The Iron Age 1930-03-13: Vol 125 Iss 11

EIRO AGE New York, March 13, 1930 ESTABLISHED 1855 VOL. 125, No. The Foreman Becomes Manager Applying Mass Production Training, Armco Has Achieved Greater Efficiency and Reduced Waste Through Its Foreman-Manager Plan LMOST every day the morning paper blares forth the announcement merger some de- scription—of small businesses combining, large institution assimilating small organ- ization, the amalgamation already enormous industries into colossal corpora- tions. practically every merger, investigation will reveal that the attempt made retain improve the mana- gerial forces the member units the same personal attention may accorded the business the merged companies. This retention managerial identity is, indeed, recognition the highly necessary individual touch production. one person bigger business has brought increased importance. That the foreman, individually the head the smallest operating unit, but collectively the most important figure industrial productivity. For many years leading industrialists have subjected him micro- scopic examination, and have realized his true value. In- dustrial corpulence has enhanced his worth. the answer the riddle still bigger business, and Armco’s Fore- manship Classes Few Years Back. Under the old plan, foremen met the class room and discussed weighty, debat- able subjects. Contrast this with other photo- showing foreman- Managers action the mills 777 safe prophecy that his mental equipment will receive more attention time goes on. View this key man industry from all sides. the only figure the industrial fabric that truly repre- sents the elements management and men. the work- ing force the visible management. His words are law. interprets and applies organization policies, tells what do, and when and how it. But from the management’s point view, this modern Dr. Jekyll quite different person. them the working force; person receive orders and see that they are executed. responsible for gang productivity. Training Has Been Too Academic All this has long been recognized, and many different plans for foreman training have been evolved. They have done much improve the general tone foreman mate- rial, but some them have certain inherent faults, smacking too much the schoolhouse, without sufficient | 4 8 q 7 £ } 2 » convey the program into the foreman’s realm. Another advantage that the results can definitely measured the cost sheet. You may ask, “Why the name ‘foreman- manager’?” The Armco personal service staff reasoned that there are general managers, works managers, and department managers, why not “foreman-managers.” Functionally, all these jobs have shadow-like similarity, decreasing successively degree and scope. The general manager, among other things, charged primarily with the responsibility producing the greatest quantity finished quality demanded the custom- ers the lowest possible cost. Even though the foreman-manager may concerned with but single operation, within his field has the same responsibility. The general manager may responsible for 10,000 persons, and the foreman-manager for 10, but both handle men. There are many more coinciding functions, but this enough show that the term “foreman- manager” logical. However, Armco’s foreman-manager train- ing should not confused with waste pre- vention program. That simply the emery ‘HE Crane Operator Can Save Damage Material Proc- wheel which whets the foreman-managerial ess. The Foreman-manager plan does not overlook him. faculties—a familiar with which and Here foreman drilling crane operator who needs greater dex- his men can work best, and simultaneously terity handling the controls regard for the University the Mill. The most widely used method the voluntary selected group con- ference, which weighty, debatable subjects like psy- chology, morale, leadership and personality are discussed the classroom. Often there much oratory, and not unusual find the loudest talkers the schoolroom practising the least the mill. The enlarged structure business demands training that will produce benefits higher rate speed. This will probably hasten the revolutionizing the existing foreman training plans. For more than years the American Rolling Mill Co., Middletown, Ohio, has plugged away foreman training, using the conference method all its plants. The growth the organization, coupled with demand from the foremen that they given more tangible train- ing which they could actually apply their jobs, led the decision scrap the old plan and plunge off into the unexplored. The new plan went into operation 1929, and its soundness has now been tested. Generally speaking, the program focused the broadening the foreman’s appreciation his own re- sponsibilities and improving his job technique. Its foun- dation the adoption three logical premises. The first that the foreman manager. his job effec- tively must have the managerial viewpoint—must know his efforts should directed lowering the costs pro- duction. Third, the most important factor contributing decreased costs the prevention waste. Waste Prevention Major Topic Waste prevention big, broad subject. Armco’s personal service staff analyzed the foreman’s job from this angle and were astonished the regularity with which each his functions points directly waste prevention. encompasses his job. They concluded, too, that because waste occurs every day right under the foreman’s nose, its measure being limited his managerial ability, the pre- vention waste would serve excellent vehicle 778—The Iron Age, March 13, 1930 improve their job knowledge. Waste Prevention Program Classified well-organized waste prevention program was se- lected, which classifies waste under six major headings: The waste labor. The waste machinery and equipment. The waste materials and supplies. The waste due accidents and The waste steam, gas, oil, air, water, etc. The waste space. oe. This, course, arbitrary grouping and can easily changed without damage the plan. analysis each these subjects shows how completely they cover the field. Take the waste labor example. was attributed three major causes—direct and contributory —idleness, poor workmanship and labor turnover, which were turn broken down into