The Iron Age 1931-11-19: Vol 128 Iss 21

ESTABLISHED 1855 NEW YORK, NOVEMBER 19, 1931 VOL. 128, No. MACHINE LAPPING EMPLOYED REFRIGERATOR MANUFACTURE ROGERS FISKE ITH THE ADVENT MACHINE LAPPING, SLOW AND TEDIOUS “ONE TIME” PROCESS HAS BEEN CHANGED INTO RAPID, “MANY PIECES SIMULTANEOUSLY,” COMMERCIAL OPERATION. THE RESULT HAS BEEN THAT APPLICATION LAPPING, WITH ITS SEVERAL ADVANTAGES FOR FINISHING THE WORKING SURFACES CRITICAL MACHINE PARTS, HAS VERY MUCH INCREASED. USE THE PROCESS LARGE PLANT MAKING ELECTRIC REFRIGERATORS AND EMPLOYING LARGE BATTERY LAPPING MACHINES OUTLINED THIS ARTICLE. Majestic Refrigerator plant the Grigsby-Grunow Co., Chicago, makes exten- sive use machine lapping the manu- facture mechanical parts for its electric refrigerators. This new plant and the machine lapping was put into practice when was first started. The lapping done flat pieces only, the parts having been previously finish ground close limits for size, parallelism and flatness. All steel parts lapped are first turned size and then heat treated produce hardness plus the Rockwell scale. They are then ground, from 0.0002 0.0004 in. stock being left for the lapping operation. The parts are then passed the machine lapping department for finishing; all parts are finished one operation. The plant makes use machine lapping essen- tially for the finish obtainable, for parallelism surfaces, and some cases obtain ex- treme accuracy size. For instance, the exact thick- ness Stellite valve seat not important are finish and parallelism. Another example af- 1283 forded the ends pump bodies, which together with the heads must have such surfaces that the bodies and the heads can bolted together without gasket, that is, steel steel, and the same time seal the joint effectively against SO, gas. Employs Battery Lapping Machines battery I-F lapping machines made the Norton Co., Worcester, Mass., for flat work con- stitutes the machine equipment. these machines two cast-iron laps—an upper and lower—are mounted vertical spindles and the work driven horizontal plane between them, both laps being contact with the work. The lower lap, driven from mechanism the machine base, rotates speeds ranging from r.p.m. The upper lap, carried spindle the overarm, does not rotate, but free float and find its own level when brought into contact with the pieces lapped. The entire dead weight this lap, about 250 brought bear the parts being lapped. The laps are made soft Ay if E = | | AL ar ‘ estimate the metal removed lapping had means the clock mounted the machine column. The machines stand back back with the lapping heads the aisle and with the motor ends staggered conserve floor space. close-grained cast iron and the cutting medium fine abrasive kerosene. The arrangement and the drive the workholder carrier these machines are important elements, since through them that the machine simulates mechanically the hand lapping motion the tool- maker his flat lap. This workholder may wide variety designs, including specials with adaptors. Its speed rotation ranges from r.p.m. and important feature that eccen- tric motion given it, throwing the parts being lapped from the inside the outside the laps and thus providing uniform wear the laps. These machines stand back back with the lap- ping heads the aisles, and the motor ends are staggered that minimum floor space required. The laps are redressed when needed correct the lap faces, making them true planes and parallel. The redressing accomplished first grinding each lap Heald surface grinder, and then work- ing pair them together upright drill press. One lap fastened the drill press table and the other rests it; between the two laps there abrasive and oil, the lubricant this case being 320 compound. means crank the drill press spindle, the upper lap made move eccentric path across the lower lap, the upper lap the same time rotating slowly. During the 1284—The Iron Age, November 19, 1931 process frequent inspection made with straight edge that extends across the full diameter the work. Pump Bodies Lapped Rate 175 Hour Applications machine lapping the Majestic refrigerator plant include the finishing Stellite valve seats, which are lapped within 0.0001 in. for flat- ness and are required have finish that without scratches. The Stellite welded into cold rolled steel ring, seven which are mounted fixture holder, illustrated. Thirteen these holders are mounted the carrier lapping machine. Another interesting application ma- chine lapping pump bodies made from No. 1020 steel. These are lapped 0.0002 in. for size and parallelism and the surfaces must such that the joints between the bodies and the heads are gas tight, without the use gasket. interesting note here that the diameter the pump bodies approxi- mately the same the diameter the holders for smaller parts that either pump bodies holders readily fit the carriers the machine. These pump bodies are lapped the rate 175 per hour with one operator attending three machines. The lapping ends rockers that length another application plant. Sixteen these rockers are set spool fixture and are held place steel band. The lapping machine fixture holds spools. The grinding operations are carried through with spools set three loads for lapping machine. From 0.0002 0.0004 in. lapping stock left after grinding and the ends are then finished within 0.0002 in. for size. These rockers are made from drill rods. Vanes which are cut from square rods, concave one side, are mounted fixtures very similar those used for rockers. They are set angle indentations made the periphery the fixture. Twenty vanes are spaced around fixture and held place steel band. The lapping machine carrier holds these fixtures. These parts are lapped limit 0.0002 in. Electric Gages Facilitate Checking Lapped Work means has yet been devised whereby gage can mounted these lapping machines and give readings within the accuracy required. benches adjacent the machines are electric gages which are vision read means flash go-and-no-go signals. These gages, made Sheffield Machine Tool Co., Dayton, Ohio, are capable checking better than and feature rapid operation, the operator’s duties being limited \ — 3 PECIAL fix- tures are made for the various pieces