The Iron Age 1933-06-29: Vol 131 Iss 26

the atural the rather where We, terde- de- turer, the pay that keep- yment the can id, can- cutter annot big the trade, nally, shing loita- ast into war neers over- Col. the Inc., en- en- chan- ation can ative erent the ioned mong rapid en- rease high. that ional vital trial IRON JUNE 29, 1933 ESTABLISHED 1855 Vol. 481, No. NDUSTRY now energetically preparing put its shoulder the wheel Industrial Recovery. given the President’s plan for reversal the vicious spiral. The able men our industry who are now giving unsparingly their time and energy consummating the complex details cooperation are sufficient guarantee will not mere lip service pro forma support that will earnest effort. The New Deal will get fair trial far the metal- working industry concerned. Even those us, and there are quite large number, who regretted the obvious subservi- ency some our congressmen and senators the wishes organized minority, will “play the ball lies” the best our ability and with good intent. The widespread agreement among employers the prin- ciple higher wages and shorter hours should convincing evidence that American capital prepared for action—not disposed reaction. After all, intent the thing that counts and which both capital and labor will judged. there selfish striving for unfair advantage either side, will quickly ap- praised the public. Times stress and change have heretofore been golden times for the opportunist. What could not accomplish under normal circumstances and conditions, was able tactics” and chicanery are longer fashion. The New Deal does away with them. can well afford part with them preserve the normal, progress-stim- ulating competition that directed toward general public betterment. | | on q | a, F ng A < pe de NP — 1019 | 2 J Special reduction gear drive for 96-in. plate mill. Gears are continuous herringbone type, cut Sykes generator. discussion design and ap- volves, some extent, the sub- ject gear cutting methods. These two branches the gear art are closely related because many cases design has been established from the type gear available, which, turn, dependent upon the machinery for cutting. For example, the machine tool field prior 1923, herringbone gears were rarely applied because ma- chinery for cutting small herringbone gears was not very highly developed, but when the continuous tooth her- ringbone gear became available clostly comparative costs with spur gears, practically every kind ma- chine tool had some herringbone gears included. Most large industrial gears are made methods and machines that were use years ago, but there has been considerable improve- ment the quality drives the medium sizes. large gears, meant gears having over in. cir- cular pitch, and medium sizes, pitches between and diametral pitch, and drives about 1000 hp. 1020—The Iron Age, June 29, 1933 Design and Manufacture fact, due this higher standard gear and gear unit manufacture, the trend motor design has been rather toward the high-speed geared motor than the low-speed motor direct connected. The improvement this range due development tool making and testing equipment rather than any marked change the designs the machines, with the exception the continuous development the pinion cutter generating system. Almost every year from 1922 1932 new machine has been built, each being improvement over its prede- cessor, with the result that the latest machine completed 1932 capable generating herringbone gears in. C.P., in. face and ft. diameter with accuracy usually as- sociated with gears only in. Expects Larger Use Generated Gears generate gears D.P. and over, however, very expensive set tool equipment required that except for the rather limited number high speed, high powered applica- Large Gears For Industrial Service THOMAS HOLLOWAY Gear Consultant, United Engineering Foundry Co., Pittsburgh tions, more common template plane form mill the teeth than generate them. probable that with the gradual accumulation generating tool equipment and with the further development the large generators this condition will change and that within very short time will more economical generate gears than form them. rea- sonable assume that, offered com- petitively, much larger volume generated gears will used, and that when the users become familiar with the flexibility the generating sys- tem, the ease with which gears are duplicated and their smooth, quiet operation, the formed gears will re- ceive secondary consideration. The number installations large gears great accuracy fairly limited; for instance, continuous steel strip mills are operated very high speeds, some high 1300 ft. per min., and all the stands are high powered. The finishing end hot strip mill will take from 3500 5000- hp. motors each stand, and quite common for the gears reach velocity more than 3000 ft. per a | than that with large change time enerate rea- com- ume that with sys- are quiet vill re- large fairly steel ft. high hot 5000- reach ft. per min., with tooth pressures high 2000 per inch face, neglecting overloads. obvious that for these installa- tions only the highest grade ac- curately generated gears should used and this automatically neces- sitates machines with large dividing wheels, very rigid construction, preferably continuously generating process, and extreme accuracy cut- ter manufacture. The weights some these gears are high tons, that great rigidity and massive construction the gear cutting machine are neces- sary preserve perfect control the gear during the generating process and avoid errors due deflection the machine caused the weight the gear. the other hand large blooming mill pinion operating low speed but transmitting over 2,000,000 torque (that say, pressures about per inch face) re- quire teeth having great strength and resistance shock and are therefore best designed with very large teeth and are generally end milled template planed. Horsepower Formula for Large Gears One difficulty which every designer large gears encounters lack horsepower formula which will include all the factors involving the life gears. There are number different for- mulae published which supposedly de- termine the load-carrying capacity gears, but all