The Iron Age 1933-07-06: Vol 132 Iss 1

Editor Consulting Editor Editor Emeritus Managing Editor Pittsburgh Detroit Boston Cleveland Chicago Washington Cincinnati CONTENTS Winged Ingot Improves Structure » re THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th New York, Y., Member, Audit Bureau of Circulations, ADVERTISING STAFF Member, Associated Business Papers Emerson Findley, 311 Union Cleveland Herman, 675 Delaware Ave., Buffalo, Hottenstein, 802 Otis Chicago Peirce Lewis, 7338 Woodward Ave., Detroit Charles Lundberg, Kent Rd., Upper Darby, Published every Thursday. Subscription Price: United States and Possessions, Mexico, Cuba, $6.00; Del. Co., Pa. Canads, $8.50, including duty; Foreign, $12.00 Ober, 239 West St., New York year. Single Copy Cents Robinson, 428 Park Pittsburgh Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, Warren, Box 81, Hartford, Conn. SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY wet Modern Metall Jobbing Found : q he ] if THE IRON AGE..........JULY 1933 Page CONSIDER the list reasons why Bethlehem offers exceptional service steel- plate buyers, unusual and extensive manufacturing facilities easily ranks first. Able personnel, experienced supervision, proper organization— each has its vital place. But there substitute for really modern facilities. great plate-manu- facturing plants there are facilities worth seeing. Modern, large-capacity sheared and universal mills that can turr out any size thickness you are likely need Complete steel- producing units right hand feed layout and organization that assure the filling your order with almost clock-like precision, even when calls for special analysis. Whatever the kinds steel plates you need, whatever the quantities involved, put your requirements Bethlehem. BETHLEHEM STEEL COMPANY GENERAL OFFICES: BETHLEHEM, PA. a ..THE IRONA JULY 1933 ESTABLISHED 1855 Vol. 132, No. Free Rides MONTH ago, industrial sentiment was almost unanimous its sup- port the President’s plan for Industry Control. The majority real- ized that something had done, and done quickly, reverse the devastating action the vicious spiral. Sentiment this subject among employ- ers, today, divided. This partly because business has been improving. But prin- cipally because the obvious efforts “organized” labor use the terms the Recovery Act means securing ad- vantaged position for class minority. That this attempt vigorously being made now quite evident. apparent Detroit, for example, where the now conducting whirlwind unionizing — ie campaign. also evident the coal dis- tricts, the steel-producing districts and elsewhere. Organizers have even gone far insert advertisements news- papers labor districts which imply that the Recovery Act makes compulsory join “the union.” course, this has been disturbing employers open shop districts, who com- prise the large majority all employers and who have maintained fair and friendly rela- tions with their help. Quite naturally, they wish continue get along without the in- terference professional “disturbers” and keep their localities free from the extor- tions labor racketeers. The natural inclination the employer, who asked carry the burden wage f | increases and shortened working weeks, without being permitted raise prices, understandable view what going on. “stop, look and listen” before agrees sign what may well “revoca- tion independence” favor Mr. Green and his fellow That one way look the situation. But there another way. The President did not objection- able features the labor clause this act. That was done those legislators who lis- ten attentively and respectfully the dic- tolerate the jeopardizing any minority. these ends Organized labor but small fraction our working population and still smaller fraction our public. more important politically than socially from eco- nomic standpoint. little fellow with loud voice. This little fellow now trying increase his stature climbing the load that Uncle Sam with the help capital and real labor struggling lift from the backs tates the labor lobby. Congress will not administer this act. The President will. And not likely let any minority interest stand the way That end not close- shop American industry, but effect bet- ter alinement between purchasing power the desired end. and production. The great majority American people classes life believe, with the President, that es- sential attain this bal- ance between producing capacity and consuming power. They, too, will not 14—The Iron Age, July 1933 the public. ride. make non-membership union condition employment the working man free join the union. This part the con- stitutional rights personal erty and private property not taken away even legislation. The same liberty which enables men form unions, and through the unions enter into agreement with employers willing agree, enables other men remain inde- pendent the union and other employers agree with them employ man who owes alle- giance obligation the union.” From decision the Supreme Court, the Hitchman Coal Coke Case. would advisable tell this little fel- low uncertain terms that had best climb down and his share the lifting. For industry cannot expected enthusi- astically strain its back order give and unpopular minority free Organized labor cannot help either the President the public fomenting discord through the exer- cise selfish opportunism. the contrary, such action may easily defeat the common cause. | at A <) L/ . » Modern etallurgy—A Factor the Jobbing Foundry jobbing gray iron foundry was simple. Usually some standard mixes irons were used that seemed make good looking castings, that machined easily, and that gave reasonably good machine surface. With slight modifications, these standard mixes were generally employed and the iron was used rath- promiscuously all classifications castings. That jobbing iron foundry practice yesterday— yet this policy still followed, unfor- tunately, the majority foundry- men today. Therefore, this slow im- provement establishes opportunity for those foundrymen who can ap- preciate the changes that have taken place recent years, and who ap- preciate that the service conditions castings should considered and that modern metallurgy should