The Iron Age 1932-06-23: Vol 129 Iss 25

Ww IRON AGE.. NEW YORK, JUNE 23, 1932 ESTABLISHED 1855 Parts Sound-Picture Film Printing Machine Made ZIEBARTH Secretary and General Superintendent Bell Howell Co., Chicago ose Limits limits close 0.0002 in. track motion picture film research, draw plans, make become necessity has necessitated extreme accuracy drawings and shop application the sound track the machines that print the models, make all necessary jigs, fix motion picture film. Whence comes ind gages, manufacture the demand for such refinement positive which are projecte try the jigs heat manufacturing? Where does the the theater screen. The ac- treat, inspect and even manufacture hine tool industry play its part? curacy which the strategic parts how are such limits maintained such machines are made and accuracy mar production work? shown this outline the manu- ufacture and inspection. When thi requires stretch imagina- facture the sprocket assembly department ready with tion when considering the motion pic- that drives and guides the film dur- product, every preliminary step ture industry understand that ing the printing process. been taken and everything limited scale when parts are few the last analysis the movie depat . . nt to ts » 1 the worl exacting demanding quality The aperture part consist ilent films, even more critical two sprockets, one integral with appraising sound films, the produc- haft and the other made was the a rture proc the } tion which has added many new piece steel and Sounds low frequency give little printing being done. part ind over the flange four machir rews and OCs a iowel | the piano) are encountered the time largest dimension. Sprocket Operations extreme machine nec Problem Turned Over Engineering Inspection Forging sity. order open the sound track and Research Department for greater clarity the industry The problem was not one merely control side, start with speeded the pictures from per deciding what results were want pection the forging. The sec. per sec. and turning the job over the then chucked the outside diamet was necessarv set motion chucking machine and rough- engineering and research department faced and center-drilled, and then sound-recording unit negative and ngineering arcn vhich. amone other ster the 0.625-in. diameter and which are projected the theater with the Barber-Colman Co., Rock end-faced and have been the first order, there that would work the limi turned still remains the problem accuracy quired. in printing. Th engine¢ ring de partment f th sre The Bell Howell Co., Chicago, Howell Co. housed and facing was quick appreciate the necessity separate building near the for accuracy. Among the important River, about away tne teps took was strive for ex- production plant The the Ket treme precision its printing ma- hood where there disturbance this point 3.925 in. 0.002 in. and 1337 AP — | | — 5 f j a 3 Vol. 129, No. ~ q | 3 } ] “he 4 My the tooth face 0.120 in. 0.002 in. The flange diameter in., 0.0005 in. The final machine operation calls for drilling and reaming the dowel pin hole and drilling and tapping for the machine screws. final inspec- tion checks reaming operations. The sprocket which mounted the flange the above piece cut from 4-in. steel bar. turned the same diameter its com- panion piece, but the width the sprocket tooth face left only 0.088 in., 0.002 in. This sprocket acts only drive, its mate having teeth the width the perforations the film, and thereby serves keep the film from moving either side. Operations Driving Sprocket The first operations consist ma- terial inspection and then cutting 4-in. bar 9/16 in. lengths. part chucked screw machine, rough- faced, rough-turned, and 19/32-in. hole drilled through the center. then chucked engine lathe, finish-faced, finish-bored and reamed, following this the piece clamped faceplate and finished faced engine lathe. Another engine lathe 1338—The Iron Age, June 23, 1932 a & special hobber equipped with single thread index worm. plate fastened sol- idly and backing-up col- lar fitted between the sprocket disks. am HOE removed from aperture sprocket, which its mount- ing the continuous contact film printer. The > % operation with nut arbor results finish-turning, after which close bench inspection made. Drilling, tapping, reaming and removing burrs finishes the part for final inspection before being mounted the shaft with the other sprocket. The center hole has now been reamed 0.625 in., 0.0005 in., and the disk has been bored 2.000 in., 0.0005 in., fit over the flange that was turned 2.000 in., 0.0005 in. The two sprockets are carefully assembled and inspected for facing flanges, turning all diameters, grooving and breaking the edges. All the above operations are per- formed the main production shop. Hobbing, because the accuracy re- quired, performed the engineer- ing department where special hobbing machine has been set up. This unit equipped with single- thread index worm and the backing plate fastened solidly the spindle. The shaft the sprocket hand- polished and into the spindle hole hand. backing-up collar between the two sprocket disks, and three set screws operating against plugs the hub q _ ~ a & PECIAL fixture holds part when forming radii ends automatic attach- ment feeds the cut- ter and out. PACING sprocket teeth closely checked. This dividing head cali- brated with divisions which equivalent 0.00014 in. circumference 4-in. circle. a & EETH this as- sembled sprocket unit are hobbed machine designed work the close the backing plate serve hold the sprocket against slipping the hollow spindle. The teeth are then hob-generated. After hobbing, the sprocket sent the inspection room where Carl Zeiss equipment used; the diam- eter less than in. this equipment will show error 0.0002 in. are sec. There are teeth the sprocket and before burrs are re- moved the teeth hollow-milled the error measurement between any two teeth must not exceed 0.0002 in. Hollow-milling the control teeth radius 0.0540 in. and width 0.1090 in., —0.0005, performed drill press, the sprocket being first clamped special fixture. | = 2.625 limits required. eccentric bushing locks the sprocket the fixture such position that lugs fit down over two teeth