manufacturers large gears temper these formulae with ex- perience. only safe say that each formula guide and each individual calculation must tempered with ex- perience and good judgment. There 1s, for instance, wide variation the types and quality materials used, ESIGNING gears strikingly large size and weight for modern rolling mill drives are outlined this article, which part the in- teresting address Mr. Hollo- way the recent meeting the American Gear Manufacturers and over usually have been form milled template planed, but within the past year, since suitably large equipment has been made available, the generat- ing method has been employed, especially for cutting large high- speed gears requiring high ac- curacy. Manufacturing processes illustrated cover gears weighing much 138 tons, the teeth which were cut special form milling machine. horse- power formula employed de- signing such gears also given. and wide variation service condi- tions. know that pair gears driving small conveyor may stressed about four times greater than pair gears driving rolling mill pebble mill and know many in- termediate conditions. We, therefore, select average load condition and from experience, select modifying service factor for each type service. few years ago would have been necessary still further modify the average load figure with factor for mounting and installation, al- low, far possible, for various inaccuracies cutting and inadequate lubrication. may reasonably as- sumed now, however, that new gears pitch when they are installed, are properly mounted, rea- sonably well cut, and are well lubri- cated, since these points have been given considerable attention en- gineers throughout the industry. may confine our modifying factors, therefore to: 1—A service factor; material factor; and 3—a velocity factor. then have guide for the determination horsepower shown the accompanying table. will observed from the above that the pitch the gears not in- cluded. This due the fact that, within certain limits, the load capacity not greatly influenced pitch, be- cause gears are designed resist pitting and wear the factor safety against breakage generally over 20. The foregoing, stated above, merely offered guide the selec- tion size; not used with- out good judgment and some experi- ence. Main Drive Roughing Stands 96-In. Mill returning discussion the de- sign and methods cutting large gears, obvious that the subject broad that whole volume would required cover properly, and this address only intended il- lustrate the difference between form- ing and generating methods, which really the only important point the subject that changing and that will affect the trend design. proposed, therefore, show two typi- cal installations. One set moderate speed gears, large physi- cal proportion, transmitting 10,000 hp., and the other, high-speed high- ly-accurate drive gear for cold strip mill. Some the methods employed the manufacture the first instal- lation are also here illustrated. The large special main drive here pictured for the roughing stands in. continuous plate mill. The distance between the stands was es- tablished the rolling schedules and Special main drive for roughing stands 96-in. continuous plate mill. The two largest gears have pitch diameter ft. in., in. face width and 128 teeth. The D.P. They are designed for tooth load 580,000 and 485,000 respectively. Pitch line veloci- ties gears this train range from 570 2540 ft. per min. Timken roller bearings are used the flywheel shafts. The Age, June 29, 1933—1021 there was problem whether each stand should driven indi- vidual motor whether one motor only could employed and the con- nection other stands made gearing. was decided that, due the fact that the slab was only one stand time, the single motor would permissible and that connec- tion other stands through gears would more economical than the individual drives. Each stand trans- 96-in. plate mill main drive gear weighs 138 tons. made two rims four segments each and center spider. The P.D. ft. in., the face width in., the number teeth 268, and the D.P. mits normally about 10,000 hp. with occasional peaks 12,000 hp. noted that the mechanical solu- tion this problem, while involving number gears very large size, actually effected saving about $90,000 electrical equipment and considerable saving flywheel ex- pense. FORMULA 1260 Mr—Material factor N—R.p.m. pinion factor Vr—Velocity factor VELOCITY FACTOR Accuracy Closely Checked Under 1.4 the time that the drive was de- 1.1 Service TYPE MACHINE DRIVEN Factor Ferrous and non-ferrous rolling mills, rubber ‘mills, ball and pebble mills, com- pressors, heavy fans, cement kilns, suction pumps and cutter heads, speed Duplex and triplex pumps, ‘steam ‘turbines, power shovels, heavy mixers, hot and Large hoists, deep well pumps, mixers, agitators, large generators, medium Medium hoists, heavy conveyors, light fans, centrifugal pumps, textile ma- Light hoists, medium machine tools, bending rolls, medium and light conveyors, Material MATERIALS Factor PINION GEAR 0.4/0.5 per cent 0.5/0.6 per cent 0.35 per cent carbon cast steel an- carbon forged steel 1.0 Alloy steel. Pinion hardened ap- 0.35 per cent carbon cast steel an- Alloy Pinion hardened ap- 0.5/0.6 per cent carbon cast steel proximate 250 Brinell 1.5 Alloy steel. Pinion hardened 500 Alloy steel. Gear hardened Iron Age, June 29, 1933 NERAL view special machine em- ploying end mill method forming the teeth large drive gears. large enough receive the gears and became necessary design spe- cial machine. The end mill method forming was selected because the tool cost was lower than cutters the rotary type and the distance end travel during cut much less than with rotary tool. Great care was taken the machine operator and the inspection department and remark- able standard accuracy considering the bulk involved was obtained. was found that near could segments assembled with temporary disks, index gear and arbor, ready for mounting the end milling machine built special for these large gears. The index gear was taken from old Gleason generator; with this equipment gears were cut accuracy 0.008 in. tooth division and contour. nporary ady for built gear and care used machining