used make castings meet these conditions most efficiently. For the same reason, those engaged the jobbing iron casting business who are among the first thoroughly understand the basic metallurgical factors involved and the proper use alloys castings can even under today’s economic conditions consist- ently improve their business both expanding their markets and better- ing their sales prices. Some jobbing foundries are work- ing out their economic problems concentrating For example: recent years, the task Allowing for all special expenses con- nected with alloyed irons special irons and then deducting these allow- ances against sales price, the basic sales price the Fulton Foundry Machine Co. today considerably higher than was 1929—even though many expenses labor and material have been much reduced since that time. And further, the volume business much higher than the normal ex- pected from the general business foundry index figures, and the number cus- tomers has more than doubled since 1929. This evidence that thoroughly understood application modern metallurgy the production iron castings jobbing work will pay. Heat-Resistant Work examine this proposition more detail, consider heat-resistant cast- ings for stoker parts, lead pots, damp- plates, heat-treating equipment, ete. The hit and miss castings former days may work fairly well and then again they may fail miser- alloy combinations DENISON President, Fulton Foundry Machine Cleveland _ ably. highly graphitized iron will grow and become rotten very rapidly. better general-purpose iron with fairly good combined carbon will soon dissociate certain stabilizing influ- ences alloys are not present. Con- any buyer castings who has heat- resistant requirements pay more for dependable product with definite properties which will regularly give long-service life. Likewise, a way increase sales improve one’s product. The jobbing iron foundry has opportunity raise the quality its castings the practical application metallurgy and the exercise care melting. The author, himself foundryman, does not advocate piling expense through sharply chases expensive alloys. Such alloys have their place, states, but they are more important than some the cheaper alloys promoting the practical solution day-to-day melting problems. opportunity any jobbing foundry- man study, both reading and experimental research, the proper metallurgical combinations which will definitely meet reasonable heat condi- tions, and what may ex- pected from iron this use. Many are possible for reasonable heat resistance, such the use special pig irons, nickel and chromium combinations, molybde- num and molybdenum-chromium com- binations—and others. Much mation available those who will search for and much offered their researches performed further the sales their products. Brake drums offer the iron foundry- man field opportunity, shown the quite general trend this year back cast iron brake drums automobile builders. The right cast iron makes ex- cellent brake drum, but many ordi- nary irons generally used jobbing foundries make drums that not only will not stand service but may even unsafe. The requirement good brake drums cast iron high strength with structure that pearlitic and sorbo-pearlitic. should reasonably stable against dissocia- tion when the drum heated service, and the graphite should small particles and well distributed. These conditions can easily and con- sistently met with good standard- ized melting practice and the proper use alloys, meet the needs brake drums. industrial machinery, good cast iron brake drums should serve very efficiently and replace other materials now use for these purposes showing superior Low-carbon cast iron with any number alloy combinations that are available, used, will make good dependable brake worth the better price needed restore profits the job- bing iron foundries. castings and brake drum castings illustrate several clas- sifications which the jobbing foundry- man should consider from scientific standpoint. The list could greatly extended include pressure castings, wear-resistant castings, gears, cast- ings requiring strength with max- imum deflection, and many other clas- sifications. Skilled Melting Essential meet the requirements today necessary have skilled melting regardless the melting medium. Good results can obtained with the cupola, air furnace electric furnace under skilled management but poor iron will also produced with any these melting mediums under care- less control. Therefore behooves the progressive jobbing foundryman establish research the exact condi- tion under which his furnace cu- pola gives best results, and then set standard inspection requirements that must met every day main- tain uniform melting. Likewise, the jobbing foundryman who meet these more exacting requirements cast iron cannot ex- (Concluded Page 68) The Iron Age, July or) | | | | | 28 | a { 7 Welding the Steel Heavy Equipment Applications dealt with the use welded steel construction for various mill parts. Applications were grouped according their use mill opera- tion. This article will consider un- related types equipment which have but one thing common, namely, heavy stresses and strains that pro- vide exceptionally severe tests welded construction. First let consider lifting ram for soaking pit crane. The one shown Fig. was built replace lifting ram for 15-ton soaking pit crane which fractures had developed the ribs and sup- ports. The entire ram was made 1-in. plates and fabricated with the articles this series aid cutting torch and the electric welding process. The four corners are made 4-in. forgings welded place, machined, and pro- vided with flat strips held with countersunk bolts. This construction was necessary because the strips have renewed due wear the ram travels and down the guides lifting the ingots out the soaking pits. The steel pipe the center was rolled two 7-ft. sections and welded circumferentially and longitudinally, making piece pipe ft. in. long, in. outside diameter, and in. thick. After the pipe had been welded hole was cut out the end plates 16—The Iron Age, July 1933 TAYLOR Vice-President, Lincoln Electric Co., Cleveland with torch approximately the out- side diameter the pipe; the end- plates were then put the pipe and tack welded place. This was re- peated with all other plates. Next the longitudinal plates were set and tack welded, then the guide bars and the flange collar the end. was then decided that the ram should annealed, after which the welding was completed. The annealing was neces- sary because the excessive stresses set the intricate design. 