leaving one tooth free between them. The hollow mill works and down auto- matically over this free tooth hardened point opposite the tooth being hollow-milled. few additional features this engineering department are inter- est. Foremen are stationed raised platforms that overlook the operating floors. The foremen estimate the time for job and then follow the time the job progresses. The use labor hours this plant im- portant, not whole for given piece, and operation opera- tion, but also check catch delays that occur during the period single operation. which dies before sending the dies the production department. When die accepted, part made labeled and hung sample board the engineering department. Scale TOOTH DETAILS Assembly sketch aperture sprocket and some the tooth details. The Iron Age, June 23, 1932—1339 mill and its accessories are housed group buildings covering area about 340,- 000 sq. ft. The mill building proper 105 ft. wide and 600 ft. long and served two 60-ton cranes. Paral- lel the mill building the motor room and the reheating furnace build- ing with combined length 600 ft. and approximate width ft. The motor room served 50-ton ROGERS FISKE Western Editor, The Age mill building construction. brick wall approximately ft. high in- sures warmth and cleanliness. Above the brick wall the siding consists steel windows and corrugated metal. The roof all buildings corru- gated sheet steel with the exception the motor room, furnace building and the slab yard, which are covered with concrete tile and built roof- ing. The inside the motor room charge slab having maximum length ft. acting separately two lines shorter slabs can charged. The furnaces are the three-zone, triple-fired type using oil fuel. Furnace roofs are the suspended arch design, and the fur- naces are provided with refractory charge end the furnace projects into the mill building and the skid designed skid plates for discharging slabs without undue shock the table are feature the reheating furnaces. crane for repair purposes. Along- side the motor room and furnace building closed slab yard ft. wide and 360 ft. long equipped with 25-ton crane. the south end the mill build- ing proper and forming continu- ation therewith are each 105 ft. wide and 1000 ft. long. The buildings are connected, form unobstructed floor surface, and are served five 15-ton cranes. These buildings house the hotbed, runout tables, coilers, flying shears, pilers, plate transfer, plate shearing equipment and the shipping depart- ment. All buildings are modern steel 1340—The Iron Age, June 23, 1932 completely lined with salt glazed brick and tastefully decorated. the west this group build- ings and separated 75-ft. thor- oughfare are the cold mills, pickling, annealing and sheet finishing group. Slabs are placed either mag- net sling chains, depending upon the size and number, magazine slab charger which discharges one slab time the furnace charg- ing table. Each three reheating furnaces have inside width ft. and length ft. from charg- ing door brow. The charging end the furnace projects into the slab yard. Each furnace provided with twin pushers which together can -------- End Squaring Shears ---+ Side Squaring | : 3 ‘ , | te Tran. er ' , Pd “ | WwW 'S = — J Q ' A ' + ' t ' ' H ' H ‘ ' ' ‘ ' ' ‘ ' ' UC} TION INDIANA HARB plates are especially designed dis- charge the slabs without undue shock the table. Each furnace has rated capacity tons per hr. This mill was supplied the Mesta Machine Co. and designed for rolling plate from 3/16 in. in. thickness and maximum width in. For continuous strip the width varies from in. in., depending upon order requirements and gage. The mill has rated ca- pacity 100 tons per hr. gage, in. wide. The furnace delivery table exceptionally heavy design, having rollers in. dia. ft. long. The first stand a-scale breaker with in. dia. rolls, in. long. the delivery side the scale breaker optional transfer slab turn- over for further removal scale. The first mill stand can used for cross rolling for spreading and provided with in. dia. working rolls and in. dia. backing rolls Shear and Cradle Inland Steel Co.’s new continuous plate and sheet strip mill Indiana Harbor, Ind., has been completed and experimental operations were started several weeks ago. The installa- tion embraces the most modern and highly perfected developments continuous sheet strip production. Actual foundation work for the mill buildings was started April, 1931, and the mill was placed operation nine months later. having length in. The mill served turntables and elec- tric pusher for delivering the slabs square into the rolls. front No. stand electric hydraulic slab squeezer for correcting widths and squaring edges. Mill stands Nos. and are the four high universal type having in. dia. working rolls and in. dia. backing rolls with length in. and vertical rolls the en- trance side. These four stands con- stitute the roughing end the mill. Approximately 100 ft. away from No. stand the finishing group starts. front this there another scale breaker the same size No. Finishing stands, Nos. in- Stands W987652 Hot Strip Mill % ‘---Mofors Sets onditioning System clusive, are four high with 24% in. dia. working rolls and in. dia. backing rolls with length in. Between each stand motor- operated looper. The mill stands have roller bearings backing rolls and working rolls and all screw- downs are motor operated through magnetic clutches. Tables between mills are very heavy construction. All gears are enclosed and all enter- ing guides are electrically operated. Motors and speed reducers for the mill drives are located the motor room. No. breaker driven 1000 hp. induction motor through suitable speed reducer. No. mill stand drive consists 3000 hp. 150 r.p.m. induction motor Table Charging Table Pushers Magazine Pusher Pit 23, 1932—1341 The Iron Age, June | A A a a a i] 3 = | | equipped with flywheel. The mill driven through gear reducer and pinion stand. Stands Nos. and have drives composed 3000 hp. induction motor, flywheel equipped, speed reducers and pinion stands. 