The Iron Age 1932-03-17: Vol 129 Iss 11

ESTABLISHED 1855 IRON NEW YORK, MARCH 17, 1932 depression year manufac- turer piston rings turned business losses into substantial gains, showing increases per cent gross sales, per cent replacement sales and 100 per cent exports. The possessor this un- usual record the Perfect Circle Co., Hagerstown, Ind., the fig ures quoted representing gains for the first nine sive and well planned sales program. The re- mainder attributable improvement its prod- uct and the methods used manufacturing it. When automobile man- ufacturers are operating great demand for piston ARD times are severe test adaptability. sible adjust their affairs rapidly changing business conditions have fared best the past two years. The organization whose operations are described this article succeeded well sponding period 1930. ascribable rings. But when auto- ROGERS FISKE Western Editor, The Age increase—and substantially that. Its merchandising policies reflect unusual alertness market readjustments. less impressive are its manufacturing methods, which are here described from the making castings, through the various machining operations, inspection. mobile sales lag for period major outlets must found elsewhere. One way expanding sales through jobbers—by increa ing the distribution replacement rings among owners old car Another stimulating export mand. VOL. 129, No. PRODUCT AND HOW MADE Those companies which have found pos- this respect that not only prevented its sales from declining but actually caused them Here where foresight plays important part. the early stages the business depression the Perfect Cirele Co. sensed the coming changes immediately started build its jobber outlets. followed through with eight-year program, na- tional advertising. introduced its type ring, which offers better performance the buyer. For sales promotion extended all possible sistance jobbers, even the extent providing three-reel talking motion picture programs, which months 1931 were exhibited over 110,000 people. The picture equip- ment the product the Bell Howell Chicago. ing product can carried only when man ufacturing facilities are 4 » ih q — - it 4 q ‘ programs include presentation talking motion picture. Eighteen factory representatives put these shows throughout the country. equate. The Perfect Circle Co. made squeezer machine with erates three plants. One the draw against the head. All molds are foundry, which housed made green sand, the top one toried building the basement ection forming the drag for the sec- which torage capacity for about tion that superimposed. All flask tons sand. ections are made cast iron, some them being scalloped contour. ton rings are cast Metal pattern are employed making from one eight ring molds sections high with center pour depending the diameter the ach The drag dumn ring. Sixty molding machines are ttom each green use, two which make dummy al ank, Each flask ection 18s blank mold bottoms. f 7 from the inside and outside the annular castings removed grinding. 656—The Iron March 17, 1932 — . The first sand placed pattern hand riddled. Sand then shov- eled into the flask section and struck level with removable ring which taken off the flask before the squeezer operates. this way the density the mold controlled. Moisture the sand closely checked the metallurgist, who calculates the nec- essary addition water. The re- quired quantity measured through meter. There are two 60-in. cupolas, which have been lined in., and third, which has been lined in. the power house alternating-current motor driving Roots blower through Reeves speed reducer which under remote control from stations the cupolas. When the foundry oper- ating capacity tons metal cent the charge returned scrap and from per cent the iron poured goes into the scrap pile. The high percentage scrap not indica- tive careless methods but re- sult the character the product and the unusually severe inspection the castings. illustrate the character these iron castings well state that the smallest rings measure 1/16 in. thick, in. wide and 7/16 in. out- side diameter. One hundred these rings weigh 2.7 lb. less than each. The average weight all rings cast oz. each. Hot metal poured center — — € ttern shov- the nec- ough hird, the ough nder the per crap iron The L re- duct hese that in. out- hese ings nter sprue from which flows ring gates which feed the ring molds. Opposite each ring gate there cast overflow button which when re- moved from the ring serves the tumbler place star. The gate each ring broad and thin and located the section the ring which removed the machine shop. With this arrangement the separa- tion the ring from the gate cannot result bad break that would cause defective ring. interesting note that the button weighs more than some rings. there are the sprue and the ring gates, all which must returned for remelting. The sand problem well illustrated the fact that from 0.008 0.01 in. 3 » 4. laboratory tests facilitates proper blending. Pouring temperature close 2750 deg. the cupola spout. Op- tical pyrometer readings are taken girls inspect 275,000 rings 8-hr. day. There also sampling de- partment the foundry, where rings are put through the major machine operations before deliveries are made 4 grinding performed machine with two facing wheels separate vertical shafts. magazine feed (at right) delivers ring time between the wheels. The unequal speeds the wheels cause the ring move gradually the opposite side and out exit (at right) where drops into barrel. the allowance the sides ring from finish machining. The sand must have high permeability and still must have fine grain size. Various sands are blended get the desired results. Each car sand stored separately. card index each tap, which means every min. record kept these tem- peratures and the floors which the various taps are poured. Rings are broken off the sprues night over barrels, which are sent the inspection department where six >, 4 “on rings are cast trees. Sprues and overflow buttons represent large part the weight the meta! poured from the foundry the machine shop. Every day more than 1500 rings are machined and tested for tension and hardness. record the character the product pouring