4.—Girders attached end carriages the process shop assembly. 36-in. beam forms the heavy section the girder. Right) Welded roll changing hook 30-ft. tons. steel casting welded the hook the lower end fits over the shaft the roll lifted. This ram has been operation for over year and has seen almost con- stant service without repairs. The cost fabrication was much less per pound fabricated steel used than that the original steel casting. Roll-Changing Hook Handles 60-Ton Loads The hook shown Fig. was built the River- side Works the Otis Steel Co., Cleveland. This hook daily use lifting loads weighing tons. designing for steel construction, heavy plate was used and the hook built the form U-section. The length from end end approxi- mately ft. The side plates consist two lengths in. plate with strapped butt joints the inner 4 | | | | a | article covers application crane lifting ram, roll-changing hook and open-hearth charging machine which, because the heavy stresses, provide unusually severe tests welded construc- Mr. Taylor. The previous articles, devoted respectively table and furnace rollers and tilting and transfer tables, mill shoes and other parts steel mill machin- ery, appeared THE IRON AGE April 20, page 620, and June 29, page 1024. sides. The cover plate built two lengths in. steel, ft., in. wide, with strapped butt joint. stiffening member was laid top the cover plate, extending the entire length the curved section, and fillet welded place all sides. steel casting was welded the hook the lower end. This casting fits over the shaft the roll lifted. Open-Hearth Charging Machine Has Welded Members weaknesses the old type open- hearth charging machines developed under the ever-increasing loads and service, the design Heavier sections steel were used. The size -rivets increased and the spacing decreased produce sections rigid possible. But there limit the size rivets which can used and the rivet spacing. Fig. Fig. lifting ram for 15-ton soaking pit crane made plates gas cut and arc welded. has been continuous operation for more than year. shows the shop assembly welded capacity low type charging machine built the Wellman En- gineering Co. for the Carnegie Steel Co. Fig. shows the girders attached (Below) Shop capacity charging machine. After erection the chargers the open- hearth platform, the were welded together. The bolts used join the end carriages and gird- ers were welded place. the end carriages the process shop assembly. H-beam forms the heavy section the girder. The outer section 20-in. I-beam with both beams welded bottom cover plate. Vertical stiffening mem- Fig. 5.—Special 16-ton gear case fea- turing oil-tight welded construction. Side plates are thick and cover plates, 2-in. thick. bers are welded the H-beam. The cross members for supporting the moving mechanism were planed as- sure alinement the shafting. Following erection the chargers the open-hearth platform the end carriages were welded together. Even (Concluded Page 68) The Iron Age, July 1933—17 | ear Lapping After Heat Treatment where the desired accuracy for certain types units could con- sistently attained without subsequent correcting operations. technique gear cutting has The patent office has large ac- cumulation ideas and devices for Fig. axis lapping using oscillating motion parallel the axes gears being run together. the correcting gear teeth, some them filed early 1880. Although uncertain the time was first initiated, lapping has been one the principal means effecting these cor- rections. important differentiate be- tween correction gear teeth the removal appreciable amount stock and merely polishing operation which great amount material removed. This article deals with the correction gear teeth with appreciable removal material. Recent advances gear correction practice have made possible re- move amount material hitherto considered impracticable, not im- ically practicable remove all the distortion resulting from normal heat treatment. Lap life has also been materially extended, and certain instances from 500 1000 gears are corrected without effecting error more than 0.001 in. the profile the lap, even though the chordal thickness the lap teeth may reduced much 0.30 0.60 in. Early Lapping Practices The early lapping practice was run pair gears mesh, feeding abrasives into the mating teeth. This was effective improving somewhat 18—The Iron Age, July 1933 DRUMMOND President, National Broach Machine Co. Detroit the performance the gears, but the light present standards was crude method for correcting the many inaccuracies which gears are subject. One the chief difficulties results from the occurrence high spots left the cutting operation. When gear having such high spots runs together with another gear, the high spots the first wear holes the teeth the second. also customary this wear-in procedure operate the gears parallel axes. Obviously the distance Fig. 2—In this parallel axis lapping, second motion employed vary the center distance between the gears. traveled sliding contact the tip the tooth greater than that traveled near the pitch line the tooth. Consequently the abrasion the tip greater than the other part the tooth. This often results adding inaccuracies rather than correcting them. matter fact, many gears have been completely ruined such methods. modification this parallel axis method uses oscillating motion parallel the axes the gears while they are being run together (Fig. 1). This increases the cutting action all points the tooth surface but unfortunately does not materially alter the difference cutting effect already mentioned. Further Development Parallel Axis Method further development this idea was the introduction second motion, that is, one vary the center distance between the gears (Fig. order spread out the line