500 hp. variable speed d.c. motor. Finishing stands inclusive are individually driven 3500 hp. adjustable speed d.c. motors through speed reducers and pinion stands. Power provided from the plant power station and enters the motor room 6600 volts, phase, cycle. For the d.c. motors the finishing stands three 5000 kw., 6600 volts a.c., and 600 volts d.c., motor-generator sets have been provided. Interest- ing accessories for the mill proper consist two 1000-gal., pres- sure hydraulic pumps for scale re- moval, automatic oiling and greasing systems, and air filtering systems for motor drives. Leaving the hot mill building the strip carried the hotbed the finishing building run-in table 340 ft. long, having individual vari- able frequency induction motor-driven rollers giving table speeds 345 1380 f.p.m. This center table extends through two in. hot strip coilers discharging coil conveyor leading into the cold mill group way tunnel under the 75-ft. thoroughfare. From the center table double chain transfer connected two side tables hotbed runout tables, 38-ft. centers and 250 ft. long, with standard mill type drives, the end in. plate leveler. The leveler runout tables are 256 ft. long with individual motor-driven ing table speeds 112 448 f.p.m. in. end shear with runout tables the same construction the leveler runouts. the ends each lo- cated rotary flying cold shear with leveler and pinch rolls with capacity for shearing plates 3/16 in. thick into lengths ft. ft. 1342—The Iron Age, June 23, 1932 six finishing stands are the foreground. The roll train consists ten stands line. and widths in. The flying shear runout tables, each ft. long and with individual motor-driven rollers, have tilting devices and dis- charge piler tables with scales. transfer car takes the plates the shipping dock the adjoining plate finishing building. Heavier plates in. thick are run down one side table, leveled and sheared. the lower end the shear runout table and just ahead the flying shears plate cross transfer, 100 ft. long, between the two lines tables, permitting the plates brought back the side table adjacent the plate finishing building. this side table the incoming end the ing another 100-ft. plate transfer located, delivering the plates roll off table, 216 ft. long, located the plate finishing building equipped with roll offs and cradles. The piles are handled the crane and deposited skids, from which they are deliv- in. rotary side trimming shear. The side shear runout table, 104 ft. long, feeds into 76-in. end shear Flying shear run-out tables discharge with pinch rolls and scrap conveyor. The end shear runout table, ft. long, connects the scale table unit with ft. long, followed Motors, speed reducers and motor-generator main mill 4 4 * 5 > TRIP carried the hot bed run-in table 340 ft. long. double moves strip either two side tables. discharge piler tables with scales. roll off table, 100 ft. long, with roll ft. offs and cradles. nit generator . ill main mil structure. The plate finishing building ample warehouse sets are housed building parallel the pressed track and dock. addition facilities have been installed for pickling, annealing drawing. The new plant will permit Inland Steel Co. produce all grades and finishes sheet steel, hot and cold rolled strip in. and over width and universal mill plates in. wide. New Steel Outlet IR-CONDITIONING and cooling means manufactured ice now gives promise develop- ing point where the needed equip- ment will lend measurable support the iron and steel industry. The Na- Association Ice Industries, Chicago, has prepared under the di- rection Emerson Brandt, secretary the technical department the as- sociation, complete manual covering engineering service, form proposal, suggestions for sales organizations and the like which designed give members the association the in- formation needed push this use for their commodity. Plumbers, heating and ventilating engineers and archi- are given full cooperation the association. sufficient number key installa- tions have been made and are op- eration lift the proposition far above the experimental stage. Appli- cations ice cooling are measure without limit because investment and operating costs are not excessive. This equipment finds ready applica- tion homes, departments and offices industrial institutions, also the- aters, restaurants, stores, business of- fices and business buildings. The possibilities are illustrated survey made Kansas City, Mo., where was found that “iced com- fort cooling,” applied only industries well offices, stores, restaurants and theaters the me- dium and better class, would result increase per cent the use ice that city. The association estimates that about 2,000,000 homes can afford the com- fort ice cooling the basis average installation costing $700 and ton. Equipment varies somewhat with the character conditions met. Galvanized sheets will used inside and outside the ice tank, which will insulated. many cases ice chutes the tank will made least lined with sheet metal. The air washer will also made sheet metal. motor-driven fan will distribute cooled air various registers through sheet metal ducts and similar ducts will return the air for recooling and rewashing. Appreciable quantities pipe will needed for spray heads the ice tank and the air washer. motor-driven pump will draw cooled water from the bottom the ice tank and discharge through spray heads the air washer. An- other pump with necessary piping will return the water from the washer the ice tank spray heads. Growth application ice cooling will also lead increased public util- ity load and greater activity among manufacturers ice-making ma- chinery, which will have its effect the iron and steel industry. The Iron Age, June 23, 1932—1343 Properties Which Characterize Chromium Plating HROMIUM has been heralded the “wonder metal” the present time. This has been due primarily unique combina- tion physical characteristics plated chromium. These properties include diamond-like markable adhesion certain founda- tion metals, high coefficient light reflection, low coefficient friction, and high temperature resistance. addition, the chemical properties non-tarnishing and resistance alkalies and all com- mon acids, with the exception hy- and certain critical concen- trations acid. These qualities chromium natu- rally have opened two distinct fields