The Iron Age 1933-12-07: Vol 132 Iss 23

CONTENTS INDEX PAGE MANAGEMENT DECEMBER 1933 PROCESSES -:- NEWS For more than quar- ter-century the pioneer the development high grade Ferro-Alloys and Metals. ELECTRO METALLURGICAL SALES Unit Union Carbide and Carbon Corporation Carbide and Carbon Building East 42nd Street, New York STAINLESS STEELS RESIST CORROSION YEAR SERVICE THE METAL WORKING INDUSTRY x fas THE IRON AGE... DECEMBER 1933 Page PLANTS for PREPARING, TREATING and HANDLING GAS AND COKE KOPPERS CONSTRUCTION KOPPERS BUILDING THE IRON AGE, published every Thursday the AGE PUBLISHING CO. Publication Office: Cor. Chestnut 56th Philadelphia, Pa. Executive Offices: 239 39th St.. New York, Y., Entered second class matter the Post Office Philadelphia under March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 132, No, 23. 4 December 1933 Editor Managing Editor Consulting Editor News Editor Machinery Editor *. J. WINTERS G. EHRNSTROM, JR. BURNHAM FINNEY Pittsburgh Detroit Boston F. L. PReNTISS R. A. Fiske A. I. FINDLzgy L. W. Morretr R. G. McINtTosH Cleveland Chicago Editor Emeritus Washington GERARD FRAZAR Contents Engineering Vision vs. Depression OUR PART Making Automotive Piston Rings Destroying Surplus Capacity Finish Helps Metal Products Sales Types and Uses Cutting Oils Steel Goes Hollywood New Equipment Personals and Obituaries Washington News Automotive Industry October Pig Iron Output Markets Construction and Equipment Buying Products Advertised Index Advertisers THE IRON AGE PUBLISHING COMPANY Fr. J. FRANK, President G. H. GRIFFITHS, Secretary C. 8. 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 Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, N. Y. H. K. Hottenstein, 802 Otis Bldg., Chicago Published every Thursday. Price: Peirce Lewis, 7338 Woodward Ave., Detroit United States and Possessions, Mexico, Cuba, $6.00; Charles Lundberg, Kent Rd., Upper Darby, Canada, $8.50, including Foreign, $12.00 Soth New York year. Single Copy 25 Cents W. B. Robinson, 428 Park Blidg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage, N. Y."' D. C. Warren, P. O. Box 81, Hartford, Conn. SEVENTY-NINTH YEAR SERVICE THE METAL WORKING INDUSTRY bs = | *. 1} | } | is 1 rae | 114 aA 1} | | 7 ok | EE: | i} x A | | 1] | Pt in Act THE IRON AGE....DECEMBER 1933 Page > a The making plates from the numerous alloy and special steels now called for engineers brings many manufacturing problems. Able personnel, modern large-capacity sheared and universal mills with complete steel-pro- ducing units right hand feed them, enable fill your specifications the letter. For oil refinery equipment such stills, refractionators, and bubble towers; for marine rail- way uses, for chemical plant any purpose where quality product required —Bethlehem has the men and the facilities and the experience that assure Steel Plates that fully measure the intended task. BETHLEHEM STEEL COMPANY General Offices: Bethlehem, Pennsylvania STEEL e DECEMBER 1933 ESTABLISHED 1855 Vol. 132, No. Engineering Vision vs. Depression engineer frequently blamed for eco- may seem ironic the critics the engineer nomic maladjustment. His ingenuity the that this visionary idea 1929 has become development the machine said have sober actuality 1933 and now seems likely upset the delicate balance the industrial structure. realized means putting men work. The Critics have answered with the simple fact that with- Public Works Administration, its routine dis- out the engineer human progress would stop. And bursements millions for sewers, post offices, progress essential. offers examples waterworks, roads and irrigation projects, has been the world’s long static, and retrogres- struck the originality the scheme. sion has always been disastrous. Allocation funds for building experimental section such seadrome seems practically as- occasionally the engineer displays vision sured. proves successful, and its sponsors are which fires the imagination his severest certain that will, money will sought build critics, The Armstrong Seadrome, developed five such floating air stations anchored the “bridge” the Atlantic with chain landing plat- Atlantic. least 125,000 tons steel would forms for flying ships, example. and thousands men would given Not recent conception, the seadrome idea has been “natural” for the Sunday supplements for many years. Even when first broached, received much serious consideration, and the basic princi- ples were outlined THE IRON AGE Nov. 14, that time, Edward Armstrong had idea has naturally met with much criticism, attracted the attention such pioneering organi- chiefly from parties whose particular interests zations General Electric Co., Sun Shipbuilding might thwarted. But the Panama Canal had employment. impetus industrial recovery, the project would inestimable value. achievement transportation, would epochal. Dry Dock Co., Belmont Iron Works, John many critics before was built. One great country Roebling’s Sons Co. and Henry Gielow, Inc., failed the job, and was left the United States. New York naval architect. significant that good know that our Government has not these firms are still interested. lost its pioneering heritage. wat |. = y ; @ YO a O Wall Tension, Lb. (For Average Thickness) Ring Diameter, In. Fig. Piston Ring Wall Tension. 0.215 Piston Ring Thickness and Piston Groove Depth and 1932 Thickness Piston Ring Diameter, In. 3 Fig. 2—Chart Showing Groove Depths and Ring Thicknesses. 