contributory causes. The operation the course hinges upon the company’s policy that the department superintendent responsible for the training his men, and succeeds fails according his ability disseminate usable information the working forces under his control. Emphasis Put Actual Practice The conference method was not entirely abandoned, but used means rather than the whole. Emphasis laid upon the actual practice the job the points emphasized the discussion. One month devoted each the subjects listed above and every precaution taken quiet the effervescent dangers campaign. Earnest sincerity the pursuit job knowledge the Each subject first presented standard plan. The works manager each Armco plant assembles his entire supervisory force, usually dinner meeting, the first each month. There the blanket outline the month’s program described. Every subject divided four, different topic for each-week. The last week each month always devoted the study the cost sheets affected that particular subject. these general meetings attempt made analyze discuss job technique. Then begun the next step the operation the plan, when the general superintendent each plant calls his department superintendents. These men break down the outline into departmental problems and discuss cor- rective measures. Such meetings are always supplemented review the previous week’s accomplishments. Here typical outline devoted the first week’s study the waste machinery and equipment: WASTE MACHINERY AND EQUIPMENT First Meeting. Week Jan. 1930 The Waste Machinery and Equipment Through Improper Operation The productiveness any machine measured its ability lend itself constant and speedy operation plus trained, skillful operators. The effectiveness machine may unsatisfactory because poor design, improper maintenance, misuse and abuse. More often, the effectiveness reduced inadequate planning and scheduling. Failure attain capacity rate operation. (a) Every machine piece equipment should have capacity rating established; (b) Capacity rating should bogy for that machine; (c) Operator should informed capacity standard; (d) Movement material and from machine should scheduled avoid idleness with attendant peak loads; (e) Plans and devices should effected whereby unex- pected delay the movement material and from machine may reduced minimum prevent enforced idleness equipment. Allowing machines run non-productive idle without shutting down. (a) Machines running idle add power, lubrication, fuel, maintenance, and depletion costs; (b) Each machine should have starting-up cost estab- lished and operator informed; (c) Each machine should have idle-running cost estab- lished and operator informed; (d) Each machine should have time limit established whereby may run idle profitably and beyond which should shut down. Op- erator should informed and charged with responsi- bility shut-down when indicated. The operator’s responsibility for proper care his machine. should responsible for: (a) Frequent and complete in- spection machine and its complementary equipment; (b) Proper adjustment turn out quality production and avoid accidental damage machine operators; Proper lubrication which in- volves sufficient oiling and greasing points needed and eliminates wasteful use material which adds slipping hazards, fire haz- obscures rigid in- spection; (d) Cleanliness machine and adjacent territory. This necessary for thorough inspection, safe and efficient operation, and proper pride machine and surroundings; (e) Prompt reporting defects conditions need- ing correction; (f) Seeing that none but authorized persons operate machine, thus preventing injury persons and damage equipment; (g) The proper application safety principles and precepts established for his machine. This week’s work offers opportunity review the situation each machine and piece equipment within all departments the light the above outline. should utilized for general clean-up and inspection every piece equipment with the idea listing all needed repairs for next week’s work. The greatest opportunity for economy lies the train- ing operators and planning scheduling the movement material prevent un- productive delay machines. Departments Hold Weekly Meetings Next the department superintendent goes into action with meeting his foremen-managers and leaders. There the weekly program localized fit departmental functions and the actual application the principles conservation begun. Here, too, are given weekly re- views the past week’s accomplishments, and the con- clusive cost sheet often produced ascertain whether those accomplishments are real imaginary. The final step, and the one which receives the most emphasis, the foreman-manager’s application the in- formation has received the job. other words, studies tonight, for many the meetings are held the evenings mill offices, and applies tomorrow. But fails apply his information, then matter for the superintendent settle. After several months operation some very interest- ing and significant by-products have been observed. While the program was designed primarily for foreman-manager training, it.embraces all the supervisory group its ramifications. Many splendid department superintendents OREMEN Have Always Fought “Bent Corners” from the Hot Mills the Shipping Department. The foreman-manager the right explaining the causes and costs damaged corners one his men The Iron Age, March 13, 1930—779 q q are deficient training some particular point, which failure understand and read cost sheets intelligently good example. With the dignity operating execu- tive uphold, possible that some them have the view that any open unbending dig out rather elemen- tary facts might the cause decreased respect from their organization. This program painlessly forces the acquisition such information, because would still more embarrassing for the group discover their per- sonal deficiency. That reaction, course, common only the proud, but practically every Armco superintendent will admit that has learned great deal about the ele- ments that make costs. not debatable state- ment say that control through the cost sheet highly desirable and necessary. Service Departments More Widely Used Another significant development the trend