The Iron Age 1930-10-23: Vol 126 Iss 17

THE IRON AGE New York, October 23, 1930 ESTABLISHED 1855 MOFFETT NALYSIS the present-day highway industry discloses three outstanding factors—the sud- denness with which has attained mammoth proportions; the quality its product and the reduc- tion construction costs. the past decade the good roads movement has grown rapidly that now almost every civilized na- tion the world setting its money and man-power work extending its road mileage. The United States, always leader the movement, maintains this position annual expenditure funds which VOL. 126, No. ighway Construction Knows Business Depression soaring above the $2,000,000,000 mark. The bene- fits from modern highway transportation flow wide range industries, such iron and steel, metal- working, machinery, asphalt, brick, cement, and numerous others. labor means much employ- ment. Many things have contributed the great in- crease quantity, improvement quality and de- crease cost roads. Automobile registration over period years has increased the United States from mere 3000 Construction concrete highway with steel reinforcing mats 1121 3 | a Q ayy S ~ the present figure 26,501,443. Some 5,621,709 motor vehicles were produced the United States and Canada 1929. Motor Vehicles Paying Heavily Whether these automobile sales brought good roads whether the greatly increased mileage improved roads created the automobile sales moot question. But sufficient say that the motor vehicle paying its way over America’s highways decidedly good manner. 1929, motor vehicle owners paid the States registration fees; LACING forced concrete pavement, paving one-half street time, and surfacing con- crete road gasoline taxes; $20,000,000 municipal taxes and $130,000,000 personal taxes. These sources created grand total $929,479,997, which probably per cent was returned once the road programs the various State and local gov- improvement present road mileage, construction new roads. ernments for use maintenance Motor Truck Traffic Aids Road Building The rapid development motor truck traffic has been another important factor the growth road mileage. Exhaustive data are hand show the part the motor truck taking commercial traffic. Only few figures, however, need given indicate the expansion this form transportation. Iron Age, October 23, 1930 survey the movement fruit and vegetables the metropolitan areas New York and Philadel- phia 1928 shows that per cent the shipments were made motor truck. estimated that 1,200,000 truck loads livestock were moved 1929 over average haul miles. Increases live- stock receipts truck ranged high per cent the nation’s leading livestock markets when 1929 and 1928 figures are compared. rail- roads operate estimated total 5900 motor trucks over the highways. The electric and steam railroads also operated 1929 more than per cent the motor buses the United States. these, 48,350 were operated for revenue and 42,000 were school use. Federal aid, created Congress 1916, has been such force the cause good roads revo- lutionize public thought the question and bring about organized effort that was unheard prior that time. With each the State highway departments thoroughly organized order obtain and match its share Federal funds, the counties and townships, some cases, have learned the value organized effort road work and have acted along this line. Federal Funds Have Been Increased The annual allotment $75,000,000 from the Fed- eral Treasury has become firmly established good investment that Congress last spring increased the Federal aid for the next three years $50,000,- 000, making annual total $125,000,000, which will boost the highway expenditures and mileage new high records during the period covered. All these things that have brought about increased road mileage have also had definite influence improved construction, better quality roads. The great forward strides that have been taken this direction are making the highway into system transportation for the commercial, economic and convenient purposes the national life. Today highway construction reflects the genius the road builder, and makers machinery and materials. Construction prompted political consideration mere public enthusiasm and the use unsuitable sur- faces and indifferent foundations have practically dis- appeared. also the practice using all the road funds for costly high- ways between great cities and letting the farm communities and small towns that lie away from these routes languish the mud. Out the picture also the former practice building township local roads that failed link with systems that led any- Engineering research, car- ried over recent years, has developed intelligent planning, comprehensive financing and mechanical construction. The manufacturers have kept pace and through careful study modern road problems have brought out ma- chinery meet, and, some cases, anticipate the demands. American manufacturers 1927 produced $27,- modern type con- crete highway bridge PEAKING for the American motor industry, White House conference recently, Alvan Macauley, president, National cally all road-building equip- Automobile Chamber Com- merce and the Packard Motor Co., told President Hoover that one the largest questions facing public authorities that road finance. TEEL mesh highway safety guard modern concrete highway Florida 727,585 worth highway machinery, increase $10,000,000 over their output six years previous. These figures will eclipsed the returns the greatly expanded programs present. New and im- proved machinery constantly being fabricated accomplish the newer methods road con- struction more rapidly and effi- ciently. Research the iron and steel industry has bettered the product from which practi- ment made. struction materials the aim many groups producing high class materials. Among them are such organizations the Wire Reinforcement Institute, the Portland Cement Associa- tion, the Asphalt Institute, the National Sand and Gravel As- sociation, the Crushed Stone Association National Paving Brick Manufacturers’ Association. Steel reinforcement, practically unknown high- ways years ago, now use and giving satisfac- tory results all States which have heavy traffic, 4 The