12—The Iron Age, December 1933 Whe JOSEPH CHEETHAM Factory Manager, Chance Co. SIDE from the importance perfect castings and correct machining, there other can factor the performance piston ring that vital long, economi- cal operation the tension. ness ring tension meant the out- 191 ward pressure against the cylinder inst walls. the basis for comparison, the ten- 193 sion measured closing the gap where the ring split, some suit- able measuring device. due Too much tension avoided. Its results are clearly indicated large oil consumption, caused ex- ing cessive ring, cylinder and piston wear. ven Common effects this trouble are out round wear both the cylinder and piston. This result calls for re- boring and rehoning cylinder block and installation oversize pistons. Too little tension results high oil and gas consumption due too little pressure against cylinder walls. This causes the ring ride over the oil cylinder walls and allows gas leakage. For these reasons, the Chance Co. has established proper ring tension which eliminates the use costly expanders back the ring and ex- cessive wear cylinder, pistons and piston rings. Upon investigation was found there were standards for piston ring tension. obtain perfect ten- sion, required combination tech- nical knowledge and practical ex- perience most automotive piston grooves are made either the 1916 1932 S.A.E. standards. Considera- tion these standards made neces- sary consider the thickness and width the ring being constant factors. After years investigation and research, the tension curve shown Fig. was set-up being necessary for trade requirements. Having these known factors, the length the insert was readily ob- tained using the well known can- tilever beam formula: 0.210 0.205 0.190 Piston Rings— Where: required E=Modulus Elasticity (3.2 10°) test Radial thickness Outside diameter Piston Ring Thickness and Width The thickness piston rings governed the S.A.E. standards can noted the thickness curve shown Fig. Chance Co. has adopted maximum piston ring thick- ness less than the minimum 1916 groove depth that installation trouble will encoun- tered older models, and also that the ring will satisfactory for the 1932 S.A.E. standard piston groove. Piston rings have been found fail due too close fit the groove. Upon examination tests, per- fectly designed and machined piston rings failed due the carbon freez- ing the rings the piston. This pre- vents proper tension against the cylinder wall. For this reason have adopted clearance from 0.0015 in. 0.002 in. between the piston ring and groove width. Nominal Width Maz. Min. 3/32 in. 0.0915 in. 0.0910 in. 1/8 in. 0.1235 in. 0.1230 in. 5/32 in. 0.1545 in. 0.1540 in. 0.1860 in. 0.1855 in. 1/4 in. 0.2485 in. 0.2480 in. 5/16 in. 0.3110 in. 0.3105 in. Insuring Proper Foundry Control Not being satisfied with purchased castings, the Chance Co. decided install necessary foundry equipment automotive piston ring apparently very simple product. But the requirements its use are trying and important that has taken many years develop the successful technique manufacturing. pro- duce ring which will accomplish the conservation gasoline and oil, well provide long service, has necessitated original methods design, foundry practice, machining and the control related factors. Chance Co., Centralia, Mo., one the few concerns that completely manufactures piston rings from raw material finished product. has required ten years research this company develop the various processes manufacture and bring quality product its present high point. this article the author describes some the methods and principles employed design, pattern-making and sand control. Succeeding articles will describe molding, pouring and machining. — Fig. 3—Gated Pattern Plate, Showing Indi- vidual Skim Gates Risers. Fig. 8—The foun- dry Sand Testing Laboratory. (A— Permeability Tester, uring Apparatus, Compression and Shear Test- ing Machine.) The Age, December 1933—13 7 4 —~ i produce its own piston ring cast- ings. consulting with foundry experts and metallurgists, was realized that the molding piston rings one the most difficult foun- dry problems known. necessitates rigid sand control, perfect metal analysis control, expert cupola opera- tion, well modern and efficient apparatus. cope with these strict demands, expert sand control men, experienced metallurgists, foundry executives and chemists were employed. order for these divisions function properly, chemical laboratory was installed whereby analysis the various pur- chased raw materials could made, and daily chemical analyses made different metal mixtures required for different size piston rings. Sand laboratory testing equipment was installed. Here again sand was Figs. and 6—X- Rays Piston Ring Gates, Showing purities and Trap- ped Gases. purchased according analysis for collodial clays, proper mesh grain sizes, permeability, strength, etc., meet the fine foundry requirements for the molding piston rings. Specially designed cupolas were in- stalled, the operation which the elements could controlled reduce the influx undesirable foreign sub- stances such sulphur, oxygen, etc., minimum. Raw material the highest type ob- tainable purchased exacting analysis. This requires survey many blast furnace products. Coke and limestone are also purchased with equal care that the undesirable foreign elements will not enter into the piston ring castings. First class piston rings must made from accurately made patterns. With poor patterns, regardless the 14—The Iron Age, December 1933 quality raw materials machin- ing, first class product cannot made. have found that piston rings cut from spool have short life and are not uniform. Therefore, was definitely decided make in- dividually cast piston rings. make perfectly true piston rings, first necessary turn the pat- terns from close grain semi-steel casting the true diameter required. The pattern then split and ex- panded gage insure even expansion and insert equal the length the gap finished ring (which one the factors controll- ing the amount tension) added. This pinned and soldered into place. The patterns are then mounted highly polished semi-steel plates shown Fig. This work done expert tool makers. The center wheel-shape part which joins the separate piston ring pat- terns, shown this illustration, the “gate” through which the metal poured the center the mold. After months scientific research (through the aid metal X-ray machine) was found that the metal should not flow directly sprue into the casting. Therefore