toward Then said he: “Bill, you investigate the waste caused spilled sheets; Henry, this your subject; Jim, you take bad piling.” Every foreman-manager was assigned subject, told investigate thoroughly all the causes contributing that particular kind waste and rec- ommend writing how the troubles could cured. These papers are assembled now one volume. depart- mental encyclopedia information, and best all, each the foreman-managers learned lot more about his own job than ever knew before. Their viewpoint entirely different, say nothing their increased interest. Manual Production Prepared Paralleling this was the request works manager that the department superintendents each prepare papers the different factors affecting yield their respective department, from the ore pile the finished product. Nor- mally, busy people not write papers unless they feel the REWS These Thirteen Armco Shears Worked Out Arrangement Whereby the Incoming Shift Takes the Discarded Gloves from the Men Going Home and Carefully Wipes Down and Inspects the Equip- ment. Every drop oil comes off and the shears literally shine greater use the company’s service departments, such cost, betterment, engineering and personal service. This attributable better understanding their functions. During the month devoted preventing the waste materials and supplies, some very interesting developments came the surface. For instance, one plant was found that ridiculously large quantity lubricants and canvas gloves had supposedly been used during the year; another plant stationery and forms costs $44,000. Al- though the relative importance these items the reduc- tion steel plant’s costs rather insignificant, yet these illustrations provided dramatic evidence waste and re- sulted the voluntary agreement budget supplies. This will eventually bring the saving many thousands dol- lars, for supplies can budgeted well other items expense. Here another example how the plan works. processing department superintendent called his men to- gether and asked them enumerate the different sources waste material process. They were written down. 780—The Iron Age, March 13, 1930 urge necessity. any rate, these papers have been prepared and will serve manual production that priceless the American Rolling Mill Co. The ready acceptance the working organization another salient proof that the program what the men want. Foremen-managers every department have en- thusiastically expressed their appreciation this form training another tool which they can use get results their jobs. has brought understanding purpose, definition job effort and greatly increased departmental coordination. The use the cost sheet check progress marks this program distinctly practical. Many foreman-man- agers did not know that the cost maintenance repairs was charged off into their operations. Since that infor- mation has been generally understood, they are vastly more interested seeing that their men protect the equipment. The foreman-manager knows what fuel, power, light, air and all such items cost his department, and consequently exerts more pressure stop any leakage. q | Probably the climax the results which might attributable foreman-manager training the recent orgy record breaking which all plants are participat- ing. After business depression, usually requires certain amount time for organization shift into high gear. However, with the return greater volume orders the mills January, the Armco organization began smash production records immediately. The last edition the plant newspaper tells the establishment new production records. Having had good look the organizational X-ray revealed the foreman-manager training plan, the Amer- ican Rolling Mill Co. now seriously considering the estab- lishment standard minimum requirement which men must able meet before they can promoted super- visory jobs. the case most industries, promotion the rank foreman was simply the execution some one’s opinion. the opinion was wrong and the man not quite “ripe” assume responsibility, assimilated the necessary amount training through the routine the job and the expense production. The minimum requirements which are now being contemplated would sort out those requiring more training well those who should never accept supervisory responsibility. this adaptation waste prevention vehicle for training new, there are many points still ironed out. broad, wandering into every nook and cranny the organization, that does not easily boil down for descriptive purposes. During the first month interesting reaction was ob- served. The organization had been accustomed the school book type training, and were expecting something that sort. Consequently, required few weeks for the true objectives become recognized and the haze dispelled. There are almost 1000 men the Armco supervisory group, located plants four different States. All them are engaged this search for usable information improve their jobs, for Armco considers training busi- ness proposition—anything that strengthens the company’s position the industry adds permanence and value the individual’s job. indeed the application mass pro- duction training. Problems Ahead Management Engineering Mechanical Engineers the Management Congress and Materials Handling banquet the Stevens Hotel, Chicago, March These were Dexter Kim- ball, dean engineering, Cornell University, and past- president the society, and Craig Hazlewood, vice- president, First National Bank, Chicago. Mr. Hazlewood outlined the banker’s viewpoint the subject indus- trial management. speakers addressed the American Society Tracing the history human progress series surges, each which brought high degree devel- opment some phase activity, Dean Kimball stated that the half century ending with 1900 humanity made more progress the practical arts and mechanics than had been achieved all history before that. Now that the Atlantic has been crossed steamer four days, the continent train and airplane two days, and communication telegraph and telephone have become almost instantaneous, the gains yet made along many engineering lines are smaller and smaller. The law diminishing returns getting its work and engineers are turning other phases activity for further progress. How the Engineer Got Into Management particular, managerial matters are naturally en- gaging their attention. This subject new, when viewed the light history whole, that many can remember when there was knowledge worth the name real cost-keeping methods. During the past few years, however, have reached the point where know fairly well what management and what can do. Al- ready have begun evaluate its mechanism and put Heretofore our contact with management has been largely empirical. During the next quarter century shall put more soundly scientific One the subjects which have come very recently, and which will tie closely management the near future, the question the most economical quantity goods pro- duce lot. This beyond the scope the fore- man and beyond that most superintendents. in- volves mathematics and particularly the calculus, and such considered highly technical. 