Age, October 23, 1930—1123 | severe climate and bad conditions subgrade. most all concrete construction today may contain dowel bars, tie bars marginal bars, but roads are not actually considered reinforced without longitu- linal and transverse steel spread throughout. According extensive research, reinforcement prevents the small initial cracking due contraction the pavement while the concrete setting, which ‘equently develops into large cracks; provides re- sistance caused expansion and contrac- tion subgrades; enables the pavement carry much heavier traffic loads without damage; prevents cracks from opening and permitting frost chemical action; ind reduces maintenance almost minimum. For instance, New York, heavy traffic State, finds maintenance cost reinforced pavement only one fourth that the plain type, and New Jersey officials $2,500,000,000 $2,000,000,000 850 $1,500,000,000 STATE 800 MILLIONS COUNTY 850 MILLIONS EXPENDITURES 1930 ESTIMATE declare reinforced pavements offer practically main- tenance difficulties. The necessity for road systems that would reach every part the vast national area has induced much research highway financing make possible in- creased mileage from the available funds. Costs all types roads are rapidly being lowered, due mass production, efficient mechanized equipment and methods, keener competition contractor-bidders and sales equipment, and better knowledge re- quirements the part both the engineers and the manufacturers. Maintenance costs also, spite heavier traffic, are decreasing, due mainly improved equipment with greater mobility. has been impos- sible finance high-type paved roads over all the systems. Actually, studies have shown them not justi- fied light traffic needs, and engineering experts have developed low-cost types giving good service. 1929, three-fourths the 32,522 miles built the State highway systems was low-cost construc- tion, such earth, sand-clay and top-soil, gravel and macadam types. the county and local roads, all but 1443 miles total mileage 45,481 were low-cost construction. The high types each case were asphalt, concrete and brick. Two great factors the continued progress Iron Age, October 23. 1930 highway industry have been the United States Bureau Public Roads, Department Agriculture, and the American Road Builders’ Association. The bureau administers the distribution Federal aid. Each year for the past years, committees outstanding leaders State, city and county highway work have studied the major problems the industry and prepared reports which formed the basis the annual convention the American Road Builders’ Association. The scope this effort seen the statement Charles Upham, association engineer- director, that the 1931 gathering Jan. 10-16 St. Louis will attract some 30,000 actual road builders hear the reports for this year and the committee recommendations for improved road practice, and view the road show with every imaginable modern machine and tool used road construction. ing has been in- creasing year year shown this chart prepared the Amer- UNIMPROVED GRADED 1,000,000 ican Road Builders’ As- 600,000 sociation RURAL ROADS IMPROVED DATE Every new type equipment and material will take its place there with the standard types that have been part the industry for the past quarter century. Among the committee subjects for the St. Louis meeting are grade crossing elimination, highway finance, equipment, location, low-cost roads and bridges, subgrades and pavement bases, airport drainage and surfacing, well discussions the regular city, county and contractors’ divisions regard- ing planning, financing, construction and maintenance. The American Road Builders’ Association held exposition all types machinery and equipment connection with the congress, with the result that delegates were given twofold idea how the United States accomplishing its rapid extension road systems with ever-increasing quality and lessened cost. These meetings men from all parts the nation and from foreign countries exert vast influence forming the highway thought the public well the industry. The highway industry 1930 occupies the envi- able position knowing nothing about industrial depression. casual glance future prospects indi- cates that long available funds increase, which will long motor vehicles continue favor. there will parallel increase road building. MILES | i MILES 523,500 EXPENDITURES YEARS Further Experiences Nitriding Steel Articles which was held Chicago September connection with the National Metal Congress, and which several papers the subject were read and discussed, the material the following columns takes three those papers with the discussions which they evoked. THE IRON AGE Oct. three the papers were covered. The seventh paper, de- voted microcharacter hardness tester, published separately. really separate topic, but the in- strument particular interest those engaged nitriding other methods producing hard sur- face steel. Further Investigations Nitriding HREE sections comprise this paper Mr. Serge- son and Mr. Deal. Section discussion ni- triding containers. Section covers corrosion tests the nitrided surface; the effect acids, bases, salt spray, salt water, tap water, oils, atmosphere, etc., are recorded. Section III the subject denitriding discussed, giving the methods and results. Materials Construction XPERIENCE with welded containers carbon plate steel has not been satisfactory. the ni- triding process, the carbon steel nitrides and time disintegrates. After 500 hr. nitriding such con- tainers increased rate ammonia flow required maintain the required dissociation (which should per cent). The longer the container used, the greater the rate ammonia consumption, the lower the surface hardness the work and the shallower the case, until point reached where, re- gardless rate ammonia flow, unsatisfactory nitrid- ing results. the inside walls the container become nitrided they act catalytic agents, breaking dissoci- ating the ammonia the walls. This has the effect increasing the dissociation and can counteracted increasing the rate ammonia flow. However, nitriding takes place only when the nitrogen the nascent state, necessary that the ammonia break the work being nitrided. the