was found necessary break the flow metal trap loose sand and gases. The sand and gases rise the highest point the mold. can readily seen that small skim gate riser adjacent the ring casting was installed for this purpose. X-ray Fig. 7—X-Ray Piston Rings, Showing Effect Quality Improved Methods Gating. pictu trap] squa patte the foun tain the bobs mills 4 Weer 7 7 the the sely use = Fig. 4—X-Ray Laboratory. (Important discoveries were made here relating foundry control.) pictures shown Figs. and show trapped gases and sand. The small square shaped object inside the ring pattern and opposite the gate called the “bob” “pollywog.” These were found indispensable they re- tain the heat the opposite side the hot metal the gate. This elimi- nates hard spots and mis-runs. These bobs are later used the tumbling mills clean castings. Sand Control found that local sands were not best for the manufacture piston rings. They would break down read- ily, and would not free themselves the steam and gases caused molten metal against the damp sand. This would cause the metal absorb the steam; thereby oxidizing and chilling the castings they could not used for piston rings. The sand laboratory apparatus in- cludes permeability machine which registers the rapidity with which the sand will free the gases during the time pouring the mold. machine allied the sand laboratory moisture machine which registers the amount moist- ure the sand. Molding sands are tested twice daily for moisture. Should the sand too dry the sharp, edges the corner the piston ring mold crumble away. These particles will entrap them- selves the interior the castings —sometimes not discernible until use. also necessary limit the maximum moisture sand too wet f = 4 will create excessive amount steam the mold. Unless the perme- ability the sand amount steam created, steam will trapped the mold and oxidized and chilled castings will result. Another machine vital the sand laboratory equipment compres- sion and shear testing machine. quite obvious that sand mold must hold its shape and have the proper bond content. This con- trolled the per cent clay and moisture. strength sand close propor- tion the shear value, check daily the strength the sand through shear test. Rather than lock the barn after the horse stolen, every floor molding sand tested before molders are al- lowed use and necessary items are added insure minimum loss production. Favors Small Industrial Power Plant OOPERATION between industrial and public utility power plants was urged Harkins, power design Co., Wilmington, Del., paper read before the American Society Me- chanical Engineers. The steam flow industrial plants such magnitude, said, and the industrial plants are located that the larger part future electrical generating capacity should installed near indus- tries. Industrial management, his opinion, must educated the ap- parent paradox that small-scale “back pressure” power generation more efficient than the “quantity produc- tion” condensing central stations. Modern technical developments, went say, higher steam pressures and mercury-vapor cycles make available more and more surplus electrical energy industrial steam flow and this technical develop- ment favors the generation elec- tricity connection with industrial processes. Sales efforts public utilities which are directed toward the prevention industrial-plant genera- tion criticized unfair competi- tion and unsound economics. The stalled industrial plants is, said, least per cent that installed public utility stations. The Iron Age, December 1933—15 ~ ; ~ i 4 ~ Sts 4 Lo Rational ize Investment, Destroy Surplus Capacity that Mr. Shuffleman, who buys securities, can bor- row money Wall St. less than per cent, while Mr. Forsyte, who owns large industrial plant, wants see promised return 100 per cent before will borrow buy new equipment? the answer that question, there may lie ex- planation much the current dif- ficulty effecting expansion credit. more final terms, this wide gap points one the major ob- stacles team-work for recovery. course obvious that the two conditions borrowing are quite dif- ferent. Mr. Shuffleman gets call money “cut-and-run” basis, with high liquidity and ample margin es- sential conditions the loan. The proceeds Mr. Forsyte’s loan, spent for machinery, once lose liquidity, that the investment conditioned uncertainties. So, Mr. Forsyte contemplates replacing some machines newer models, even though they may have proven superior economy operation, first discounts the sav- ings safety factor, then considers the possibility their being idle and use him, and then the further chance that next year may able buy still better machine, perhaps for even less money. And long has not enough confidence make the change, the mechanics who are ready build the machine are minus their regular jobs, and the Forsyte employees using the inferior ma- chines, and produce less wealth than they might. Under such circumstances, fu- tile rail bankers for refusing lend funds which the Forsyte fra- ternity does not even want borrow. course there are many who wish take greater risks than are justified, and the banker sees that granting loans such quarters merely jeopard- izes other credits which are now safe, only following good banking practice refusing the loan. the deadlock broken, some means must found engender confidence rational program new capital investment. Then our Forsytes will again willingly use their credit and next will need guard against 16—The Iron Age, December 1933 LOSELY mood. Capital Goods and Prosperity There wide-spread belief that prosperity will not return until there high volume investment capital goods. need not debate which cause and which effect; de- fine prosperity state expand- ing national and individual wealth, which increasing investment pro- ductive equipment improvement housing facilities are tangible evidence, then may per- ceive two cardinal conditions which must met before full revival can expected. First, must