The Iron Age 1932-05-26: Vol 129 Iss 21

IRON ESTABLISHED 1855 NEW YORK, MAY 26, 1932 Vol. No. Making ingenuity shown produc- tion managers and other plant executives laying out and equipping plant obtain costs that will assure market broad enough permit mass production well illus- trated the electric clock depart- ment the Electric Auto-Lite Co., Toledo. few months ago the com- pany decided that could equip plant unit for the manufacture clocks cost that would allow them low the price which any these clocks were being sold counter the time. This means that production costs the making clocks must far enough below the retail price allow, addition the manufacturers’ profit, fair re- turn both the distributers and re- tailers. clock-making department was laid out and equipped for economical mass production. The outstanding feature _of this the assembly department, for, without progressive assembly line provided with efficient tools for sub- and final assembly operations, mass production and low unit costs could not have been attained. as- sembling, work routed for the most economical handling, the system being very similar that employed the assembly line automobile plant. clocks hr. was established basis operation and the assembly line was laid out for this capacity. This production per day was attained and maintained for considerable peri- ods, and apparently could kept indefinitely were orders sufficient PRENTISS Cleveland Editor, The Age ANKEE ingenuity re- specter luxury products. The latest so-called luxury brought within the reach the masses the electric clock, which now being manufactured re- tail price $1. This feat was accomplished the applica- tion mass production methods. volume. Within days after decision make the clocks was reached the layout was mapped out, equipment was place and time- pieces were being delivered off the sembly line. Clock Cases Are Die Castings Clock parts are made two ma- chine departments. Worms, hob bearings, buzzer cores and some other parts are produced automatic ma- chines the screw machine depart- ment, and gears, gear housings, rotors and some other parts are made on punch presses the stamping partment. third department vided for painting. this, the ectric Clocks Mass roduction Basis and some the backs are painted booths and are air These, with the assembly department, comprise the clock making set-up. spray- dried Development the die casting dustry both production and product shown the use die castings instead stampings for clock The have exceedingly thin section only 0.040 in. thick. per cent the clocks the material. cases. wall rom have these remainder The back { to YU cast cases being ol plastic are brass and the supports for the back well the dials, are ings, these parts being too close the magnetic use steel. Steel parts are used the magnetic circuit. The gears and worms are except shaft gear, which Bakelite with linen base which helps eliminate brass noise Conveyor Belt Used Assembly The clock assembly department factory bay. The final embly bench, 180 ft. long the center this conveyor belt, de, which moves speed ft. per min., and which the partial- embled clock moves for suces des the bench are machines for the various a embly ope rations. As- embly done girls each side average operations lea assembly line fter the first piece, the gear housing whicn are assembled, starts the line. The motor assembly tied circuit permit the 7 F f D | 4 = 3 ) ) thr 2 g > > ) 3 | j af 4 y 14 en 155 we with other assembly operations. one side the assembly line are number assembly benches where sub-assemblies are made, these also being provided with machines for embling operations. ib-assemblies are made point rectly opposite where they the final assembly, and t ed tney ire set on i mall ¢ D enc! Common bread along the assembly and sub-assembly Hubs are staked gears, bearings plates and various other assembling operations are performed with foot- power, spring-trip type bench presses built the Taylor Fenn Co. Bear- ings are reamed size after assem- and small holes are drilled and reamed high-speed bench drill press built Adolph Muehlmatt. Numerous riveting operations are re- TART line for final assembly electric clocks. Special-type arbor presses for rapid operation are shown the table, the girl operating one the presses. the foreground are foot-power bench presses used sembling Arbor Press Speeds Assembly interesting tool developed the plant for assembling work, which has helped increase rapidity opera- tion, small hand-level-operated arbor press. This has round hole the bottom, line with the ram, for the insertion interchangeable fixture. Not only may different fix- tures used one machine, but any fixture will fit any other the standard tools. This press has adjustable stop, that piece pressed fixed distance the part number these presses are used for pressing shafts into worms and gears, pressing starting knobs, hands shafts, and other similar operations 1156—The Iron Age, May 26, 1932 quired the assembly, and most these are done tubular riveting machines equipped with special fix- tures, Some riveting done small Toledo press. Most the rivet: are steel, cadmium plated. Some hav- ing heads that are exposed are zinc- plated and some are brass. Making the Rotor Interesting methods are followed making the rotor, which steel disk about in. diameter with teeth around the and hole the center for the rotor shaft. one press operation with double compound die the piece blanked, large slug punched out the cen- ter and small hole punched the center the slug for the rotor shaft. The hole made punching out the slug permit the placing the piece arbor for cutting the teeth. After this operation the slug pressed back place. Succeeding rotor assembly reaming out the hole, pressing the shaft and grind- ing the outer diameter. The core laminations, which are made silicon electrical sheets, are stamped press with pusher feed and adjust- able length stroke. After cutting off, the pieces pass through the die into chute and are stacked lots 1200 more. The laminations are placed lower end the assembly line, with clocks ready for testing before shipment. the part assembled placed the belt conveyor the center and moves forward for the