ammonia breaks the container walls probable that the nitro- gen will become molecular and inert before reaches the work. Thus the increase flow really produces diluting effect and considerable part the nitrogen cannot used, owing its becoming molecular and inert the walls, hence less nitrogen available for nitrid- ing. the ammonia flow not increased, the dissoci- ation will become high, which produces soft case, due the reversing the reaction the liberated hydrogen. would appear therefore that ideal container would one inert the action ammonia nitriding temperatures. Containers Stainless Irons High-chromium (0.10 C—16.0 Cr) and high-chro- mium-nickel (0.10C—18.0 Cr—8.0 Ni) have been used. 1000 hr. these containers have given good re- sults. Above this, however, the same trouble arises with carbon steel containers. Nitralloy steel drillings nitrided container when new show approximate nitrogen content per cent. After 2000 hr. Nitral- loy drillings nitrided under the same temperature and time conditions show only per cent nitrogen. This explains the lower hardness and lower corrosion re- sistance. Sand blasting the nitrided surface the container gives temporary relief. Another cure sug- gested heat the container 1500 deg. while passing ammonia through. This again gives only tem- porary relief. Monel metal. with low manganese content, has been used 1000 hr. and has shown tendency ONTAINERS for use the nitriding process have practically inert the process they are not lose efficacy after short Elaboration this topic, together with others along the general line the nitriding process, and its benefits, are carried the article herewith. This involves among other things con- sideration nitriding large pieces and also furnaces and other equipment for the process. The Iron Age, October 23, 1930—1125 5 Sketches various types seals nitride. The dissociation has remained constant, with given rate flow and temperature. Check runs nitrided Nitralloy steel drillings show that the nitro- gen content the same early and recent runs. Sat- isfactory nitriding still being obtained. This metal shows much promise, but longer period service )) must obtained determine its worth. Enamelled Surfaces Enamelled tests carbon steel, enamelling iron and stainless iron were subjected various nitriding conditions and temperatures. All hard enamels were excellent 950 1000 deg. that they gave signs bubbling, flaking creeping. From 1050 1200 deg. most the enamels flaked bubbled. Further work being done enamels withstand temperatures 1200 deg. For longer life nitriding containers and low ini- tial cost, the carbon steel container enamelled inner surface presents excellent possibilities. Monel metal Monel metal-lined containers, although more expen- present second promising material. the methods sealing the containers, the liquid seals present the most efficient. Low-melting metal alloys should used where seal subjected nitrid- ing temperature and oil where the seal outside and may kept cool. deep seal powdered chromium ore has shown much promise. Corrosion Resistance Surface the nitrided surface most noted for its hardness and resistance wear, another prop- erty perhaps equal importance its corrosion re- sistance under many conditions. study various corrosive agents and their effect the nitrided case have been made the laboratory and observed ser- vice. [These tests were described somewhat tabu- lated From the results, evident that Nitralloy not adapted for use acid solutions, such sulphuric hydrochloric. extremely resistant, however, alkali, atmosphere, crude oil, ethyl gasoline, natural gas combustion products, tap water and still salt water. While slightly attacked aerated and alternately wet and dry salt water, there also seems 1126—The Iron Age, October 23, 1930 action between and brass contact, either still moving, immersed hard water. When the Surface Must Denitrided the nitrided case presents interesting and fertile field for investigation. Applications are known and others undoubtedly will develop where, after the part has been nitrided and service, change design becomes necessary, which requires additional machining. Such would well apply, for example, core dies the die casting industry and forging die inserts and upsetting die inserts. While denitriding and softening for machining can readily accomplished, renitriding presents serious dif- ficulties that the denitrided but unmachined parts cannot have their surface hardness materially raised renitriding. review the work denitriding clearly points the following facts: Denitriding dependent upon the temperature and time and not the media. The lower hardness denitrided case the re- sult appreciable loss nitrogen content. Denitriding temperatures above 1400 deg. accompanied marked diffusion case toward the center. The rate diffusion directly proportional temperature. obtain high maximum surface hardness subsequent nitriding, necessary remove entire- all the denitrided case. Discussion Denitriding and Renitriding ENITRIDING involves raising the temperature container the point decarburizing. This temperature such cause warping and of- ten the scrapping highly finished parts, according one speaker. This fact, however, was reported not give particular trouble, because finished parts are usually not subjected such treatment. Some the tubes used small nitriding are expected last for 1000 hr. operation. The opin- jon was expressed that, could prophesy definitely for each tube that will last 1000 hr., would much better position than present. Some tubes out very quickly, while others may last for years. Sharp reduction the resistance corrosion nitrided article was reported when very fine surface film skin removed (say, 0.0005 in. thick). The idea was expressed that the corrosion-resisting factor covers the very merest film the surface only, and that the removal this film leaves the article about before its resistance corrosion. Renitriding after denitriding was discussed with the aid sketches the blackboard, two which are reproduced here. The author has found that, when the original nitriding was done about 950 deg. and becomes necessary renitride after de- nitriding, the hardness comes back without difficulty. spoke