting new owner ordinarily comes contact with only that lack interest his own mind the part closely with its dical inspections designs, ing the pro- cedure, the opinion Mr. Judge, most profitable one in- deed. “The man- ufacturing estab- lishment which giving the same consideration its pattern equip- ment that gives its plant equip- ment being excellent dividends the way reduced costs and advan- tages which its competitors not have.” The Age, January 23, 1930—293 q estruction Galvanizing Pots Examples Under Practical Conditions Show the Why and Mechanical Defects Chiefly Fault ESTRI TION i inizing ] e! ractica netime are tne direct cause « fa long, ora short, pot e! ng cond I aeais wit! many) ractor , i inless definitely organized is difficult t The next question “What is a good chemical com- properly concer nswer would be, “One that meets the specifications.” But practical galvanizers know that many pots which meet these specifications. For example, howed 0.12 per cent carbon, 0.40 per cent manganese, 012 per cent phosphorus, 0.030 per cent sulphur. Wher vithin the specifications, that the ques- \\ still can asked, “Why did fail?” The life was short comparison with the usual pot definite l A nN ch ai quicl TI I I mediats ther What kind steel y r galval ne } iy these two steels have been set American Soci for Testing Materia tions are issued under designation and the final number indicates the year original idoption standard, or, the case revision, the last 18. 21. Kettle Side Near the Top. The character the alloy shows low temperature. Note show wha ould that the alloy thin, also Many kettles have failed, and the answer which came was that the steel when tested met these specifica- under similar conditions. The practical conditions found The question always is, “Why did fail?” indicated the cause the failure steel making required answer thi Segregation the steel base. usually can traced three definite causes Localized overheating i Making = Another pot which failed showed the following chem- ] Seg ratior . Segregat ical analysis: Oxidation ‘ per Mechanical defects 0.411 per cent and oxidation are chemica metal- S 0? per ce! reasor nechanical defects from rolling and physical tests and have part due one the above three causes. Each big field for discussion. Suffice say here per cent mposition and character the steel base 0.018 1ld he ] ely scerutinized in not failyny kT} > } lid ClO scrutinized in p aliure. The chemical! Sulphur 0.041 per cent sition and the qu lit I ne teel are fac tors which 5 or Iron Age, January 1930 Trace extremely interesting compare the chemical composition the steel these two pots, which failed Pot Immune from Failure eventually fail, and two pots fail ing niz ), 401 H iB Pittsburgh IG. 2—Zinc-Iron Alloy from the Inside the Kettle Side, About Foot Lower Down Than the Alloy Shown Fig. Note how the increase in temperature character of the alloy service, with that pot which lasted for three years. The analysis the steel this latter pot given below: (‘arbor Mangane I’*hosphoru Sulphur Silicon Tungsten Nickel \ Chromium Vanadium N Molvbdenun only fair state that the first two pots had production much greater tonnage than the last ex- ample. This, however, does not tell why these other kettles did not give the same service the other doing the same work. would require too much time into the discussion this particular phase practical destruction galvanizing pots. The matter will dismissed saying that there are four distinct reasons for pot failure which cannot very well covered any set specifications. The four ad- ditional factors which steel should have, addition meeting the required specifications for this kind, are The steel should sound. There should segregation the steel. The steel should thoroughly deoxidized, and IG. Alloy Still Farther Down, and Just Above the Zone Extreme Heating. Note the char- 4 tor > acter this alloy, developed still greater hea tL the proper pouring temperature. The steel should not have any mechanical defects rolling, handling from ingot plate form. Overheating Pots HEN and how are pots overheated?” This ques- tion may answered definitely number ways, which are Deliberately, times prosperity, overpro- uction. getting out rush orders Deliberately, guessing the metal temperature instead using pyrometer. poor furnace design. metal capacity. the method heating the pot. having too small heating area. common tind galvanizing kettle which has failed three days, two weeks, eight weeks, 4—Zinc-Iron Alloy the Upper Zone Extreme Heating Area and High-Heat Inten sity Note the increased thickness of the alloy formed, shown the small piece alloy lowet right All pictures are reduced one half in size three months, four months, six months—in fact, almost any