next operation. ( — f , q a a a Clocks, after being assembled, are placed racks trucks and are given running test for the coils hand, coil, and the coils are placed holders revolving table the assembly line. The Final Assembly Final assembly starts with assem- bling the gear housing the parts that make the gear housing as- sembly. This assembly includes drill- ing and coining operations, putting } bearings and assembling vertical and cross shafts. Then the rotor front plate and the two-pole assemblies are added. Inspection for tightness fol- lows, this being done blowing air the rotor, which driven speed 25,000 30,000 r.p.m. ceeding operations assembling parts the gear housing assembly include assembling contact brackets, alarm shafts, coil and cord dial, leads, Structural Changes Razor Blade the rolling and forg- ing per cent carbon, per cent chrome steel, such used for rustless razor blades, has been inves- tigated Zieler (Stahl und Eisen, Jan. 14, 1932). the difficulty had been shown lie the eutectic net- work where crack formation starts, samples 0.85 per cent carbon, 13.6 per cent chrome steel were heated different temperatures and quenched water determine the temperatures which the eutectic network reap- peared and ascertain how avoid its development. Sections from the four sides 3-in. square ingot showed that the carbide bands sur- rounding the eutectic diminished with rising temperature owing solution, disappearing 2100 deg. F.; 2190 the formation new, finer and more uniformly distributed eutectic was observed; and 2300 deg. in- cipient fusion the austenite the grain boundaries was detected. Cylinders in. long in. di- ameter, turned from the same ingot, were heated temperatures from 1475 2300 deg. and hammered about 1/5 in. thickness. 2100 deg. there was increasing de- formation the eutectic network, but Rolling and Forging 2300 deg. newly developed net- work became apparent, indicated its lack deformation. Samples from 4-in. billet from 6-in. ingot bon, 14.32 per cent chromium steel exhibited finer carbide structure lower temperatures forging owing the double working; well-devel- oped network was apparent 2300 deg. Test pieces reduced one-fourth 2100 deg. and then water-quenched from different temperatures showed very fine carbide structure 2000 then austenite formation, and deg., higher temperature fusion grain boundaries. dropped uniformly from Rockwell hardness 1700 deg. quenching which temperature hardness decreased very slightly. ove Evidently the eutectic melts slight- above 2100 deg. The re-forma- tion dependent the time the steel held this range temperature and the form the original eutec- tic. Finely divided carbides require longer time this temperature flow together than only partially dis- torted networks require. The form and alarm dial and hand the back. The back assembled clinching arbor press. Hands are then assembled and the mechanism oiled. The dial wiped and the gears are put in. The final assembly operation putting the mechanism the Leaving the assembly clocks are put test racks and are run for hr., after which they are placed cartons for shipment. Chrome Steel the eutectic constituent depends the type working, was impos sible destroy the network entirely broadside hammering the ingot, while thorough forging produced fine, uniform carbide structure. The tendency crack greater rolling than forging Here the trouble may result not only from overheating the material rolled, but also from insufficient pre- liminary forging break the net- work structure the interior the great care this respect because coarse eutectic structure the center the ingot. Thus forging 6-in. ingot of 1.1 per cent carbon, cent chromium steel in. square proved insuf- disrupt the coarse clusters The correct degree forging must determined for each size ingot examining the reduced section ascertain when destruction the network complete. Other experiments showed grain re- finement heat treatment su- the material was properly forged, the latter being necessary any event. The Iron Age, May 26, q ide . aft = Su- 3 - ed | SAND HANDLED AUTOMATICALLY UTOMATIC provided installed recently the steel foundry the Machined Steel Cast- Alliance, Ohio. move- ments sand handling conveyors 1] hr sor} ] controlled through conveniently ted control Another inter- esting teature 1s the measurement ol sand weight order make sure the same mixture maintained each batch. Hopper type for weighing are connected and handling system. Sand handled with grab bucket tored two large hopper type bins the sand storage department. these for foundry sand and ther for core sand. The same aut atically operated conveying equip ment handles both grades sand from these bins storage hoppers above sand mixers the foundry. Sand passes through gratings cement floor the storage room bins into hopper and short apron conveyors, one for each bin. From this conveyor the sand discharged Iron Age, May 1932 PRENTISS Cleveland Editor, The Age ipon continuous 18-in. belt con- veyor 100 ft. long that carries the sand the end the foundry where the mixing equipment located. This conveyor well the two hoppers and apron feeding conveyors are lo- cated concrete tunnel. Leaving the conveyor belt the sand delivered overhead storage hop- per tons capacity located above the sand There are three these hoppers adjoining each other, one for foundry sand, one for core sand and third for reclaimed sand. All equipment for sand from the time leaves the bins the sand storage room until livered the overhead hoppers au- tomatically controlled. Reclaimed sand dumped into bin one side the sand mixers and passes through hopper apron conveyor be- neath the floor; thence means bucket type elevator reaches the reclaimed sand bin. This part the trolled. Beneath the three (for foundry, core and reclaimed sand) hoppers weighing hopper. operated gate beneath one the hoppers opened and when the scale dial shows the required amount sand the scale hopper, the flow cut off, and the same way sand weighed from another bin, thus assuring proper proportion new foundry and reclaimed sand core and reclaimed sand the batch. Then another hand operated lever opens gate which dumps the sand from the scale hop- per into the mixer. Sand mixed