lapped. The fixture for the vanes the left, that for the Stellite valves the center and the spool fixture for the rockers right. inserting the work between the anvils and removing it. the piece within the predetermined limits, amber light flashes; undersize green light flashes, while oversize, the flash red. intervals during the lapping operation, the fixtures are removed from the machine and gaged. lap- ping operations approach the limits required necessary for the operator use caution and make more less frequent tests. Mounted each machine clock means which some measure the metal removed can had because experience has taught that certain amount metal will removed given time. After lapping, small parts are put wire basket and dipped tank full Dearborline, made the Dearborn Chemical Co., Chicago. Larger parts are run through Niagara washer. The parts are then sent the central inspection department where they are checked electric gages the same type installed the lapping depart- ment. Same Gages Used Central Inspection Department One advantage furnishing both these depart- ments with the same type gages that the event controversy the heads both depart- ments will discuss the matter from the same point view. The lapping department direct charge sub-foreman who reports general foreman charge lapping, surface grinding, bore grinding and outside diameter grinding. ~ The Iron Age, November 19, 1931—1285 4 | ae, Pa CONVEYING EQUIPMENT AND COSTS PRENTISS Cleveland Editor, The Age OUNDRY floor space has been reduced one- third its former size with decrease capac- ity the modernization the Cleveland gray iron foundry the Westinghouse Electric Mfg. Co. addition, various economies have been effected that have resulted marked reduction the production cost castings. Installation three con- veyor lines for continuous molding and pouring and sand-handling system are the outstanding changes that have been made. Before the recent revamping this foundry, molds were set and poured the floor. However, the modern practice continuous pouring was followed. tae 1286—The Iron Age, November 19, 1931 This foundry reequipped interesting ex- ample what can done, without making building alterations, installing mold and sand conveying equipment old building standard type steel construction. The sand-handling and preparation system the foundry floor, with flight conveyors for distrib- uting the sand located low heights they not interfere with the operation overhead traveling crane over the greater part the foundry floor. How- ever, the top the sand storage bin extends above the crane runway, preventing crane travel over tion the floor. The only under-floor construction the conveyors for small molds. Photograph taken from the opposite end shows shakeout grating, mold- ing machines and mold- ers’ sand hoppers, and the right center the inclined belt conveyor that carries the mold- ing sand from the re- ciprocating belt the shakeout the sand preparation equipment above the foundry floor. “a REDUCES FLOOR SPACE OLD PLANT EDUCTION floor space one-third its former size and marked lowering production costs are results modernizing old foundry, described this article. The principal changes were the installation three conveyor lines for continuous molding and pouring, and sand handling system. The equipment was put without making building alterations. required because the absence basement beneath the building was the construction tunnel for conveyor handle the sand from the shakeout grat- ings. This necessitated the tearing the floor only above where the tunnel was located. Modernization this foundry and increase its efficiency was part the company’s program shifting the manufacture castings used its numerous products. Motor brackets and miscellaneous castings formerly were made this plant, but the mold conveyor the car type for handling small molds, with the pouring platform left. Floor space conserved having the two sides the conveyor only ft. centers, which also makes convenient for shifting weights from molds the cooling side those the pouring side. manufacture these was transferred the com- pany’s Trafford City foundry. The Cleveland foundry now used for making smaller class castings, the average weight being although the out- put includes street lamp posts weighing 750 more. Included the production are all castings, such brackets, arms and supports for ornamental lighting fixtures, castings for electric ranges, electric irons and for industrial electric furnaces, for its Mans- field, Ohio, plant, miscellaneous meter castings for its The Iron Age, November 19, 1931—1287 | 7 a 4 : q ome ta? Newark, J., plant, and grid resistors for its East Pittsburgh plant. Two Continuous Mold Conveyors The conveyor system the rearranged foundry occupies floor space 108 ft. With its three molding and pouring units has capacity 500 tons per month based day and five-day week. The continuous mold conveyors are located side side. Two that are used for the smaller work are duplicate units. These are approxi- mately 200 ft. long and are the car type. The two sides the conveyor are except near the ends, where one side loops out provide 5-ft. turning radius. .The distance between the two conveyor tracks only ft. center center. The narrow space between the molding and pouring side the conveyor and the opposite cooling side not only saves floor space, but makes convenient shift weights from molds the cool- ing side new molds the opposite side, this being done near the center the conveyor. The conveyor consists four- wheel flat top cars in. long and in. wide, set about in. apart, being Separated sufficient distance allow shows the circular sand storage bin, table feeder, final tempering belt and rectangular shaped mold conveyor. Iron Age, November 19, 1931 TRAVELING pouring platform and pouring zone for one the conveyors for small molds. Back the mold conveyor the pug mill, for mixing the sand, and the sand elevator. them make the turn the end the conveyor line. Equipped with variable-speed transmission, the con- veyor has speed range ft. minute, but usually operated ft. minute. One these con- veyors has moving pouring platform that travels the same speed the conveyor and the other stationary platform, both