have sufficiently high valuation human skill and effort. Second, there must greater security against impair- ment capital values. The effect low human valuation was brought home the writer very forcibly several years ago when doing some re-organization work large European factory. Time after time, would figure using some the more advanced American machines, only find that human labor was cheap, didn’t pay save it. When wage scales are arbitrarily lifted and aA the operating hours machinery, says the author, does not tend build wages volume stability. the contrary, penalizes the efficient units make jobs for the obsolete ones. would far better wipe out the obsolete and inefficient in- dustrial units and let the efficient ones become prosperous. Surplus capacity, believes Mr. Losely, should bought the industries concerned, and de- stroyed. And prevent new surplus obsolescence from em- erging from the ashes the scrap pile, proposes “competitive franchise system.” labor made worth more, whether code, strike Lewisonian ukase, may seem species bootstrap levitation. The actual economic proc- ess however rather analagous the jacking and shoring struc- ture; properly done, proportion quite within the limits engineering possibility. have, however, contend with feeling against the use labor-saving devices which has recently become rather prevalent. endeavored show recent article THE IRON this feeling, while quite irration- al, has modicum logical basis when the technological gains are misapplied. Over the long-term period, must obvious that saving labor wealth, providing the labor released then constructively where. Under normal conditions, saving one place creates additional demand another. Either the savings are passed the consumer, freeing that much purchasing power for other goods; wages are increased, giving workers greater purchasing power; the savings are retained the ma- chine-owner and normally spent, either via the dividend route for further plant improvement. If, however, the last alternative becomes too prepon- derant, that nearly all the proceeds labor-saving devices are continu- ously re-invested more machinery, then technological progress becomes barren and loses its attractiveness. Interpretation the manufacturers’ census figures gives quantitative indication that industry generally went much too far this latter direction. the middle 1929 the futility our industrial competition for superior manufacturing armament became widely apparent—profitless prosperity was the term—and investment pro- ducer goods began lose its popu- larity. Rush for the Exit Our present impasse small part due sudden reversal style. had concurrent attempt get out from under and convert fixed as- sets into cash, ignorance the fact that less than per cent the world’s weal bulli geol proh sup} cren cult quid the the wag lowe gold gold said tora men the take gold cons tion stor the play mac ers nea bor, raw the But bor cost tua deli pre too gar pen pro elal init tior inv ran era eco pen per (in bee mo try ves tall we = sv SY @ wealth the form precious metal bullion and failure realize that geological conditions commercially prohibit any sudden increase the supply (even per cent annual in- crement gold stocks quite diffi- cult attain). Hence, attempt achieve impossible degree li- quidity, drove our workers fruitless search for gold. Instead the classic iron law wages, have the law the slaves gold: The wage the outcast hireling will lowered the yield the poorest goldfield needed satisfy the world’s gold-hunger. And have got down said that the crying need for res- toration confidence capital invest- ment and consequent abatement the craze for liquidity. Then can take back our workers from 30c day gold-mining and put them $10 day construction. Let’s Examine the Rules However, neither reasoned exhorta- tion nor emotional ballyhoo can re- store confidence. need examine the rules which the game has been played. the rules which have made play unattractive, now good time change them that the play- ers will come again. will help first look the outline the in- dustrial process. the last analysis, merchandise nearly 100 per cent the product la- bor, the original appropriation crude raw material from nature being only the smallest part the final product. But the method organizing this la- bor decisive influence the final cost. mass production re- quires that labor first expended design and manufacture tools and their housing, before commencing ac- tual operations. any case delicate question management econ- omy decide how far with this preliminary investment labor. too little spent preparatory or- ganization, there will heavy ex- penditure direct labor per unit produced. the preparation too elaborate, the direct labor cost may exceedingly low, yet recovery the initial investment impossible from sale the product. Judging observa- tion and taking part corrections investment ratios fairly wide range industry, the following gen- eral orientation leads maximum economy: The minimum overall ex- pense converting materials bought into merchandise sold attained allotting follows: Direct labor per cent; equipment, rent and obso- lescence per cent; management (inel. per cent. The exact figures vary several points according the industry, but have the past been this approximate order. The more permanent and stable indus- try, the greater the allowable safe in- vestment and the lower the percentage direct labor will be—and, inciden- tally, the greater the ease with which high wage rates may supported. Those who oppose labor-saving ma- chinery should pause realize that high wages can only paid continu- ously when the production process it- self competently organized and op- erating under stable conditions. This requirement stability and security needs emphasis. the or- ganization the producing unit continuously exposed threat stop- page the flow work will obvi- ously less attractive either own- er, management lender invest much new equipment, place