standard revolv- ing pan type mixer which auto- matic unloading device been added. When has been ground, plow within the pan diverts the sand belt conveyor beneath the floor. This discharges into short elevator, which turn delivers into boxes cu. yd. capacity, which overhead carries the foundry floor where the foundry sand used fac- ing sand. case the sand going hoppers that supply the snap flask ENERAL view the sand handling equip- ment. The inclosed con- trol panel the left. = | " 4 ‘ department core machines, irried steel buckets having end rate for dumping. The other han- dling boxes are wood. The control the mixer and its unloading equip- ment either push button the machine the control panel. second sand handling and mix- cated the side the one and scale for weighing, but serves smaller mixer which not equipped with unloading device. This Simpson mixer. mean through which the sand delivered into the overhead hoppers the flow sand may switched from one the other set hoppers. The automatic control system for operating the sand handling equip some the features and the design the control panel. ing feature the panel that 100 per cent fool proof. All contactors and relays are the back the panel, leaving only control keys and push buttons the front the ARGE sized molds are ram- med with moves tracks two parts the foundry, be- ing carried track the other overhead crane. par The attendar move that will cau itactors and relay inclosed and the devices + + nterlockin keys handles; the one the right illustration the control the four outer keyholes other only the two center Explaining right, which are used for throne) nrougn sand that goes mixer, one for new sand, core sand and the third for sand. start the system tion the main line switch board turned and then ter line contactor is closed the push buttons shown The proper key then conveyors start and the } i nd ré T pa IStpr ir co f tu largel one for le eciaimed of sand that being moved delivered int« the proper bin. There are three light bulbs above each control keyhole red, green and amber lights, the showing that the bin full, with red AND mixed amounts that are controlled auto- matically weight. The sys- tem, which includes bins and conveyors noteworthy arrangement, directed from foolproof control claimed sand well molding and core sand come under the automatic regime. The foundry specializes large thin-section castings steel. Two Sandslingers are in- cluded the equipment, one them for core making. Close watch humidity conditions the foundry prime factor operation. ber tha being filled and the green that empty. The operator to watch only the green light When bin full the conveyors are shut off automatically limit switch the bin and the system starts auto matically handle the other grade In case it desired to stop the flow one grade sand bin the key turned “off” position. This stops the feeder the sand upply hopper, but the conveyor belts not stop until all the sand the belts has been delivered the hoppers the end the system. Should the system handling, say, foundry sand (Concluded on advertising page 20) The Iron Age, May 26, 1932—1159 3 3 j 4 ted a l is Ws 2 in g mn the 1ed in n ind pan hit and t hy an un yi Cs. at tne nandiing ind opera or. back Or, ma DY one the right. rted, the ac- ask 4 | “ay ‘ a - Are Becoming Factory ely coming ex- another and harass orderly con the authorship Thomas Foster, participation the fac- truction. chairman, National Bridge Work the house thing increasing Long Island City, New York. ly thi way ] hnildine . many ings have been supplied the fac- companies have spent considerable acnieving tories for mere fitting into the whole. ums money development work, what long time since, the case and two the country’s notable in- ile, and for that the ordinary and even average build- dustrial corporations the second ) ; +h oe } yter into 4] hings that enter ing, there has been much call for the line manufacturing might men life. The building industry expert cabinet worker joiner. tioned the moment actively centage Whole features permanent parts studying the problem large way, the building have been delivered even after expending round sums actory. say the site ready for immediate incor- money. Individual effort seems poration into the building, though the unabated and there can ques- the and fitting costs still are commonly too tion that results will continue some approach made high. Now the demand for more hown and home design will take manufacture the shop and less new features. Also building costs monev the site. The procedure, word, will gradually receding for some been spent experimentally breaking away from tradition. time come. Apart from the general and In. will employ methods, processes, ar- deflation the real estate situation, ention has not been idle. and manv rangements and appointments hitherto the movement can mean nothing more near thought not feasible, with harn clearly than that existing dwelling Succe ing advantageous factory practices. houses will suffer depreciation the ing direct proportion Steel bound have larger plae light that more will obtainable ure traditional the future home. Articles which for dollar the new structures ethods. scattered effort all through wide margin than represented the individual will give way 1926 and 1927 were one the earlier the older construction. ale enterprises. The indica- manifestations the several inde- One those who have gone long tions are that not only will the stru pendent movements then under way way applying the factory idea ire different, but the work hape the use steel house residence building Mr. Foster, al- will handled new way work requirements. Since then the ready referred to. Others have em- ibly lead radically conspicuous addition the literature phasized the importance unit man rganization the building the subject has been the six arti- ufacture parts, turn out quan- elimination the sixteen cles appearing THE IRON AGE tities duplicate items relatively teen trades which stumble over August and September, 1931, under few sizes, designed that variety design Thomas Foster exterior wall slab that light enough put units ft. wide and the height the story. The slab offered waterproof, fire- proof and affording good resistance the flow heat. One Mr. advanced designs (At Right) provides for applying factory-made parts the ordinary fireproof building, the drawing showing the carrying the floor the covered beam. 1160—The Iron May 26, 1932 hay Hn work)? 