and measuring the gear segments or- der assure accurate joints and key- ways without offsets. Measurements are made from monuments and means pin gages. measured the total inaccuracy was 0.008 in. tooth division and contour. secure accurate joints and key- ways without offsets was necessary use extreme care machining and measuring the work. Monuments and (see illustration measuring gear segments) were erected accu- rately alinement with the machine tool; they consisted angle plate with in. diameter round secured same order facilitate measur- ing with pin gages three directions. Monument represents the center the gear and the distance equal the diagonal measurement from the inside and bottom one keyway the same point the other end the segment and shown the They were also located from the cut- ter the distance equal the radius the inside face the keyway and shown the illustration the dis- the triangle. (Apparent inclination monument photographic dis- tortion caused position the camera.) Point the center all arcs the segment and used setting milling the second keyway distance way that locates the setting (Concluded Advertising Page 14) 3 A. rg 4 4 Pax x bolt holes match the gear spider. The work done radial drill. The spider shown the right ft. planer. “x q 5 finishing ends hot strip mills employ motors ranging from 3500 5000 each stand, and gears weighing much tons. Gear pitch line velocities are over 3000 ft. per min., and tooth pressures are 2000 per inch face. Such gears require high accuracy; for cutting them this Sykes generator was installed last year the the United Engineering Foundry Co. The Age, June 29, 1933—1023 q rad Weld GREAT deal work has been done and great deal written about the fabrication struc- tural steel for buildings, bridges and similar structures arc welding. Little has been written relative the welded fabrication parts enable the steel mills use their own product the construction conveyor tables, transfer beds, roll tables, mill shoes and various sup- ports. Welded design offers excellent means cost reduction since there substantial saving weight and greater possibility more econom- ical distribution material. This ar- ticle outlines some the results ob- tained arc welded construction various large mills. Several tilting tables have been fabricated arc welding. Fig. shows lifting table designed han- dle slabs 15,000 lb. This motor- driven unit has rollers, rests arc-welded pivot base and has coun- terweight balance, thus relieving the load the lifting device. The side frame the lifting table shown Fig. made from H-beams 345 the foot. There are two these sections which form the side ‘ 1024—The Iron Age, June 29, 1933 ing the Steel TAYLOR Vice-President, Lincoln Electric Co., Cleveland comparatively little has been written about the use welding building mill machinery, much progress has been made this field application, this second article Mr. Taylor shows. The first article describ- ing the construction welded steel table and furnace rollers appeared THE IRON AGE April 20, page 620. frames the table. the left and top edges the flange plate welded the entire length the H-beam, which ft. long, with short cross plates for the roller shaft bearings rest on. These plates and braces serve two purposes: First, support the bearing second, retain the grease for the bearings and gear. The series braces welded the bottom the plates, extending down the flange the H-beam, act support. Un- derneath the section where the two flanges the H-beam are welded cross plate welded give additional strength. different view the side frame shown Fig. The weight the complete structure shown 14,000 The cross beam used support the side frames the table also welded steel. extension made angles and plates welded the top the beam. used hold the pusher and designed that after several passes the slab through the rolls, when the slab may require turning around, from the lifting device comes be- tween the rollers, raises the slab from the rollers, allowing the pusher turn the slab. The pivot base, shown Fig. made H-beams 345 lb. the foot. The flanges the six cross beams are cut back the depth the flange the web and the end in- serted between the flanges the two parallel H-beams and welded, forming complete square. The plates welded the four corners are machined and used supports for bracket ar- rangement and shaft which the table pivots. The base for the lifting device was the foot. (See Fig. 5.) This view Fig. 1—This motor- table has rollers and rests welded pivoted base. designed handle slabs weigh- | | side weight own the lso ide the hold that slab may be- from the cross the in- two rming velded and ar- the was lb. view shows how the flanges the H-beams were cut out and the end inserted be- tween the flanges the parallel beams, explained above. Fig. the completed table shown its high position ready receive the slab comes from the rolls. There course tilting Fig. 2—Side frame lifting table shown 345 Ib. the foot. table the opposite side the rolls; this similar design, except that does not have the plunger for lift- ing the slab the pusher arrange- ment, Small Tilting Table for Bar Mill small tilting table for bar mill was recently constructed Germany. The assembly this table, built for steel mill Germany, shown Fig. The frame made heavy I-beams braced sheet steel and scrap iron. The entire construction was based the principle elimi- nating expensive machine tool work 52525535: S: 5:5: 5:5: 5:2 far possible, substituting the cutting torch and the welding ma- chine. The table rests shown and balanced lever and counter- weight that the leverage system Fabrication Steel Mill Machinery acting will not bear the entire weight the table. All connections are electrically welded without the use gusset plates. Bids received for the supplying and installation this equipment, includ- Fig. 4—The pivot base for the lifting table also made heavy H-beams. The flanges the six cross beams were cut back and the ends inserted between the flanges the two parallel beams and welded. Fig. constructing the base for the lifting device, the flanges the H-beams were cut out and the ends inserted between the flanges the parallel beam. Fig. welded steel bar mill tilting table