particularly taking rectangular sec- tion and grinding off one surface 3-deg. slope, run down through the various stages harden- ing, and then using such specimen for renitriding test. mentioned above, the portions which have ‘ Asbes TOS A . Ashestos Strip Covered || AA Ying Fire Powder Alloy Seals Sea! | /~RO: E METAL 2-/ CAN | i} “NICKEL received the smaller amount hardening, going down the slope the grind, will take the full hardening effect when the original and repeat work are done the normal nitriding temperature. When, however, nitriding done higher tem- perature, say 1050 1200 deg., the same condition not met. the first place, the original nitriding does not give hard material. the second place, the renitriding, under the same conditions before. follows practically the same curve that originally experienced, until point reached where the first nitriding had practically petered out. Then, what might considered virgin nitriding effect was produced about the same the specimen had not been subjected the previous treat- ment. This means that the core was unaffected the high-temperature nitriding, whereas the areas previ- ously nitrided would not respond well subsequent repetition the treatment. Nitriding the Larger Forgings OINTING out that, one year ago, 300-lb. nitriding charges were the rule, Mr.-Higgins stated that to- day’s charges may run anywhere from 10,000 000 lb. His paper was presented largely the form lantern slides, illustrating wide variety heavy pieces which his company has subjected the nitrid- ing process. Nitriding steels has increased tremendously the past year months, principally smaller forgings. the past year the designing engineer has reached out and become bold enough try forgings weight and design never before attempted. result, not unusual today nitride forgings weighing from 100 3000 From the practical standpoint, there differ- ence the method nitriding large forgings from the nitriding the small forgings. The same pro- cedure followed, and almost invariably the same re- sults obtained. Preparation Materials obvious, however, that more care must exercised the selection steel and preparation the larger forgings. Large blooms are more difficult obtain free detrimental inclusions which, when present, will interfere with the strength the core and the uniform hardness the case. Internal strains forgings are ever present and more the larger sizes. These strains, many cases, require many three normalizing treatments before the final finish machining can accomplished without distortion. Extreme care must exercised piling large forgings the nitriding box; forgings should sup- ported v-blocks, equally spaced, prevent sagging. This the utmost importance. Even though dis- torted forging can straightened, the question ever present—will remain straight and give the sat- isfaction expected service? Summary Observations Nitriding large forgings can accomplished with every degree safety and satisfaction enced small forgings. Care must used selec- SS Harness, Harne 0 _ o- = Depth Depth Below Original Surface left the relative hardness depth below surface decreases, when nitrided 950 deg. right, the solid line gives result 1100 deg. Dotted line, renitriding after 1100-deg. nitrid- ing, shows core unaffected high-temperature work tion material, forging, heat treating, machining, normalizing and piling the box. Growth appears progressive forgings rang- proximately 0.00025 in. for the smaller size 0.002 in. for the large size. distortion present materials are carefully prepared. The close temperature range the box as- sures uniform hardness throughout. Possible uses nitrided steel are limited only the boldness the designer and the vividness his imagination. Whether not its application par- ticular service practical can determined only af- ter thorough engineering discussion. Even this dis- cussion may not clear all minds doubt, which event, trial service well worth making. the steel success, big success. Hence any timid- ness hesitancy, any condemnation the process account its newness, not warranted, view the possible probable gains. Discussion Nitriding Large Forgings ECHANICAL strains pieces subjected ni- triding 950 1000 deg. are likely relieved during the nitriding process, according one speaker. This means that such distortion find following the nitriding process perhaps due, more than anything else, the previous condition the piece which the work was done, insofar internal strains are concerned. For this reason was sug- gested that normalizing, get rid these strains, should the practice, preceding nitriding. Mr. Sergeson called attention the fact that Mr. Higgins’s furnace the first large nitriding unit knew which fired with oil. Usually gas elec- tricity used for heating furnaces for this purpose. called attention the fact that the growth object being nitrided seems about equal various solid sections, regardless the size. Thus, round bar with 2-in. diameter will expand about 0.002 in. hr. and 5-in. round will expand the same amount the same time. This question growth was touched the closure when Mr. Hig- gins said that found direct and progressive growth solid forgings which could pretty well predicted advance. But with rings bushings (Continued page 1199) The Iron Age, October 23, | | Kodak Company Uses NEALEY Gas AUGMENTING writ- tricate operations, the motion picture now being used industry graphically. has been found that motion pic- ture will the method doing job quicker and more com- pletely than typewrit- ten verbal instruction. advantage supple- ment engineering speci- fications tools and feed, speeds and similar late . . . motion this field, and manufac- turer the equipment has been extending its eign countries for the and other cameras, film, special written specifica- were prepared for each operation. However, national use, was found that such special instructions and specifi- cations were limited translation, especially with technical shop ter- minology. Hence was found advisable make motion pictures each machine while opera- This Iron Age, October 23, 1930 was done, one New York long film being used for number machines, and suitable captions being interspersed identify the dif- ferent operations with the written