4] tudent E A aA “A i & Interview with Thomas Foster eT, Olé rk, tions the few units. How ever, such have commonly been con- fined the framework, merely re- placing wood frame, for with one light steel members and providing otherwise for the usual methods and materials for the com- the structure. this, tra- lition has hardly been upset. has been not much more than substitution. ral Mr. Foster’s idea that not merely the framework, but the closure its completeness must factory fabricated. would parts walls and roofs finished both the outside and inside Precision the factory will make the tractor-derrick will the trument for erection. His idea that the extent which the shop will control subject expansion the art learned. Larger and larger sections surfaces fully completed will well constructed that fit ly ting will b a matter of little or no idjustment. The shop-fabricated house, should emphasized fairness Mr. pearance first olds, and can obtained with al- most any suitable building + “Convenience also prime fact adds, “and that matter de- sign and not materials. must try find materials that will improve each square foot floor, wall, parti- tion, and roof without adding their ‘ost and with the possibility low- ering it. The problem select the materials that will sufficiently consideration, ACTORY fabricated homes are the answer demands for lower cost them course will incorporated current ideas Style, arrangement, color and con- Modes dwelling places construction. popular designs and equipment. venience have become paramount requirements. have departed farther than ever from the static. Ingenuity will utilize standardization and yet secure individuality. The selection building materials will through cycles experiment but steel will likely have expanding use general house construction. The whole development represents casting aside traditional concepts and practices. hat can combined floor slab. Sketches them are given cost r the poorly n accompanying illustrations efficient homes now built such larg: The floor slab measures in. from quantiti for sale low the finished ceiling the finished must approach mall floor, resting steel beams ft. lem without prejudice both apart, the beam encasement. ise materials.” beam sections and the thinnest and reappraisal the need that holds the concrete the slab but will suffice quote Mr. the finished ceiling and plaster the effect that there little required. Any type finished flo need for cellar today. used. The bottom flanges small house, eams exposed the ceiling may date the heating apparat rative just beam and may for winter storage accommodate indirect light pleasant prospect the exterior and interior necessary foot pace proof against leakage. the cost, and tion, Mr. Foster points out that ‘ for a car cast in the ice of the nation fro beginning and, incidentally, lends itself functions the home, great variety color treatment from the weather, fire and vermin, to ise of enameled tee] heets obtain nce and privacy and abl attractive shades that would provide beauty, must kept make for pleasing exteriors. Out Mr. Foster’s lies proof foundation which may f The Age, May 26, | = : = i / 7 3 2 > + § 4 4 ect | Foster wall il ne I Y in. to 6 If Ur l lab ft. wide and high the room uld weigh about 600 to 800 Ib. He ¢ Imate that such a lab with waterproofing would cost not 60c. per sq. ft. place. has igned partition slabs, delivered the hed both ich slab roor } rht wel er 170 lt i! Monel Metal Shaft Unusual Strength MONEL metal shaft in. diameter and ft. long, strong er to lift a Na le eature d played at he rece t York Motor Boat combine number unu properties, with immunity rust either salt fresh water. Weighing 1534 the shaft forged from solid monel metal bill in. diameter weighing 2046 and then machined. Its physical properties, which longitudinal and transverse tests, indicate yield point 76,310 1162—The Iron Age. 26, 1932 ] an a columns. engths, se ing The cl 1) uu as of ARTITION slabs wide and ft. high were used the office building the National Bridge Works Long Island City. Two men are 4x9-ft. slab which has just been cast and still green enough bend under its own weight. comprehend the instal- wiring the slabs. the thinness the wall slabs, the columns hus affording space for heat- umbing piping within the Even the chimney vis- delivered in, say, three into position means derrick. Somewhat larger than ordinarily the case follow from the use the walls and partitions. admitted that there likely in. and ultimate break- strength 100,875 lb. per sq. in. considerable prejudice again the shop fabricated house but one only consider the changes throug which the automobile has gone lieve objections will disappear after the other. And the accompany ing illustrations are offered chitect’s study show the results different combinations and designs wall slabs for the same floor plans two-story six-room house, including porch one end and garage the other. “We not yet know,” says Mr. Foster, “the possibilities better living conditions that the shop fabri- cated house will bring, but know that all labor-saving devices have added the value the one that labors, have shortened his hours and increased his comfort. The shop fabricated house will exception the And Mr. Foster in- clined believe that any early real- ization the practicability the factory-built home would prove tre- mendous impetus toward getting the country back level normal ac- tivity. for these high strengths, showing 27.5 per cent elongation in. with reduction area 57.3 per cent. | — q design ation na partitl the variety, ing ualizes of the room would ubstantially sound-proof = > his presidential address October meeting the American Iron and Steel Institute two years Charles Schwab emphasized need “being able evaluate true economic facts our busi- departed from his frequent agricultural terms and ex- ressed his beliefs the means tabilizing the steel industry nau- terms, and said that was believer that one the best vays assuring