1850 the average wealth the American people figured out about $353 each. now above $4,000, and the real sense there has never been year when has not advanced. The national wealth 400 billion dollars and annual income billions has put point never before approached any nation earth. Much this has been due the work the engineer and his connection with industry. are the first people any great size decide that everybody shall educated. This coincides with our economic progress and results from the fact that that progress has provided with excess this world’s goods. Management’s Ramifications Conquest disease the most important, most far- reaching and most hopeful element progress which have ever had. Many diseases will never become extinct; shall not conquer them all completely. Occupational diseases, however, are coming rapidly under control, and this function management. Poverty cannot abolished completely. But can abolish compulsory poverty. There something here still for management solve. There must some way smoothing out the hills and hollows our cycle busi- ness history and that way avoid throwing men out work. Early Appraisal Labor Displacement Mechanization element displacing man-power was factor well recognized the beginning the cen- tury. the census report for 1900 analysis was made what was happening along this line, and the editor that report had the temerity prognosticate what was going happen. The matter did not work out badly thought might, but had been bad enough and has become one our big problems. Thus the problems ahead management are great. They will form great challenge our economic prog- ress and our economic sense. That they will solved, however, practically certain and there seems the horizon nothing worry about. The Iron Age, March 13, 4 2 | ’ ; y ‘ Rational Choice Tool Steels Fourteen Types Embrace Per Cent Tonnage Used—Problem Selecting Proper Steel Not Easy JAMES GILL* CCASIONALLY quite unusual order will come our company specifying certain steel for specific purpose. One can never forget—it read something like send ft. 1%-in. round ted Cut Superior high-speed steel, which understand the most expensive steel can buy. hope that, after make axle for auto from this steel, will have more trouble from breakage.” Certainly exaggerated case irrational selection, yet the plant almost every large manufacturer can found operations where the efficiency could considerably improved the proper selection tool steel. This should not all surprising when consider that every manu- factured article, you cannot name exception, somewhere the process manufacture must depend tools tool steel, statement well worth thinking about. Again, there are some 600 700 brands tool steel the market, some 200 300 which are fairly wide usage, and many manufacturer the selection the proper grade from such array bound baffling, yet, study carefully the composition these many brands, will find probably over per cent the steels wide usage will group themselves into something less than general types. Before considering these general types let review briefly the effect the many alloys, rather elements, the command the tool steel manufacturer. Three Groups Alloying Elements Alloying elements used steels may roughly divided into three groups, based whether not the element *From paper delivered before the New York, and also the New Jersey, chapters the American Society for Steel Treat- ing. The author chief metallurgist, Vanadium Alloys Steel Co., Latrobe, Pa. 7 f ~ « Te 4 ¢ f - a IG. 1—Photomicrograph Per Cent Carbon Steel (x500), the Car- bides Being the So-Called Spheroid- ized Condition 782—The Iron Age, March 13, 1930 completely dissolved the iron, combines with the carbon form carbide, partly dissolved the iron and partly forms carbide. Such classification can best based only the general affinity the alloying element for carbon, since both the amount the carbon and the alloying element present determine considerable de- gree whether the alloying element will dissolved the iron, combine with the carbon, both. Elements which are dissolved the iron generally in- crease the strength and toughness the steel and those which combine with the carbon form carbides increase the hardness. Therefore, elements which are partially dissolved the iron and also form carbides have the gen- eral tendency increase both the toughness and the hard- ness. The major portion alloying elements come within the third group, that is, are partially dissolved the iron and partially combine with the carbon form carbide. steel, the carbides being the so-called spheroidized con- dition. shown for the purpose illustrating what meant carbides any type steel. The iron these carbides may replaced other elements such chro- mium, tungsten, etc. Fig. shows chromium carbides high-carbon high-chromium steel and illustrative the action that class alloys which are essentially carbide-forming. Fig. shows nickel containing per cent nickel and all appearances has exactly the same structure were piece pure iron another pure metal. There material out solution. This general action nickel and representative that class alloys which combine with the iron form solid solu- tion. Fig. shows three pieces steel which have been hardened and fractured. The pieces are approximately in. round. One piece represents per cent carbon tool IG. 