op- erations basis intense econ- omy. The intangible investment elaborate organization, with its re- searches, designing and experimenta- tion, often important and almost costly the physical equipment. The mere threat broken continuity sufficient discourage the creation those conditions which alone high wages based liberal invest- ment become practically possible. Organizing for Volume Stability What industry needs, then, some form organization its own pro- cedure which will provide much greater degree stability volume each its own members, that each may develop its own set-up optimum effectiveness. Recently adopted procedure cartel lines, universal reduction operating hours for machinery, does not fulfil the con- ditions; that procedure penalizes the efficient units make jobs for the ob- solete ones. would far better wipe out the obsolete and inefficient and let the efficient become prosper- ous. One the major obstacles now con- fronting the Recovery Administration can hardly surmounted unless resort precisely such clearance operation. Inasmuch this point vital importance the steel and machine-building industries, worth slight digression outline it. Referring again the manufacturing census, find that there has been for years remarkable difference the wages paid different industries. For example, the average wage for the year 1929 1.7 million wage- earners textiles was $1,010, and 0.9 million the woodworking indus- tries, $1,060. Iron and steel and ma- chinery, the other hand, paid the same year almost million workers average wage $1,530. Year-by- year calculations the value added The Iron Age, December 1933—17 different industries per worker em- ployed indicate that the high- pay industries that technological gains are the most pronounced. Mechanization and Wage Rates Obviously, more effective mechaniz- ation the backward industries would provide enormous stimulus our near-dormant machine-building trades. But more lasting importance, should bring with much higher wages the heretofore low-wage in- dustries and follow the original impetus opening huge per- manent market for equipment mil- lions homes. The question is, can crank these low-wage industries off the dead center where low wages dis- courage investment new machinery, and lack mechanical progress has made higher wages impossible? the Recovery Administration should attempt fiat raise the low min- ima these industries—and note- worthy that the President signing the cotton code made lengthy comment the low rates—there would once the ancient management problem meeting the pay-roll. can only done abandoning obsolete equip- ment; some disturbance vested in- terests unavoidable. one feasible way out the dilemma, with some compensation for the disturbance, yet finally arriving true economy to- gether with greater safety for invest- ment, suggested that the licensing provisions the Recovery Act might used inaugurate what would term “competitive franchise sys- tem.” This briefly outlined fol- lows: Self-Government Council Where industry can organize it- self with central planning council forecast demand—and that general- possible with fair accuracy the major industries—such industry should proceed eliminate useless equip- ment and prevent the installation excessive productive capacity. The necessary steps would be: (a) Forecast probable demand under most favorable conditions, prefer- ably terms machine-hours’ production required each month. (b) Determine the available capacity machine-hours, the basis hours per week (except con- tinuous processes) for existing serviceable equipment. The 70- hour week selected normal, since usually permits optimum operation two shifts, each with normal sleeping periods, and al- lows temporary expansion hours for seasonal needs. (c) Make tentative reconciliation peak-loads, with the objective securing maximum employment stability, using few 90-hour weeks, mostly 70-hour, and some 35- 40-hour weeks, with alter- nate weeks lay-off for each shift (Concluded Page 60) ¥ "42 4 = “= a > 4 3 per > | > How Finish Helps ROBERT MITCHELL, Ph.D., and HERBERT SIMONDS MANUFACTURER products naturally wants know whether his cleaning costs are too high. also should interested whether they are too low. may that better cleaning job would result more salable prod- uct, and from this point view too great economy cleaning may mean extravagance manufacturing. Un- til recently, cleaning too often has been considered necessary evil the metal working industry, and even now the sales advantages good cleaning are frequently overlooked the scramble for lower production costs. When manufacturer has assured himself that doing good cleaning job should, from sales angle, then entirely fitting for him try and find less expensive way doing the same quality cleaning and this article intended tell him some the economies found actual cleaning practice. To- day industry happens that some phases activity have been de- veloped from efficiency labor saving point view far than other phases, and this means turn that there are now greater opportu- nities for effecting savings among such phases activity have been ne- One the divisions most fequently overlooked those studying plant operating economies unquestionably the cleaning department. Equipment, materials, and methods are contin- ually changing and improvements and | Fig. Identical samples grease composed largely mineral oil were placed these four cylinders, together with four different cleaning compounds, They were shaken and allowed stand, and the appearance shown gives indication the relative effectiveness the cleaning agents. The sample the left (1) shows emulsification, and the oil sticks the sides the glass cylinder; (2) indicates emulsification but less adherence oi] the vessel; (3) shows good emulsification and foaming; (4) shows excellent emulsification, adherence oil, but some foaming. 