floor found hard the entire output that floor scrapped. Dirt holes 12% per cent the pieces tested cause the product of a floor to be scrapped. Rough casting ring losses are vided into foundry and molder losses Molders are paid the Bedaux sys- tem, which includes quality bonus. The foremen, also, are paid quality bonus. Losses are exhibited pans rack the inspection depart- ment. Each molder has pan and there are also pans for various kinds The Iron Age. March 17, 1932—657 = out a ~ 4 ; foundry losses. These boxes are numbered and are open inspection molders and other foundrymen that the character losses can studied the individuals concerned. Piston rings are transported bar- rels from the foundry the machine shop. The count rings made weight. the receiving room the rings are put numbered barrels each which permanently mounted three rollers. With each barrel goes routing ticket, which vided into sections each which the number the barrel printed. Each ticket section designates operation after the completion which removed and sent the section also shows the number ings originally the barrel, and blank spaces are left which re- cord the number rings delivered from the previous operation and the loss Castings Cleaned Grinding The first machine shop operation snag grinding. About dozen rings are laid loosely cradle-like fix- ture and the inside and outside are rough-ground. The grinder double-spindle machine, each spindle being parallel with rubber roller which forces the castings against the grinding wheels. Although this rough operation, still must curately performed. The next operation rough-edge grinding, which performed machine with two facing wheels vertical shafts. separate motor drives each shaft, one which ro- " ‘ — Age, March 17, 1932 tates slightly faster than the other. magazine feed delivers ring time between the wheel faces. The unequal speeds gradually carry the rings across the wheels the oppo- site side, where they are dropped into barrel. This equipment was made the Gardner Machine Co., Beloit, Wis. All grinding operations are con- nected central dust removing The Arter Grinding Machine Co. was the builder the grinders for the finish-edge operation. These ma- chines are equipped with magazine feed magnetic clutches, one face ring being ground time. After finish-grinding, the rings are inspected 100 per cent for machine defects (quality finish and size) OINTS are sized miller. The ring compressed size special fixture. and foundry defects holes), thus saving time which would other- wise. lost subsequent operations. The first cut the joint mill- ing operation, using two thin cutters which two rings time are fed hand. Beginning with this oper- ation barrels are longer used, but instead metal tote boxes, which are mounted angle roller floor stands. Overhead, throughout most the shop monorail system. Rough face turning, like all other inside and outside turning operations, interesting because methods used remove metal under condi- tions that permit the rings assume their true circular shape when in- stalled engine cylinder, thereby exerting equal radial wall pressure. From rings are first closed with split pot air vise. The air pot rubber-lined cylinder that fits over the arbor which the rings are mounted. When air pressure applied the ring joints are closed and the rings take natural unstrained position the arbor. They are clamped this position for rough and finish turning the outside surface. For inside boring the rings are com- pressed air-operated pot and put holder sleeve. They are then released the rings proper shape for boring. The amount metal removed the boring oper- ation determines the tension the rings. Tests for tension are made after this operation. Two Operations Performed One Lathe Mounting Rings are now ready for grooving and slotting operations. They are first placed pot that the euts 7 4 4 7 4 = = 4 7 (+ - ~ oles), tions. mill- itters fed oper- but | are floor most ions, hods sume in- reby osed The that and ined are ugh ace. om- and hen heir the ade ine ing are uts + are then clamped this position air fixture lathe that has milling cutters mounted the front and the back the tool carriage. The endless channel first cut the outside edge. The channel cutters their work when the mandrel ro- tating. When the channel finished these cutters back away. The lathe spindle stops rotating and the rotat- ing slotting cutters are advanced. When slot has been cut, the cutters are backed out and the mandrel indexed the position the next slot. Then the rings are compressed fixture and final milling cut made size the joint. The final out- side turning clean-up operation performed lathe. For this INGS pressed air- operated pot and put holder sleeve for the inside boring op- eration. moved determines the tension the rings. chines, barrels give the diameter are line. They eration the joints are placed lin (considering oil-regulating ring only) and special pot used bring the rings proper shape before taking very light cut. rings are then air blown before final inspection. lows: There 100 per cent inspec tion after finish grinding disclose all defects. addition, there percentage inspection the floor after each operation. Final inspec tions are follows: 100 per ceé Percentage Percentage for Per i [i ta I I I Per t ‘ I nt All the operations here described are performed 4,000,000 rings month when running capacity. Soy Bean Oil for Cores investigation the suitability soy bean oil either sub stitute for, diluent of, other oils used for making cores was conducted the Engineering Experiment Sta tion the University Illinois, Ur- bana, Ill. Results are published Bulletin No. 235. Some the conclusions follow: Raw soy bean oil produced cores with tensile strength slightly tensile an average higher than the average strength cores made from semi refined varnish soy bean oil. The addition kerosene raw soy bean oil caused gradual reduction the average tensile strength the cores the percentage kerosene the mixture The addition Japan drier raw soy bean oil slightly increased the tensile strength the cores. Various additions both Japan drier and kerosene raw with soy bean oil produced varying tensile strengths which fol lowed definite rules over the