2—Photomicrograph (x500) Re- veals Chromium Carbides High- Carbon, High-Chromium Steel — 7 7 a steel without alloys and shows very fine grained definite case around the outside with tough core. The middle fracture also per cent carbon steel but containing 0.90 per cent chromium, and, even though hardened from the same temperature, the chromium has caused greatly increased depth hardness that the case extends almost the center the piece. The other piece per cent carbon steel containing approximately 3.50 per cent chromium and will noted that hardened entirely through the section. varying the quantity and proportion alloys, the number steels which can produced having different physical properties unlimited. somewhat surpris- ing that the most widely used types tool steels fall into few groups they do. Let consider these general types first and later, wish, consider the variables these types that may particularly adapt them for spe- use. Fourteen Types Tool Steels Embrace Those Most Used Table have listed steels type compositions; that is, this table are shown the approximate percent- ages alloys that distinguish any one these steels and place class field itself. Practically every tool steel manufacturer will make one more steels that would fall each the groups shown and, although the com- position between different steels the same group made different manufacturers may vary considerably and would impart them widely varying physical prop- erties, yet essentially these steels would the one type. Undoubtedly per cent all tool steels used this coun- try today far tonnages are concerned would fall within one the types. Table roughly compare the physical properties these types steel dividing these physical proper- ties into three groups only, that is, high, intermediate and low. understand the properties these general classes tool steels and knowing the properties required steel for various types tools, should able properly classify the general type steel necessary for the major portion our tools. Then after once having selected the proper type steel can consider what effect the vari- ation composition and heat treatment may have this steel more particularly adapt for the tool question. Every manufactured article somewhere process manufacture dependent upon steel tools. Therefore, there unlimited number specially designed tools, yet the major portion tools will fall within compara- tively few classes. There are three very large classes tools, namely, cutting tools, shearing tools and forming tools. Nickel Steel Containing Per Cent Nickel. Note resemblance pure iron (at left) IG. 4—Macrograph, Actual Size, Three Pieces Steel Hardened and Fractured (Below) Cutting tools might further divided into three types. First, tools possessing single cutting edge and used for practically continuous cutting such lathe planer tool. Second, tools possessing two more cutting edges and used for practically continuous cutting such drill, tap, chaser, broach, Third, tools possessing number cutting edges, each edge taking short cuts and functioning only part the time, such milling cutters, hobs, etc. may interesting call your attention the ac- tual manner which many cutting tools remove the chip. Fig. shown something the general action cutting tool. lathe tool shown cutting chip from large bar, and will noted that the type steel being cut the chip breaks ahead the tool for consid- erable distance whereby the actual wear not much the point the tool slight distance back the point. Steels which are said free cutting throw their chip cut this manner. Fig. shown the action lathe tool cutting steel which exceptionally tough and tenacious that the chip does not break ahead the tool, thereby causing rapid wear and excessive heat the point contact the tool. This the manner which chips will break from stainless irons and steels and this which causes most machinists state that steel machines with dif- ficulty. steel used for cutting tools must, therefore, have the ability withstand wear and the heat generated the cutting edge. Toughness, though considerable importance cutting tool, much less importance than the two properties named. Therefore, for cutting tools find that high-speed steel largely used. high-speed steel not used, then there usually some factor involved, such cost, smoothness the finish the cut, etc. there unusual factor involved, un- doubtedly high-speed steel going prove the most economical the end. There are certain types cutting tools, such taps and dies, that are widely used pipe fitters and others that are hand tools and are, therefore, both somewhat abused and little used. such tools carbon steel the neighborhood 1.10 1.20 per cent carbon quite gen- erally employed. Where the finished cut must unusually smooth sometimes high-carbon steel finishing containing from per cent tungsten used. Again, the cutting materials other than steel may find some the special steels better adapted the operation, all which represent unusual condition. Knowing, therefore, the necessary property for steel possess for this class tools makes evident that high-speed steel going largely used. Then may become necessary consider something The Iron Age, March 4 | t e a | n q > - 4 > q 7 4 Type Si. Mn. Cr. Va. with 0.15 0.30 Mn. oil-hardening No. 2..... 1.00 1.30 0.40 0.60 0.40 0.60 the type high-speed steel its carbon content. know that brittleness high-speed steel somewhat pro- portional the carbon content. also know that, within certain limits, the higher carbon, high-speed steel out- wear the lower carbon high-speed steel. Therefore, for tools which have well backed cutting edge, such lathe planer tool, best use high-speed steel having high carbon content, that is, the neighborhood 0.75 per cent, use steel the type, such the cobalt high-speed steel. For the major portion drills, taps, chasers, milling cutters, hobs, broaches, etc., the regular composition high-speed steel containing the neighborhood 0.70 per cent carbon, per cent tungsten, per cent chromium and per cent vanadium represents the best balance between toughness and cutting efficiency and is, therefore, best adapted for such tools. There are instances, however, where toughness must gained sacrifice cutting efficiency