being the same height the conveyor. There also short pouring platform located in- side the conveyor loop opposite the stationary platform that, case flask should not poured moves along the regular pouring platform, may poured the opposite side the line after passing around the loop end. These conveyors were built the Jeffrey Mfg. Co. Molds are made snap flasks and small steel and aluminum closed flasks. Metal slip-over boxes are placed over the snap flask molds before pouring when found desirable for certain molds. Molds poured these conveyors are made Osborn squeezer-type - 4 q molding machines. There are these machines, seven for each conveyor arranged two adjoining rows, the rows being 10-ft. centers. Molding sand for these two lines machines supplied one flight conveyor that serves two rows sand hoppers which extend down from beneath the flight conveyor sufficient angle from the perpen- dicular bring the discharge ends above the two lines molding machines. The flasks are shaken out over grating the end each conveyor and the flasks and bottom boards are returned the conveyor the molding machines. Intermittent Mold Conveyor The third molding conveyor, which used for larger work, 210 ft. long and built rectangular INAL tempering belt conveyor, re- vivifier and cross belt conveyor. the fore- ground corner the réctan- gular shaped mold conveyor. form. This plate-type anti-friction conveyor, be- ing constructed 6-ft. 36-in. plates, the under side which are rails which run rollers be- neath. This conveyor operated intermittently make pouring easier and provide longer cooling time. operation divided into seven groups five plates each. While one group the molding sta- tion the second group the pouring station, four are the cooling section and the seventh the shakeout. This conveyor moves ft. predetermined speed automatically controlled, then stops min., during which time the molds are made, poured and shaken out. The time travel between stations min., making 5-min. cycle, which may varied from min. However, there change the time the conveyor motion. This conveyor was supplied the Link-Belt Co. This company also installed the sand handling and preparation system. Molds handled the intermittent conveyor are made six Osborn machines arranged pairs each side the conveyor. pair consists jolt roll-over machine for the drag half the mold and jolt squeezer for the cope. Most the molds are made closed metal flasks. Molds are poured from both sides the conveyor from two stationary platforms along the pouring zone. There are five shakeout grat- ings the shakeout end the conveyor line and the same level the conveyor. roller top car moved hand 2-ft. track between the conveyor and shakeout obviates the necessity lifting the flask. The shakeout men shove the car point opposite the flask, pull the latter across the top the car and tip over the shakeout. Space inside the rectangular conveyor utilized for storage flasks and bottom boards. Iron from each the two cupolas poured into 2500-lb. tilting ladle that set front the cupola and from these ladles poured into bull ladles that are carried Cleveland hand-operated monorails the pouring stations where the metal transferred hand ladles from: which all molds are poured. The cupolas have 72-in. and 78-in. shells lined down in. These are operated alternate days. Reciprocating Sand Conveyor The sand handling and preparation system, which has capacity tons hour, has several interest- ing features. The seven shakeout grates for the three molding units are straight line near the side the foundry, and beneath these under the floor recip- rocating conveyor which carries the sand from the five shakeouts the one side and the two the other the center the conveyor. The movement the con- veyor one direction carries the sand from one end the point discharge, and its reverse movement brings sand from the opposite end the same point. The Iron Age, November 19, 1931—1289 ii » The sand passes from the reciprocating conveyor belt that runs through the foundry floor incline about deg. and this elevated hexagonal-shaped tapered screen. magnetic pulley the belt removes pieces metal. Passing through the screen the sand drops another belt conveyor which carries twin-paddle pug mill, water being added before reaches the mill. After mixing the pug mill, passes into the boot elevator which carries cross belt that feeds into 150-ton circular storage tank. From the bottom this tank passes over circular feeder belt that car- ries Rapp revivifier for final tempering. From this the sand falls cross delivery belt which feeds the three flight conveyors, one serving the two smaller molding units and the other two over the two rows molding machines that operate with the third mold conveyor. These flight conveyors deliver the sand the molders’ hoppers. Sand that overflows from the ends each flight conveyor passes into discharge pipe which carries back the shakeout conveyor. Excess sand run through the system both make sure that there always.enough sand fill all the hoppers and order put some tempered sand back into the shakeout and assure greater uniformity moisture the sand coming back into the mixer. Used sand sometimes hot and dry and contains less moisture than other times. The prepared sand that goes through the system and added the used sand amounts about per cent the total. adding prepared sand the used material, the foun- dry able hold the sand reaches the mixer Water Added Sand Two Points One practice sand preparation that not gen- erally followed that water added the sand two points, first before entering the mixer and again the discharge end the storage tank. not desirable store tempered sand too wet con- dition and simple matter add water the sand comes out the storage tank too dry, goes the storage tank rather dry condition and the additional moisture needed added when leaves the storage tank. With very wide variety work, considerable attention has been given provide molding sand that can used for all classes castings. Close- grained sand with fairly high natural bond used and occasionally coarse sand added increase the permeability. The foundry tries hold its sand the A.F.A. permeability range 25. electrically operated monorail