range data collected. Cores made with proportions linseed oil and those made variou soy bean oil were strong made with linseed oil. Cores with mixtures linseed oil, kerosene, and soy bean oils decreased strength the bean oil were increased. The ten ile strength the cores made with percentages kerosene and the soy bean oils, and mixtures soy bean oil and kerosene, was found proportional the iodine number the soy bean oils and mixtures ean oil and kerosene. The Age, March 17, 1932—659 + for ARGE savings the making forging and trimming dies have resulted from the devel- opment the Ford Motor Co. engi- neers process which hard- ened master die driven into heated block steel, much signet ring used make impression wax. This process, which for the want better name has been called “die typ- ing,” has been developed such extent the Rouge plant Dear- born, Mich., that many parts for the car are now forged trimmed these new-type dies. Dies are one the most important items the cost making automo- biles. Extensive use forgings the Ford car and truck tated maintaining large staff skilled mechanics repair place worn-out dies—an industry small proportions itself. course, considerable staff maintained, but the production dies 660—The Iron March 17, 1932 — this group dies made the typing method, those above are types; those above are dies: and those above are trimming dies. has been increased tremendously the typing method. maintained and the forging dies are found give somewhat longer ser- Small Dies Typed Mechanical Press Some the smaller dies are typed punch press with capacity ranging from 400 600 tons. type the die for the steering gear for instance, necessary make type with projections the same shape the impression desired the dies, although enough larger than the die typed allow for the shrinkage that will encountered when the typed die coolse Pieces steel suitable size are heated temperature 1700 deg. lead pot. One the heated steel blocks placed retaining ring and pushed into place directly under the master type which mounted the ram the press. The master type into the heated billet. Some parts, however, as, for stance, the star punch for the gasolin gage nut, require somewhat ent process. this case the type consists ring with star pression worked out the center enough larger than the punch quired allow for shrinkage. This placed the bed the press and flat piece mounted the ram. When the billet put place and the press tripped, the billet driven into the master die. Steam Hammers Used Large Dies the larger dies, such Ajax dies, trim dies, forging dies, 2500-lb. steam hammer used. The type consists set hammer die blocks. the bottom block the thickness the die mad The top block machined similar manner, except that the cavity the bottom the block. The cavities retain the heated metal and cause flow and around the master, filling sharp corners and various intricate places. some cases when difficulty experienced filling cor- ners small projections the dies vent holes the master die, thus per- mitting the gases trapped com- pressed these vents without ing the flow metal. Ordinarily these type dies, bil lets are heated temperature 2100 deg. essential that the temperature the same for all typed any one master, this mas ter allowed accommodate cer- tain shrinkage. the temperature allowd vary, dies will not uniform size. Billets Ground Eliminate Scale Another very important factor typing dies the control the at- mosphere the heating furnace and ) & ae — — aa oud be > Me... 1. q 4 > | MAKING FORGING DIES LOWERS FORD COSTS ram. and lriven Dies Ajax The die mad use aster, when dies drill the protection billets when heat ng. Since the dies require ma- chining, scaling cannot permitted. Ford method avoiding scaling grind one side the billet nsure that all decarburized material, which might- have resulted from roll- ing forging temperatures previous- employed, has been removed. Fine charcoal other material, such cast iron chips, placed the die mmediately after typing keep down oxidation. the case large hammer dies, such connecting rod dies, camshaft dies, steering arm dies, much easier type inserts and fasten them larger blocks make the } locks. Forging trim dies are also typed great advantage. The openings these dies are typed accurately that the only work necessary finish them few strokes with file accom- modate the “wear the forging dies” and shape the bottoms. Some idea the savings effected the die typing method can gained from the Ford production rec- ords. For instance, one crew two men can type die inserts for con- necting rod forging dies (40 sets) hr., whereas estimated that from hr. are required sink one set rod dies the method. certain set trim dies required hr. the old method and only min. the new. ball seat punch die took hr. the old method and min. the new. Typed Dies Have Long Life top that, the productive life typed dies about per cent longer than cut dies forging and upset work and equal cut dies trimming work. This, according the Ford metallurgists, due the fact that the grain the steel surface typed dies more dense and the fibers are flowed accommo- ALLED “die the new process here described has greatly reduced the time required produce forging and trimming dies the Rouge plant the Ford Motor Co. this process hardened master die driven into heated block steel, and the used form the dies are them- selves made the same typing method. From one master die Ford able turn out 500 1000 types, from each which 200 800 dies can produced. date the shape the impression the die, whereas dies made the conventional method the ends train of the hammering interesting note, too, that the types used form the } themselves made the same that from one master Ford able make from 500 1000 types from each which 200 800 dies can made. This method vhere great number the same kind dies are consumed and replacing the typing master comes frequent. When this done, master hammer dies mad which resembles the dies that are ulti mately made, but which that the dies are three shrin larger than the car part which One shrink used when the type made, another when Impact Value Rails High Temperatures impact tests elevated temperatures number rail steels, recently completed the Bu- reau