for the application electro-deposited plate. The first thin coat bright chromium, usually ished nickel plate, for ornamental purposes. The second thick de- posit either bright dull chro- mium hard foundation metal for abrasion, corrosion, high-tempera- ture resistance. Although chromium playing most important role both high- speed steel and rustless iron, this dis- cussion will limit chromium plate only because the function chromium alloy different from that surface coat. The iron industry interested in- tensely the so-called “hard chromi- um.” Although hard chromium holds unlimited possibilities, this applica- tion such recent date and the technique exacting that will require research and scientific plant control make each particular type plated article success. order establish basis for decision the suitability chromium for vari- ous purposes, worthwhile con- sider carefully the different physical properties chromium. Abrasive Hardness natural that the layman should expect hardness have value for chromium with absolute Iron Age, June 23, 1932 Consulting Engineer Pittsburgh “wonder metal” the pres- ent, has many distinguishing prop- erties when used plating material. Some these, discussed the author, are abrasive hard- ness, crystalline structure, brittle- ness, coefficient reflection, temperature resistance and coef- ficient friction. How difficulties porosity and adhesion the base metal have been overcome are also outlined. constant, such specific gravity for example. Instead chromium has exceedingly wide range hardness, the hardest alloy steel. For instance, metallic chromium, made tion furnace, may scratched with finger nail. Likewise chromium plate may have corresponding range hardness, depending conditions deposition. The writer was the first make quantitative study and publish re- sults the influence current den- Hardness Current Density Influence current density the hardness chromium. sity the hardness chromium. typical curve showing this relation, here reproduced, expresses the cur- rent density amperes per square inch and the hardness minutes re- quired cut through plate 0.001 in. thick. The dotted curves show the change hardness the variation temperature. Also, changes hardness are caused the additional interrelated variables concentration chromic acid, the sulphate, the tri- valent chromium, and the iron con- tent. With machine which the writer developed for quantitative abrasive hardness test electro-deposits, found that the hardest chromium has 1.2 times the hardness the hardest metallic tungsten, 1.8 times the hard- ness the hardest tool steel; and three times the hardness nitralloy. industrial operation, the hardest chromium has about seven times the average life equal thickness the hard alloys. Since commercial plates hard chromium usually are limited from 0.001 0.10 in. thickness, evident that the best application hard chromium under conditions where the permissible surface wear comparable the thickness the deposit. Crystalline Structure From the scientific side, in- terest note that chromium tends crystallize cubical lattice. But from the practical angle, more importance study the influence the different operating variables the texture the chromium. chromium plating, hydrogen liberated coincident with the deposi- tion chromium. Due osmotic pressure, the hydrogen shot off with projectile-like velocity and, there- fore, driven into both the chromium plate and the foundation metal large quantities. Chromium has high affinity for hydrogen and thus may absorb several hundred volumes this gas. The texture the plate related very closely the ratio the chro- mium deposited that the hydro- gen liberated. For instance, exhaustive tests current efficiency have proved that the optimum value current efficiency for brilliant deposit about per cent chromium efficiency and, therefore, per cent hydrogen efficiency, the small amount cur- rent consumed the partial reduc- tion the chromic acid neglected. Research shows that any variation the operating conditions which af- fect this chromium-hydrogen ratio not only changes the brightness, but also influences the hardness the chro- mium. This extreme hardness, asso- ciated with large hydrogen liberation, may referred terms hydro- gen hardening. But regardless nomenclature, the concurrent plating chromium and hydrogen apparently set crystal stresses which are evi- denced hardness. Tests show that the hardest depos- its are formed unusually high cur- rent densities, thereby necessitating Where only lustrous surface de- sired, relatively low current densities, the order 100 amp. per sq. ft., may used. Porosity Deposit applications which the purpose chromium prevent tarnishing that the plate impervious that the foundation metal will not at- tacked. When chromium used only for abrasive resistance the porosity the deposit may secondary importance. Since chromium gives faithful re- production the foundation metal, any pin holes the under metal will carried through the chromium. Therefore necessary close the pores slightly porous material vvv author, with first large chromium plated re- flector ever manufac- tured. was made 1924. UTOMOBILE bumpers low) being electro- cleaned with plate nickel copper. With soft deposit copper, experi- enced polisher can flow the copper buffing wheel, thereby forming impervious intermediate plate. Under certain operating conditions extremely porous deposit chro- mium caused entrapped hydro- gen bubbles. Also dirty bath tends form porous deposit, that con- tinuous filtration desirable fea- ture chromium installation. The dogmatic statement often made that all deposits chromium are comparatively porous. This contrary fact. Instead possi- ble, the correct control operating variables, plate deposit chro- mium which extremely impervious. excellent test for the degree plate thin coat chromium highly polished thin strip copper. Then dissolve off the copper the use nitric acid. The degree (Concluded page 1381) The Iron Age, June 23, in. id of Beryllium Alloys Have Commercial Possibilities P-TO-DATE information the most recent developments the metallurgy and appli- cation beryllium found pa- per entitled “Beryllium,” Prof. Alfred Stock, Technische Hochschule, Karlsruhe, Germany, delivered