progress even eel let the cost sheet our are many forms cost eets the steel industry, merous, perhaps, the degrees mpass; and some are useless executive and the operating lost his bearings. cost sheet for pig iron, for in- ts, for coke, for coal, for rolled roducts may correct the last cimal reflecting the cost that product for the past week, month, and may include every de- tail labor, supplies and materials ntering into the manufacturing cost, yet that cost sheet may prove poor compass for guiding the ex- utive, the sales manager the op- rating manager. Mariners compare their compasses vith the true North and make their adjustments accordingly. Cost Figures That Executive Should Have executive steel company hould able glance compare the actual cost shown the cost heet for each his prime products vith what should have cost that month’s prices and analyses raw naterials, that month’s capacity inder operating conditions. The ual practice compare month’s with the cost the preceding ionth, the same month year ago, with the cost some other plant. Such comparisons are not good busi- where metallurgical operations ire concerned. “The Comparative Cost System” Frantz, now vice-chairman the Rolling Mill Co., back 1911, when was general manager arative Cost System RALPH SWEETSER the iron steel in- dustry common prac- tice compare plant’s costs for given month with the costs for the preceding month the same month the pre- vious year, with the costs another plant. Similarly, customary omit charges for depletion and depreciation raw materials until the final balance sheet the company prepared. These methods, according the author, are not con- ducive good business. Out- lining system cost-keep- ing for blast furnace plant, which, however, can ap- plied other types plants, explains how “true” costs can ascertained. His ex- position divided into three parts, the first which pre- sented here. iT I ut rinter nt of Steel Co. Mr. tok how pig iron cost were compared with one Soon learned that the petitor’s cost was for iron furna making only iron blast furnaces, each making lots of several different kiz of ir (Bessemer, foundr and mal during the same Stee ndustry i t neet ind che lling re greatly at ituation questior is, “What would iron rythin ked out should?” That question was inswered until after the World War hen found for measuring the capacity blast fur- I { ind the produ vy of a fur naceman, and when alue per cent reduction the asn In COKIN Coals From pig iron, the comparative cost system was applied coal, coke, and even ingots. Based the princi- ples metallurgy and cost account ing, the comparative cost system can applied any branch the steel industry, and also other similar in- Description System Limited Pig Iron The comparative cost system for pig iron only will described here. Pig iron usually intermediate product steel plant, spite the fact that the origin pra ] ] } tically all the steel now being The true cost pig iron seldom shown the cost sheets steel com panies, because the manufac cost the pig iron does not reflect its proportion the fixed charges the accessory plants that provide the raw materials for the blast furnace, such the coal mines and coke usually the fixed charge are cluded only the balance sheet the final the corporation When, “vertical operations,” the heet for pig iron does not flect the cost depleti and depr ciation raw material but these tems are included the lump sum for these account iter a manufac turing costs, then the true cost the iron not the execu tive who what the pig i hall be to other d irtment ket those rare where the iron cost sheet ems ide difference between that cost the cost pig iron integrated lant especially tru n paring costs of steel plant lo (Concluded on Lg 1199) The Iron Age, May 26, 1932—1163 at ha = . one ; of ol ling tter bri- dustries. ao ices : one urs hop tion A eal- the tre- the ac- 5 4 ‘ All-Welded Switching Locomotive DEVLIN Engineer, Industrial Locomotive Division, General Electric Co., Erie, Pa. | YOR witching ervice at Bush 4 New York, there was lilt ently completed the Erie plant the General Electric Co. seven The mechanical portion, in- cab, underframe and trucks, ited from and plate Bolts and truck frames this 60-ton Diesel-electric switching lo- comotive are welded structu- ral shapes and plates. The underframe fabricated beams and plates. The motors are stalled all-welded truck ave been used only for those por- requiring occasional removal The truck frame consists essential- three members; two side frames in., 151-lb. girder beams with 22-in., 108-lb. girder beam serving the bolster. The bolster beam welded directly the side members, frame = ‘ | Iron Age, May 26, 1932 the joint surfaces being reinforced with heavy gusset plates and brace plates. All welds are continuous and, except few minor points, all welds the truck have been made with type heavily-coated electrode. Load carried the journal boxes through double equalizer bars located either side the girder beam web. transmitted each bar through four helical springs. The platform underframe has two 14-in. 100-lb. columns for center sills with interme- diate and side sills 6-in. channel. The engine mounted directly these center sills. For end sills plates are used, deck plate extends over the entire plat- form and attached the longi- tudinal sills intermittent welds 10-in, pitch. End plates are attached %-in. continuous welds. Body bolsters are attached all sills continuous welds. framing made 2-in. tee sections with continuous welds all joints. The side and roof sheets are attached welds 6-in. pitch, except the outer surface the sheets, where, order provide water-tight joints, continuous welds are employed. will noted, the side sheets are placed inside the framing. This per- mits tying the edge the sheet two places, the intermittent weld the inside and the continuous weld the outside. addition this, the backs the tee section, projecting through this manner, produce paneling effect the cab wall and break what would otherwise monotonously plain surface. ‘ — \ AS ~ OA SLAG YARD BLOG SLAG BREAKING PIT : ~ = 0G = 2 = PL atTroams = =— i > > id, ] il] q de ie Seto hearth plant No. the Illinois Steel Co. South Chicago. New Steel Plant South