Standards, showed that the was marked for all rail steels tested, and also was found 0.60 per cent carbon steel bar stock which ten- sile had shown secondary brittleness. The reduction the amount en- ergy absorbed the notched speci cen under impact mens, when brok the secondary brittle range, had been considered some investigators the phenomenon blue impact test than tensile but the results these tests, when type used make the die, and finally the last shrink making car part. ompared with the tensile results the entire temperature range (20 700 deg. indicated that the crease the amount energy sorbed manifestation the phe nomenon secondary brittlen more complete account vork was published the February number the Bureau Standard Jour? al oT Re arch. The revised simplified pra ommendation covering forged now available printed form, cording Division Simplified Pra tice, Bureau Standard Severa items are included the revised ommendation meet railroad quirements and mands. Copies the book can obtained from Superintendent uments, Government Printing Offi Washington, for 15c. each. The Iron March 17, tr are exposed to the ntiy solin laste) rin r ju h S per- ( com- etaré- bil it th die , Mas a cer- ure 1S be ct cale at- and PULVERIZED COA COMPLETE pulverized coal nace storage bins. The entire system system for firing melting fur- dust-tight. All smoke from open- naces, annealing ovens and ing fire doors therefore elim- boilers was installed last year the inated. iron and Promal foundry the Ewart Works the Link-Belt Co., Indianapolis. From the time The system was put without in- terruption plant schedules. The present capacity the coal prepara- receipt the plant until enters tion plant sufficient permit add- oven the coal mechan ing more ovens furnaces produc- cally handled. signaling and tion increases. The system de- electric control feature the distribu- signed and arranged that future ad- ditions can made without disturb- tion the pulverized coal the fur- — Real 662—The Age, March 17, 1932 SYSTEM SERVES ing the main coal distributing line losing any part the existing equip ment. Let follow lump coal from its receipt the plant the firing line. The incoming car over receiving hopper underneath the switch track and the coal dropped into this hopper. From there inclined steel apron conveyor car- ries the Link-Belt crusher the preparation building alongside the track. This crusher has capacity tons per hour. The apron conveyor equipped with magnetic head pulley take out the tramp iron before coal enters the crusher. The crushed coal, reduced in. lumps, drops into bucket elevator, which carries concrete storage silo 700 tons ca- pacity, shown the From the silo the coal fed gravity chute into the pulverizer Corner the pulverizing plant showing 60-ton signal board and 4-in. diameter Coal, after delivery the plant, crushed and silo. Coal preparation plant Three-ton pulverized coal bin, screw for = q t 7 ii — —~ 1 quip from otted neath there has The 60-ton -in. diameter crushed and plant screw for firing “kiln roller mill,” where pulver- ized and dried the same time. With the kiln mill separate dryer re- quired, thereby reducing the cost the preparation equipment and subse- quent operation. Air for drying the coal the pulverizer heated separate oil-fired heater and enters the pulverizer 300 deg. This gives temperature from 110 150 deg. the pulverized coal dis- charge pipe. Automatic control provided that the heater shut off when the air reaches the desired max- imum temperature. This can reg- ulated suit conditions. The excess air used for drying passes through cyclone collector the top the pul- verizer for cleaning and discharged outside the building. Because the use air separation the desired fineness easily maintained. Fuel Weighed Before Distribution Distribution dry pulverized coal the various furnaces and ovens storage bin, 5-ton blowing tank, (at left). powdered coal conveying line carried bucket elevator 700-ton storage seen behind the silo (at right). 7 5 exhauster and turbulent flame burner, used boiler (above). FRANK General Manager, Ewart Plant Link-Belt Co., Indianapolis coal is fed In ILERS, OVENS AND AIR FURNACE ispatching the furnaces ito 5-ton weighing mounted with weighto areriiratal accurately records the amount fuel _collectine lin yaral 1? thy made by means of a pneumatic cor A dust-collecting line, paraliel to the onveying line, removes the fine coal veying system controlled from cen- tral signal board the main stor- age hopper. The coal conveyed through 4-in. standard steel pipe, di- rect the various units fired. tion dust, which carried off cyclone ted one the furnaces. illustrate the vstem, as /E S S +} ith the the 5 x-belt j Ca- by a i@ er or 7 outed — | The Age, March 17, 1932—663 refuse; the boilers deposit the bottom the furnace and removed occasionally the immediately colored ligh and perfect control, avoiding any pos- with hand firing, only ofte eeded for furnace No. The fur- the manhole cover not attendant pushes electric but sealed. The entire transport system worked out for automatic operation the central signal board, the perator that coal de- sibility overfilling the hoppers red The spilling the coal. Everything abso- Types Burners Used presses button which releas lutely dust-tight and safe. The cost Three different styles witching valve pulling pen transporting coal compressed are used. The melting furnaces chain. Automatically differen air averages 6c. ton. all equipped with stream-line burners, Valves Give Close Adjustment Air quired for metallurgical melting. board, informing the No. open, Returning No. furnace, find annealing ovens are all equipped with from the main feed lin the hopper filled with coal ready for high-low velocity burners which give | “ =) - -+-——— - FOUNDRY \ ICK R j 5 | onveying Line 4 that additional furnaces may served without disturbing the system losing any part The coal-conveying line laid out existing equipment peration. screw feeder attached flame short conveyed by compre O} iir (15 pressure) and, the bottom the hopper feeds flame for starting and long flame for the coal the desired rate, positive- bringing the front the ovens and aches predetermined level controlled Link-Belt P.I.V. va- holding