located back the shakeout, and this carries castings the cleaning department buckets which they are placed after being shaken out. Grid resistors from the shakeout roller conveyor about ft. long table where the gates are removed. Then they are piled bins front the sandblast. Leaving the sandblast they are placed boxes and move another sec- chines, the two rows served one flight the foreground car- ries the overflow sand 1290—The Iron Age, November 19, 1931 7 the distrib- uting veyors which de- liver the sand the molders’ hoppers. tion roller conveyor the grinding and chipping. With its present layout the foundry able at- tain high production small parts. Seven molders are able make 245 resistor grid molds hour, Vanadium Can Delay the ESULTS systematic investigation the physical properties iron-carbon-vanadium al- loys varying composition from 0.10 3.0 per cent carbon, and 0.40 16.0 per cent vanadium have been reported Hougardy (Stahl und Eisen, May 1931). binary iron-vanadium alloys the effect vanadium pinch out the stability field gamma iron, 1.1 per cent being sufficient eliminate the gamma field. The marked affinity vanadium for carbon form the carbide V,C, per cent unites with 0.175 per cent increases the amount vana- dium required produce this effect. the vanadium content carbon steel in- creased, more and more iron carbide converted V.C, until, when the proportions are V:C 1:0.175, more iron carbide remains and the transition disappears. With further increase the vanadium content, the point raised and the temperature lowered, until when the percentage vanadium equal per cent 0.175, the gamma iron region pinches out the phase diagram. Vanadium carbide does not occur pearlite because forms double carbide with iron carbide, although there may partial solid solubility the two carbides. Vana- dium carbide not soluble alpha delta iron, but appears dissolve slowly gamma iron with in- creasing temperature. The physical properties the alloys are explicable hour for each man. recent order for 50,000 brackets for small motors the foundry turned these out the rate 240 molds 480 castings hour, two patterns being put each mold. a Quench Hardening Steel terms the occurrence the two carbides; the transformations between iron and carbon occur only when the vanadium not sufficient unite with all the carbon. Above certain vanadium content, depending the amount carbon, the hardening quenching delayed that finally the steel cannot hardened even the most drastic quench. These steels exhibit bright, coarsely crystalline fracture which unaf- fected heat treatment. The delaying effect vana- dium raises the temperature required for quenching give surface hardness and the same time ap- pears lower that required for internal hardness that sometimes happens that superficial hardening cannot accomplished without hardening the interior. long Fe,C pearlite present, the trans- formation occurs, but the presence vanadium inde- pendent the amount raises the temperature the change about deg. Vanadium tends shift the gamma iron region the diagram toward the high- carbon side without changing its area but leaves field the iron-rich side which gamma iron does not form. this field occur the steels which show transition, not harden and have coarse grain. Excepting the vanadium carbide, new struc- tural components were discovered the investigation the ternary system 3.4 per cent and 5.6 per cent The Iron Age, Nevember 19, 1931—1291 | ject that deserves and requires the most serious thought. Payment bonus for starting one’s daily work time fundamentally wrong. Its introduction into any industry business should avoided. PUNCTUALITY bonus management sub- Where such incentive plan has been installed, however, discontinuance its use may prove more detrimental than keep it, for the reason that em- ployees class object changes and are invariably skeptical the motive which prompts the change. Any so-called scheme for any purpose, therefore, should always considered thoroughly before adop- tion. have heard much about troubled industrial relationship and new era for industrial relations. American industrial relations are higher plane today than ever before the history capital and labor. The relationship between employer and em- ployee longer one discord and strife, each insisting and fighting for his particular rights, but relationship which may characterized co- operative and mutual one. The success one the success the other; the failure one the failure the other; and the interest one the interest the other. Contract Presupposes Punctuality Why, then, punctuality bonus? The sanctity contract, oral written, expressed implied, must always maintained. This cardinal princi- ple the law contractual relations, and judicial de- cisions follow this basic rule. Every person employed this country, the absence expressed oral written agreement, contracts impliedly observe the hours labor, rules and regulations his employer, and perform satisfactorily the duties assigned him. 1292—The Iron Age, November 19, 1931 consideration this the employer agrees pay for services rendered wage agreed upon the time hiring, amount equal the wage paid others him for similar services. From the hour the em- ployee required begin work until the hour set for quitting, exclusive the luncheon period, the em- ployer’s time, during which pays for services per- formed. Any additional payment made for this period consti- tutes over-payment not involving new obligation. the case piece work, task and bonus systems additional payment made for increased production, but the initial rate set and must met receive the regular wage. the case punctuality bonus the employer paying additional wage for something the em- ployee obligated without extra compensation. For employer pay his employee bonus for being time would analagous employee paying his employer bonus for receiving his wages the day set for payment. The obligations are not dissimilar, for each merely doing what expected him, accordance with the terms the implied contract. Why Not Penalty for Tardiness? Tardiness, like absence, affects production. in- dulged habitually proves serious both the work and the morale any organization. lieu pay- ing bonus for punctuality penalty