time one may set. The difference kettle life caused many different things. very common cause short kettle life the method used start the new Starting from slab packed the pot the severest test perhaps upon the pot, although even this respect results have varied widely. For example, not long ago it was stated by the owner of a very large kettle that pot which had been melted hr. had given better life than the previous one, which hr. had been required melt in. Overheating night has often been the direct cause pot failure. Only one who has actually looked after the heat galvanizing furnace can appreciate how hard keep from overheating the pot. This especially true where the night watchman also fireman. The damage which done properly illustrated The damag hich pot with absolutely new metal and which had not had a pound of production put through it, which ac- cumulated 4400 lb. dross to 1100 deg. Fahr. The iron to form this dross was de- had been 1 overheating for hr. rived entirely from the pot, since material galvanized it. Dissolving, the action The Iron Age, January 23, 1930—295 Lee the becomes extremely rapid high ratures this ntinued for any great length time the iror will diss completely through the + + ~~ f the > ‘ ar over? i the productior This excused Alloy Lower Zone Highest Intensity. Attention called the still greater thickness the alloy, which this point almost an inch (lower section) the price the pot per pound producti ained very low. But this does not change cond way, since the pot life subject principles. The pot may stand continued ting for some little time. the other hand, very quickly, giving extremely short and cost times rush orders the pot may fired quickly. There nothing hard pot extreme variations heat. The short and the wider the varia- tion heat, the damage done. The best nditions are heating with erature variati also gives better fluxing nditions and will tend produce higher roduct Many plants still allow the pot perated and ntrolled | a yractical gaivanizet vho Ss consideres good guessing the metal temperature. such plan any attempt knowing scoffed at, and considered mark inferiority not able guess the tem- perature. other industries guessing has been elimi nated large extent. eventually will entirely eliminated the galvanizing industry, the view gradually becoming general that extremely costly guess. Not only the pot life shortened, but also the dross production increased, and the quality the ating lowered. Onlv recently has the matter of ga inizing turnace lesign become importance. For over years the ndustry got along very well with the old coke-fired pots small fire-doors each side. With zinc 7c. ind, the dross made 96.5 per cent zinc, the los overheating soon mounts money value. not uncommon find operating galvanizing kettles pro- lucing per cent dross alone. The furnace design may reduce this dross much less than half this quantity. Pots which large quantities dross are produced are usually pots that are overheated. poor furnace design the basic cause the overheating. design galvanizing furnaces should take into 296—The Iron Age, January 23, 1930 the metal capacity relation the desired on. pots are quickly burned out, owing fact that the metal capacity far too small elation the production being put through. The smaller the metal capacity and the higher the production, the the dross and the shorter the pot life. There relation between the quantity heat that ipplied given unit time and the metal and the production. these three factors are not correctly balanced, the kettle will lose temperature the dross will accumulate large proportions, and the pot will fail after few months’ operation. The method heating may vary widely, even when kind fuel used. For example, coke- fired pots the fire-box width varies from in. Thi ] the draft doors and their number also vary, well as the size of the coke used as fuel. These fac- seem unimportant; but they are extremely impor- anyone with practical experience with coke fires testit\ A] ras is used as fuel, the method designing the combustion chamber, the number, siz ition the burners, the type burner, the size lower used, ete., all influence the kettle life The relation heating area total area also great importance pot life. most pots the actual ating area, through which the major part the heat received, extremely proportion the total area which may heated. particular example this condition may mentioned the small area coke- fired pots directly fro the fire doors. Most the heat received directly front of, and slightly above, the all draft openings. Pots Fail Any Overheated Point The second question, “Where pots fail?” may answered saying, “Anywhere; wherever overheated.” Practice shows that some pots fail the dross line, fail the