weakest lapping, which oc- curred the pitch circle. This phase gear lapping has greatest development. Some have gone far equip their machines with radio attachment which makes audible the sound the gears they are being run together. this operation, lapping halted the operator soon the characteristic sound has diminished minimum and before starts increase again. Under the above gears assume conjugate shapes, but the tooth, when completely processed, does not take the form involute curve nor the finished gears move with uniform motion. Another principal avenue attack this problem has been the use separate lapping element. This has resulted increased lap capacity, the material chosen for the lap softer than the gear processed Fig. 3—Large diameter worm laps are made correspond angle with the hob which the gears were cut. and such character that more readily held the abrasive com- pounds. fact, special lap ma- terials increase the ratio lap wear Another practice embraces the use emery sticks, profiled the shape the teeth, and still another (Fig. uses large worm laps made cor- respond angle with the hob which the gears were cut. The large worm lap proved more less suc- cessful, providing the operator used excellent judgment and accuracy the work gear was relatively high. Worm Lapping Used for Years Worm lapping, wherein the worm many times larger diameter than the gear being corrected, has been used for watch pinions for the last years. Originally these laps were made cast iron and later alumi- num. fact, the practice still followed some plants that make | 4 -G | = => n | a gears this type. view the highly competitive nature the in- dustry and the low purchase price the product, lapping time for watch pinions necessarily quite limited. Worm lapping has also been used limited extent the recent past for automotive gears but without significant success. This process de- pends too largely upon the judgment the operator. continued too far, the work seriously damaged. Set-up also proves troublesome that not possible run the gears their correct position until lapping com- pleted. The set-up has con- stantly adjusted and this has ten- dency throw serious variations the tooth profile. These objections are intensified the fact that high speeds are used and the cuts are taken lengthwise the tooth profile. The contact period the tooth point greater than that the pitch circle which, previously explained, re- sults the irregular removal stock. Due the large lap diameter, recutting very expensive and the difficulty accurately reforming the lap teeth, which done grinding grooves the worm, easily recog- nized. Internal Lapping Still another effort solve the troublesome variation the amount cutting different points the gear tooth entailed the use master internal lap (Fig. having the same number teeth and profile the The work gear reciprocated inside this lap, contact- ing first one side and then the other its teeth. intermittent indexing Fig. 4—Internal lapping. The work gear reciprocated inside the special lap, contacting first one side and then the other its teeth. spreads excessive wear over the sev- eral lap teeth. The result this type lapping, however, shows little im- provement the eccentricity the finished product. Any given lap rapidly assumes the characteristics the average the gears processed. excessive error occurs several con- secutive pieces, the lap tends take the same shape work units. Another objection this means correction due the lengthwise cutting the gear teeth which in- clined produce washboard effect and excessive noise the operation the completed product. also quite difficult secure accurate master laps. The current practice pro- ducing the lap cast over master gear and then run into methods developed inaccuracies gear teeth are outlined this article, which also includes data lap- ping compounds. The subject one that being given increasing attention, with the double objec- tive assuring maximum quiet- ness and strength gears under increasing speed and load condi- tions. The article from ad- dress the recent meeting the American Gear Manufacturers Association. shape with variety selected gears. This practice eliminates the variation due rolling contact with other gears but introduces factor excessive wear, certain teeth the lap are seriously scored. Split Worm and Rack Laps Another variation gear correc- tion equipment the use the split worm lap which takes backlash be- tween the gear and lap while running correct centers. This results one half the worm operating one side the tooth and the other half the other side. The tendency this action cut tooth profile rapidly but the sacrifice angular correction. The internal gear has also been used another way, that is, allowing the work gear roll with the lap, Fig. The action here success- fully corrects tooth profile but the expense machine time. Another obstacle lies obtaining internal gears the necessary size and ac- curacy. Another method gear correction relies the use rack lap, Fig. The teeth the work gear are par- Fig. 5—Internal-external lapping. this case the work gear permitted roll with the lap. allel the length the rack teeth. This method corrects gear inaccuracies with relative success except index error. Inasmuch any given tooth the work gear continuously contacts the same tooth the rack, wear due index error becomes cumulative. The initial cost the rack and the cost its accurate recutting have also proved serious objection. Lapping has been done shown Fig. using pitch circle disks limit the extent lapping, and when lapping helical gears, this has been coupled with master helical gears, per- mitting endwise sliding one gear against another. This practice has the same objection indicated above, that the speed lapping the various points the teeth irregular. Three laps have also been used, running with one gear shown Fig. the gears being oscillated their shaft. This multiplication simpler method one lap with axial reciprocation the gear. combination internal lap and external lap with multiple gear parts running between them shown Fig. This device indicates the pos- sibility flapping gear both sides the teeth the same time, brake can used either the central outside