should ex- acted for tardiness. employee knows that must begin his work time and failure means forfeiture, fewer persons will late. the other hand, employee knows that not required arrive time, but will paid bonus does, the average person likely sacri- fice the incentive and yield the greatest all BONUS RODRICK, Industrial engineer, Washington UNCTUALITY required assumed the contract employment —oral written. Mr. Rodrick argues for penalty discourage both tardiness and unauthorized absences. further recommends making the employee feel how contributing, punctuality, the success the business whole. temptations—a few additional minutes sleep the morning. Crimes are punished not much because the State must avenged for the wrong done deter wrong-doing. penalty for tardiness there- fore corollary, since tardiness can best reduced example. One employer, with whom the writer has had experience, employing thousands workers scat- tered factories, has always caused tardy employee lose one hour’s pay. Tardiness these shops has been kept minimum. Planning the Next Day’s Work The efficient foreman plans his daily work day ahead, and tardy employee often responsible for upsetting whole planning schedule. Both tardiness and absence may divided into three kinds: unavoid- able, authorized, and unauthorized. the first class fall such cases cannot foreseen anticipated from day day. The second class comprises those cases concerning which the employer informed, the day before. The third class constitutes those cases which are inexcusable. The second class affects pro- duction and advance planning the least. regulation every well-governed organization should that employees required report, telephone otherwise, the shop foreman cen- tralized office every emergency unavoidable absence tardiness. Violation such regulation without justifiable excuse should always the cause for disciplinary action; and continued abuse, under con- ditions which warrant it, should result discharge. The same disciplinary measures should apply un- authorized absence and tardiness. Punctuality virtue all things, and most men, like children, have taught the value the prin- ciple. industry and business this virtue in- important element successful management. terest employees their work making them feel that they are contributing the success business what industry needs. Wherever this has been accomplished employees not have paid extra time. has been well said that little more industry wouldn’t hurt industry. a New Protective Coatings for Steel Pipe procedures for protecting steel pipe from corrosion have recently been developed the Mannesmann works according Deutsche Bergwerks-Zeitung. “Tornesit” rubber derivative which may dissolved suitable ve- hicles and applied thick thin paint the cold metal. “Herolith” product the synthetic resin industry which applied the liquid state the object special process followed drying ovens. The strength each case about that coat strong paint. The hardness increases time and the coatings are not softened heat other influences. Tornesit generally gray, Herolith brown. Both materials adhere very firmly the metal surface. They remain elastic and are not loosened bending the protected pipe. Neither affected cold dry heat 275 400 deg. When dry, Tornesit and Herolith are odorless and tasteless and not affect the flavor drinking water. Both offer protection from stray electric currents. The Mannesmann research department has tested the resistance the coatings many chemicals. all the materials tested which are apt trans- ported pipes, Tornesit was attacked principally hydrogen sulfide, tetralin, and bentol the liquid form. was only affected alkalies. Even sulfuric and nitric acids did not attack these coatings. The Iron Age, November 19, 1931—1293 } a = Ae. ‘fre 4 \ Ae ABORATORY and field tests all-steel cable construction with steel drum. Design reels have proved their economic advan- tages over the all-wood reel and the wooden steel reels and development shop practice for their manufacture have been brought high de- gree perfection the Hayward Co., Chi- cago, which produces and sells steel reels under license arrangement with Electric Research Prod- ucts, Inc., subsidiary Western Electric Co. The Western Electric Co. now has more than 000 steel reel drums use. There have been drum failures, though the first 300 drums were put service June, 1926. Advantages the steel reel are: They cannot rot, there renailing damage, rough edges which damage cable sheaths cannot develop with hard usage, repair cost extremely low and they are ex- ceptionally strong torsion, impact and crush- ing strains. Their range usefulness probably best illustrated the fact that they are made head diameters ranging from in. 108 in. and outside widths from in. 53% in. Drums Are Made from Sheets Shop practices center special equipment for flanging and forming and electric arc welding. Bar- 1294—The Iron Age, November 19, 1931 CABLE REELS GROWING OUTLET rels for steel reels are made diameters that range from in. in. either galvanized blue an- nealed sheets gages that range from No. No. 10. The drum formed standard bending rolls and the longitudinal seam closed semi-auto- matic electric welder. This shell then flanged slipping one end over mandrel which clamped after having been fitted gage for proper width flange. The flange rolled spun down driven rolls which rotate the shell. The mandrel this machine moved backward and forward ways. After both flanges are formed, the drum removed punch press, where the rims are punched for through bolts, which, the scheme assembling reel, pass through the opposite side sheets and the drum flanges. These flange holes are punched oversize and flanged take pipe ferrule, which welded angle chip, which turn welded spoke the head. The standard design have one through bolt for each spoke. Heads are fabricated from side sheets in. 108 in. diameter and thicknesses that range from No. gage sheets 3/16-in. plates. The outer edge swedged offset that the rim channel fits over the side sheet which electrically welded. This construction gives smooth inside HELLS, after hav- ing been welded, are mounted the mandrel this ma- chine and the flanges are rolled spun down. 7 7 FOR