built recently Germany. ing foundations ordinary type con- struction, averaged $11,900. rede- signing for welding and adapting existing equipment where possible, the actual cost was only $1,025. approach rotary shear was built for the same mill that installed the tilting table first described. The cross supports this approach are made 8-in. ship channels with an- gles in. in. in. welded the ends. These support the two side frames the tables and also the cover plates that between the rolls. The H-beam that forms one side the magnet carrier which travels small rollers the length the beam and controlled and operated motor cable drive. The motor for driving the rolls which convey the plates the shear Iron June 29, 1933—1025 | Fig 3—Another view the lifting table side frame. The complete structure weighs | ble and = = - . = = > sets all-electric welded struc- tural steel base. The gear and line- shaft covers are all welded and made oil and grease leakproof. welded steel rotary shear back- table has also been built. Welded cover plates that fit between the rolls were provided this design. These plates rest the I-beam, and are intended prevent the possibility the end plate getting under the rollers, which might otherwise occur because the wide space between each roll this particular design table. These table plates can re- moved case repairs. This sec- tion table has all-welded steel rolls equally spaced. Transfer Tables Fabricated the Field the left Fig. can seen transfer table consisting all- steel welded rolls. The framework the table made 15-in. I-beams ft. long. The cross beams are set concrete foundations with sepa- rate 12-in. H-beam welded the side frame the table. The entire instal- lation the transfer beds, with the exception chains and motor bases, was fabricated and electric arc welded the field. Fig. shows the framework the transfer table with cross beams, bear- ing blocks, lineshaft brackets. The bolts shown merely beams alinement while welding. After the tables were lined and lev- eled up, the bottom flange the I-beam was welded the cross H-beam. When this was completed the table frame was turned over and welded from the bottom side the I-beam, thus making four welds each end H-beam I-beam. welded steel kick-off table made four 30-ft. sections 15-in. I-beams, and 15-in. channel H-beams has also been built. The I-beams form the side frames and the H-beams support and tie the frame together. Between each roll arc welded lifting arm which serves remove 1026—The Iron Age, June 29, 1933 the plates from the table and place them piles. Fabrication structural parts such mill shoes, sub-bases, bearing supports, etc., steel welding extremely cently the rebuilding 12-in. merchant mill the Canton works the Republic Steel Corpn. order keep costs minimum and make use their own product, welded steel construction was used wherever possi- ble. The work was planned and car- ried out under the direction Thayer, chief engineer the Repub- lic corporation; Leonard Larson, chief engineer Massillon district, and Donovan, electrical and me- chanical superintendent. Shoe Plates and Sub-Bases Welded Construction One the most interesting phases the rebuilding was the construc- tion the various parts the fin- ishing stand. was decided build Fig. 8—Framework transfer table showing cross beams, bearing blocks, lineshaft brackets. Bolts were used hold the beams alinement while welding. 7—This com- plete transfer bed, with the exception chains and motor bases, was fabricated and welded field. both the sub-bases and shoe plates steel. For this purpose some 84,- 000 hot-rolled hot-sheared low- carbon steel bars were used. Five shoes were necessary; for stand and 10, three shoes ft. in., ft. in. and ft. in. length and for stands and two shoes each ft. in. long. One the longer shoes shown Fig. consists two bottom two top members in. 10% ft. in., the top and bottom members being joined web plate place. They are reinforced three wing plates the outside and two the inside. Four cross mem- bers join the longitudinal sections shown the accompanying graph. After welding, the shoes were machined, the top being beveled 60-deg. angle, and holes drilled receive the foundation bolts. There are approximately 1400 lineal feet welds the five shoes, the } | plates 84,- low- Five and and each in, plate velded and mem- photo- and were lineal the 4 total weight being 64,400 The estimated weight castings was 77,- 280 Ib. The sub-bases which the shoe plates rest presented very simple construction problem. Five them were made, and the welded steel con- struction saved approximately 4850 lb. weight and reduced the cost nearly per cent. Two bearing pedestals were built quickly with cutting torch and arc welder. Guide guide boxes, bearing brackets and many other parts were also welded construction. The shielded proc- ess welding, using Fleetweld elec- trodes and welders manufactured the Lincoln Electric Co., Cleveland, was employed. Three-sixteenth, and in. electrodes were used, the latter principally for the large fillet welds the mill shoes and sub-bases. addition officials the Re- public Steel Corpn., the author in- = Fig. five 18-ft. welded mill shoes. About 1400 lineal feet welding was required the five shoes. debted for much the data this Copeland, Carnegie Steel Co., Mun- hall, Pa., and also Osna- Product—Beryllium- Copper ONSIDERABLE progress has been made the last year product—an alloy beryllium with copper. report this development was made paper Edwin Cone, New York, entitled, “Beryllium- Copper Castings—Foundry Practice, Heat Treatment, Properties,” pre- sented session the non-ferrous division the American Foundry- men’s Association its annual con- vention Chicago, June 23. For some time there has been keen interest the rather rare metal, beryllium. Some research, particu- larly Germany, has been conducted its recovery, its properties and its effect alloy with steel, iron and non-ferrous metals. The major part the investigations has covered the effect beryllium alloy with copper, with the emphasis this country the wrought rolled products. Recently the research has broadened into the foundry phase the subject. “Master Alloy” Furnished The whole subject has, however, been handicapped