gear; the other gear being driven. Crossed Axes Lapping With the increasing pressure the automotive industry for silent trans- missions, has become imperative for the gear maunfacturer elim- inate all errors gear teeth very much higher degree than was heretofore considered necessary. These errors include profile, index, eccen- tricity, helical angle and quality finish. These insistent demands for higher quality have resulted development two new lapping practices within the last three years. Both are based the use separate lap and crossing the axes gear and lap. The first known cramp lapping (Fig. 10) which the lap tooth given abnormal thickness and which the feed reduces the center distance between gear and lap. The lap teeth contact both sides the gear tooth; cutting being accom- plished lapping compound fed into the gears during operation. Cramp lapping very rapid and ideal means correcting exces- sive eccentricity index. has be- come standard practice number shops manufacturing automotive gears. explanation, let say + Fig. 6—Rack lapping. that any material change effected the center distance between gear and lap compensated change the angular setting the axes, inasmuch the lap and work gears mate the same way pair skew gears. This angular relation the two axes the machine column. The setting controlled the use angle checking fixture (Fig. 11) which in- dicates the tooth error the use The Iron Age, July 1933—19 f - | | q | 4 = A a = 4 | | \ | Fig. 7—Restricted center distance lap- ping. Pitch circle disks are used limit the extent lapping. rack tooth and integral sine bar. The radius the sine bar the same division the vernier column scale the lapping machine. Angle Reduced Less Than Deg. Although the worm lapping process was the first use crossed axes, the angle between the axes that proc- ess approximately deg. The new practice crossed axis lapping, introduced 1930, reduces this angle less than deg. and frequently ranges below deg. The angle used any given case the dif- ference between the helical angle the gear and that the lap. The results attained these newer methods have been significant that practically per cent the lapping tools purchased since their introduc- tion incorporate the new principles. One outstanding case comes mind set gears having the following errors: Involute, 0.004 in., eccen- tricity, 0.005 in., cumulative index, 0.008 in., helical angle, in. radius. These gears were corrected final involute error 0.0005 in., eccentricity, 0.001 in., cumu- lative index, 0.001 in., helical angle, 0.001 in. radius. Although considerable material had re- moved attain this result and back- lash was considerably increased, extreme example what can done means the newer lapping methods. the second these methods, known power tailstock lapping (Figs. 13, and 15), the center dis- tance between gear and mains constant and power tailstock used effect braking action 20—The Iron Age, July 1933 Fig. 8—Three-ring lapping. 7 Fig. 9—Combination internal and external lap with multiple gear parts running between them. the work gear, which driven the lap. After the work gear has been driven given number revolutions one direction, rotation reversed and progresses the opposite direc- tion number revolutions com- plete the cycle. The brake operates throughout the continuous cycle, first one direction and then the other. Thus both sides each work gear tooth are given the same amount processing. the cramp lapping, the axes are crossed. both methods angle checking fixture used control angular relation work and gear lap. The radius the sine bar the same division the vernier column scale the lapping machine. Fig. 12—(At Right) Lap- ping machine arranged for cramp-action lapping. automatic electric reversing and timing mechanism controls the num- ber revolutions. Lapping Compounds Greatly Improved The cutting lapping compound has also been given great deal study and has shown remarkable improvement recent years. Lap life has been raised from approxi- mately 100 gears 500 and high 1000 special cases. lap which was used for automotive transmission gears shows total chordal thickness wear 0.079 in. with only varia- tion 0.001 in. profile. Too much attention cannot de- voted the proper choice and inspec- BP 1 tion grain size and quality lapping compound. There vast difference the character in- dividual grains any given size Fig. Ring” cramp lapping method. Both this and the method separate lap and crossing the axes gear and lap. Excessive eccentricity index corrected rapidly. material. For instance, grain specified for abrasive paper quite unsatis- factory for gear lapping because contains high percentage needles and slivers. Grain for lapping com- pound should rounded, irregu- lar shape but never needle-like. Tests have proved that efficiency cutting action and lap life can greatly increased proper choice grain and lubricant. have used two lubricants, one oil soluble solution for washing kerosene and the other water soluble solution for washing oil soda water. The same size and quality grain are used each and the same amount grain. Nevertheless, carefully conducted tests the water soluble compound very much more —O =~ ct = ‘ 4 \ = A \\ / S39 il } | efficient than the one having the oil base. With one exception, all plants our customers’ list are using the water soluble compound. not believe the average shop man ap- preciates the potential saving avail- able him the proper choice cutting medium. Lapping Time About Min. Per Unit Standard lapping time today for reasonably well cut gears about min. per unit having in. face and diameter. This assumes reasonable control gear cutting and heat treatment. have found other shops that machine time for lapping gears similar size amounts others, handling carburized gears in- accurately machined, machine time has amounted much hr. Errors this magnitude should eliminated adequate control gear cutting and heat treatment. recall one job having eccen- tricity 0.010 in. in. gear. The teeth were out parallel with the axes much 0.010 in. in. and the index jump from tooth tooth was high 0.004 in. The holes were ground out line with the teeth the extent 0.005 in. in. Such condition course requires supervision rather