top, some fail the middle the sides, ome the bottom, and some the corners. all depends how they are heated. Failure, however, 6—Final Destruction 2-In. Fire- Box Steel Side usually occurs due overheating. This statement nade the sense knowing that segregations and im- purities will cause quicker destruction than good sound metal. Examples How Pots Fail The third question, “How pots fail?” best an- swered illustrations from full-sized pot which did fail. Fig. shows some the alloy from the inside the pot the top the side. The temperature this particular pot the top was very low, due the method firing. was coke-fired kettle with eight fire-doors each side. These openings were very small propor- tion the size the pot and body metal heated. This shows clearly the result overh the side fe | | the galvanizing pot, and how the destruction | IS DY iv about practice. The cause failure high concen- tration heat over small area the side, which stimu- lates the dissolving action the molten zine upon side. The point failure the dross line and largely due the fact that there little circula- tion the metal this point carry off the hich heat intensity from the coke-fire directly the other side the steel plate. Some pots fail the dross line, some the the side, some the middle the side, and still other the corners. The underlying cause failure aln every case found localized concentration hig heat intensity small area the steel Answer the next question, “When pots fail?” “any tin soon the dissolving action the zine rogresses ent rely through the thickness the side the pot.” One pot failed from sliding the slabs etal. The side was already thin, when slab pushed +} h ana lk kL P ] thin section the opposite side, and knocked hole Vanadium Steels Used for Railroad Equipment the annual meeting the American Society chanical Engineers held New York during Decen ber, 1929, Charles McKnight led discussion the “Alloy Steels the Railroad Field” reported THE IRON AGE, Dec. 12, 1929, page 1592). Major Norris Vanadium Corporation America contributed discussion vanadium alloy steels that same meet- ing. After noting the increasing tonnage alloy steels going into railroad service, primarily because their en- hanced strength, Major Norris said that nearly all the failures investigated him were due such things tool marks, sharp fillets and faulty lubrication. Very sel- dom the quality the material inferior. Vanadium used per cent the alloy steel loco- motive forgings and castings, not deoxidize the metal (as has been often stated), but for its alloying qualities after the deoxidation has been accomplished cheaper and more powerful deoxidizing elements, such silicon and aluminum. imparts fine grain size and improved strength. Steels containing vanadium appreciable amounts, sometimes even low 0.05 per cent, show less dendritic segregation than vanadium-free steels, almost complete freedom from Widmanstattian patterns the microstructure after casting and before thermal mechanical treatment, and are characterized unusually fine grain, which they retain higher temperatures. Vanadium has strong chemical affinity for carbon, and when present the iron carbide strengthened and hardened, shows less tendency coalesce form into large masses, and tends remain the condi- tion. Therefore, segregation carbides less comn vanadium steels, and lamellar pearlite does not readily occur ordinary rates cooling. This tendency vanadium form sorbitic pearlite, even large forgings, unique and valuable property. > = | 5 Major Norris said these metallographic and chemical characteristics are responsible for the increased strength and elastic ratio carbon-vanadium steels, without mate- rially lowering ductility. Shock resistance, endurance un- der reversed stresses, resistance abrasion and response heat treatment are all improved. Troubles encountered railroad men with quenched and tempered forgings, his opinion, are due inade- quate heat-treating equipment and experience, and for this reason primarily the alloys suitable for use the nor- malized (or tempered and annealed) condition were de- veloped. this treatment unrelieved quenching strains are left the forgings, and physical properties are obtained practically equal those mild quench and tempering treatment. Typical physical properties normalized and tempered Pots fail Another failure irred night e nad r ] nt t pit and around the fire-box thre eeks get all the metal cleared t r another time to be dis ssed as The Theory annealed carbon vanadium forgings are shown the Exception was also taken Mr. McKnight’s figures for minimum requirements for normalized and tempered alloy astings, shown the second line the table. cording Major Norris, the minimum specifications shown the third line are easily met carbon-vanadium the table. Even higher ductility can had from vanadium castings (see last two lines the table). p Red Elonga- tion Y | Tensil tion i Point, Strengt Per Area Lb. per Lb. per Cent Per Chemical Sq. In. Sq. In. in 2 In. Cent Analysis Mir ngs, normalized Carbon i, ac- 0.30 to 0.4 Mc- Manganese ee . 