STEEL NOTHER example the substitution steel for wood reels for cables. Although steel reels were first put into service only five years ago, more than 50,000 have now been manufactured. The pro- duction process makes use electric arc welding for the assembly. Drums and heads for the reels are made from sheet steel and the reel ring composed channel sections. surface. The rim channel formed press brake, rolled circle and closed electrically welding the seam. The spokes are formed channel sections. Formed gussets extend between spokes the rim. Assem- bling operations are performed cast iron, manual- rotated tables that are 108 in. diameter. Table surfaces are machined and gage holes are spotted facilitate the assembly various sizes reel heads. channels are welded place two-arc auto- matic machine. TEEL reels are made diameters 108 in. Over 50,000 are use and there have been fail- ures service. The reel ring first centered table and then gage holes are marked for the number spokes re- quired. The spokes are laid place and clamped, after which the gussets are located place. This skeleton then welded and transferred another table, where the skeleton spokes and gussets with center ring place welded side plate. The work then moved another table, where the rim channel welded place automatic machine The Iron Age, November 19, 1931—1295 7 A- ; i which has two arcs spaced 180 deg. apart. The seam closed the side where the rim joins the side plate while the motor-driven table makes one-half revolution. The head then turned over and the rim channel automatically welded the gussets and spoke ends. Steel guides are welded inside the gussets facilitate the insertion the bolts which hold the lagging place, and provide added strength the gussetts resisting radia] and loads. These bolts are the stephead carriage type and fit into square holes the lagging and outer edge the rim channel. Case-hardened wing nuts are made with projections the bearing surface. Slight in- dentations are pressed the gussets when the bolt holes are punched that when the nut tightened locks place. Covers, lagging, are made corrugated steel sections for serviceability and convenience han- dling. Each section extends over the distance gaged two spokes with ample overlap make continu- ous cover. Corrugations are formed lengthwise the diam- eter the reel. Each sheet cut and trimmed size and rectangular slots are punched for the lag- ging bolts. The sheet then corrugated ard 300-ton press fitted with dies that one corru- gation made with each stroke the press. Fitted the back the press notched gage bar that the operator moves the sheet back one notch the bar after each stroke the press. This method corrugating used because affords the degree accuracy needed when using sheets gages from No. No. 10. The corrugated sheet flat comes from the will have the proper contour fit the rim the reel. This operation performed corrugated rolls. The two outer edges the lagging are flat they will form close fit the outer surface 1296—The Iron Age, November 19, 1931 a PLIT mit adjustment these rolls lagging various widths can shaped. the channel rim. Therefore, the corrugated rolls are adjustable, and split collars can moved make the rolls adaptable for various widths lag- ging. Heskamp Process for Utilizing Blast Furnace Dust results four years’ experience the appli- cation the Heskamp process for handling blast furnace dust are discussed Milden (Stahl und Sept. 10, 1931). The dust discharged from the mouth the furnace caught collecting chamber from which passes over screens. The coarse particles are recharged the ordinary man- ner, but the fines are conveyed drums where blast blast furnace gas atmospheres from two- stage rotary compressors stirs the dust and blows back into the furnace stack through special nozzles. The height these nozzles the stack great importance, for they are too high the charge above will not filter out the dust blown in, and too low the high temperature will result undue wear the nozzles. blast 83,000 cu. ft. per hour was found capable introducing 500 600 tons dust hours. Nozzles with life 15,000 20,000 tons dust handled were developed. The apparatus very simple, requires the atten- tion only one operator and produces disadvan- tageous results the furnace operation. The follow- ing data represent average comparison the daily yield and coke consumption with and without the Heskamp process over period about month: Coke, Dust Pig Iron, Lb./Ton Blown in, Tons/24Hr. PigIron Tons/24 Hr. Without dust blast 919 2,130 With dust blast 978 2,030 122 The results were good that one plant the Vereinigten Stahlwerke equipped all its furnaces with the apparatus. DRESSING SHEET AND TIN MILL ROLLS ERIC MORT, Inland Steel Co., Indiana Harbor, Ind. ORMULAS for establishing depth concavity and cross sheet and tin mill rolls have been use for many years. The matter, how- ever, has not any means become exact science, there are many variables depending upon individual practice and experience. This con- tribution the subject may compared with that published THE IRON AGE April last, written Harry Wible. The present treatment said the author contain the possibility preparing charts showing the variation the height the arc representing cross with the chord the same arc, whereby the roll turner can obtain the required concavity direct reading. only the past few years that efforts have been made reduce the problem the concav- ing rolls mathematical basis. There have been attempts establish the type curve which the curvature correctly dressed roll belongs. number writers describe hypocycloidal, but the correctness this description doubted. The grinders now general use dress perfect are circle, and rolls concaved this manner give every satisfaction the mill. the writer’s knowledge, the mathematics roll turning and/or grinding was first discussed John Mort paper before the Swansea Technical College Metallurgical Society February, 1929. This paper was abstracted Blast Furnace and Steel Plant, December, 1929. The relations between depth con- cavity and “cross,” together with other factors, were established, the formulas submitted having been use over number years. with considerable interest, therefore, that the