than lapping. One the finest runs remember was lot 30,000 gears. Rejection for gear noise after lapping was only per cent and the lapping time averaged min. per gear. Lap life this job was approximately 900 gears per cutting, and the lap was recut twice, which gave total life 2700 gears. These were standard automobile transmission gears sev- eral well-known designs which were accurately cut and treated. Grinding Before Lapping When excessive distortion occurs due high carbonized heats large gears, has been found very advan- tageous take single roughing cut with grinding machine re- meve this excess before final lapping. recent test, which the grind- ing time in. diameter gears was min., was possible take single grinding operation min. Fig. 14, Fig. 15—Lap- ping machines arranged for power tailstock lap- ping. The center dis- tance between gear and lap remains constant and power tailstock used the work gear, which driven the lap. The amount braking force regulated suit the work One side the gear teeth acted upon time, and reversing the rotation the mid- point the cycle, both sides the gear teeth are corrected. and lapping time min., total min. the lapping oil-treated gears, the standard lapping time varies from Fig. “Red Wing” power tailstock method lapping. in. diameter, and the proportional size the gears indicates the in- creased lapping time required for the same cutting and heat-treatment con- ditions. Use accurate laps the finish- ing heat-treated gears gives the shop operators very clear indication the errors the cutting, the high parts are easily recognized. production runs, has fre- quently occurred that the cutting operations were subject prompt investigation due the appearance the gears after normal lapping, the lapping cut showed the profile angle the gears error. Steel Railroad Tie FORM steel tie and rail- road track construction that connection have been patented Walker, manager the Walker Co., Macungie, Pa. section track built according the system has been constructed for general inspec- tion, shown the illustration. The tie comprises pair I-beams (5-in. beams for track with rails), the two beams being separated lengths channels, bolted welded the beams separators. The space between the beams may filled with concrete and otherwise the tie rests the road ballast the case timber ties. The rail fastening includes U-bolt which passes through hole the web each I-beam that the cen- ter the bolt has fulerum support the beam and the bolt shanks are inclined upward and away from the rail base, with the two shanks span- ning the top flange the beam. Nuts (Concluded Page 68) tite, - + 6 ~ | (sé é wl, ff / | \ | ; 4 ROSS-SECTION winged ingot shows the marked concentration the segregation and piping the central triangle the ingot. winged ingot method cast- steel developed the Firth- Sterling Steel Co., McKeesport, Pa., from invention Gerald Firth, general manager the com- pany, now past the experimental stage. has been used the manu- facture steel various grades dur- ing the past two years, and ingots weighing from 1000 10,000 While the unique character the in- vention has been recognized the sev- eral countries which have granted pat- ents it, after examination the “prior art,” its possibilities method improving steel are just being realized. This method casting, described THE IRON AGE, Feb. 1933, page 197, eliminates undesirable struc- tural condition the center in- gots which steel makers have been trying for years overcome. Along with the improvement the center has come distinct advance qual- ity and uniformity without crease cost. some alloy grades, there slight increase, but many grades, the winged ingot offers ac- tual savings over present methods, because the reduction ingot dis- card and increased recovery subse- quent operations. Center the Common Ingot The macro-etch (hot acid) test which has come into general use fo- cused the attention both users and steel makers the structure the center bars and billets. Steel mak- ers have endeavored offset the ten- dency steel segregate and throw absorbed gases along with non- metallic inclusions the center ingot during cooling. the same time, they also tried eliminate “pipe” and porous conditions which cause excessive loss due the heavy cropping cutting back necessary remove all traces bad center. incidental but very important phase the problem was the aim secure steel which would relatively uni- form structure all parts the cross section forging billets and finished bars. ordinary practice, when molten steel poured into square similar ingot molds, there first quick chilling where the metal contact with the mold forms into “chill crys- tals,” followed gradual cooling the metal from the surface toward the center the ingot. During this cooling, the evolved occluded gases along with impurities, such non-metallic inclusions, are “frozen out” the solidifying metal and forced toward the center and to- ward the top the ingot. result, the steel toward the bottom and nearest the surface the ingot has the best structure. Hence, there the tendency toward bursting ~ and 2—The lines progressive solidi- case conventional ingots are shown Fig. for the vertically cast, and Fig. for the more less horizontally cast. 22—The Iron Age, July 1933 inge DONALD CLARK Firth-Sterling Steel Co., McKeesport, Pa. the center forging the strain comes the weakest structure. many tools and dies the impacts intricate patterns come that portion the die which made from this central part the bar and billet. other tools, such ordi- nary chisels, the cutting edge made from what was originally the center the ingot and billets. many parts machinery and equipment, metal formed that the greatest stresses come that part which originally the center rather than the outer part ingot, billet and bar. Cooling Lines Studied discussing various methods used eliminate this undesirable center structure, the progressive cooling ac- tion which occurs within the ingot must visualized. Taking cross sec- tions, this action may illustrated the accompanying figures wherein the light dotted lines show how the cooling crystallization progresses from the surface toward the center. Fig. shows the cooling lines the conventional