the high cost the metal. But the last year costs have been lowered decidedly the Beryllium Products Corpn., New York, which has reducing plant Marysville, Mich. There now avail- able combination beryllium and copper, designated “master al- loy,” containing about 12.5 per cent Be. This sold base raw material for introducing beryllium into beryllium-copper products, the Castings aim being secure final range 1.50 2.50 per cent Be. For wrought products about 2.25 per cent regarded standard with 2.50 per cent for the cast material. the foundry field, most the commercial work thus far has been done the American Manganese Bronze Co., Holmesburg, Philadelphia. The author, who visited this foundry, reports that, general, foundry practice for the beryllium-copper cast- ings closely resembles that for phos- phor-bronze castings. Details the precautions necessary melting and introducing the beryllium are given the paper, temperature control within narrow limits being necessary. Close regulation pouring tempera- tures also essential. Heads and gates are necessary insure even flow metal the mold and solid product. Melting loss low and feature the high value the scrap because the possible high recovery beryllium. Precipitation Hardening Feature One the most interesting fea- tures beryllium-copper alloys the results obtainable from their proper heat treatment. These alloys are precipitation hardening, which greatly enhances their proper- ties. They resemble the aluminum and magnesium alloys, partly because beryllium light metal, one-third lighter than aluminum and only one- sixteenth heavier than magnesium. The paper gives the details the heat-treating cycles. general the alloy, cast, annealed and bruek, Germany, all whom submit- ted papers the second are welding prize competition recently conducted the Lincoln Co. quenched water, which results the solid solution the beryllium. Precipitation hardening then follows various temperatures, and stip- ulated heating periods followed normalizing, which greatly enhances the properties. Tensile strengths over 117,000 lb. per sq. in. are obtainable with Brinell hardnesses over 400. the rolled products, tensile values 196,000 per sq. in. are cited. Besides high physical values and hardness, heat treatment bestows un- usual electrical conductivity, wear re- sistance and thermal conductivity, which are discussed the paper. Some Industrial Applications The concluding section the paper has with applications beryllium-copper These have not yet been extensively explored but those already demonstrated are interesting. Because the many possible properties which can de- veloped judicious heat treatment, many other uses will come light the industry develops. Some the uses cited the author are fol- lows. the aviation field, extremely interesting application bearing sleeve 2.50 per cent beryllium-cop- per castings, which several hun- dred have been made. They are essential factor new adjustable pitch propeller, now being introduced, which promises radically change flying methods and hazards, and increase speed. has been found this case that the precipitation-hard- ened castings can easily machined after this treatment, eliminating the necessity doing this before harden- ing. Another application beryllium- copper propellers for racing boats. (Concluded Advertising Page 14) The Iron Age, June 29, 1933—1027 = q | pe 36; 7 : 4A Camshafts are being successfully die cast vertical molds which are bottom poured. automatic die-casting machine has been put into practical op- eration the production cast-iron camshafts and this brings the whole subject die casting iron and steel into prominence. The so-called per- manent molds the iron foundry in- dustry already have achieved some success and high production semi-au- tomatic operations casting ma- chines the Holley type, such used the Laval Separator Co. and described THE IRON AGE June 15, are now established practice several plants. this article the distinction be- tween die casting and permanent mold casting essentially one pressure. Die-casting machines use permanent molds, but addition the molten iron forced into these molds under pres- sure just the long-established practice die casting the softer metals such the zinc alloys. The introduction permanent mold machine into the average foun- dry probably will meet with much resistance did the introduction the molding machine. However, seems destined occupy prominent place eventually. Great strides are being made the technique sand molding, and elaborate equipment has been devised reduce minimum the number operations and the ef- forts the sand molders. Stripping plates, vibrators, jolt roll-over ma- chines, and ingenious material-han- dling devices are some the prin- cipal features. highly mechanized sand casting foundries empty flasks reach the molder roller conveyor from one side, are filled, tamped and stripped machine, and when com- plete leave the same conveyor from the other side whence they pass the first this year 1028—The Iron Age, June 29, 1933 Die Casting the start continuous pouring op- eration. Some Disadvantages Sand Casting Production some such method often large and efficient, but even its best, sand casting technique has many disadvantages. Extensive floor space required for molds, molding machines, sand storage, sand handling equipment, and sand recon- ditioning machines. The cost han- dling sand must always appre- ciable item because the large vol- ume involved. These disadvantages may grouped under the heading cost. Other disadvantages may listed under the heading quality. The late Dr. Richard Moldenke, one the greatest authorities sand molding, said shortly before his death that one his strongest desires was “to know how finish sand mold would peel perfectly.” one his many tests made sand molds with the best pos- sible coatings and after the castings had been made examined their sur- faces under high powered glass and all cases was able see “patches sand” adhering the castings. Such sand inclusions are avoided the permanent mold. The actual grain structure castings apparent- This machine actual production cast iron camshafts remote controlled from the switch- board shown the left foreground. The overhead pipes