contribution Harry Wible, THE IRON AGE April 1931, viewed. Mr. Wible’s treatment the subject differs radically from Mr. Mort’s, and was apparent from the outset that there would discrepancy the results obtained the two methods. This present article comparison discussion the two methods and undertaken the hope that solution the problem will eventually result. certain that, roll-turners are make use for- mulas their work, this question must settled for all time. Mr. Wible gives actual formulas, the writer has taken the liberty deriving the following from the information his article. proposed adhere the nomenclature used Mr. Mort, for purposes reference. Length arc, equivalent amount “cross.” Roll diameter. Roll radius. (1) (2) will the amount concavity the roll. the concavity shared equally the top and bottom rolls, will half the total concavity, the latter being expressed inches millimeters. will assumed that equal which sufficiently near the truth for all practical purposes. equation for finding may derived from (1) and will possibly found rather more simple h=2 (3) Mr. Mort gives the following equation for finding The Iron Age, November 19, 1931—1297 om 1 x = | th ~ AY € which one-half the total depth concavity, being equal minus the “cross,” given the radius the roll and the depth concavity required: from which may derived: (5) Taking 28-in. diameter roll and cross 2.50 in. and using equation (1) (Wible) obtain: 0.028 in. Now, using equation (5) (Mort): 0.056 in. Using another Mr. Mort’s formulas for check: (a/0.0175 0.056 in. this example Mr. Wible’s formula gives figure which half that obtained using Mr. Mort’s for- mula. This particular case, however, and the rela- tionship not general, will seen from Table Table (Wible) was calculated means Equation (1) and Table (Mort) means Equation (5), both for in. diameter rolls. the text Mr. Wible’s article appears the fol- lowing: “As one-fourth roll cross (e), con- cavity must figured find depth and then multiplied give the total depth concavity.” (See Fig. 1.) This statement seems warrant little further explanation. The inference that there direct linear relationship between and 2.—Determination the depth which roll should dressed for concavity providing the proper cross, and being points. 1298—The Iron Age, November 19, 1931 Table Concavity Wible Mort 1.0 in. 0.006 in. 0.009 in. 1.5 0.021 in. 2.0 in. 0.018 in, 0.036 in. 2.5 in. 0.028 in. 0.056 in. 3.0 in. 0.042 in. 0.081 in. definitely not so, cursory inspection the for- mula will prove. examination Mr. Mort’s formulas and figures makes apparent that his argument hinges one point. and are the intersections the straight- edge with the end the roll body, the distance 3.—Plan roll, showing the relation cross the roll dimensions. the concavity which the roll dressed? This seems evident, the crossed straight-edge must horizontal plane produce chalk line even width along the roll body. If, then, the figure illus- trates the true state affairs, the formulas must correct, they are simply deductions from the first principles mensuration. Should mill operators recognize the value for- mulas applied roll turning, then charts may prepared showing the variation with for the different diameters use, and within the limits which rolls are ordinarily dressed. the turner’s orders are expressed terms inches concavity, has only read off the chart that which will give him the required concavity. New High-Quality Foundry relation quality various kinds pig iron the quality the gray cast iron obtained from the cupola process was discussed Professor Piwo- warsky the September meeting the Verein Deut- scher Eisengiessereien. The use low-carbon pig iron special quality has been shown insure qual- ity the resulting gray iron, while with high-carbon pig iron the presence fine-grained graphitic struc- ture guarantee the fineness the cupola prod- uct. the latter case better properties resulted from the use ingot cast pig iron than from coarse- grained, sand-cast material. series tests low-carbon material, better results were obtained from melting gray sandcast iron than from white, metal- cast iron which had later been ferritised heat treat- ment with development temper carbon. sys- tematic plant-scale investigations the actual rela- tions have been worked out, that cast iron 3.5 3.6 per cent carbon may produced with tensile strength 37,000 per sq. in. The new special grade iron called “Migra-Eisen” (ab- breviated from micrographite). | | a a ~ \ q ‘ ‘ ‘ \ , | | ELECTRONIC CONTROL MACHINERY RAYMOND FRANCIS YATES Member, Institute Radio Engineers RODUCTION gages, which the movement the anvils ampli- fied electrically the remarkably sensitive vacuum tube, will perhaps bring into common use standards precision that present are unattainable production work. This application, well other developments the use electronic tubes, discussed this con- cluding installment series three articles. PPLICATIONS ordinary vacuum tubes will discussed this article, the two previous installments having dealt chiefly with the photo-electric tube, mentioning the vacuum tube only when used this connection amplifier. When understood that electronic tube capable detecting degree energy representing only few billionths ampere, some idea its remarkable sensitivity obtained. is, matter fact, the most sensitive device yet discovered man, sensitive indeed that the great problem those who would use for purposes mechanical measurements has been that controlling this sensi- tivity. Research has finally brought this about and today new applications are constantly being found for the vacuum tube. Literature the theory vacuum tube operation voluminous and many men are familiar with this device that attempt will made here into this matter. The tubes mentioned are the ordi- Condenser Measuring Unit Fig.1.