square ingot filled vertically when top bottom poured. varying the taper, the depth pipe may changed but the cooling action remains practically the same, giving clearly defined difference be- tween the structure the surface and the center. Attempts cast horizontally various angles re- ferent cuts may attempted bring access the segre- gation centers, which may removed, milling. $ q 7 4 : 7 7 | | | 4 | bad | 4 te sult moving the toward one surface shown Fig. where the poorer structure off center but still well within the ingot. This central structural condition has been eliminated splitting in- gots lengthwise shown Fig. where the billet was cut two and the center milled planed out; Fig. where the ingot was split into four parts and one corner each removed take out center steel; cuts through the ingot, eight good split ingots were formed while the ninth central one was discarded, carrying with all the steel more method necessarily costly, because the number cuts necessary the case the type illustrated Fig. the necessity milling planing, the case types Figs. and the winged ingot method, in- got having cross section similar vious that cooling along the lines illustrated the above sketches, the chill crystals form immediately three sides and then the solidification, progressing indicated, forces im- purities and gases toward the central section—the triangle Fig. Be- fore these “winged” ingots are cool, the wings are cut off the lines indicated (X, the drawing. The cutting done with torch. The heat the ingot helps make very inexpensive operation. the case some the higher alloy steels, necessary machine-cut the wings. These cut-off ingots are then cogged the regular way and carried - \ 4.3. the winged ingot was developed make for uni- formity tool steels, the author believes that the unexpected economies realized manufac- ture, together with dependable uniformity quality, open field for the ingot the making all kinds steel. through the rolling hammer-finish- ing operations such way that the differences structure between sur- disappear. The breaking down and the refining the structure which oc- curs greater extent the sur- face than the center forging and rolling corrects the difference between sides and The uniform heating for the finishing operations, together with the scaling hammering and rolling, equalizes the difference structure which originally occurs due the chill crystals the three sides, and the absence them the fourth. Physical Properties Improved Although physical properties tool steels have never been considered basis for the selection steel for cut- ting tools, comparison the physi- cal properties the metal various parts billets made from the ordi- nary square ingots, and the same rela- tive portions billets made from winged ingots, discloses striking superiority the way uniformity the winged ingot product. also refutes possible criticism the struc- ture the fourth cut side. Pieces for tensile and impact tests were taken the positions shown Fig. from billets made from winged ingots, and also from corresponding portions, Fig. billets made from When tests were made was found that the transverse specimens taken through the center the billet from square ingot show elongation and reduction area values about one-half the values specimens just below the sur- face. The tests specimens from winged ingots showed these values the test pieces through the center almost the same specimens from the outer and specimens from inner (torch cut) side the wing. The inner and outer sections show values nearly alike the average that cannot said that one bet- ter than the other. The tensile strength and elastic limit figures not show any material difference. Izod impact tests the values pieces taken from square billets were about four-fifths the values specimens while the winged ingot, specimens were almost the same and specimens from (the “cut side”) were even higher than the others. Further tests determine the effect cutting one side ingot were made hardening cylindrical pieces about in. long and checking the warpage see there were any tendency toward more less motion distortion the cut side. The tests again proved this side the same the opposite, there being more warpage one direction thz another. Drastic etch tests, course, reveal very slight variation between one side and the other the case larger pieces, but the smaller sizes, difference perceptible. Field tests have confirmed shop tests, indicating that tools, dies and parts made from winged ingots have greater resistance fatigue, impact and wear than those made the usual way. forging, there less danger rup- tured centers, and heat treatment, less danger breakage, all because the more uniform structure. (Concluded Page 68) 6—The lines cooling the winged ingot with segregation impurities and gases the central triangular section. correct any differences structure the ingot surfaces and Fig. from that the cut-off surface, Test specimens from positions shown Fig. the billet from winged ingot show uniformity physical characteristics such are not found the case specimens from the corresponding positions the billet from the ordinary ingot, Fig. The Iron Age, July 1933—23 q + q veh > = ge 5 | fe 2) | . ae 4 3 3 4 Engineering Week Chicago Technical Societies, Fair City, Give Intensive Attention Their Meetings Chicago, came close July The leading engineering societies the country, selecting the city the Century Progress World’s Fair the place their mid- year conventions, scheduled them all for substantially the same time. Fif- teen national organizations convened. Attendance exceeded expectations some cases but general might better described only fair. The ex- position was the drawing card against the deterrents the depression, and brought goodly numbers Chicago, but the technical sessions did not suf- fer because the proximity the show. fact, the affairs the en- gineering associations got first at- tention. Except for Wednesday, June 28, which was set apart En- gineers’ Day the fair, few took time attend the Exposition until their society obligations had been met. There was bewildering array terest single individual came simultaneously; yet the necessity foregoing one another the gatherings