carry air under pressure for cooling. against sand molds, and when pres- sure added, die casting, fur- ther improvements are apparent. present engineers many fields are cooperating never before the study foundry technique. Never before have they had such array alloys draw upon and such pre- cision methods melting and casting. The result has been the development practical die casting technique for iron and steel and the production superior quality castings. Technique Die Casting Die casting iron differs much from the usual method permanent mold casting the latter differs from sand casting. Die casting low melting point alloys, although com- paratively recent process, has been practical operation this country for nearly years, but big step between the die casting alloys melting under 1000 deg. and those melting from 2500 3000 deg. was necessary deviate sharply from the usual non-ferrous die cast- ing practice, and description the design and operation large die- casting machine now producing iron camshafts may serve indicate some the chief items departure. This machine, known “Cast-o- matic,” was designed Mor- ron 7 > pres- fur- fields lever rray pre- ting. ment for tch- ling. ris and now commercial opera- tion large Pennsylvania manu- facturing plant. was built cost about $25,000. With its “con- troller” and reservoir ladle weighs 60,000 Ib. and about ft. long, ft. wide, and ft. high. Castings weighing from 250 and ft. long have been successfully produced and the normal capac- ity tons simple castings hour. Some idea the size and rug- gedness the casting machine may had from the fact that for large intricate castings the molds frequent- weigh from 5000 6000 Operations Controlled Camshaft “controller unit,” which may located any convenient distance, controls all operations. Briefly, this “controller” motor-driven, cam- operated, multiple-valve device hav- ing simple and easily adjustable cams which hydraulically regulate all operations with close accuracy. The actual movement parts secured electric motors and hydraulic cyl- inders. Metal from sealed contain- forced (thus “bottom pour- into the mold varying rate flow, starting slowly and winding fast, thus intensifying the pres- sure the mold nearly filled, and driving the metal into all corners the mold. For emergency, and for “setting up” the machine, any all these operations may switched direct manual operation, omitted altogether. Provided molten iron the proper analysis and temperature deliv- ered that there always supply the reservoir, and the annealing oven temperature maintained correct- ly, the process automatic. With the controller motor running, the oper- ator merely pushes button and the sequence starts. Sand cores, they are necessary, are picked and lo- cated the mold, metal cores are pushed place, ejector pins are with- drawn pouring positions, and the two more parts the mold are closed. Coincident with these oper- ations, metal from fills the pressure chamber pre- determined level, maintained means automatic scale which the pressure chamber rests when free position, and the spout through which the metal poured automatically withdrawn. After all these things have been accomplished the pressure chamber elevated and clamped tightly against MORRIS and HERBERT SIMONDS AST-IRON camshafts for use well-known automobile are now being successfully pro- duced automatic die-cast- ing machine. This article de- scribes some the operating details this connection, well some the results recent research work the field die casting iron and steel. Pro- duction cast-iron crankshafts and gray iron valve stem cast- ings machines designed Mr. Morris was briefly dealt with The Iron Age April 27, page 665. the bottom the mold. this posi- tion the opening through which the pressure chamber was filled closed; the plate which closes has valve- controlled opening for the introduc- tion reducing gas under pres- sure. This gas used force the molten iron “nozzle” gate and into the mold. The pressure varies depending upon the design the cast- ing. The molds are designed with vertical parting, thus providing am- ple vents ahead the rising metal. The bottom pouring holds together the incoming metal, prevents entrap- ping air, and greatly reduces oxida- tion. The point entrance metal the bottom the mold cooled circulating water “trap” the metal that point soon the casting has set under the continuing pressure which feeds the shrinkage. Soon after the casting has set, re- verse operations start. The metal cores are withdrawn, the mold Die-casting machine production cast iron pipe. metal core used and withdrawn the cylinder shown the top the machine. necessary pull the core out the hot metal just the right moment after has started freeze and before shrinks. The Iron Age, June 29, 1933—1029 7 - bate nuch nent from low com- nin big llovs oys hose 3 opened, the casting remover arm inserted and the ejectors come into action. All this happens within few seconds. The hot casting swung around the remover arm and placed position the anneal- ing oven, the doors which open and close automatically proper syn- chronism. Immediately after ejec- tion the casting and while the mold wide open, preparation started for the next casting. The mold cleaned strong air pressure and coated with inert soot. then cooled and inspected (by system lights and mirrors) and the whole se- quence starts over again. Types Iron Used Not all irons are suitable for die casting even under most favorable conditions. general, the experi- ence those who have operated die- casting machines indicates decided preference electrically melted iron. Much has been written the effect the electric furnace grain structure and that subject will not dwelt here. Occasionally ex- perience shows that the analysis must changed with variation type castings. However, this not serious difficulty castings may easily grouped according the iron requirements. Many the same principles used sand casting apply die casting. sand casting the temperature which the metal enters the mold proper should con- sistently low, but die casting the metal should hot the point entering. Nitridable cast irons are being suc- cessfully die cast, but with higher percentage rejections. The stain- less