18—The Iron Age, December 1933 innovations cleaning processes de- velop just other lines. Some the items considered merely oretical possibilities late 1929 have since become established rou- tine practice. Compounds the Future Electrolytic cleaning soap baths, electrolytic acid cleaning, vapor de- greasing, the use solvent soaps and so-called wetting agents are exam- ples recent developments. Today new materials which were commer- cially unknown 1929 are struggling for recognition and many are destined become part the cleaning prac- tice tomorrow. Some these are the alkylated naphthalene sulphonic acids, the sulphonated fatty alcohols, the naphthenic acids from petroleum, the orthosilicates, and the sodium metaphosphates. Cleaning intimately associated with both preceding and subsequent operations and therefore must studied relation the complete production problem any given plant. The nature the dirt removed dependent upon the nature the operations which make clean- ing necessary and the dirt encountered metal working variable that impracticable formulate any definite close classification. Yet some determination the nature dirt important. Study Nature Dirt Most engineers study samples the actual dirt encountered, trial with various types cleaning com- pounds. the dirt difficult clean, its proper cleaning re- quires specific compound, may that use different slushing oils, cut- ting oils drawing lubricants machining previous cleaning will change the nature the dirt that can either cleaned more easily, more thoroughly, cleaned with lower cost compounds. example common problem will help illustrate this. Straight mineral oil not saponifiable nor can alkali. Most industrial lubricant compounds are mineral oils containing sma deri ifial Soa cau eve! the and and oil. cial per sur pou oth get bili oft ing cle it tic Sales Minimize Cleaning Expense small amounts fatty oils their derivatives, and the latter are sapon- ifiable with alkali, forming soaps. Soaps will emulsify mineral oils and therefore possible clean with soda ash, both which are inexpensive. Such how- ever, slow and incomplete because the soap forming process itself slow and the amount soap thus formed usually inadequate for the prompt and complete emulsion the mineral oil. Because these difficulties, spe- cial compounds have been developed penetrate between the oil film and the surface cleaned. These com- pounds already contain some soap other wetting agent. Testing Compounds Certain preliminary tests often give indications suitability clean- ing compounds. shaking c.c. the oil grease removed to- gether with cleaning solu- tion, and noting the ease emulsion, bility emulsion, judgment may often passed whether clean- ing material will will not function large scale. Several different materials may compared this way making set emulsion tubes and shaking them all together. accompanying illustration shows one such test. four tubes were placed four different cleaning com- pounds and four identical samples mineral oil. All were shaken uniform- and simultaneously and allowed stand few minutes which time photograph was taken. Emulsification clearly shown. The same kind test may made indicate the effect the cleaning material suspending solid- particle-dirt. Weighed equal samples the dirt may put each the tubes and shaken with the cleaning solution, and the effect the latter breaking and suspending the dirt noted. Some large users clean- ing materials who buy specification use this testing method and they carry further. The initial cleaning solu- tions which are being compared are progressively diluted with water and their emulsifying and deflocculating powers with compared. This, certain extent, gives measure the lasting power the solution. Test for Discoloration comparing emulsifying ability, good plan take several sample being compared, hold.them all together uniformly, either clamp hand, and shake, say times, and note the quality the emulsions and compare, and then shake thor- oughly until all samples are emulsi- fied, and allow stand, and note with watch the different times separa- tion. These tests are best made temperature around 140 deg. because with higher temperature there will trouble with the stoppers blowing out the tubes when shak- ing. the cleaning zinc, die cast metal, small preliminary test the beaker bucket will gen- a & accompanying article, fourth metal finishing, tells how some manufacturers have made substan- tial savings cleaning expense adopting modern methods and equipment. The series being prepared under the direction Mr. Simonds for The Age. Dr. Mitchell technical director, Magnus Chem- ical Co., Garwood, erally allow sound conclusion drawn concerning the suitability the cleaner question from the angle metal. Labor Biggest Item has been said, with great deal truth, that cents out every cleaning dollar goes for labor and overhead. This percentage, course, varies with different jobs but the average case the labor the biggest single item expense. is, there- fore, most important, establishing cleaning process, carefully select that cleaning material and method which will keep the other more expen- sive factors minimum. Actual yearly cost figures from one large plant are: Water (including rinsing). 1,597.00 Cleaning compound ....... 