even temperature. Each the three 20-ton ovens has one burner; the ten ovens are storage bin the furnace, tomatic limiting device closes riable Spe ed transmission, for combus- valve and stops the coal flow. tion. the pulverized coal enters ame time third light flashes exhauster picked the equipped with two burners each. the central control board tell the air tream and delivered The three 200-hp. horizontal return- perator that No. furnace has been burner. Here the air and coal, tube boilers used for heating the en- proportions, are thoroughly tire plant are equipped with the tur- The system interlocked that mixed and blown into the furnace. bulent type burner, which gives the switching valves for drawing Valves are provided that give close short, hot turbulent flame suitable for from the main line cannot open adjustment air and permit precise this class work. The secondary air the pendant chain until the op- control combustion. This completes for combustion controlled erator the central control board the cycle operation. gate with atmospheric intake. eleased the valve. The safety man- Only small amount ash Aside from the convenience auto- hole cover each individual formed when burning pulverized coal. matic controlled operation, this system hopper also interlocked that the case the melting furnaces, making very definite savings coal can conveyed into the hopper this goes off with the slag and other both labor and materials. the an- Iron Age, March 17, 1932 +) | | li f nealing ovens, for instance, severa nstance, several number economies have been dation and ofte peration. ecause the temperature elimination hand firemen atio co: throughout the entire oven is uniform ; a7 an men 1s a Oleg ratio of coal to iron. sed castings can be placed in anv part re- ae 4 t On the boile rs, which are operated gardless size castings and more uniform for heat urnere oO S1Zeé and come out thor- f ‘ omy [for heating the pliant, the re 18 the oughly annealed. There very ron are important result. Very double labor and fuel and narked saving fuel cost. Former- aeg. the advantage more easily con ner with hand firing, these same ovens and above, the spout. also trolled heating plant. required 752 lb. fuel per ton the iron retai The system was installed astings annealed; now, with pulver- perature the longer than with Grindle Fuel Equi th u <quipment ivision ot zed coal, the cons hand firing per cent ought down to an average of 500 heats so far have come out minus 01 tograpt are published |} ninu Lograpns are puolisned Dy courtesy of per ton. plus five points carbon. Less oxi that ~ osts for the Business array injunctions for the guidance the business administrative dends and establish con executive was central feature address given recently before ervative dividend Chamber Commerce Rochester, Y., Harold Coes, manager the industrial department the New York engineering firm Ford, Bacon Financial Policies | DasIs ire 20 j ) ‘ t } } ing each important item that needs taken into ment replacement, setting consi eration appraising improving the condition one’s own industrial equipment replacement reserve fund enterprise erprise. from the depreciation charged into Markets and Marketing check performance against the the cost sale vants, where wants it, what Beware the evils over depart- quantities and what price. plan for their orderly replacement. organization and administration Ascertain the extent dle 7 too manv cases. assets are influencing production cost selling prices. lle capital issets must without return under and pushed and those eliminated. established base salaries; that both true costs the basis the developed and those which opera- the business neratio het denartmen : Vage rates and set up ar onomics distribution substituted. operation between departments, tween executives and between line and readily understandable wage incen Analyze the pricing and discount officials tive system, one best suited the short policy with view developing type business, its traditions, and for means for setting, establishing set means the character the worker and and regulating prices and discounts, rol ess and ned ult lower production costs Each <eepi materials and goods, predicated ping comparison Study employment tabilization one and prices methods, adopt such plan and are budgeted amounts—to resu The Company Organization lease working and its velop such methods the present tate the art and circumstances will eturn economical, logical or- permit regularize employment and en- ganization, one best suited the busi- Establish planning department protect the stable employee ness. Distinguish between line and plan production consonance with rives staff functions and positions. Select sales, regularize production, ble for personnel based the qualifica- vide adequate service the custome! ary air tions imposed the duties per- and permit the operating executive : 1OT ot waste o material an abt standing throughout the organization attain the predetermined objectives. better handling methods, better and auto- the duties, responsibilities, author- the depreciation and div aut the depreciation and ywer cost processing methods, elimi Sy stem ; < I ae nd poy ana estaD!l ha policy nation of unnece sary overhead, and ngs Establish standards management that will prevent diverting funds for the elimination obsolete equipment an- using cost records and the budgets renewals and replacements divi- and methods. The Iron Age, March 17, 1932—665 | — HEAT TREATING IMPORTANT HERBERT SIMONDS EAT treating apt considered auxiliary outside opera- view leads material handling inefficiencies the heat treating department which would not countenanced the machine shop. Such inefficiencies are not serious perhaps when one two pieces only for three purposes: multi-piece assembly are tempered. But they become serious when heat treating specified for nearly all parts the construction airplane engines. Many improvements the handling material through the heat treating department the Pratt Whitney Aircraft steels Co., Hartford, Conn., are described the accompanying article. this case the company has considered its heat treating integral part its production sequence and has raised operating standards ac- nkshafts