the sixty-first general meeting the Electrochemical Society Baltimore, April 23. Investigation Ger- many this comparatively new metal has been quite extensive. stated the author that the fused electrolyte process, which the large-scale manufacture alumi- num and magnesium based, was not successfully applied beryllium until very recently, due largely the very marked affinity the metal for oxygen and carbon and its high melting point 1300 deg. The au- thor used mixture beryllium fluoride and barium fluoride, operat- ing the bath 1400 deg. Molten beryllium separates the water- cooled iron cathode. Details the process are given. Some the im- portant facts the paper relating alloys the metal are presented the following abstract. recent years Siemens and Halske (in Germany) have carried ex- tions the practical utilization beryllium and its alloys. account the high cost the pure metal and account brittleness, which makes difficult work, beryllium not likely become metal for general use, however at- tractive may because its lightness. The statements the press concerning the use beryllium aeronautical construction must regarded fantastic. However, the distinctive properties the metal make most valuable for variety special uses. For ex- ample X-ray tube construction, beryllium’s X-rays (nearly times that aluminum) has brought about the introduction beryllium windows cm. diam. mm. thick) such tubes. The high the metal for ultra-violet light, and its very low tendency sputter cathode ray tubes, are likewise valuable charac- 1346—The Iron Age, June 23, 1932 teristics. The beryllium are has been used for photochemical purposes. Metallic beryllium may electro- plated upon copper, nickel, iron, aluminium and alloys the light metals using melt alkali fluoride and beryllium oxyfluoride. keeping the bath proper tempera- ture, and subsequently heat-treating a SOME FACTS ABOUT THE ALLOYS MALL additions beryllium copper have resulted surprising properties tem- per and hardness. Beryllium bronzes are about resistant corrosion the tin aluminum bronzes. Probable commercial value for the beryllium-iron alloys indi- cated recent researches. Alloys iron, chromium, nickel and beryllium show chemical resistiv- ity corresponding the rustless steels with excellent hardness, strength and elasticity. deoxidizing agent the casting copper, beryllium has proved commercial im- portance. increases the con- ductivity cast copper. Cost beryllium has been re- duced from $30 per Further reduction expected from more extensive use. the deposited metal, possible obtain superficial alloy beryllium with the underlying metal, resulting firmly adherent coatings having beryllium alloys. Beryllium Deoxidizer for Copper Beryllium deoxidizing agent the casting copper has proved commercial value. few hun- dredths one per cent phos- phorus, heretofore most commonly employed the deoxidizer, cause marked decrease the electrical con- ductivity the copper. the other hand 0.01 0.02 per cent beryllium, which combines with near- twice its weight oxygen, excellent deoxidizer for high conduc- tivity copper castings. Besides the high conductivity, the casting dense, smooth and flawless. Thus for example, sand-cast cop- per, which usually relatively low conductivity, can produced with conductivity which slightly lower than that drawn electrolytic copper. other words, the conductivity ordinary cast cop- per cent. When beryllium em- ployed for this purpose, added the form alloy with copper, containing per cent Be. This al- loy prepared directly trolysis will described below. Furthermore, cheaper electrolyte than the one described above, one containing some aluminum im- purity, may employed. The high cost the beryllium employed further offset the increased con- ductivity the castings that cast- ings smaller cross-section and lower weight are required. Alloys with Aluminum and Mag- nesium The light alloys beryllium with aluminum have not come ex- pectation. These alloys have been investigated especially America. There difficulty preparing Be-Al alloy-castings any composi- tion. also possible secure flawless rolled sheets (down thick- (Concluded page 1383) | Industry and agriculture join hands this Vermont plant the American Fork Hoe Co. Farm Manufacturer Combats the Depression TAFT Manager, Batcheller Works, American Fork Hoe Co., Wallingford, Vt. precedented conditions resulting from the current depression business are making simultaneous efforts. The first these for the protection and self-help our work- ers, the second the improvement our production processes and the third for improved sales program our Eastern trade area. give clear idea how these efforts are being prosecuted will discuss each one turn, the order given. our endeavor meet the un- The advantages having in- dustrial plant small town farming community has been well illustrated during the past year the experience the Batcheller Works the American Fork Hoe Co. Wallingford, Vt. the May 14, 1931, issue IRON AGE the situa- tion this operation with respect the employment problem and how had been handled that time was described and commented upon. Since then there have been new develop- ments which appear both significant and suggestive. have continued along the lines ex- plained the previous article. That a Club” but one the novel ways which the Batcheller Works the American Fork Hoe Co. at- tempting combat the depression and mitigate its hardships upon the employees. addition en- couraging self-help for the work- ers, the company improving both its production processes and its sales program. is, practically shut down during good part last summer when many the men could find work the farms during the haying season, work their own and other people’s gardens, and otherwise get along with greater degree security than would possible winter. During the closed season the Sales Depart- ment did its best, during the pre- vious year, accumulate many backlog activity for the winter. However, during the first year gen- conditions, newly enacted foreign tariffs, and other factors have resulted still more re- ducing our total volume produc- tion. This has made necessary further spread the work available the stagger system and the selection the