1,183.00 Other items (inc. 500.00 average, efficient metal cleaning solution preparing work for Fig. semi-automatic barrel completely replaces former scratch brushing and pickling former cost cents per dozen shovel blades. The tumbling operation costs approximately cents per dozen shovel blades the same type. The barrel loaded the sides with the tumbling compartment empty. Rotation causes the pieces come from the end compartments the center tumbling compartment. Rotation the opposite direction causes the cleaning stars return the outer compartments that the work may dumped from the barrel without loss stars. The Iron Age, December = i ‘ of e- electroplating similar finish, should clean 900 more square feet per pound cleaner. This applies heavily loaded work still tank cleaning. electro cleaning mechanical washing machines, 1000 sq. ft. per lb. cleaner may obtained. recent competitive test one the largest plants the East, cleaning material costs per 1000 parts ran between 20.6 cents and cents. The parts were pressed steel panels and box tops (averaging lit- tle less than sq. ft. each) coated with mineral oil. These were anodically cleaned min. boiling solution containing oz. cleaner gal. The cost various cleaning com- pounds ran from cents 12.5 cents, but the lowest total cleaning cost figure was achieved with compound costing 9.5 cents. recent letter from Ranso- hoff, Inc., large manufacturer metal cleaning machinery, the following statement made concerning some the technical aspects this work: “Investigation showed our customer was using trisodium phosphate and soda ash which were not suited the principal the mechanical washing machine furnished. changing specially designed compound were able reduce costs some $3,600 year.” cleaning tripoli from nickel sil- ver flatware before electro cleaning for silver plating, 2000 pieces may cleaned with pound soap. Beyond this the solution becomes loaded with dirt that cleaning too slow and not complete. The cleaning operation averages min. and the parts are all carefully hand packed and out the cleaning baskets avoid scratching. Cleaning compound cost this operation one the least important factors. Labor 20—The Iron Age, December 1933 charges and certainty cleaning are the factors watched. steel company few years ago decided give its rivets added sales appeal means better finish. process automatic cleaning and barrel burnishing rivets all sizes was worked out which produced clean, bright rivet that looked almost though had been individually polished. The expense per rivet was extremely low. Proper Alkalinity Ordinarily, sufficiently reduce interfacial tension between oil and cleaning solution for rapid emulsion, figure. Most metal cleaning prefera- greater. Plain soap gives solutions 9.5 10, depending upon the concentration, the type soap, and the temperature. bring the soap the more effective higher working level fortified built with alkali. Alkaline silicates probably are the most effective for this purpose. Their alkalinity the buffered type. That is, they release alkalinity their solutions only gradually, and progressively. When dissolved, small part their (chem- ically combined) alkali released the solution free alkali. this which raises the the degree alkalinity the solution. this free alkali consumed neutralized the cleaning process, more the combined alkali splits off into the water thus maintaining the balance the solution the proper cleaning range until the solution exhausted. Caustic potash caustic soda, and phosphate, are often combined these buffered, built-up soaps achieve & Fig. Bronze cast- ings for coffee grind- ers and mixers are belt type semi-automatic washer. The machine has solution capac- ity 100 gal. and this kept effective the cleaning compound per day. The compound added merely placing one the wire mesh baskets. subsequent rinse necessary. certain desired results. The silicates have added advantage that their solutions possess colloidal properties which appear augment the colloidal properties the soap deflocculat- ing and holding dirt emulsification and suspension. Phosphates are par- ticularly valuable where metathesis with insoluble lime compounds the dirt necessary, removing lime-soap greases. The type and amount soap used importance. Only relatively small percentages soap can used cleaning solutions and must soluble, free-rinsing type, either low titer, sulphonated oil, stock. Many soaps have poor solu- bility solutions high alkalinity. Tallow soaps, laundry soaps, the ordinary hand soaps are entirely unfit for metal cleaning. Save Pennies and Spend Dollars designing manufacturing proc- esses use lubricants and cutting compounds which have high per- Fig. are rusted tion. tice bling tion for Ib. the nat was vise cut and barrel, pumped over the work while tumbling claimed reverses and this discharges the work. neut labor saved against ually pensi soap. ting this clear cleat alun linit | ore 11. tion 12.5 are dra min Fig. Auto kit tools are cleaned and anti- rusted one opera- tion. The former prac- tice called for tum- bling cleaning solu- tion for hr. with gal. After studying the nature the dirt was possible de- vise compound which cut the time half and cut the amount 100 gal. rw centage saponifiable oils, us- ually possible clean with inex- pensive solution containing alkaline soap. Pennies may saved cut- ting down buffing compositions but this often adds dollars subsequent cleaning operations. The nature the article cleaned is, course, necessary con- sideration. For instance, and aluminum their alloys are rapidly attacked solutions greater alka- linity than while tin spangled even etched solutions above 11. Brass tarnishes slowly solu- tions 12, while above 12.5 tarnishes heavily. high silicon, can pitted above Mineral oil pitches and waxes are best held permanent emulsion oil emulsions and for drawing, this range should kept mind. But removing these cleaning, other factors enter. barrel, rubber lined that dilute acid can After cleaning, the drum automatically that approximately per cent the and neutralizing steel tanks. Where the dirt consists chiefly oil, more alkaline cleaner works faster although gives less stable emulsion. And yet this very insta- bility can turned advantage, for allowed stand idle, the solution will permit large part its sus- pended oil separate making pos- sible remove both the oil and the sediment and thus “regenerate” the solution described previously this series. Many other factors are important studying cleaning relation the nature the article cleaned. Some these are the fact that cast aluminum more porous and sensitive alkali than rolled aluminum, that lead brass more sensitive alkali than brass containing lead, that flat piece may call for one solution whereas threaded knurled piece may require another. Mechanical Economies process best