special types taps and chasers, particularly chasers that are used pipe cutting. For tools this class then necessary high-speed steel containing lower car- bon content than normal. Problem Shearing and Forming Tools Not Easy With cutting tools the selection the proper steel comparatively simple, since the major portion cases the used must sufficiently high carbon harden with near file hard edge, but approaching the other two large classes tools, that is, shearing tools and form- ing tools, the selection not simple. Shearing tools would include that very large class tools which cut material either hot cold with shearing action. Thus the beginning can separate two large general classes shearing tools, those which are used for shearing metal cold and those which are used for shearing metal hot. Shearing tools would include all types shears, punches, blanking dies, etc. Simple, plain shears will generally fail from wear abrasion. Therefore, the shear well backed and the material cut not too large, high-carbon high-chromium steels will prob- ably give the very best results, and such steel now being very widely used for shears for the cutting tin- plate, spring steel, unannealed bars, etc. If, however, the shear not rigid type and there considerable play the blades, toughness may greater importance than wearing ability because danger breakage, which case the chrome-vanadium tool steels are quite widely used. Again, the shear may used for cutting material hot and the shear itself may become heated use, then high-speed steel may give excellent results; or, toughness also factor, tungsten hot- work die steels may used. Punches are made almost every type steel con- ceivable, from straight carbon steel the highly alloyed steels, such high-carbon and high-chromium. Punches will usually fail from wear, although failure from breakage must not overlooked. The size the punch, the thick- ness the material being cut and whether not hot cold are all vital factors the proper selection the steel. far the major portion all punches made punch manufacturers are still made carbon tool steel, has been found that carbon tool steel, hard- ening with hard case and soft tough core, combines excellent degree fair wearing properties and resistance breakage. soon the steel used for the punch becomes heavily alloyed the punch will harden through its section and fairly brittle. However, for many punching operations the Comparative Physical Properties Working Wearing Quenching Temp. Depth Type Steel Toughness Hardness Ability Medium Movement Failure Case Dep. Dep. Low Water High Low Shallow High C-Low Interm. High Interm. Oil Low Low Interm. Mn. Oil-Hardening No. Interm. High Low Low Low Interm. Mn. Oil-Hardening No. Interm. High Low Oil Low Low Interm. Low C-Low High Low Interm. Low Interm. Interm. Low High Interm. Water Interm. Interm. Deep High Cr........ Low High High Air-oil Low High Deep High Low Water High Low Interm. High-speed steel....... Low High High Air-oil Low High Deep Co. high-speed steel.... Low High High Air-oil Low High Deep 784—The Iron Age, March 13, 1930 | | - punch rigidly held and accurately set that danger from. breakage very small, which case high-speed steel and high-carbon high-chromium steels are quite widely used. Where the material being punched hot, tungsten hot work die steel very generally used. Blanking Dies Difficult Problem The problem the selection the proper type steel becomes more complicated when reach that class shearing tools known blanking dies, due the fact that the design the die, the amount movement permis- sible hardening, the number times may ground without going under over size, etc., complicates the con- dition. Many types blanking dies have thin sections adjacent heavy sections, condition making heat treat- ment difficult. Therefore, the very beginning often necessary choose oil-hardening steel overcome ing the material cold has increased popularity, due the closer tolerance and better finish that can obtained the finished part. Because the many types form- ing dies, somewhat more difficult choose the proper type steel than for cutting tools shearing tools. Because the shock involved many types forming dies, toughness greater requisite than the ability withstand heat wear, and thus find chrome-vanadium, chrome-nickel and chrome-nickel-molybdenum forging die blocks generally used. Steel for Other Types Dies Certain types hot-pressing dies where the metal forced hot under pressure into the impression demands steel that will not sink slough off from the high heat. For such dies tungsten hot-work steel very generally used. Other types hot pressing dies are water cooled IG. 5—An Attempt Cutting Tool (from Engi- neering, London) possible danger breakage during hardening. Likewise, the permissible movement that may take place the die may make oil-hardening, non-deforming steel necessity. However, have number steels which will satis- factorily harden oil, such the manganese non-deform- ing type, the 1.25 per cent carbon, per cent tungsten type, the high-carbon high-chromium type and high-speed steel. Any these steels will harden satisfactorily oil and the same time danger warpage all the types quite small. the die has thin walls, may neces- sary sacrifice wearing qualities for toughness, which case the manganese oil-hardening per cent tungsten oil-hardening type may represent the type selection. Many blanking dies are very expensive cut and are nature where failure almost wholly from wear, which case high-speed steel, pack hardened, high-carbon high-chro- mium steel are the best types use. Blanking dies used for hot work may made from either high-speed steel tungsten hot-work die steel. Forming tools usually class that large group tools which have impression which transferred the work. Such tools may operate either hot cold metal and may impart their impression with shock, such forging die heading die, the metal may forced into the impression under hydraulic pressure. most cases the material formed heated order that will flow more readily, but during recent years the form- Toot arall« Crack Deve away Periph ?, IG. 6—Action Lathe Tool Cutting Steel Which Exceptionally Tough while operation, and for such dies both chrome and tungsten