45,000 80,000 25 45 1.0 to 2./ carbon- | Vanadium 0.18 i or Nickel N r- 1.5 to 3 » (Norris)... 57,000 90,000 24 47 Minimum tensile properties of large nickel-vana- dium steel cast- Average values to Silicon be expected from Manganese 0.80 nicke] vanadium Nickel 1.50 casti 59,000 28 58 Vanadium 10 Limitations Welding Aircraft view the extreme exactitude which governs the design and construction airplane, there are many features welding that while permitted other indus- tries are prohibited the manufacture aircraft, said Charles Kirkbride, Naval Aircraft Factory, Philadel- phia, address before the recent meeting the International Acetylene Association. Edge welding avoided this one the most prolific sources welds known. The joint should not loaded with surplus metal, this only means more weight and gives better chance for cracking. Tension welds are avoided possible. Two welds are not made too close together thin gage material because there not enough metal available for proper stretching meet the double shrinkage, and cracks will result. Both sides thin sheet should not welded unless absolutely necessary. The practice fiilling holes with weld also discouraged. The Iron Age, January 23, 1930—297 q 7 i+ q | + lin +} lining | irst line the adjoining table. q q castings having average properties shown the fourth § i anagement Movement Increasing Numbers, the World Engineering Congress Proved, Are Studying Scientific Fear Resulting Unemployment Deterrent DR. LILLIAN GILBRETH scientific ities and technical schools and evinced marked interest. ment division of World Engineeri Touches Technological Unemployment Japan Congress, Tokio, began The discussion was opened Dr. Schlessinger, the Wednesday morning, Oct. Technische Hochschule Berlin. had been for small room time visiting Japanese plants and made some drastic criti- her remotelv located. what had seen, but most kindly and con- Excellent visual devices structive fashion. spoke noticing the factories gns, arrows irked plans Japan, crowding, machines rusting, labor cheaper than supplemented guides machine tools. saw need for better buildings, espe- language facility cially the smaller shops, also need for equipment. exceeded the wil noted too many workers for the jobs done; one shop lingness help, got Japa 2000 workers there were 200 more than would have nese and foreign been needed Germany. Apparently the surplus workers residen the Interna- felt that scientific management needed, but that Mar must followed through, adequate output insisted on, and the resulting unemployment the dispensed with ene! orkers accepted necessary, during interim period least. This raising the problem technological un- employment seemed likely lead heated discussion, nter, table long enough provide ampk which was postponed later session. The second paper, “Development and Trends Stand- read abstract, the Japanese who read revelling the job. there were many more Japanese than all the ther nationalities combined, was early and wisely sug- gested keep the Japanese group always touch with procedure, even the expense the rest us. English ngineer engaged efficiency work, liscussion was translated verbatim into Japanese, but English, ability translate easily, fluent Japanese into English only brief substance, when asked ptably from Japanese English, for. Abstracts, charts, blackboard illustrations, did energy, sense humor, and ability sweep asid much keep touch. The second session came the next morning. was chairman, easy job, Mr. Araki had all order, Equal Mr. Uer “efficier even special procedure when Prince Chichibu, who was ader industrial gy, well known visiting all sessions, should come ours. Dr. Mauro pre- United States and Europe because his visits, sented the two listed papers one—his own, “The gar Taylor Society Europe,” and that his col- cal and Practical Aspects Management,’ Science Organization Italy.” Both presented the problem 298—The Iron Age. January 23, 1930 neres pressions the congress wer: correspondent the World Engi: ss technological unemployment paramount importance, and general were agreement with Prof. Schlessinger’s argu- larger part whom ment the day before, that anese. Many idents from the univer every worker urged max- imum efficiency and output, matter this meant increased unemployment for time. Japan. Dr. Gi! Mr. Spacek, Czechoslo- vakia, and our Prof. Roe stressed the need adapting the appli- { > ~ 7 "Loa | 4 | ' preside { int storing and moving hats