specifications. This film, projected the foreign plant, gave the foremen and operators immediate and comprehensive grasp, not only the equipment and general method manufacture, but also the essential details, and proved invaluable aid. general, the plan used these pictures was show first title which identified the operation and “keyed it” into the written specification, followed “close-up” the material part before and after the operation question. Following this title was used give briefly the material and equipment data. long shot the cycle was then given, show the arrangement and layout, followed close- the principal cycle show the details. How the Operations Were Visualized Details manufacture the 16-mm. reels for the Ciné-Kodak will serve show how this idea carried out. will require little imagination grasp the great value visual instruction through motion pic- tures, contrast with the difficulty getting quick and comprehensive grasp all these details covered the following description: The side disks flanges are made from aluminum blanks. The first operation trim size and per- forate the round square hole the center. This performed Bliss punch press, the seated opera- tor filling tray the front the press from the original packing case and feeding from the tray. Air blows the trimmed blank through chute into tote box the rear the press, while the scrap blown into box the left the press. All presses this division are equipped with non-repeat mechanisms and guards which swing across HEN the shoemaker sticks his last his results are likely worth while. This precisely what manufacturer motion pic- ture equipment has been doing transmitting instructions for opera- tion machinery its foreign plants. Motion pictures form large part the instructions ~ i | 4 front the dies when the press tripped, push operators’ hands away should they little slow any time. The non-repeating device consists safety clutch which will not allow the press repeat, matter how long the treadle held down. Operation Stamp and pierce flange Bliss 19, the blanks being tote boxes high-lift trucks left press, while the finished blanks are blown through chute into tote boxes the rear. Operation Burr flanges Bliss 19. Operation Emboss flanges Bliss 19. Operation Blank hub Bliss inclinable. The material the same for the flanges, with gray finish, except that comes flat sheets 11/16 in. in., sheets making 1000 pieces. Operator feeds press from original packing cases, and disposes floor the left, while the blanked pieces drop through the press into trays the floor. Operation First, form hub Bliss 19, the formed pieces being blown into trays the rear through chute. Operation Second, form hub Bliss 21. Cleansing the Parts After Forming Operation Washing consists putting the parts through combination washer and dryer sheet steel, about ft. long and ft. wide. divided into three parts, washing, rinsing and drying, the dry- ing compartment being heated with gas burners. The whole equipped with traveling chain conveyor which protrudes from each end form loading and unloading tables. Another chain-type conveyor runs parallel and close the main conveyor the washing compartment, and the parts are held, between the two, from being knocked about the sprays. water 160 deg. F., pumped through nozzles showing, they do, just how the job should done. This article tells how they are used and gives idea the purposes and results. Decorations these pages are made from moving picture strips used this educational work. They represent various operations in- volved making Kodak parts. Pictures Instruct Mechanics form the sprays. Clean water 150 deg. used for rinsing. Jets air from perforated pipes blow off excess water and six gas burn- ers keep the drying sec- tion 450 deg. For the tops and bottoms the reels solution sodium cyanide used rinse. Operation Bench assembles one flange hub. This performed girl operator. Operation 10. Spray inside hub and flange with special Ciné black paint. Operation 11. Spray inside round hole flanges. this operation spray hood outfit equipped for two girls which includes gun-type sprayers, trays, masks, The air pressure and the 5-gal. tank The hoods are provided with gages showing pressures from tank lines. Operator secures hub and flange from tray, positions mask, sprays and disposes tray portable bench side hood. The parts are baked after The whole setup spray booths and bake ovens single room built specially for these opera- tions (12 Five spray booths are placed along two walls and five ovens along the others. All paint-laden air from the sprays drawn The Iron Age, October 23, The Iron Age, October 23, 1930 partitions the hoods motor fan and exhausted outside the building. The excelsior absorbs the paint. Fresh air sucked from the outside another fan and distributed throughout the room duct with eight openings. There are four periodic ovens and one continuous type oven, all sheet metal construction and heated with gas fuel. The continuous oven, which used for wired motor-operated, two-position valve the gas supply line. There also recording pyrometer the disk type. The baking interval hr. and capacity for 6000 pieces hr. Safety devices all kinds are used, including two Foamite bottles just front and above the oven, which are equipped with fusible links. case the oven room temperature rises above the limit, the \ \ sa ONTINUOUS gas-fired oven (bottom, 1130) for dipping and baking japan Kodak parts. They pass through rods carried the two side chains. Fire extinguishers top picture are con- nected for automatic operation case trouble. Battery rotary carburizing furnaces (top, 1130) fired with gas. Continuous washer and dryer element, rinsing element and gas-fired drying element. parts that can dipped instead sprayed, about ft. long, ft. high and ft. wide. equipped with two parallel chains with rods suspended between short intervals. This conveyor rises from the bot- tom the top the outside the oven before enters, this portion being exposed for convenience loading and unloading. Inside the oven the conveyor descends and rises times series rollers, returning the loading end separate compart- through speed-reduction gear train. Heat supplied two atmospheric gas pipe burn- ers