was overbalanced the opportunity making numerous con- tacts with all classes engineers. Meanwhile Chicago was not conscious the presence the engineers, many and varied were the activities the city and the exposition. That fact was probably salutary; other- wise, with some fifteen groups meetings progress one and the same time scattered hotels, the im- pression might well have gone forth woeful lack solidarity the engineering profession whole. Among the associations holding im- portant meetings were those the civil, mechanical and industrial en- gineers, together with the Econometric Society, the Palmer House, the mining and materials engineers the Stevens, where the American Foundrymen’s Association had just completed its main sessions; and the electrical engineers the Edgewater Beach Hotel. There was notable two-day meeting the open-hearth committee the American Institute Mining and Metallurgical Engi- 24—The Iron Age, July 1933 neers, division which has come virtually society within society. The meeting the materials peo- ple was the regular annual convention the American Society for Testing Materials, and this organization, spite series uncomfortably hot and humid days, proved intensive usual the formulation and modification specifications and other standards for engineering ma- terials. The American Society Mechanical Engineers offered im- posing list sessions covering most the divisions mechanical en- gineering. The open-hearth delibera- tions the mining engineers covered scope program that promises develop sooner rather than later codification steel-making processes. Joint Activities the Societies joint activities the engineers were signalized principally banquet the Stevens Hotel, June 28. There was also open-air meet- ing the stadium Soldiers’ Field witness the bestowal the Gug- genheim medal Juan Cierva, Spain, for the development the autogiro, one which came the field for the ceremony. dinner the boards direction the four founder societies June was addressed the presidents those societies, including Dr. Fred- erick Becket for the American In- stitute Mining and Metallurgical Engineers and Dr. Potter for the American Society Mechanical Engineers. This dinner party served crystallize views the matter closer coordination the engineering societies and the establishment singleness purpose matters broadly concerning engineering. boat ride Lake Michigan, Thursday night, arranged the Chi- cago section the American Society Mechanical Engineers, also brought the engineers together. Industrial executives among the en- gineers took advantage the op- portunities discuss informally occasion the problems met connection with the covery movement, but probably the more fruitful these meetings were those held connection with the con- vention the American Foundry- men’s Association the end the preceding week. The meeting this technical organization the foundry industry brought divisional groups to- gether they could discuss the ques- tion under the direction such in- strumentalities the Malleable Iron Institute, the Gray Iron Institute and the Steel Founders’ Society. The observation the Chicago meetings that codes practice are slow the making, particularly the branch industry without trade association. The evidence these arranged and accidental group meetings also that the better or- ganized manufacturers will show the way meet the requirements the legislation and also that the trade as- sociation movement has decidedly new lease life with individuals high qualifications considerable de- mand conduct those associations. The joint banquet served reas- sert the engineer’s large part pro- moting human happiness the face the charge that his achievements mass production and the high efficiency mechanization are responsible for the distress the times. The speakers, Edward Mehren, president the Portland Cement Association and for years editor Engineering News- Record, and Dr. Karl Compton, president Massachusetts Institute Technology, emphasized that the engineers have brought state living that highly favorable for the extended development higher i q | q N ) | base ethics and morals, that what has already been accomplished in- dustry has proved especially the value research and that the key for the future cooperation along with re- search. The banquet sounded high note gratitude for the benefactions the engineer, while emphasizing his large opportunities and heavy re- sponsibilities the future. There was also joint evening meeting, June 27, the engineering societies and Section (Engineer- ing) the American Association for the Advancement Science listen ing, manager the research and education department the Metro- politan-Vickers Electrical Co., Man- chester, England. addition, several the days there were large joint luncheons, with single notable speaker each case. Elsewhere and later, space available, the main features the technical contributions the meetings will presented. Also separately will covered the high points the specification writing the American Society for Testing Materials. One the events the meeting the Society for the Promotion En- gineering Education was the bestowal the Lamme medal Dean Dexter Kimball, College Engineering, Cornell University, Ithaca, Y., who, incidentally, was the author the meeting the Econometric Society address entitled, “The Engineering Economist the Future.” Testing Materials Affairs THE American Society for Testing Materials was able operate within its current income, ex- plained the report its executive committee, and did not have call upon its surplus, nor upon favor- able balance $5,200 from previous years’ operations that had been set aside contingency fund. The membership was reported 3733 June about per cent less than the peak the society membership. Tentative revisions existing standards may hereafter accepted for publication between annual meet- ings the recommendation Com- mittee E-10. The executive commit- tee also reported the appointment the society and chemical engineer, United Gas Improvement Co., Phila- delphia, American member the Permanent Committee the Inter- national Association for Testing Ma- terials, the late Dr. George Burgess. Dr. Gough, superintendent the engineerin