cordingly. rly they rankshaft bearing urface gives fror more satisfactory results the t t nave a isual babbitt metal Room ime strength those Great care has been taken give high ide from bar stock, The metal used signing and equipping the heat treat bearing composed ing department. All furnaces copper and per cent electrically operated and automatical hen used rburiz controlled. Such features Fic neat condition the heat treating department established practice and not just for the picture. The Homo furnaces se’ down into the floor for convenience loading are shown the left 666—The Iron Age. March 1932 & ‘ ‘ | 7 ny bins +} rt it factory grait — Gry are irefull rts now made from the tubing nave | | } — J J — aoors, neignt Of hearths and 1o0ca hown in Fig. 4. [The furnace in thi lange t flange with the sn th it have been studied from the mat ise used for uppermost. This avoids warping handling standpoint. Recording arts. der the effect high temperature and vrometers have been Handling material through reat the give continuous charts the heat carefully arranged give minimum ing pal one these cycle. The neat condition of tl lost n The trucks which ar giving de tails of t} char partment may seen from Fig. ised transport material the larg struction. The loading hich shows electrically perated furnace are all f standard « on, T turnace na Homo furnaces set the floor with platforms the same height out make and the inspection benches the furnace hearths interesting tru ight. The low position the letail the design charges furnaces is for convenience in loading trucks is found in the platform . hown in Fig. 5 n 1 unloading. The top of the fur whi h, inste ad ot I eing made <¢ I { | T} ese, W h ( h are ot I cle 4 naces level with the platforms plates, the usual case, are held short space above the Experience has shown this est arrangement even though cylindrical containers swung from the trucks and lowered into the fur- juenching tanks, which are all the ated close the furnaces, are sup continuous circulating system and tank with its piping and overflow partment substantial savings labor and materials have been made here tipped over show the method lifting with dolly charger ble the operator to nm tne ir! fa ] harger under pot and ird into the furnace i rv + pre ti, luy and t} the } desigr the ig the harger position for lifting ictual ethod charging nin Fig. Here long har ised make possible place the pot the rear end fur handle may appear accidental, The Age, March 17, 1932—667 | | <a 4—An individual welded quench tank located close each fur nace. The oil for quenching kept room temperature circulating and col.ng system 1G. 5—Trucks the heat treating department have platforms the same level the hearths the fur naces which they serve curve the long handle the dolly charger important part the design which makes pos sible for the operator lift and place the rear the furnace 668—The Age. March 17. 1932 4 = 4 ai 3 $ : } a 4 = wi — é = ~ 2 4 Parts heat epartment from the hrough one then, after circuit door and her door take t again their place the machining sequence. group similar parts into the treating room contains the steel nalysis the parts and the cor- esponding definite temperature hedule for the tempering. the cam ring mentioned, irdening heat ed. Quenching is in oil at roon temperature and the draw tempera 350 deg. Piston pins, which 1620 deg. F., then quenching and drawing 550 deg. ing usually 1650 deg. Plating Economies Made plating room adjoins reating room and also Many are copper pla certain areas only insulate reas from the case hardening o thus keep them soft for l machining. The usual method ner is to fi copper plate the entire piece and then machine Largest Testing Machine Applies Loads 3,000,000 Lb. world’s has just been complet argest testing macn) ed in table level with the Baldwin-Southwark Corpn., ddystone, Pa., and shipped University California, ] al. long Ib. epts compression and load. tension ac- stroke and will The the columns is 10 ft. ft. long. Since the specimens minished machine pply loads 3,000,000 between table laboratory floor truck may drive between the and the specimen lifted tly from the truck body mns ting machine Table Machine Stationary itionary, foundations. The ram fastened this table. The cylinder, therefore, the movable element and istened lug extensions two lium steel screws in. diameter, long, threaded reads per inch. means long ronze nuts which are bedded cross-head (which carries als weighing system and, lower grips for tension testing) transmitted from the rews to the cross-head. being he loads are the threads, however, not pro- the load has types testing machin During loading there movement nut and screw ther. The function raise or lower the lower relative to one an- I tne crew and ross-head that the space available for testing may changed the specimen tested. mpression tests are carried out { en ne lowe ( ne l n while tension tests are veen the upper cross-head and around lower cross-head stands the floor line and tions toa ft. below The a § > —_ ae, = 4 which al irdene inutacture! nave reporte qin lity in gettin coppe ce lIALeLY ( rae 4 or tne He T eC} I tal is a rr: AS W hit Aircraft pilar H i I | tect n W n ‘ il a i! ne ‘ pper ( tin Telit ry I at ‘ lire! By + ‘ uct nin iayer! I Mr. hhe heen able how i aA ‘ Be the re ght the T ne fi equ re iT na oL tne hird I iT i for the applicatior } mit + ! Th permit presence i tance le tor tenso! eter lings, for examina incorporated ryt 1 for maintenar at I I naint ance er an iIndennite for application load increment, irt, y ++ fray it } ‘ pe pil in illa tne r \ ! ne or commercial ] i } heer nst ed ‘ iT 1 Chester, Thoug primarily i ft meet tne ent the American Societ essels, can used ist well any other welded constructi and for the examination and forging regula the plant, special ments have been made the Sur mpany handle outside work esign which permits one-man opera- steel, are harden orn eave anot $< 4 l- X-Ray Service Corpn., | > The Iron Age, March 17, 1932—669 aluable for refrigeration work, and Bun capable withstanding high pre ntroduced and temperatur The tubing steel tube fabricated readily equipped with all stan copper-brazing process. This product ird