located close the bottom and extending almost across the oven. temperature 400 deg. au- tomatically maintained with temperature controller links let and the Foamite sprayed over the booths and into the oven. the same time all the fan motors and air circulation are stopped thermore, the motors the fans exhausting the products combustion from the oven should fail, the gas supply automatically turned off solenoid valve. Pilot lights are supplied keep the burners going when the gas supply on, and this gas supply cannot turned until the pilots have been lighted. Operation 14. Final assembly the reel accom- plished Bliss with two dies. The operator secures hub and square hole flange and positions die, places jig around hub, puts round hole flange jig, trips press for assembly, moves reel with jig left page 1200) The Iron Age, October 23, > | Special Information Obtainable from Mechanical refer the four classes accounting work: historical, analytical, critical and constructive. many cases records each class may satisfy the demands made them from the other classes. other words, record primarily historical can once analytical, critical and even constructive. Records designed are very valuable management and are inexpensive compile and maintain. The use mechanical sorting and tabulating equipment makes comparatively simple obtain information that may say falls new class, so-called combination all-inclusive class. description will given several records that have proved great value machine shop, and should apply particularly all shops manufacturing machine similar products. Burden Report most accounting authori- ties that the production cen- ter machine-hour rate burden application about the most consistent for ma- practice. This theory applies definite rate for each machine the shop, Planer No. 10 Machine machines definite depart- ment. therefore becomes DIRECT LABOR DEPARTMENTAL ANALYSIS Week Ending important that the shop management know what extent the burden being consumed each ma- chine department. The first step burden distribution the alloca- tion given piece equipment all expenses which have bearing upon the use that piece equipment. Then the normal hours that the machine department can expected work are divided into the expense and the normal rate obtained. Form the columns headed “Normal” show these normal hours and the normal total burden for these hours. the second column, headed “Used,” are entered the actual hours worked and the actual normal burden those hours. the last column, the “Under Over Absorbed” hours and burden are shown, which the BURDEN REPORT 3 Form 1—By means the burden re- port control oper- ations visualized and good results are AA HOURS PAY BURDE HOURS Pay VRDEN E Raw Stock 1132—The Iron Age, October 23. 1930 account numbers t Week Ending be g and the mechani ] safe tg ae — wt h it is prepared for analvsi THOMAS FRANK* Treasurer, Cincinnati Planer Cincinnati Accounting difference, plus minus, between the actual hours and burden and the normals shown the first column. Cards Show Efficiency Departments tained directly from the weekly job time cards direct productive labor, mechanical tabulation. The cards are sorted the sort- ing machine departments, and machine equipment numbers, where rates for individual machines have been determined. They placed the tabulator. the total figures for any department machine appear, they are copied the report form shown. This report very valuable HEN special report unexpected topic regarding business wanted, usu- ally wanted hurry. Unless, however, plant equipped with the proper type apparatus whereby the report can had promptly, many laborious hours may expended before the result attained. This article shows how one company makes use its tabulating equipment for these special reports. The suggestiveness lies the fact that new uses are continually being found for the equipment, and that much information now available which heretofore could not obtained reasonable expense. productivity efficiency all departments and ma- chines. Thus, for example, let take machine Number 693:—The report shows that was run only hr. out normal possible run 31.2 hr., leaving the shop management, shows glance the unabsorption 21.2 hr., the burden cost which $27.56. What the INDIRECT LABOR DEPARTMENTAL ANALYSIS Was lack work, break- | | ~ Shippin __ Planer Engine Lathe down, inefficiency the fore- man, improper planning supervision, possibly un- balanced production? This report places the disposal the shop manager the vital statistics his shep. keeps his fingers the pulse production; enables him see the effect Above all, shows him the __Milling Machine | | * Form Analysis indirect labor costs, ments, various accounts cost dollars and cents the idleness each piece equipment each depart- ment. also shows him the overload any machine department caused over- Week Shipping Form 4—Classes orders analyzed departments couns | PAY nours Pay hours Pay nours Pav hours Pav BURDEN The Iron Age, October 23, 1930—1133 time work. (See machines Nos. and Form 1.) With report this nature his desk every week, the shop superintendent, even the foreman, has means feeling the pulse the shop. With the facts clearly shown them, they can take the neces- sary steps correct conditions that tend increase costs, slow production cause other troubles common machine shops. The total the “Used” column for burden amount becomes the figure for bookkeeping entries absorbed burden. Direct Labor Report accounting systems use machine shops provide for symbol number for all expense account classifications. Each week expenses pro- duction charged with the cost the production the shop. facilitate compiling such charges, form such Form may used. The departments responsible for the production, which the ex- pense charged, the case may be, are shown the left. The columns are headed according the account number charged. The example shown indicates the first column direct labor expended orders chargeable Work Process. The other columns are charges expense accounts direct labor charges for work done for the internal consump- tion the shop, such tool maintenance, etc. For analysis departmental production the hours, pay and burden are shown separately. From