heads families and others with dependents for the handling what work there has been. Wage Rates Not Reduced have yet put through gen- eral reduction wage rates, for the short time schedule two and three days work per week has reduced the real wages that have not had the heart cut the rates addition cutting the time. Individual members the com- munity have also cooperated won- derful fashion helping themselves all available ways. This has been especially true the matter se- curing wood from the woodlots with which the mountains all around our valley are covered. This natural fuel supply has been worked such vol- ume that has become real eco- nomic factor our community life. have cooperated with the men the extent offering the use the (Concluded page 1382) The Iron Age, June 23, 1932—1347 mn n- C= n- 1d What Will Industry With the Technical Graduate pect making $11,350 year within five years after they have graduated, according this year’s class poll, but some other schools the graduating classes are not hopeful, graduates, par- ticular, are facing serious problem this year when manufacturers have altered policy previously well estab- lished take definite number graduates each year into their ranks. One the leading technical schools the country reports that only 3.4 per cent its graduates had located positions previous whereas past experience from per cent had been placed that time. This school enjoys excellent relations with manufacturers and this year was contact with from 250 300 companies endeavoring place its graduates. Another school reports that the only positions secured its graduates this year are with highway commissions. The results questionnaire sent technical schools indicate that average about per cent the 1932 graduates had positions the time graduating. This compares with average about per cent recent normal years. The number 1932 technical students graduating about the same for 1929 and the number enrolled the schools reply- ing about 105 per cent the 1929 figure. average, 130 industrial companies have been contacted endeavor place graduates each the schools interviewed. One school states that this year carried cor- respondence with additional 250 companies. This same school with its widespread experience the large companies are taking few grad- uates none all and that the only possibility placing 1932 graduates seems with small companies who may take one two men here there. All the selected group schools have enjoyed excellent co- 1348—The Iron Age, June 23, 1932 a & HIS summer new army technical graduates some 10,000 strong will seeking its place the industrial life the country. Does industry need these young men? past years manufacturers have sent repre- sentatives technical schools pick out groups men bring new energy, new youth and new ideas into their organizations. This year things are different and even the large manufacturers are inclined ignore the new technical graduate. Obviously here problem industrial well social significance. The accompanying article, based the results questionnaire sent leading technical schools and representative manufac- turers, analyzes and presents some the sugges- tions received. operation with industry the past the placement graduates. Few Graduates Taken Metal- Working Plants representative group manu- facturers the metal-working field was sent questionnaire similar that sent the technical schools. these companies not single one had any definite plan for adding graduates its personnel this year. few ex- pected take one two for some special reason. most cases this reason was family connection. Per- haps the father the graduate occu- pied executive position with the company brother had influence. leading manufacturer says, “We not plan take any college grad- uates this year. the past have added our force from tech- nical graduates each spring.” Another manufacturer states, “We have had apprenticeship course the past, but have suspended and not plan take any graduates into our employ this Another company re- ports, “On account the industrial situation have not been able place all the graduates who en- tered our training corps last year and feel that our first obligation place these graduates who have been receiving training for year more.” This particular company con- ducts regular training school for young men wishing enter its em- ployment. the past this training school has been regarded im- portant manufacturing asset. Another manufacturer connection with this perplexing prob- lem, very definite need exists industry for the development group men who are broadly fa- miliar with the business. Specializa- tion has emphasized this need. Com- petition changing into demand. result new type appren- ticeship being developed somewhat. similar the earlier type but higher plane. During recent years expansion our company has developed courses for groups men selected from grammar schools, high schools and from technical institutes and col- leges. For two years expansion these activities has been discontinued but substantial program still car- ried on. That part the training which based the performance productive work has been curtailed reducing the number working hours Classroom activities have been increased for the apprentices order enable them more effectively use the resultant additional time. harmonizing the immediate demand for reduced output with the future probable demand for skilled and more broadly trained men. times such these the value apprentice training apparent both (Concluded advertising page 18) ‘ Wr. 4 but mploy re- en- and been con- for em- aining im- prob- sts fa- ializa- Com- mand. ona ars eloped lected chools ion tinued car- led hours have ces time. yne emand future highly men.. lue both 18) 4 V-8 an oil holes are drilled through the crankshaft from one bearing another 14-in. upright drill equipped with automatic hydraulic step-drilling unit. setting fixture assures proper location the oil hole the crankshaft with the oil groove the cylinder the new Ford V-eight car the accuracy efficiency found throughout the Ford organiza- tion better exemplified than the production the crankshaft. Every crankshaft subjected minute in- spection, Ford-designed testing devices, moves through