fitting This method fabrication insure me ( iT l tne . vall, the inside and outside diameter es al mad¢ ) ate I I ng a 1 . . being held ithin limits close tee triy I truce } nner te proud j ind freedom from scale the 1] > + the tube. The furnace temperature t 1i0us! thr ign a contr ied at « about 2100 deg. F., which we!] and the alloying effects are such ] na I i i tru } apart the product come During the forming operation, Fig. shows enlarged section fed into rolling ma- Bundyweld tubing, illustrating the ehir ere if carmed ove ta velded bond between the walls the ructure and showing the means with ant DV Lape . tube formation. The product lie reirigerator n the automot ind for graph the joint wher edges and I ete a vell a inv otner ibrati ductile the joint, illustrating the treatment, cellent bond between the cop per and the steel ling easy ind Bundyweld steel tubing, showing the double-walled structure 1932 March 17, ge, 670—The Iron APPLICATION ( ome together, showing the thin layer copper-iron alloy within the joint tirmly bonded the steel. Two furnaces are used work. Thirty-one strands tubing, varied lengths about ft., are fed and discharged driving rolls each end the furnace, the speed being approximately ft. the production each furnace about 3700 ft. tubing The tube mills run speed fur- one minute, and hour. minute, each the output ft. taking about care of The tubing cut straight lengths comes from the mills and then fed through the furnaces and cut into shorter lengths, after which formed specified individual shapes. coils the users. delivered lengths quirements meet re- One furnace used for brazing tubing siz outside di- cre Ne — the other used Thirty-one within the heating chamber which and while are means each furnace, tubing supported the heating chamber the steel guided through The heating units each furnace divided into four zones, The larger the two furnaces rated 157 kw., 220 volts, 3-phase, q 4 nace ae amet tubes +. 4 > fs ' AKING steel tubes the aid copper-brazing process under atmospheric con- trol gives excellent results ycles. Its inside dimensions are ap- the quality the product, ac- onsists individual tubes attached particularly trying conditions electrolene the Bundy Tubing the alloy tubes within the furnace. must met. The product plant Detroit foll smaller furnace rated 123 kw., similar sweated tubing, but volt, 3-phase, having has advantages over that type nside dimensions approximately in. high. fabricate and shows good made mounted the side walls and floor. higher temperatures these Electrolene made this producer trated Fig. rated kw., than ordinarily used air, contains total about per cent 110 volts, single-phase, cycles, the fact that the controlled atmos- these two output approximately 300 cu. phere protects them from oxidation hydrogen and carbon monoxide ft. hour. With the auxiliaries for reasonable period life. excellent reducing properties, hown the picture, the equipment Controlled atmosphere electrolene very effective and entirely automatic operation, electric furnaces consists largely economical gas use for controller quiring attention other than hydrogen and carbon monoxide, be- atmosphere applications. this in- casual inspection and ordinary ing supplied electrolene pro- stance the cost electrolene cautions the furnace operator. ducer which re-forms city gas with steam and heat. This device ment which has sists passing city gas and controlled amount steam through the chamber the electrolene pro- ducer approximate- 2000 deg. F., where the hydrocarbons (methane and illumi- nants) dissociate into free hydrogen and arbon. The carbon and steam also enter into reaction which iberates additional juantity hydrogen ind carbon monoxide. Electrolene pro- ducer for supplying controlled atmosphere copper-brazing furnaces employed Bundy Tub- fer int nrovimat fay ana ne he a ct) 4 an ir- ne ver re- li- , = 4 q The Iron Age, March Lubricant Must t} ntenar rins ‘ No? Ca rie re ric tT? eer re i n thre to one aa Itab grade re Lar ] eff. ‘ ( tne preterre ‘ | ne l ‘ nlied wy matte \ 4 ring manu ne large? ! led ng ae pn l \ ixnage or whe! 1 circulatir + ] entire ipon the method Loy ne operating tam ana } a vempera The lron Age, March 17, 1932 windage effect the revolving addition comments relating the use grease and oil, this second article Mr. Reswick discusses the essential charac- teristics good ball roller bearing grease. includes also interesting discussion lubricants for extreme pressure condi- ticns, rolling mill anti-friction bearings, and the development grease that provides greatly increased protection for bearings operated high speed and under heavy pressure. The first article appeared THE IRON AGE March 10, page 608. i re ( provi n ‘ ait tne rorm ol wick Lee ©) EVE vhen straight mine! hat The housing ball bearings complaints ant ricated with grease should may traced filled more than one-third full. When hich results not level higher than the center } bearin } re grease the peripheral speed n that tne use electri lipped with | il] d rolle: tremely large size, such used the necks rolling mills, the speed bearing with grea nt interval ind ta vel ot keeping dirt and water out 1s ver important, grea the lubricant bearings this ty} Roller Bearings Oil Lubricated rge size roller bearings over Specifications for Grease diameter, operated speed advan- Good ervice from ball and roll the proper grease used. greases should not used they break their constituent rves asa olant for the ° el ne S ausing e ol to sepa it from the soap. good grade ! complicated design 4 more economical than cheap grea for use expensive ball roller ation and leakage. The oil quirements good ball and roller bearing grease are enumerated contamination with the bearing, while high speed eral quality, the grease must eal suck and free from any injurious fillers and foreign abrasive matter. 4 7 | & ' | i «i f T? nents may have tendency dirt from the MAURICE RESWICK Chief Enzineer Pennsylvania Lubricating eitv and oft} Yr prone t nal t ed te? me? \ Iron one al nul ] Get I Conditions d at differer The cor i en? } «i Tree al Ci il e! tr nig ( i ( W } must not disintegrate drive ind roll Mill operat graphite, talc, pumice, rosin, fre d the rollers. ; ir-nigi mill HDacKIng The grea than lime base greases prope! earing elements and must not extreme any active free acids alkalis atures but will regain action acid alkali cooling, while lir base grea balls rollers and races, and conditions. The melting point rease must De tree trom uncombine | tnan t 17 t yont.