study this information, compared with reports for other periods, complete picture the activity each shop department may obtained, with the benefits resulting from accurate complete informa- tion. Thus, Department 12, will seen that 169.0 hr. were spent upon salable production and 40.1 hr. small tool maintenance. This would indicate gross disproportion for productive department, and the causes thereof should investigated and cor- rective measures adopted immediately. The totals each column furnish the bookkeeping department with information necessary complete entries the expense and inventory accounts for the payroll dis- bursement for labor. fact departmental analysis the direct labor payroll. Indirect Labor Report ORM similar the Direct Labor report, ex- cept that reported only the departmental charges for indirect labor, such supervision, fore- manship, instruction, labor and helping, time-keep- ing, stock-keeping, and other miscellaneous shop clerical work, etc. The charges are entered against the department responsible for the work. other words, the charges are made the department chargeable for the work done. The totals the columns are again the source information the bookkeeper for payroll distribution entries. Form Depart- MAINTENANCE ORDERS DEPARTMENTAL ANALYSIS mental analysis ACCOUNT NO yy account wo. V 8 accounrT| +——_+_4 + +—+ = __Blacksmith 4 | | | DEFECTIVE LABOR AND MATERIAL ANALYSIS DEPARTMENTS Month of DEPARTMENT NAME DEFECTIVE MATERIAL MAY Form 6—Defectives have their own anal- ysis, both labor and material and department 1134—The Iron Age, October 23, 1930 BURDEN | — The shop management glance can pick out any in- creases indirect labor and check the causes. serves EXPENSE REQUISITION DEPARTMENTS excellent check-report against which plot the re- sults economy programs. ulant for continuous “savings-campaign.” v¥3 accr. No. Class-of-Order Report many small shops Blacksmith not practical expedi- ent keep elaborate rec- Planer Engine Lathe > | ords the office work planned ahead for -the shop, work for each machine Boring Mill Machine Drill Press each man. there Painting need for some control the work. This may obtained some degree the use the Order” report, Form All the job-time cards are again sorted departments and the class orders, whether they are Job Or- ders, Repairs, Stock Orders, Tool Orders, Lot Orders, Maintenance Orders Ac- count Number Expense Charges. Vertical Boring Machine Grinding Serew Machines This gives the shop man- agement glance the re- sults the week’s work each department the shop. shows the exact amount work turned out each department hours, labor pay and burden. The ratio productive, salable work other classes work may readily seen. Thus, one department spending unusually large number hours work charge- able Account Numbers, and only small proportion regular production for sales, the plant manager may take such action seems necessary change the condition. Other uses this report may suggest themselves from time time. The report makes complete statistical analysis the payroll each week, and the figures shown thereon, plotted graphic chart, make very interesting well instructive piece information for the general manager. borne mind that all these reports are made directly from the job-time cards each week means mechanical sorting and tabulating equipment. The various sortings the cards are completed the rate 400 minute and tabulating and adding the rate cards minute. therefore evident that the cost obtaining these reports negligible, com- pared with the benefits had from the informa- tion obtained. Horizontal Boring Machine Form Expense requisitions form another jected close anal- ysis Where the punched-card system various monthly reports may made up, with minimum time and effort, which will once fur- nish all the necessary information for the bookkeep- ing and cost departments, and serve executive report well. Monthly departmental analyses and distribution Maintenance Orders (Form 5), Defective Labor and Materials Spoilage (Form 6), and Expense Requisitions (Form 7), are very valuable manage- ment exercising control expenditures. The analysis maintenance orders shows the hours, also the amounts labor pay, burden and materials, ex- pended maintenance for each department the shop. The management thereby enabled ascer- tain which departments are kept the best running condition, and can pick out glance those that (Concluded page 1201) The Iron Age, October 23, 1930—1135 NO. NO No. | no. | NO. NO. no. No. NO. | | | | | ; | | | | | 15 3/04 | | | % al | = | | u | | — = rT | | +4 — | | | | | | | | | —+ + + +—+4 + + 4 + é | | + + + + + + + | | | | | | isi 14h Wa Goo | 4 Tox! 4 a | q 4 4 q i} Manufacturing and Warehouse Unit for Link-Belt Coast Trade FRANCISCO’S manutacturing facilities have The new buildings are located tract recently been given important addition the which within min. trucking distance down- result completion new manufacturing town San Francisco. Highways leading the plant plant the Link-Belt Co., Chicago. This develop- are exceptionally well located for trucking and rail- ment the outcome long standing and carefully road switch track convenient the new unit. laid plans for plant adequate size take care modern Spanish design, the office building both manufacturing facilities and adequate stocks for houses the administrative offices, sales, advertising, the Pacific Coast trade. purchasing, accounting, engineering and other depart- The new plant was not built expansion, but ments, and assembly hall for general meeting pur- rather provide greater erection and aisle space and poses. more room for storage materials process, well Back the office building, before the manufacturing for stock. also provides better work- building reached and connected passageway, ing conditions for the employees. All manufacturing the warehouse, which three-story concrete yperations are located the first floor and the lay- structure, ft. 120 ft. The first floor this struc- construction the plant has been carefully ture ata level with the floor the manufacturing planned permit future expansion the growth building and shipping room, and the second floor usiness justifies level with the main floor the office building. The