steels have been handled easily 1030—The Iron Age, June 29, 1933 die casting operations laboratory research work, and least one com- pany contemplates duction this field. Experience in- dicates that many the alloys give less trouble than the plain steels, but too early make any general- ization. Table gives ten different irons which have been success- fully die cast and which, group, will meet almost any condition which the foundryman will encounter. Close-up view the control mechanism used either automatic manual production iron die castings. central camshaft used regulate valves which turn operate the Top view the die- casting machine now production cam- shafts. The mold has been removed show the mold-hold- ing jigs and the op- erating mechanism. The quality die castings shows the same advantage over sand cast- ings does any permanent mold productions. These advantages were outlined article permanent molds THE AGE June 15, page 940. Because the pressure used die casting, some further ad- vantages are evident. Surfaces are said smoother, less tumbling required, and plating and galvaniz- (Concluded Advertising Page 14) various parts and processes the casting machine. shows cast- mold were anent 15, ad- are ing vaniz- tion ate the Current Trends and Expectations The Metal-Working Industry Survey The Iron Age the steel-producing industry doing from week week volume busi- ness, because the production rate reported each Thursday THE IRON AGE for the cur- rent week. may easily know just what This true also automotive production and orders, which are reported with regular- ity and considerable accuracy our columns. But there are similar systematic statis- tics report the business volumes the users and fabricators metals; the varied industries which transform metals into ma- chinery and consumer products. THE IRON AGE, the following original survey, gives detailed cross-section ac- tual trends and expectations this im- portant branch the industry. the buying steel and other metals were speculative nature, some sup- pose, would find this fabricating branch Definite Trend Toward Rehabilitation happy position say that our steadily in- creasing volume business reflecting heartening improvement. While there still remains much accomplished the way bolstering prices before can enjoy any material measure profitable prosperity, feel confident that the various trade associations, operating within the several branches industry, will correct some the difficulties that have seriously attacked the price structure. for the outlook the future, confidently expect that the increased public works activity will strengthen the merchandising potentialities our contractors equipment. The improvement renewal parts business reflects definite trend toward the rehabilitation industrial pro- duction equipment. the industry lagging behind the produc- tion steel and other materials. But, the contrary, find, the result this survey, that producers fabricated metal products have apparently kept pace, gains, have even exceeded, the gains the producing industry. course, this survey cannot accepted representing the entire field metal fab- rication. But is, believe, large and fair cross-section. The charts which are shown represent the trend volume orders shipments from month month this year. They not represent actual volumes, but represent the percentage increase volumes, vice- versa. The overwhelming unanimity gains, this branch the industry, its diversified representation, should certainly indicate, our opinion, that American industry well started the road recovery. Harnischfeger, President, Harnischfeger Corpn., Milwaukee. eee MAMJ Whole Trend Has Changed MAMJ OLIVER MACHINERY CO. have shown better production operations and in- ERIE FOUNDRY CO. Grand Rapids, Mich. creased volume business progressively each month Erie, Wood Working Machinery since December. Forge Shop Equipment April, per cent over The whole industrial trend has changed. For example, April, March cent over March the new beer business runs not much barrels May. 300 May, cent over the old saloon days. Breweries are being remodeled and April. will per new warehouses have been demand. have been June will 100 per cent over building additions not only breweries but glass fac- over May The Age, June 29, 1933—1031 4 4 die- ie now cam- old has nism. vs 4 } : — q F MF KA nt er As ril MAM ALLIANCE MACHINE CO. Alliance, Ohio Cranes and Steel Mill Machinery per ent ver MAM CUSHMAN CHUCK CO. Hartford, Conn. Chucks MAMJ WROUGHT WASHER JFMAMJ CRUCIBLE STEEL AMJ CASTING CO. Cleveland STRONG STEEL Steel Castings FOUNDRY CO. babe Ti > ner cent over Buftalo HALL MFG. CO. Michigan City, Ind. Gages and Flue Gas Toledo, Ohio Tools per cent ove March per cent over Apr HAYS CORPN. Analyzers April, 9.4 per cent ove MAM hay Viay Electrical Equipment April, 19 per cent over MAMJ Mar h : per cent over April CHICAGO HARDWARE FOUNDRY CO. North Chicago Hardware Castings April, per cent over March MAM May, per cent over OHIO BRASS CO. over Mansfield, Ohio STOVER MFG. ENGINE Car Equipment, Insulators, co. Valves, etc. Freeport, April, 17% per cent over Engines and Farm Equipment March. April, per May, per cent over April March 1933, per cent May, per cent over over May, 1932 April 1032—The Iron Age, June 29, 1933 tories and other aging Many other factors help account for the heavier out- put. far the building industry general con- cerned, there occasion for pessimism all. Gloom being rapidly dispelled and going around number cities lately, including New York and Chicago, find there very much better feeling. fact, there seems definite confidence that the upturn actually has come, find that the market for raw stiffening, with prices going up. establishments connected with the pack- Robertson, President, Robertson Co., Pittsburgh. Crane and Shovels Are Being Put Work have yet found distinct improvement the way new crane and shovel sales, but our repair account, both last month and far this month, indicates that more machines are being put work than hereto- fore. This turn would indicate that fast idle machines are absorbed, new ones will ordered, are very hopeful the William Waite, Sales Manager, Browning Crane Shovel Cleveland. Outlook for Business