orks, Chicago, Includes 640-Hp. Waste-heat Boilers new open-hearth plant The furnaces have are four 10-ton charging the Illinois Steel Co. hearths, measure ft. outsid the pouring side the building uring Ol t South Works, Chicago, consist of bri kwork and are par 1103 ft. are four traveling ranes of 70 ft. : z fourteen 150-ton stationary fur- in. center center. They pan, each 225-ton naces, with provision the pan bottom type. hoist and 50-ton auxiliary. Stee! for the installation one addi the tapped into 150-ton ladles. There nal furnace. ft. wide 1682 ft. are four pouring platform The capacity the fourteen units in. long and the pouring side Fourteen 640-hp. waste-heat boil estimated 1,600,000 tons in- wide 1715 ft. in. long. The ers the horizontal fire-tube type, per annum, sufficient for the charging side served two travel- each having 7960 sq. ft. heating needs the wide flange beam mill, ing ft. span, each hav- urface and 460 sq. ft. superheat described the issue March 1932, ing 150-ton main hoist and 40-ton ers, generate steam 275 per page 541, and the new slabbing and auxiliary. Hot metal supplied plate mills the South Works. 100-ton capacity ladles, The charging side the mixer (Concluded advertising page 22) The pit side the South Works open-hearth units served four traveling cranes 225 tons capacity. The Iron Age, May 26, 1932—1165 or es us A = elative Wear Metals Due Abrasion WEISS Link-Belt Ewalt Works, Indianapolis, Ind Wear Metals” dis cussed Louis Jordan, Wash- ington, Mechanical Engineer- ing, Volume 53, No. This subject most interesting one all manu ENERAL scheme facturers and users product. The and close-up de- users product are familiar with tails the apparatus the results wear and know that for determining the wear reduces sections, resulting comparative wear reduction strength value metals. dentally, wear renders equipment made for precision work valueless its effectiveness for preciseness lost wear the parts progresses. Mr. ABRASION TEST VALUES OTHER STEELS AND METALS Jordan his article discussed wear Rockwel Valuc and the combination the two. reheat The Link-Belt Co.’s interest the ‘arburized—one reheat wear metals was induced primarily Carburized—one reheat larly for power transmission chain i—reheat suited and the type treatment 60-C which should applied order obtain maximum wear value Comparative 1923 Hayward, one the Link- Belt Co.’s research engineers, com- menced his investigational work and draw 1.907 was decided that time that that time disclosed the fact that 1200 1.341 but little information was available Comparative covering this subject. Consideration Wear was given the manner which urfaces would abrade. Where two 1.038 cooperating metal surfaces are sepa- rated film lubricant sufficient- Camparative adequate withstand the bearing Brinel Wear Val pressure, wear occurs. the 1.239 ciently spread and dimension less than the thickness the oil film, the 1.804 foreign material will not abrade. the presence abrasive material thicker than the oil film, the metal surfaces will abrade. the subject abrasives disclosed that the abrasives wear non-uniform due 0.549 nized that must have uniform Age. May 26, 1932 4 4 A . 4 J ject nu- hat ha ent as lost Mr. ear ion, the rily icu- ain est ent to nk- and the order ascertain the material best suited insure maximum wear value minimum cost for power chain purposes, the Link- Belt Co. developed the apparatus described this paper, which was presented the joint meeting the Materials Handling Institute and the American Association Detroit, May low-carbon steel was used the comparator material. Comparative wear values several metals are reported. attack and that must ive uniform material serve Finding uniform lap was ents were not uniform the rate eir attack due glazing over surface. Experiment proved that rotating machined cast-iron dough- it-shaped disk, supplied with fixed amount uniform abrasive the presence fixed amounts water, irnished uniform lap. Water was elected account the thinness film and its ability keep the mo mperature uniform. aped disk was rotated speed vhich would not build centrifugal tion point which the leave the lapping disk befor mtacting the test specimens, Selection was made uniformly zed abrasive, which would keep turn- over itself and which would merely scratch the surfaces being Thi irts being tested frosted appear- ince, indicating that the abrading ction was not that cratch but that was more turbulent action. The abrasive se- ] LUOTI, action gave the cted was mesh Crysto decided that th | weight under fixed pressure per uni area should the measure istance the material the abra attack. The comparator material vas next ascertained and this was dis- Key steel, 0.08 0.12 cent carbon, and all determina- which appear part thi aper have been compared with the ney teel. \ cle cription the ae hich a especially develop d tor tne ipra tration which enera heme and tt close-up detail Ol gray iron disk “A” rotated indicates the circular one pound 1.E.N 40 the mate eight are rvide tion. The hown actuated for ive flow The flow trolled from water disk tion unifor disk the erials being The type hown } no + rai o flo > 1 f +} 1 +} nv! tard ted I nea TY I t Wear Valu ved raw ©) q i 1.410 Oil que S00 draw 1 \ ved 1.3 Oil « nel 1.837 Oilgq l wy 1.236 + ) Ww 1.483 I iraw 1.577 sof raw 1.331 1.412 i 1.