and coats the The meeting arted time, largely ecretary, Mr. Araki, whom Section New Yorl The r nt erat + were were Tl * IRo in cation the specific situation. They held that finding employ- ment for workers displaced was important part the work scientific management. Mr. Araki said thought this could done Japan, and told how the jinricksha men, out jobs, autos displaced the jinrick- shas, were trained chauf- feurs. The third session was the morning Friday, Nov. The first paper was Ordnance Vice Admiral Godo, “Some Experiences Man- agement Marine Shops,” and was excellent subject matter and dealt detail with forms and mechanisms agement, route sheets, etc. was illustrated charts and blackboard work, easy follow, though Japanese, and aroused long and detailed discussion, all Japanese Japanese. This was most interesting, proved that the mechanisms scientific management are as We ll nts known and use Japanese engineers. Studen practising engineers, followed easily and attentively Without detailing succeeding sessions, the chief contr bution Section XII the congress was made, from standpoint advances technic scientific ment, doctors medicine and doctors philosophy, not engineers. The latter furnished illustra tine hit VU tions and “progress reports,” significant, interes not new, except for the added emphasis technological unemployment. The others dwelt psychological matters and problems metabolism among workers. was most interesting that many Japanese more than could seated each session) followed the program with deep attention, interest and understanding. Their presence, discussion and reactions showed: acceptance the principles scientific manage ment. Stress research. Acceptance the “machine age.” Fear technological unemployment. for the foreign delegates, these, like the Japanese, were most agitated over the question technological un- employment. There was not time discuss job analysis, and determination job specifications and personality analysis and the determination personality specifications remedy for unemployment. This was unfortunate the Japanese have great aptitude for such work. the many lectures given Prof. Roe and often consecutive talks before the same groups, had + el opportunity discuss the industrial revolution, fect unemployment and the technic scientific manage- ment, especially motion study, affects employment and hoped that those most inter- ested management Japan realize that the aim sci- entific management prevent, not increase unemployment. found much interest scientific management Japan. The largest organized group consists members the vari- ous engineering societies who have formed group very like the management section the American Society Mechanical Engineers, except that open civils, mechanicals, mining and electricals who ested management problems. The Institute Industrial Ueno has also engineer mem bers but open gists, doctors, executives and interested ment especially affects the human element. The Association for the Effi ciency Promoting Movement inder the direction one the popular newspapers, the Hochi- Shimbun, Tokio. The lectures sponsored this associa- are open the public and attract large audiences. was privilege meet the leaders all three associations. The engineering group anxious spread management throughout Japan—cooperating with the other groups but keeping the leadership the the technically trained engineers. “efficiency” group feels that the chief need con- sideration and preservation the human element, so, while glad admit engineers membership, emphasize the leadership those trained human sciences. The “efficiency promoting” group hopes extensive education and popularize the movement. The situation not unlike that the United States possibility duplication effort, yet much still done that one hesitates suggest amalgamation. here, must hope for cooperation among the different groups, and taking over suitable activities each group, ac- everal them, visited Europe and the United States, have studied the literature care- fully, have some cases translated revised the stand- ard works. The younger men are being sent over for training American colleges and industry. The chief needs are, their part, longer study here, realization that the installation scientific management not “white collar job” and the development cedure adapting the technic the specific problem. course these are also the chief needs this country. Management engineers from foreign countries are given every opportunity see Japan what being and will increasingly invited lecture expert work done Japanese management men. But there feeling that Japanese industry and business should systematized the Japanese. certain that Japan nation interested more efficient management, studying and applying