« + Whether standing operation, ferred for the reason that the bearing apacit sticky. Also there should soap lather, while lin ase grea ize and the dency toward oxidation harden- are water repelling. bearings (rollers and races) the grease. The soft consist- for the fact that ready ner £ +) ) ne ¢ y ne + tained all times The Age. March 17, 1932—673 m perato! tarted increase t ist not corrode the highly polishe soda base grea may = 4 \ 4 Ba = j is ‘Pia 3 { ¥ \ approacn it quite closely | t grease are nevi ne Kener otte? eparate it and 1 nainiv on ;: Int f the ©) pecaus tnelr te nperatul iri a t are fiatter rie iter race, WNII¢ ne } d. and a ecause re rougn leakage Ol Volatiizatior t n iowet! power col! imptior vated temperature certall rreast causes channeling and leads nger life and easier lubricatior lili Mainlaln a Ca NADLE ¢ rea a la equipped with rolley hearing Ty } ] rit | ‘ i 15 ne, ete.. should be contained in the I mii il! fied lin The ments rene! na and a} ive a tenaency O out, accumu la Dase grease na yrreace rolline w tiny th, hal he ance of re er } ing tr a } Early Inspection Saves Labor castings while reciable part its cleaning cost. The inspectors are located just ahead the sand blast and ire paid bonus based the percentage defective castings this point while the ads and gates are still on. The cleaning labor the rejected castings naturally saved this method and other advan tages are claimed. The “green astings” detect more than per cent +} total number defectives > Brass Used for Repairs ECLAIMING worn machine parts first building them with metal deposited with welding torch and then grinding 11 many shops. One shop manager, instead using steel welding rod build such worn parts, has found that can use brass rod deposited with oxy-acetylene torch with con iderable saving labor. many parts, such udes, shafts and piston rod this manager has found that the use brass build slightly worn surfaces results prod- about satisfactory the } steel part Small Orders Billed Higher manufacturing loss small orders frequently overlooked and this especially true with the present reduced demand. recent check-up small orders, 674—The Iron Age. March 17, 1932 manager die casting plant was surprised find that was handling good deal unprofit able business because the small quantities now specified customers who formerly ordered large volume and therefore enjoyed favorable prices. The die equipment for the smaller orders was hand and paid for and first glance found difficult account for the loss. Further study items such cost handling dies, labor, and machine time during set up, supervision, paper work and billing, about the same for small order for large order and this meant that even where the complete die equipment was furnished, the small order, profitable, usu ally would have carry con- siderably higher unit price than the large order. Jigs Save Welders Time MANUFACTURER steel snow plows has taken much pains designing bench jigs for holding the various parts place for welding. These jigs has built permanent parts the bench and has arranged them that the various joints come convenient position for welding. Needs Bricks; Finds Sunshine FTER operating for nearly brick building with few win- dows, shop manager found need for some bricks and decided take them out one his plant walls. this way se- cured the bricks that needed and, incidentally, secured new vindow and more light. now contemplating putting many similar windows many points around the plant and thus securing excellent supply bricks. Customers’ Service Department MANUFACTURER chine tools operates tomers’ service department. Thi department keeps some twenty designers work the manu facturing problems tive customers. Work comes the attention the department the form samples and rough specifications. The usual job redesign the part from point view low machining cost and then adjust the re- designed part the customer’s requirements. Softens Nitrided Surface MANUFACTURER elec- trical equipment was recent- faced with the problem ma- chining nitrided steel part. placed the piece sodium potassium chloride maintained about 1500 deg. Fahr., and then, after allowing cool slowly, was able machine and afterwards nitride give its original surface hardness. Fast Production Reduces Stock Needs IGH speed equipment some times offers saving other ways than direct pro duction costs. manufacturer steel barrels installed equipment which enables him make from flat sheets and deliver customer’s order the fact, transform sheet into barrel and have painted and dried and the delivery truck allin one hour. This high speed production makes possible for him carry stock manufactured products and relatively small stock sheets. = = { 4 | I > FOR WORKS MANAGERS Steel Performance manufacturer steel tubing has saved himself efinite performance for the steel buys, instead specifying hysical chemical characteris- cs. Such performance specifi- ition has forced steel companies cooperate with him and thus levelop the material best suited his needs. This method uying usually welcomed the steel makers and applica- many kinds steel and uses. Acid Controlled for Cleaning cleaning pre- paratory plating involves amount acid used, the veight metal and the time re- uired. For best results the arious factors must carefully djusted. One plating plant has the cost the nickel lating brass parts the fol- wing procedure. The pieces dumped into open aluminum vire baskets and then dipped two acid baths. first contains per cent vater, per cent nitric acid and per cent sulphuric acid and second contains per cent vater, per cent nitric acid and per cent sulphuric acid. The iration the dip approxi- itely two seconds each bath. Vashing clean running iter. Plating Freezing assembling accurately ma- chined and polished steel parts sometimes happens that two freeze together making isassembling cult even impossible. Such conditions are met with the fit