@58 ( 1.639 1.540 © lraw araw ira 19° 1 ] a iw Oil a i) ju ood q 4 ( pus ; id W As¢ t | a project« ring rea l prevented rotating with means V-shaped nife radi the lapping paral | h a diagonal of th juare te \pproximately 1400 determinat ract illy all existing mat ils nformation listed + rane aiue i ] j ar at 4 ‘ d } Ke ore a For « n 1040 steel received from the i 1 Br neil hardne ot lob | (¢ ided on tge 1180) The Iron Age, May 26, 1932—1167 ABRASION TEST VALUES HEAT-TREATING STEELS tS 1.7 1.4 $77 Oi) quencl NO \ 1.88 4 r k lis 44 > nce - ~ hat t it n orde! load adistribdu- were cam 3 + < ia t 1e less ne Wate Wa ( the the lubricator “D” and the leansed ccumulation I the lapping medium. abraded. der hat I specimen the og- + ‘m L-1n juare 1 order to pr Method Flash Welding flash welding difficult and what current does take? briet terms the flash weld- ing two sheets consists hold- ing the sheets butt position and slightly separated space one end which little wic than the other. current 1500 amperes volts then turned and flash started the narrow end the opening. This flash quickly spreads throughout the entire length the joint and held until the edges reach the proper welding temperature. this point the electricity turned = y sheets are then moved ther with a quick positive mo- tion which squeezes out the metal the initial contact the edge: form ft Lead > aon rorm two one on eacn side { } } or the joint anda also rings to tner Dpeneath these beads the soft | urbed I etal of the hee ot the age This trorms a tected l emobdrittied weld ich are hard nush with the heet surface leave inner bea 7 ing and already ex- I ned <¢ nnot aet out de and hich ct 1 tronger than the base meta the sheet Heat Treating Aluminum dificult heat treat aluminum alloy castings? While heat treating alumi- num alloy done principally for Iron Age, May 26, 1932 HAT company makes auto- matic oilers for punch press work? Who publishes “Industrial Furnaces”? How can maintain the price standard steel con- tainers the face competitors’ cuts? Who makes long silicon steel strip? These and many similar questions have been received this department and regret that the problems space policy prevent including the answers these pages. However answers have been sent direct wherever possible and your question, too, will answered either letter this department can find its answer. Please address Forum Editor, Iron Age Publishing Co., 239 West 39th Street, New York. feature appears bi-weekly and offered clearing house for everyday problems the metal working industry. The answers presented are not always endorsed Tue AGE editors. work, have found con rable success its use our jobbing foundry. Our practice heat treating the general sequence familiar the heat treating steel. We, ver, soak the aluminum part the high temperature for longer time than would teel. quench oil and then llow the parts cool slowly over 300 deg. F. The ac- tual work of heat treating alumt- about num more difficult than the case steel but believe that success the person first try- ing this heat treatment will come only the many factors have been adjusted actual experi- ence. have been able in- crease our tensile strength per cent and get nearly twice Welding Alloy Steel How does the cost weld- ing 18-8 alloy steel compare with that welding straight For true comparison specific cases would have taken the relative cost varies with the thickness the material and also with some other factors such whether the welding produc- tion work the field. general way feel that the cost welding the alloy would about one and one-half times the steels. both cases the welding time approximately the same but the materials used for alloy steel welding cost double and fre- quently treble the cost carbon steel materials. heat treatment often necessary with the alloy when might not with the car- bon steel. €;. A. M. — Nitriding Difficulties trouble with spalling parts after nitriding. there any way overcoming this? have had the same trouble and believe that nearly all con- cerns nitriding commercial basis have had this trouble. due decarburized surface nitriding steels during the heat cycle. have found that ac- curately controlling the tempera- ture the furnace can reduce this decarburizing negligible percentage. often difficult get the proper control fur- nace the low temperatures used for nitriding. not know any way however completely overcoming this difficulty. — a — —— —— Cracks Deep Drawing How can small cracks which frequently appear corners deep draw work such steel window casings and refrigerator parts? Most every company ences some trouble developing new deep drawing work. The most obvious answer this inneal the corners where cracks apt occur. this with mall gas jets arranged play the metal just before enters the severe draws. Another cause the difficulty may the design dies. find many cases where difficult problems are en- countered that slight alteration modification made our mas- ter diemaker will turn the trick. Cracking corners sometimes avoided increasing the clear- ince between the die surfaces that particular point that the metal free flow naturally around the corner without undue tressing. Other expedients are ise grease oil, the use more rigid presses and the divid- ing the draw into two opera- tions with annealing between. 18 Location Stockroom room the best way for small manufacturer handle his raw material? (This the second appearance this question, the first answer appeared No.7.) opinion, small manu- facturer should all means cen- tralize his stockroom for the fol- lowing reasons: central control; reduction inventory; small- FORTUNATE factor the present business unrest the lack resentment. find that our employees recog nize that the present situation world-wide and that are making every effort improve conditions for them well for the company. believe that spirit loyalty and under standing between employee and employer can now developed never could under boom conditions and sure shall emerge from this period deflation better fortified meet competition and serve industry. —Mr. MacMorris, Factory Mer., Skayef Industries, Inc. Hartford, Conn. personnel required room service; less filled duplicate bins j c 7 7 closer check the inven- Lubricant for Piercing What the best lubrication use small brass and cop- per piercing dies? the cold piercing steel plates with hardened die and punch, the use white lead lubricant was found satisfac- tory insofar the operation concerned but the objection white lead that more less liable produce infection mild scratched. Several plants have been successful replacing white lead with lead oleate drawing compound which has superior film strength compared with white lead solutions and does not pro- duce any physiological effects the operator. the case piercing brass and soft copper terial, while the operation not severe when steel pierced, the lubricant used on the dies and punches must sufficient ad- hesiveness to prevent “pick ups” the die and punch, which most cases are evidenced by the copper-plated appearance ot the tools For ordinary operations, the use of a soluble