fast she can and will ulti- mately both introduce scientific management into her own activ- ities and make contributions echnie to be used every especially interesting and significant that many Japanese are applying the prin- ciples motion economy their own work programs. There management chools universities. Courses are being planned and every vis- itor from the management field urged devote all his time rive The Iron Age, January 23, 1930—299 } — LG cording its fitness. = ~ — Conveyors Aid Production Problem Pump Manufacturer Increases Output Better Use Plant Rather than Expansion Floor Area gas pumps and wate! imps ecided problem more efficient use plant facilities, than expansion floor area. Consequently has rearranged its factory eliminate waste space and installed comprehensive conveying ste handling materials Gasoline pumps, the companys main product, embled along conveyor line which begins the west end the plant and progresses directly the east end the only deviation being journey the calibrating room, which housed separate structure. isolation the calibrating room from the main building = = Incidentally, the ft. high, has been along the assembly line station Work- men standing this platform are located the right ble. wooden platform, about height place the glass measuring tank the pum are stored adjoining the platform. Moving Into Calibrating Room After the tanks have been assembled, the pump, still the small truck, moved hand turntable the track, where passes side track leading the Known station the calibrating room interwoven with tracks and turntables that pumps can transported any point desired. here alibrating room. that pumps are moved hand measuring station and are connected underground storage tank. ALIBRATING Room, Where Adjustments for Measurements Are Made, Interwoven with Tracks and Turntables That Pumps Can Transported Any Point Desired legal stipulation, prevent danger from fire ex- plosion. Assembly work begins station along the conveyor line. The cast iron base the pump placed hand workman small flat four-wheel truck operating track built into the floor. The pump remains the truck until after has been tested the calibrating room. station the pumping unit added. This unit previously has been assembled separately and has passed rigid mechanical inspection, well practical operating inspection, during which subjected gasoline test more severe than the hardest actual usage. This prevents faulty pumping units from going into as- sembly, only discarded the final test, after the pump has been completely built. The pump assembled part part until, station the glass measuring tank, forming the top the unit, attached. simplify the assembly work much 300—The Iron Age, January 23, 1930 the case both visible and piston type pumps, permanent adjustments for measurements are made gallon gallon the gasoline pumped from the underground tank, and are checked gallon gallon allowed flow back. After the test the calibrating room, pumps are moved the track back the turntable the main assembly track, and again take their toward the east end the building. distance about ft. from the turntable the track ends, and the pumps are moved roller conveyor, the top which level with the floor. From this point until the pumps are packed for shipment customers they not leave the roller conveyor. station the steel casing added and the pump then travels paint booth, where the first coat paint sprayed the inside and outside the casing. passes through the spray booth, the roller conveyor ~ UMPING Units for Gaso- line Pumps Are from Testing Stations As- sembly Line Skid Boxes Electric Trucks (Below) Mee EGINNING Assembly (Above). Cast iron base pump placed hand small four-wheei truck operating track built into floor. Pump re- mains truck until after has been tested calibrating room Roller Conveyor Forms Outer Edge Two Sides Water Pump De- Being Used for As- sembly Work and for Tempo- rary Storage Pumps (Below) OMING from Calibrat- ing Room, Pumps Move Roller Conveyors (Above) for Remainder Journey Shipping Room. Here the casings are receiv- ing coat paint 2 The Iron Age, January 23, 1930—301 equ with turntable facilitate the spraying opera- the machine shop means load chart. the the spray mps move tem left the chart listed each machine the shop and its I ng stand Wi I igniy tney 1 tate numbe the extreme right is recorded the hours of room second and third coats nachining time each machine for 100 units each Between painting operations they are model pump. the center the chart tabulated rary drying the number machine production hours scheduled ahead. second aint has been have information upon which regulate properly the rving the crating floor, wher machine tools, that many tools cor edule for the current week listed the upper Water pumps ssembled separate department. Among the benefits resulting from operation the served nechanical conveying equipment and from close control tion considerable manual labor. 