Now More Promising May business was ahead April and April better than March. would further advise that the outlook for business more promising than for the past several months. Huther, Huther Brothers Saw Mfg. Co., Inc Rochester. Definite Improvement Taking Place can say, with certainty being truthful, that indications are that definite, not spasmodic, im- provement has taken place. Our own specialties will be- gin seasonal upturn July, and are expecting bet- ter season than that 1932, which was the lowest have ever experienced. Inquiry more active and indicates better sales during the last half the year. Henry Schwab, President, Milwaukee Pleasing Pick-up Printing Machinery PPARENTLY the fear inflation passing out the minds the printing industry and are receiv- ing decided increase business June over that both April and May, and, business does continue has far this month, June will show very pleasing number orders and will compare with March this year, the best month orders nearly two years. Thomas, President, Wesel Mfg. Co., Scranton, Pa. Lines Indicating Better Business Weather from our activities, and serve the ma- jority industries, feel that general business definitely the upturn, although will probably ir- regular. The orders are receiving are generally small, but the quantity inquiries and orders larger now than any time for the past two years. Many our accounts which have been more less dormant are becoming active our barometer lines. production 2: : 7 / March 7 | pack- vier out- stepped up, industry will not permit tie-ups caused hand mouth buying tools, with stocks hand, and this condition should reflected considerable con- increase volume the tool industry. Gloom Woodworth, President, number Ex-Cell-O Aircraft Tool Corpn., find Detroit. seems ally has nas been Believes Improvement General our opinion, and come contact with good MAM President, many individuals who represent various lines not only Co., this State but other States and they are all the OHIO NUT BOLT CO. same opinion, that business has been increasing gradually Berea, Ohio for the past two months. Nuts and Bolts And, according all indications, continue im- FROST CO. prove. Financial difficulties are gradual improving. Kenosha, Wis. repair Cieveland Union Engineering April, per cent over indicates Cleveland. March Toledo Scale Reports Improvement Manager, during May exceeded those May, 1932, ovel per cent. Industrial sales during this period were per cent above the same period last year, which in- dicates that industrial activity definitely increasing. MAMJ addition, May showed per cent increase over April, which had been the best month since Nov., 1932. MAM OHIO ELECTRIC MFG. CO. Toledo, Ohio. BONNEY FORGE TOOL Allentown, Pa. have slip back step two every once while, MAMJ fully believe that are the highroad better BOWEN PRODUCTS conditions. lace CORPN. ful, that undoubtedly big increase the confidence the Lubricating Devices, Etc. odie, people. They longer believe that this country Apr cent bet- George Whyte, President, per cent over have Macwhyte Co., indicates Kenosha, Wis. President, OTTAWA SILICA CO. ANY propositions which have been held for sev- eral years are coming back life, every case MAM improvement. Some these inquiries are becom- MAMJ ery ing active, very active, the present time. STREINE TOOL MFG. out Purcell, President and General Manager EX-CELL-O AIRCRAFT New Bremen, Ohio TOOL CORPN. Tools Detroit Optimism Apparent fg. Co., apparent optimism throughout the coun- MAM Pa. try which promotes buying attitude and have every confidence that our business will continue showing SULLIVAN MACHINERY improvement. Hays Corpn.. Mining Machinery Michigan City, Ind. siness MOTOR WHEEL CORPN. MAM ir- Looks for Continued Gradual Improvement Mich small, ATURALLY, feel very much encouraged over Chicago now our are now the outlook, the improvement which attribute partially the fact that would difficult conceive conditions going very much worse than they were the beginning the year, and any change would seem Valves, fittings, etc. The 29, 1933—1033 Age, June 4 q 7 ee MAM FEDERAL MACHINE Turbine Blowers WELDER CO. Exhausters Warren, Ohio per cent over March March, per cent over February April, per cent over March May, per cent old normal. June will per cent normal the Administration policies, which could not fail cre- ate more feeling confidence. The Administration policies, course, are still tried out, and while have nothing but commendation for the attitude the President thus far, remains seen how much sup- port will given him and what his further attitude will case adequate support not given the policies set forth him thus far. the whole, however, believe that are definitely the upgrade, and while complete recovery will un- doubtedly slow, think will continue with possibly slight recessions from time time until real prosperity can said have returned. Frost, President, Frost Kenosha, Wis. Notes Better Sentiment note great improvement the sentiment the plants that contact, but there still some hesitancy making commitments for machinery, but are hopeful for the future. Leonard, Consolidated Packaging Machinery Buffalo. Price Situation Improving month May was increase 100 per cent over April, and the present indications are for continuance improved business. feel that the greater production requirements have MAMJ OSTER-WILLIAMS AMERICAN HOIST Cleveland DERRICK CO. Threading Equipment St. Paul, Minn. cent over Hoists and Derricks March April, per cent under May, per cent over Apr March. | V be | pe cent May, 64 per cent over Ay ril over May will 200 per cent over May made necessary for customers purchase quality mer- chandise again, which has tended eliminate good deal the low priced, low quality competition. feel sure that the needs the country will provide greater volume business than have enjoyed since 1930. Anderson, President, Morrison Machine Products, Inc., Elmira, Real Test Will Increase Wage Buying Power are certainly moving forward again de- gree which perhaps has not been equaled since the depression began. The question is, will they continue, and regard this, suppose that one man’s guess almost good another. The inflationary processes which have already raised c