the crankshaft department which with machine tools new construction. Aside from the special equipment for machining the crankshaft, the depart- ment contains special double-deck heat-treating furnaces, “spinning” machine devised Ford engineers for quenching work after heat-treat- ment insure uniform hardness and Straightness, pan-type conveyors carry away chips from machine tools and filtering system for cleaning the coolant supplied machines. customary many Ford de- partments, the crankshaft department served overhead monorail chain conveyor with hooks suspended hold crankshafts vertical posi- tion. Machine tools are arranged parallel rows with the conveyor run- ning between them sufficiently close the operators that they not have step away from their work obtain fresh stock. There practically place for the storage crankshafts, which move swiftly into and out the department. All machines motor- driven and equipped with safety de- vices. Center-Drive Line Bearing Lathe Performs Several Operations When the crankshaft comes into the department from the forge shop, both ends are centered special cen- tering machine ascertain balance well locate machining points. Operations the Ford Crankshaft BURNHAM FINNEY These machines are adjustable ver- tically and horizontally. There fol- lows the turning the front cheeks, front bearing diameter, time gear fit diameter and the fan pulley diameter, the turning both cheeks the cen- ter main bearing and center main bearing diameter, the turning the rear main bearing cheek, rear main bearing diameter and the form the oil slinger, straddle turning the inside and outside face the flange and turning the outside diameter the oil seals and the flange. All this work done center-drive line bearing lathe. The crankshaft placed the lathe and dropped the saddle under the flange and under the stub end. The centers brought hydraulically, picking the crankshaft off the saddles. The center the flange end the crank- shaft drilled fixed distance obtain proper alinement cheeks while machining. this machine the crankshaft driven means equalizing driving dogs the center drive. The center portion the bearing machined with broach. Upon completion this operation pair rollers brought against the broached portion the center bearing order support the crankshaft against deflection during the work that follows. The power feed then engaged and the front, rear and center bearings machined. Power feed through electric motors and automatic, providing rapid coarse cheeking feed, fine turning feed, rapid traverse the unloading position and stop the machine. The lathe automatically The Iron Age, June 23, 1932—1349 5 | » oiled through force-feed lubricators with alemite lubrication the sliding surfaces. This machine does the work formerly handled five machines and turns out crankshafts per hr. Four Pins Cheeked, Turned and Filleted Simultaneously multaneously pin turning lathe. After heat treatment, similar lathe used for finish turning the pins. This lathe takes cuts one time and has hydraulically-operated chucks for holding the crankshaft place. After the crankshaft has been chucked, the operator All four pins the crankshaft are starting button and the mechanical rough cheeked, turned and filleted si- = All four pins are rough cheeked, turned and filleted simultaneously pin turning lathe, which takes cuts one time. The machine equipped with hydraulically-operated chucks, and with force feed lubrication system. 1350—The Iron Age, June 23, 1932 feed motors give the necessary se- a RANKSHAFTS are normalized hardening furnace (lower unit) 1650 deg., quenched special spinning ma- chine (right) 1500 deg., and drawn the (upper unit) 1000 deg. quence feeding operations. The main drive for this lathe multiple V-belt connected speed reducer. eliminate the possibility oil holes being out line with the main- bearing oil groove and the connect- ing-rod oil groove, 5-in. oil holes are drilled through the crankshaft from one bearing another 14-in. up- right drill equipped with automatic step-drilling unit. This ma- chine has setting fixture assure proper location the oil hole the crankshaft with the oil groove the cylinder block, Despite the heavy character the work, necessary resharpen the drills only aver- age every holes, and drill break- age has been reduced almost the vanishing point. With the automatic hydraulic step- drilling unit, the drill cannot jump when breaking through the work. The operator starts the drilling process moving lever the hydraulic unit “on” position, the drill ap- proaching rapid traverse and going into feed just before striking the crankshaft. After drilling termined depth, the drill reverses and backs out its original position rapid traverse. The drill then drills the second step, going into feed predetermined distance from the bot- tom the hole. This process con- tinued until the work completed, when adjustable stop trips the > | The tiple er. oil are up- ma- sure the sary eak- the ump The ap- oing the and bot- con- ated, the control lever “off” position, return- ing the drill the starting position. Crankshafts Heat-Treated Double- Deck Furnaces For heat-treating crankshafts two special electric hardening and drawing furnaces have been installed. They are double-deck design, the lower deck comprising the hardening unit and the upper deck the drawing unit. Crankshafts are charged into the hardening furnace operator who puts them hand chrome- nickel alloy shoes two lines front the pusher head. When the timing device the furnace makes contact, the shoes are moved into the furnace and simultaneously heated crank- shaft automatically removed from the discharge end the furnace and placed within easy reach the quenching machine operator. After being quenched, crankshafts are replaced the operator the alloy steel shoes, which are auto- matically elevated and pushed into the draw furnace. the discharge end the draw furnace, crankshafts are hung overhead monorail con- veyor carried the next opera- tion, while the shoes move the op- erator the charging end the hardening furnace. The heat-treating cycle, therefore, automatic, except for the initial loading the crank- shafts they enter the hardening furnace and for the operation the quenching machine. Crankshafts are normalized temperature 1650 deg. F., quenched 1500 deg. and drawn 1000 deg. line bearing lathe turning operations, doing the work form- erly handled five machines. 