—An oscillating tube circuit for precise mechanical gaging. nary radio type that may purchased any radio supply house. Tubes Oscillate Required Frequencies There one function vacuum tubes that must understood and that their ability oscillate “regenerate” producing high-frequency currents. high-frequency currents simply meant alternat- ing currents that, instead having cycles per second, have cycle oftentimes reaching into the millions. The cycle such circuits will depend upon several factors such the amount wire the circuit (both straight and coiled), the capacity (supplied condensers, both fixed and variable) and the amount resistance. Circuits may designed operate practically any frequency the use the correct amount inductance (the amount wire, usually coiled) and the correct amount capacity. Engineers not often call upon ohmic resistance control oscillating circuits. The facts just outlined partially describe the simple theory interesting application vacuum tubes; application that, the opinion the writer, will become great importance the mechanical world. With this principle, mechanical measurements may made with heretofore undreamed-of accuracy. Not only that, but the case measuring material like wire and sheet, these measurements may made con- tinuous and even ring alarms stop machinery that out adjustment. The diagram Fig. illustrates the operating principle the measuring device suggested above. The Iron Age, November 19, 1931—1299 Vacuum Tube Tube Resistance really very simple and easy understand. Two circuits are interconnected such way that one vacuum tube produces one frequency and the other, another frequency. two sound waves different frequency interfere with each other, third note frequency produced and the frequency this “beat note” will amount the difference frequency. Thus 1000 and 1200 cycles meet, beat note 200 will produced. This circuit designed function this principle, although the frequencies involved are much higher than those mentioned. This beat note current measured specially calibrated meter which translates the beat note into mechanical metric units. was previously stated that frequency such circuits controlled partly capacity. Capacity may altered means variable condenser having metallic plates separated air and arranged bring about variable effective surface rotation changing the distance between the plates. The later action employed the electric ultra-microm- eter under discussion, the electrical measuring unit taking the form two-plate condenser arranged circuit that extremely sensitive variation distance between the plates. The slightest variation will change the frequency the beat note and this turn registered the special meter. Fig. the mechanical arrangement the special condenser shown, the plates and forming the units the condenser while the anvils and contact with the work measured. Other Successful Industrial Applications This very interesting principle has already found several practical applications. One them con- nection with wire mills where accurate, automatic check kept the product. The same principle has been applied paper mills, and the writer recently viewed, its experimental form, new measuring instrument for automatic screw machines. Many other 1300—The Iron Age, November 19, 1931 Condenser Adjustment Condenser Fig. anvils and variable condenser the apparatus diagrammed Fig. applications are rather apparent, and seems obvious, even this early date, that future inspectors and machine designers, not mention foremen and super- intendents, will called upon understand the oper- ation electronic devices. The successful application still another elec- tronic principle should special interest ma- chine designers. Reference made new type electrical stroboscope that makes possible study the action machine parts while they are function- ing very high speed. Regardless the speed, the parts the machine appear perfectly stationary al- though they may revolving 1800 r.p.m. The device now being used examining the valve action airplane motors, mention one its more impor- tant uses. Grid-Glow Tube Used New Stroboscope With this apparatus, beams light flashing and off perfect synchronism with the moving parts observed form perfectly stationary image. The rapid change light brought about the charge and discharge what known grid-glow tube, another pure electronic tube. (Concluded page 1349) re-reeling speed this wire drawing machine regu- lated thyratron (elec- tronic) control ment which compensates for increasing diameter reel. This device was described THE IRON AGE Dec. 1930. Contacts Spring 4 ‘ BOO Forecasting Business Business Forecasting, Dr. Lewis Haney, director, Bureau Business Research, New York University; 378 pages, illustrations. Published Ginn Co., Boston, 1931; price $3.40. One the particularly interesting features Doctor Haney’s book lies his explanation his P/V line, which has become well known readers THE IRON AGE through his studies the economics the metal and metal-working industries, which have been carried this journal for several years. This relationship between price commodities and the available volume, when analyzed the light knowledge all the surrounding factors having bearing, has given rise the use the line indicator what the future holds store. Practically the whole book devoted the subject the use statistics business forecasting. This in- volves many things beyond the mere possession these statistics. For any definite purpose they must se- lected for the work hand, they must analyzed not only from the bare facts presented, but also with re- gard seasonal movements, and the steady growth output other features through the progress the years. Business cycles are given extended treatment, with hypotheses concerning their causes both within and with- out given business given country. The author traces depressions the excesses boom period, makes them from this standpoint more less psychological, and shows just how the expanding bubble collapses when final- pricked sufficiently sharp instrument. traces the difference between major crises, such those 1921 and 1930, and the minor manifestations 1924 and 1927. Human nature being what is, cannot see any likeli- hood early abolishment the recurrent periods excessively large business volume and distressingly poor business, lack employment and destitution profits. Business general tied back question man’s requirement monetary reward for his efforts. Profits large the scheme, and stretching after measure profits which produces boom and es- tablishes the conditions out which eventually the Forecasting general business trends, forecasting for particular