ae the north end the manufacturing building, space provided for steel shop 1136—The Age. October 23, 1930 4 Wide aisles lead from the machine shop the main manufacturing building, which the right-hand background floor area the warehouse building 28,800 sq. ft. Between the warehouse building and the manufac- turing building located the shipping room, which served the spur track one side and drive- way for trucks the opposite side. Beyond this structure the manufactur- ing building, containing chine shop, steel shop, plant office and their auxiliary de- the light-machine section, with five transverse bays occupying total area 150 ft. 200 ft. Castings are brought truck and unloaded the east doorway. The flow work from the door- way through the various operations and then either the high bay for assembly the shipping room routed the large-tool sec- partments. This structure designed with high crane bay ft. wide and 300 ft. long. The heavy-tool section the machine shop located take care manufacturing facilities, and also adequate stocks, the Pacific Coast the Link-Belt Co., Chicago, has com- pleted new plant San Francisco. tion the machine shop are handled the 10-ton crane and carried direct the ma- chines. the north end, par- alleling the high bay, and with north saw-tooth skylights, are the south end this bay and the steel shop the north end. For its entirelength this building served 10-ton double-girder cranes, while smaller cranes and hoists are located various focal points throughout building. Heavy materials may picked the cranes any point the length the building and carried the shipping room for loading out truck railroad cars, they may transported the north end for direct loading cars. the east the high bay This plant has number worth- while features design and con- struction which are brought out briefly the adjoining paragraphs. three 30-ft. bays, 150 ft. long, for the lighter work the steel shop. Plates, shapes and bars arrive here cars which are set inside the steel shop under the crane. The new plant offers ex- ceptional opportunities for use modern manufacturing methods. Facilities for handling incoming materials are strictly up-to- date. Work process flows logical channels and storehouse and shipping facilities are ample meet the most exacting requirements the shop. Machine tools are spaced that products being manufactured move easily through wide aisles The Iron Age, October 23, 4 4 = > Forging Steel and Steel for Oil Well Casing ANUFACTURE forging steel the basic open-hearth furnace was the subject paper that aroused much interest one the sessions the Iron and Steel Division the Mining and Metallurgical Engineers. The author was Steel Oakmont, Pa. Another paper almost equal interest was devoted eagan, Edgewater development alloy steels increased strength casing for deep oil wells. This author was Bremmer, assistant superintendent hot mills, Spang, Chalfant Co., Inc., Ambridge, Pa. Mr. Reagan’s paper was “Practical Observation Open-Hearth High-Carbon pointed out that the making basic open-hearth steel for rolled steel wheels, locomotive Manufacture ires, carwheels and forgings various kinds industry. rolling stock and the specialized Increase weight high speed now demanded necessitate the use steel the for these purposes. The ransportation highest quality writer had basic open-hearth steel and the results obtained such defects changes open- hearth practice. studied defects Bottom-Cast Steel 12-Sided Ingots Basic open-hearth steel used has 0.50 0.85 per cent carbon, 0.04 per cent maximum phosphorus and sulphur, 0.15 0.35 per cent silicon and 0.50 0.75 per cent manganese. The steel bottom cast 12-sided ingots standard 88-in. body and 14-in. hot top lengths, but varying diameter from in. Ingots for special forgings are made molds various sizes and designs. These are sliced cold lengths, depending This affords good opportunity into blocks various lorgings to be 1138—The Iron October 23, 1930 ladles through bifurcated spout, which gives opportunity for inspection. Heats are tapped into two for changes practice. Selection raw materials for making high-quality open-hearth steel was declared the importance. materials uniform analysis and high quality are required. Perhaps the most important the basic pig iron, which should contain 1.30 per cent silicon and least per cent manganese; phosphorus under 0.20 per cent and sulphur under 0.05 per cent are desirable. desirable for several reasons, basic utmost Raw High man- primarily high residual manganese the bath melting, with corresponding saving manganese require- ments the final additions. Why High Silicon Desired High-silicon pig iron desirable because causes heat melt higher carbon than when low-silicon pig used. This results considerable saving, pig iron. High silicon also increases the temperature the bath. iron tends give heavy, viscous slags, which require additions large quan- tities fluorspar thin them. The analysis basic pig iron should constant. uniform analysis in- sures uniformity open-hearth operations and pre- vents the use excessive amounts iron ore heats that melt too high. also assures freedom from heats that melt too low and require the use iron ore. Heavy melting scrap for basic furnaces should free from small sections with high oxidation loss, should contain alloy steel and should not contain much badly rusted scrap. Low-magnesia limestone desirable. Selection the proper type furnace important, A — also. High tonnage and quality rarely are found combination forging steel. all factors exerting influence the kind ingot produced, perhaps the most important the ingot mold. For each kind steel there design mold most suited its purpose. Cracks ingots causing rejections are due the mold design. should not have heavy wall section. The writer had found that the interior molds, instead growing larger, gen- erally supposed, actually grows smaller. Effect Mold and Mold Wash Ingot molds made from cupola iron have more ac- curate inside dimensions than those made from direct metal, but the latter have longer life. The form mold used the author’s plant has heavy band around the top prevent cracks the wall. Another change design the gradual taper the flutes perfect circle the open e