hot-work steels are used. Hot heading dies which are used for forming the heads bolts demand steel that will withstand the heat and the same time sufficiently tough prevent breakage. For such dies chrome hot-work die steel and the low-car- bon low-tungsten steel used. Deep drawing dies used for the shaping sheet stock must have excellent wearing properties and the same time sufficiently tough withstand the very heavy pressure used for drawing. For such dies carbon car- bon-vanadium steel still quite generally used because the hard case and the tough core that results the hardening such steel. high-chromium steel has been used, and though wears exceedingly well there usually always considerable danger breakage. For forming dies which are used wholly for the form- ing cold material carbon carbon-vanadium steels are still most preferable. The shock involved the use tool this type enormous and the tool may fail from sinking, chipping, breakage wear. Because carbon tool carbon-vanadium steel hardens with in- tensely hard case, the depth which case can some- what regulated the quenching temperature used, and because the hard case backed soft core seems adapt this type steel better for cold heading than any type steel which has yet been developed. The Iron Age, March 13, 4 Wage Incentives Manufacturing Must Large Enough Bring Forth the Results Desired—Penalty Clause Desirable Payroll Investment GREAT problem before industry today obtain for the manufacturer while the same time increasing the earnings the employee, said Kift, general superintendent, Edison Electric Appliance Co., Chicago, speaking before the Chicago meeting the American Society Mechanical Engineers. His paper was entitled “Management Factors and Re- sponsibilities Preliminary and Coincident with Installa- tion and Operation Wage Incentives.” For great many years shop employees have been given this form consideration; less attention, however, has been paid office employees, and right here large waste. Mr. Kift cited many instances, from the operation his own plant, prove the points made. said that every person the plant, from the general manager down the sweeper, working some form wage incentive plan. Double Bonus Arrangement told about certain foremen operating group bonus plan who got about per cent bonus and then stayed there, week after week. Investigation showed that they thought that was about all the company would per- mit them earn, addition the regular daily rate. such case the foreman was put further bonus, based cost unit output. This cost then dropped far below what had been, and stayed down. Best results obtainable are those achieved when the gang working steadily all day long, but not pace which will tire them out. The so-called speed artist does not last. the same time good man have had around, because the other men learn something his short-cut methods get results and certain portion this stays with them. All plans for carrying out incentive wage problems must kept up-to-date with the times conditions change, full benefit had from them. What Incentive Plan Must Involve Fundamental principles indicate that the employee’s compensation should reflect his contribution the com- pany’s success. The plan must contemplate sufficient increase the man’s earnings induce him increase his production materially; this means that must gain per cent more over his daily rate. The plan must promote team-work. must have sufficient flexibility fit with chang- ing conditions. must unlimited its application. must sufficiently simple operation that will take minimum clerical help keep going. fair both employer and employee and thus promote mutual confidence between them. one hired, under such plan, for very definite purpose, and must possible measure his contribution the general success. Cooperation for Profit All Concerned Detailing department after department, the speaker showed how different kinds difficulties were met and overcome special treatment each case. pointed 786—The Iron Age, March 13, 1930 out that the installation such system rational basis makes thinkers out the department heads. They never attempt put through wage increases for friends relatives, but they are eager put them through for men who are capable earning them. Most incentive plans need penalty clause, take care cases which come every once while, correct conditions not reached directly the regular methods. Groups men which are too large too small fail get the best results out such plan. his own work Mr. Kift has found that group from men girls appears about the right size obtain most satisfactory results. Executive and Cost Phases Wage Incentive Plans NOTHER method getting this question wage incentives was taken John Paul Jones, the Standard Oil Co. Indiana, Chicago, paper which the title given above. stated that management must pay according the value the work produced the man the group receiving the pay. Progress com- pensation methods rests essentially with management whole. Payrolls are the management investment which return must accrue both the company and the workers. The more return which obtained from the payroll investment, the more satisfactory becomes the particular cost the product turned out. Wage incen- tive plans thus should devised make the payroll in- vestment give greater returns both employer and em- ployee. Payrolls may heavily increased, thereby some other cost cut greater total amount. Competent Planning Essential adequate survey will result having the super- visor much help man his work. Planning the whole system essential accomplish this result and set responsibilities. Both job values and task values must carefully studied. How much money paid for job and how much work done have thought out advance; the same time, measuring device must had determine the work done. Incentives should large enough bring out the required desired results. Labor relations this basis must based sound facts and not preconceived ideas. Method Handling Penalties incentive plan, thorough success, must based something like fifty-fifty split benefits between the company and the wage earner, was brought out the discussion. Wage incentives, know them, said George (Concluded page 836) | Large Forgings Now Being Nitrided