2.—Greatly increased itput without adding manufacturing floor area. 3.- ~ “ apital for new structure. 4.—Constant checking tely under the overlying roofing. apparently comparatively rare occurrence. However, copper material the use which for roofing pur- tive atmospheric agencies. Hence any factor which tends importance than would for cheaper material. Studies failures and the results laboratory tests bureau, cooperation with the Copper and Brass Association, showed that the corrosion not due the action the wood shingles. Under Glass Mea material other than copper itself present. However, any porous and absorbent roofing, such wood shingles, will hold water between the roofing and the flashing for longer time after rainfall than slate similar non- porous materials and therefore more rapid corrosion will units the result. appears that flashings will more likely and The experience vith smoke salt due proximity the ocean. Lab tests indicate that the following simple and inexpensive precaution will eliminate troubles due Method Visual Control line The method consists placing strip moothly finished, hard, dense wood, preferably water- are rded chart for instance. about in. back the edge the roofing, and roduction and nailed down tightly against the flashings. the tests, times the test exposure which caused line corrosion the current calendar year. Period for example, repre- difference will found under actual service conditions. 302—The Iron Age, January 23, 1930 line corrosion flashings will occur after yr. more activities service under conditions severe New York City. = | The producti pI ljuction manager 1 kant | Spring Formulas Correction Standard Stress Formulas Essential with Small Coil Diameters— Conventional Methods May Far Error JOSEPH KAYE ELICALLY spirally coiled springs, arranged resist rotary motion torques, are called springs. The principal stress thi type spring flexural and universally considered uniform character. The purpose this article show that this stress, while flexural, not uniform acros: the section the wire; and furthermore show that this non-uniformity calls for correction the stand: conventional formulas covering this type spring. This correction the maximum amounts cent increase for helical springs hav- ing index (ratio mean coil diameter wire di- considerable practical importance, particularly view that ever arising condition design space limitation, which often forces the use helical springs with low dexes. The correction the maximum stress formula for spiral springs does not reach such magnitude, because the index the minimum size coil rarely less than 10. Basis Current Design Practice The present standard formula for maximum stress based upon the fact that the initial free position wire straight, shown Fig. Under this assump- tion, the wire bent into circular shape mean radius and the maximum stress less than the elastic limit the material, the stress gradient across any radial and the neutral plane coincident with the geometrical center. practice the initial shape torsional spring straight, but circular, shown Fig. (left), and inside fiber shorter than the outside fiber initially straight wire (Fig. right) the radius curva- ture infinite and the lengths fibers and equal. Since these fibers are actually unequal lengt the corresponding fiber stresses when the spring deflected will likewise unequal. Referring Fig. sume for the moment that the neutral plane does not shift from the geometrical center have, This gives rise the stress gradient shown Fig. However, would impossible for stress gradient this type exist, because the compressive stresses would obviously not balance the tensile stresses. Consequently, there must shift the neutral plane toward the cen- ter curvature, shown Fig. Assuming tha plane radial sections the wire remain deflection, have from Fig. bearing mind equa tion (1), (2) *Consulting engineer, New York. WOOD" Settin t reases) re tain, dth the where the mean radius a ] » 1) that, the index decreases (or curvature the ratio tends increase, while the nultaneous decrease with increased curvature nds decrease the ratio becomes necessary, herefore, know the law governing the relation Dp > Fig. Present Standard Spring Formulas he Fig. Stress Gradient Basis Present Standard Spring Formulas terms the index definition and experiment, ve nave Where the constant the modulus elasticity, the stress and unit deformation respectively the inside fiber; and the stress and unit deformation re- the outside fiber; and and the stre unit deformation respectively any other fiber. ig. 67 we have, of the wt e initial lengths are 9r, and spectivel Substituting these values (4) ob- the u figure p I + ‘ of the has been omitted necessary The Iron Age, January 23, q { i + from which have, Now, since the tensile stresses must balance the com- pressive stresses, may write . 