drawing com- Ol pound combining percentage graphite recommended For severe operations, extra film strength lubricant such lead oleate type recommended looking the prices steel pipe and tubing Tut are given. The schedule complete for diameters and kinds pipe with discounts each classification. How can figure prices? Co. Deduct the discounts from the base price 10c Ed. The Iron Age, May 26, 1932—1169 As — q £ (l= 4 ré as & as d i ice a q re- on Oy ir- of rts n y 1 ble on eat 4 ice ble ur- sed ely | é 4 Heavy Lathe Removes Metal Rate Tons Hour faceplate. End thrust the head- ingsten-carbide too claimed for thrust washer. illustrated, which built wide and ft. long; the maximum Schiess-Defries A-G, distance between centers ft. The Germany, and being ways are chilled cast and are the United States Kauermann rectangular section. Openings the Fountain Square Building, Cincinnat Fountain Square Building, bedplate facilitate chip disposal and machine driven 150-190 tray-shaped bottom collects any oil direct-coupled that drops from the guides, thus pre- two carriage venting soiling floor and founda- which carry front and tion ind rest, and tools can nto hown the close-up view the headstock end. These carriages oper- of t » hed slate ha t+ the the late the left ate independently each other. Lon- ne - tock ae nown, an arrangemen ritudinal feed is obtained by means providing rack and pinion, and the cross feed means gears and feed screw There are changes each; the longitudinal feeds range from 0.0135 0.24 in. and the cross feed from 0.006 0.015 in. per revolution the faceplate. The two front slides with their ympound tool rests have feed and each accommodate three different tools, while the rear slides ground teeth, and the first case-hardened alloy steel nion mesh with the facepla ring ipported bearin the headstock drive, attention has been given lubrica main spindle lubricated counter-shafting, whi revolves ball bearings, and the haft journal-bearings are lubricated eans automatic oil isible delivery. All gears ontinuously flooded with lubricant The faceplate, which in. lameter, is forced and crewed to j the driving spindle. prevent any icking faceplate dogs when der pressure, the dogs are fitted with locking device consisting Six can operated simultaneously The slides and the ferent tools. rests are made steel castings. All operating controls are central ized the carriages within reach the operator his working position. For rapid power adjust ment, each carriage provided with integrally arranged motor. These motors, well the main driving motor, are controlled means push buttons. The tailstock massive con struction and has spindle in. diameter. The maximum weight that can placed centers said the tailstock when under pressure, locking device consisting pawl engaging rack inside the bed provided. This locking may ob- served conveniently and action checked the operator. The mechanism for advancing drawing the tailstock spindle ar- ranged close the center permit convenient observation and manipula- tion. The tailstock has hand-operated traverse but may traversed power when connected the slide. Two steadyrests with adjustable car- rier blocks take the weight the Safety devices are provided make operation “fool brass plates are mounted near operating controls facilitate attend ance. The total weight this lathe tons. The main drive 150-190 hp. variable-speed engages rack cast motor, arranged shown the upper view. Iron Age, May 26, 1932 — _ A i The motor mounted the exten icces to tne gear ine pindte in. diameter the front jour- nal and revolves gun metal bushes. ¢ 4 § ? Universal Grinder for Variety Light Parts grinding wide variety light parts manufactured smail ots, well for use toolrooms, the Landis Tool Co., Waynesboro, Pa., offering new 24-in. self-con- tained universal grinding machine. The machine entirely motorized. The traverse drive motor, rating, mounted entirely within the bed, protected from grit and water. 1/6-hp. work drive motor the headstock and the 1-hp. grinding wheel drive motor the wheel- base. Control all three motors from the front the machine. The water reservoir integral with the bed, which box type. The work carriage traverses and flat guide with chilled sur- faces; covers each end serve keep grit and moisture the guides when the carriage traversed either its extreme positions. The drive from the traverse motor to- ward the front the machine means flat leather belt; taken through positive clutch the final point application, which rack ind pinion. Three traverse speeds are obtainable cone pulley ar- rangement the side the machine. lever provided the front for disengaging the clutch when de- sired traverse the carriage The grinding wheel-head flat guide with chilled surfaces. The hrome-vanadium steel mounted steel back babbitt bear- ngs, and driven from the right- hand end flat belt from bal- anced motor mounted top the wheel-base casting the rear. Stand- 5-in. grinding wheel. The wheel-head may swiveled its slide and the Wheel set various angles without nfluencing the direction the feed- movement. These units are also mounted lower swivel which can turned feed the wheel differ- ent directions. plain wheel-feed nechanism used. Headstock drive motor mounted hinged plate permit maintain- ing proper belt tension. Six work speeds are obtainable. Provision made prevent dropping the work after the motor has been stopped. The spindle may rotated for live grind- ing locked for dead spindle grind- ing. The upper part the head may swiveled full deg. for face grinding. dj — This grinder, intended for variety small-lot work, entirely motorized, and all motors are controlled from the front the machine ball-bearing internal grinding fix hand reversing switch reverses the ture supplied; mounted direction motor rotation for inter- front the wheel-head and driven electrical belt from pulley attached the equipment, the net weight the ma- regular wheel-spindle motor pulley. chine 3050 Ib. Resistance Heating Unit for Soldering application direct fixed the base and the other ad- controlled heating the electri justable through distance ft. resistance method shown the ac- means motor-driven worm companying illustration. The duction unit, spur gears and rack,