New Jersey Forge Company Installs Large Oil-Fired Furnace for Hardening Rolls Locomotive Forgings that large plant the Philadelphia district has put nitriding furnace for supplying the needs its customers. The Camden Forge Co., Camden, J., has now operation one the largest furnaces the country for case-hardening forgings with ammonia gas. The new demand coming from railroads, which are experimenting with nitrided forgings for locomotives, from plants which use certain types steel rolls and from other companies interested the possibilities this new development. large demand for nitrided forgings has sprung Large Oil-Fired Nitriding Furnaces feature the new furnace the Camden company that oil-fired—probably the first one this type existence. the usual car type and the car the nitriding box, which ft. in. long, in. wide and in. deep, making possible treat forgings within these dimensions. The nitriding box made per cent chrome-iron alloy which is, course, heat-resisting. The furnace was built Ryan, Scully Co., Philadelphia. One large railroad has placed orders for nitrided forg- ings for bushings, cams, pins, hangers, gears, guides, etc., ITRIDING New Oil Fired = x Company for six locomotives. The idea compare the wearing qualities these forgings with those alloy steel and other types. Larger forgings the nitrided type also are being produced. Nitrided Rolls for Paper Mills One the most interesting developments thus far the decision large paper mill company use nitrided rolls. claimed that they will not only surpass alloy steel rolls hardness but that the life rolling corru- gated paper will much longer, sufficient offset any extra cost. The size these rolls, which are hollow bored, can apprehended from one the illustrations. Some the other forgings which have already been nitrided the Camden company are shown other illustrations. Steel Used for Nitriding word about the steel used for nitriding. special alloy steel containing aluminum 1.25 per cent), chromium (1.50 1.75 per cent), molybdenum (0.15 0.25 per cent), with silicon 0.20 0.30 per cent and manganese 0.40 0.70 per cent. The carbon from 0.10 per cent and the steel usually open-hearth electric. Extremely wide physical properties are possible, de- The Iron Age, March 13, - pending the heat treatment. The following are the ranges: Yield point, per sq. in....... 60,000 180,000 Tensile strength, per 80,000 225,000 Elongation, per 35.0 10.0 Reduction area, per cent..... 70.0 35.0 The hardness resulting from the nitriding process about 1000 Brinell, supported core which has not been affected. Thus the engineer can have his command machinery part any desired strength, accompanied surface the highest known resistance wear. The thickness the case varies from 0.001 in. 0.031 in., depending the length exposure the ammonia gas and the temperature. the nitrided part has been prop- erly annealed before hardening, there warping distortion and the growth dimensions only slight, about 0.002 in. Changes dimensions are most noticed rings. With very thin wall space, the increase the outside diameter averages about 0.5 per cent and the THER End the nace Showing Apparatus for Introducing the the Box increase wall thickness about 0.0005 in. 0.0007 in. every face. Some Possible Uses Nitrided Forgings New possibilities design are thus offered the engi- neer. pointed out that the automobile, such parts cams, helical gears, timing gears, steering mechanism, pump shafts, etc., are ideal subjects for nitriding. Also valve seats any parts subject the erosive action gases liquids. may require boldness, however, for the engineer apply the process such parts loco- motive axles order help solve lubricating problems for hard surface aid lubrication. The application the nitriding process regarded its infancy. But there the possibility being able nitride Diesel engine piston rods, large crank pins, and some types running nuts subject constant wear steering engines. The Camden Forge Co. confident that, more and more, large and larger forgings will need Large Nitralloy Roll for Paper Mill for Rolling Corrugated Paper. This was hardened the new furnace. nitrided piston rod for Diesel engine 788—The Iron Age, March 13, 1930 x ; nitrided, and has therefore installed the necessary apparatus which thus far has been working successfully. These liners are being incorporated lead extrusion presses where maximum toughness and hardness are re- Tendency Heat Treatment Alloy Steel Forgings quired. Among other quenched and tempered forgings, which are now the vogue, are sugar mill rolls containing 3.50 per cent nickel; eccentric shafts with 0.90 1.10 per cent chromium and 0.20 per cent vanadium with elastic limit 100,000 per sq. in., and tungsten-chromium forgings having 1.75 2.25 per cent tungsten and 1.50 per cent chromium. Besides the development nitralloy steel forgings, the Camden company turning out several interesting prod- ucts its large plant, which equipped make forg- ings from small ones all sizes very large marine forgings. Prominent among these are forgings for loco- motives many types. these the tendency use The Camden company particularly well equipped handle heat-treated forgings any these and other types, nitrided not. has large heating furnaces and quenching tanks well annealing and normalizing fur- naces. And its large plant there are hammers and OLLECTION Forgings (Above) Miscellaneous Gears and Other Forgings Which Have Been Hardened Ammo- nia- (at Right) normalized annealed forgings alloy steel instead the quenched and tempered products. these, rail- roads such the Norfolk Western, the Northern and the Union Pacific, and the Delaware, Lackawanna West- ern are using low-nickel alloy steels containing 2.40 2.70 per cent nickel with carbon range 0.17 0.27 per cent. the same class there the carbon-vanadium steel forgings, normalized annealed, for which there steady demand. These forgings average 0.50 per cent car- bon and 0.18 per cent vanadium. Closely allied this the low-carbon chrome-vanadium steel containing about 0.20 carbon, 0.45 0.55 chromium, 0.75 0.90 per cent manganese and the usual content vanadium which are high favor. There also the growing use the me- dium manganese steels containing 1.50 1.75 per cent