6 nee E - can! equal zero, we ive 0 7 a ry 71 ( - ), we have, j j — » Fig. Basis for Development the New 1 Forn ulas C + l 7 u log. (Cc - 1) Likewise, 7 ed ») Ce -(c + 1) C2. Therefore, combining these two 5) ressions separately with (9), obtain, Equations (10) and (11) give the relation terms the index and the diameter the wire The distance which the neutral plane shifts from the geometrical center the wire, due initial given the following: i ( ( or, ( 4 l —— log 12 in c Now, from the condition that the ilgebraic all moments equals zero, 304—The Iron Age, January 23, 1930 which reduces or, 14) A Substituting (14) (6) obtain the maximun stress, 2a ¥y, | « Fig. Stress Gradi- Fig. Corrected ent False Assump- Stress Gradient, ion Shift lowing for Shift Neutral Axis Neutral and since given (12) have, Replacing the expression the brackets ky, which might the stress correction factor for torsional springs, obtain the correct formula for calculating the maximum stress torsional springs. Fig. the values for dif- ferent values the index are plotted for convenience springs this type. should noted that this correction factor increases with lower index, and amounts almost per cent for helical springs having index shows more clearly Fig. 9.) Since the index varies for the spiral spring, should stated that this formula should applied the sec- tion the spring having the lowest index. Formula for Correction Deflection Fig. shown section coil before and after / - ty A ] / After ig Detlech Ou Derivation New Derivation New Formula for Stress Formula for Deflec- tion deflection. The load applied tangentially the load circle, the radius which Geometrically, D D = PF 18) (19) Dividing (18) (19) obtain c+ or, Likewise, inner portion helical spring. The index increases with wire length spiral spring, that the maximum stress formula may applied only one point this type spring, namely, the extreme inner point. Cumulative Effect Important the application the deflection formula are not concerned with condition single point, but with the cumulative effect conditions all points. Since the index constant the helical spring, formula (22 may used for the accurate determination the deflec- tion this type spring. This formula not strictly valid, however, for the spiral type torsional spring, be- cause, stated previously, the index varies this type spring. The value for the spiral spring therefore found substituting some value less than the maximum and greater than the minimum Since the minimum value for given spiral spring usually the same order the constant value helical springs and the maximum value ranges between and follows from study the curve Fig. that the general magnitude for spiral springs unappreciable and may ignored, the determination deflection for helical springs. The stand- i Fig. Correction Curves for Both Stress and Def (Upper) and Curve Showing Shift Neutr prings therefore recommended the most correct rmula use the design this type torsional pring. This formula may expressed follows: Fig. the distance which the neutral plane shifts from the geometrical center, or, more strictly, from the enter gravity, plotted against corresponding values and since the value given (15) have, the index The resulting curve equilateral hyper- bola whose asymptotes are the vertical and horizontal (assuming remain finite and constant) the original or undeflected form the wire becomes straight and the the shift extremely small; for example, where 1/32 Replacing the expression brackets Ay, which the shift for index equal only 0.00025 in. might call the deflection multiplication factor for This fact, and the fact that the difference length sional springs, obtain, between the inside and outside fibers for coils large index small proportion the coil radius, account for Referring equation (2), may noted that the unit the correct formula for calculating the deflection stresses the inside and outside fibers approach equality torsional springs helically coiled. The correction factor may simplified further Making this substitution and remembering that ro/d obtain, to Fig. values have been plotted against cor- responding values the index with the result that the magnitude this correction shown almost inap- preciable. fact, the correction for the deflection helically coiled torsional springs may ignored entirely. the other hand, the correction for maximum stress this type spring cannot ignored, since the curve Fig. shows that for index values less t