4 Crankshafts are quenched Ford-designed spinning machine. fixture prevent twisting warping while has three stations The hardening furnace powered 700 kw. and the draw furnace 390 kw. Ninety crankshafts hour are hardened and drawn these two units. secure uniform physical proper- ties and prevent twisting warp- ing, crankshafts are quenched caustic solution special spinning machine designed Ford engineers. The operator takes crankshaft from the end the hardening furnace with ‘Nal They are held rigidly revolving the rate 480 The machine and tongs and places fixture this machine, which holds rigidly within limit 0.015 in. There are three contact points the machine against which the crankshaft rests during the spinning action. That is, soon the crankshaft makes this contact, begins revolve the rate 480 r.p.m. The machine has three stations and motor operated. Stations move from one position another when the operator steps lever. (To concluded) The Age, June 23, 1932—1351 New Squaring Shear Combines Structural Steel and Cast Construction and accurate operation and lighter reciprocating parts that are claimed give longer life with lower operating cost are features new power squaring shear intro- duced the Niagara Machine Tool This shear cuts %-in. plates 10-ft. lengths, and available with gap structural steel and cast construction. Housings and bed are semi-steel cast- ings and the holddown, crosshead and transverse bar are steel. The cross- head welded construction, con- sisting vertical member and horizontal member tied together with triangular web sections for strength and rigidity. The heavy truss rod provides increased rigidity and pro- vides center adjustment. The cross- head counterbalanced with large springs inclosed cylinders; this fa- cilitates functioning the clutch and results more even application power, which reduces the strain wearing parts. The shear equipped with the company’s individual spring foot hold- down, claimed assure even pressure spite variation the thickness the metal being cut. possible cut sheet and 1/16-in. sheet simultaneously opposite ends the shear. Heavy and light sheets can cut one immediately after the other, without making any adjust- ments. The holddown pressure transmitted the transverse bar, re- lieving the main shaft this upward stress. Main shaft has four bearings, two the housings and two just outside the application load, that the load applied short well sup- ported section the shaft. The gears clutch wheel and pinion have hob generated teeth. Front, back, bevel and side gages are standard equipment and slitting gage fur- nished the 18-in. gap shear. The back gage self measuring 1/64 in. and can instantly locked the desired position. Each end adjusta- ble independently. Facilitates Barrel Burnishing conjunction with battery burnishing barrels, the portable motor-driven equipment unit consisting steel tower and base mounted three 5-in. roller- bearing casters. Rolled into position, the base extends under the burnishing barrel, the contents which are emptied into separating tray that sets hopper mounted the base. The upper side edges this screen- bottomed tray are flanged rest steel rollers mounted the hopper. This facilitates riddling, burnished articles being retained the tray while the burnishing materials drop through the hopper, from which they can returned the barrel without removing the tray. This storage hop- per provided with screen that per- mits all compound water drain off the balls. Reloading the barrel can started while the previous load still being riddled. special elec- a shoveling eliminated and time saved un- loading and loading burnishing barrels means this portable equipment. The contents the barrels are dumped into separating tray and the burnish- ing materials are returned rels may serviced this loader. eliminates hand shoveling and waste time loading and unloading the barrels. This machine, designated Abbott Ball speed-loader, was de- signed Hartley, materials handling engineer, New Haven, Conn., and manufactured and marketed un- der license the Abbott Ball Co., Hartford, Conn. L-shaped Rigidity construction and lighter reciprocating parts are obtained combining steel and cast members. 1352—The Iron Age, June 23, 1932 tric motor drives the conveyor system through speed reducer. Levers operate four rustless steel gates the bottom the hopper. The design these gates prevents over- loading the burnishing materials are admitted non-corrosive mal- leable iron conveyor buckets that form continuous belt (patent applied for), controlled rustless steel guide sheet underneath the hopper. The buckets carry the burnishing mate- rials the chute the top the tower, where they are discharged into the burnishing barrel. stated the machine will serve from two burnishing barrels, depending upon the nature the work. The Regorod welding rods and elec- trodes recently announced Bastian-Blessing Co., 240 East On- tario Street, Chicago, are described new 22-page catalog. The line includes gas welding rods, bare ahd flux coated electrodes, and cast-iron, bronze, tobin bronze and aluminum welding rods. Regite, alloy tungsten and molybdenum for hard surfacing, also described, fluxes, welding torches, hose and other Rego apparatus and supplies. > y and roller- sition, are that base. creen- est opper. nished tray drop they ithout hop- per- drain barrel load ystem steel The over- erials mal- form guide The mate- the into stated upon New Rotary Forging Furnace Has Water Seal interesting development forg- ing furnace construction shown the rotary furnace for oil gas firing brought out the Gas Machinery Co., Cleveland. this furnace atmospheric control main- tained water seal which serves prevent infiltration air and syphon vents the side walls carry away any water vapors. The furnace has been designed improve the quality forgings reducing minimum scale forma- tion decarburization, \} CENTER” thus prolong die life and al- low the finishing forgings closer tolerances. found allow for uniform temperature control with low t