suited the work, the next consideration the design the equipment itself. Much has been done recent years the moderniz- ing cleaning equipment and the economies here fall under two head- ings, better cleaning and better han- dling. not hand what can done mechanically. This applies course production work where volume being handled. There are very few cleaning operations today which can- not some degree handled mechan- ically. Proper heating units and automatic thermo-regulators provide economies steam gas bills. Inadequate heating does not run fuel bills but es 4 — “igh, may costly slow cleaning, tied- production, extra labor costs, and sometimes refinishing tion, and some cases tank covers prevent steam loss, are worth while large installations. With steam heat good idea have both open steam pipe and closed steam coil the cleaning tank. the morning the solution can quickly brought the boiling point with the open steam line. The con- densate formed sufficient float off which has separated out over- night, over the overflow dam. The closed coil then suffices maintain the solution the boiling point. With hot rinses the open steam pipe alone needed, continual overflow needed keep the rinse surface clean. Where running rinses, spray rinses are used, water may saved with series rinses the counter- flow principle; that is, the rinse water several compartments flows against the work travel. Economy the purchase the cleaning materials may achieved only analysis costs for the final result. Choice cleaning compounds should based upon over-all cost per unit cleaned and upon performance. Many large concerns today buy clean- ing material the basis lowest cleaning cost figured from cost per pound multiplied rating factor which they have determined actual production test the material. the suppliers whose materials have been tested, the three best, say, (on the basis unit price rating) are asked bid each purchase. This not only insures the best cleaning value but keeps the situation competi- tive. The Age, December 4 4 “es cling the turning, drilling, sawing, threading and grinding metals, the work done the machine and the heat generated performing this work are concentrated relatively small area between the tool and the work piece. The power consumed converted into heat due friction and displacement metal. idea what actually happens may had referring Fig. The pries tears the chip away from the work piece, rather than cuts, evidenced the wedge-shaped crack the metal ahead the edge the tool. The sharp edge the tool merely clears and smooths the surface, while the heaviest work done some distance from the edge where the chip bears down the tool and begins curl, break crumble. action takes place being many “tool points” there are abrasive grains the stone the area contact with the work piece. Functions Cutting Oil reduce friction and dissipate the generated heat, the use spe- cial lubricant and refrigerant the form cutting oil becomes neces- sary, particularly rapid production work. The principal functions which good cutting oil performs are follows, the order their impor- tance: source heat—and lowering the consumption power. 2—Carries away and dissipates heat from the tool and adjacent parts and prevents the drawing temper from the tool. also dis- tributes evenly the heat transmit- ted the work piece throughout its extent, preventing distortion and contributing accuracy machined size. into the crack the metal above the cutting edge the tool, preventing the accumu- lation and packing fine metal particles this space which might cause the breaking off the edge the tool and gouging into the face the work piece. cutting oil having the lowest surface ten- sion possessing the best “wet- ting” properties performs this function best. 4—A good cutting oil acts flushing agent, washing away all metal particles. 5—It leaves protective, rust- preventing coating the work piece, the tool, and all adjacent ma- chine parts. 6—The correct oil will also give added finish, which reduces time grinding other finishing op- erations. When working with different metals variety machining operations, various types cutting oils are re- quired order obtain the best Iron Age, December 1933 results from the standpoint tool life, smoothness and accuracy fin- ish, considering also the further pro- cessing the worked material. Almost all the common fluids, including air, water, milk, etc., have been tried out cutting medium with varying success, until practice modern production work became standardized leum products, which form the basis cutting oils. Five Types Cutting Oils Cutting oils common use may classified follows: oils. Straight mineral lubricating 2—Mineral oils compounded with lard oil. 3—Sulphurized mineral oils. 4—Sulphurized mineral oil with lard oil. 5—Soluble emulsifying oils. Straight mineral lubricating oil such ordinarily available ma- chine shops still commonly used odd drilling, tapping and reaming jobs done slowly. The best that may said favor straight oil that better than lubri- cant all. quantity production work has been found that lubricat- ing oil, regardless price, the most expensive cutting medium, viewed from the angle tool life, quality work, and cutting speed. The frictional resistance and pres- sures involved metal cutting are such magnitude that ordinary lu- bricating oils will not stand up, the oil film breaks down readily with the result that the tool quickly dulled, obnoxious fumes are generated, and the work erratic. Field for Mineral Lard Oils When mineral oil compounded with animal oils, particularly inedible lard oil, greater “oiliness” results. the term “oiliness” meant here the improvement performance cutting medium, whatever the reason may be. The addition animal oil neutral mineral oil changes its chemical properties, and, among other things, the affinity the com- pounded oil the metallic surfaces increased, resulting more firmly-adhering and stronger oil film. Until about years ago mineral lard oils were considered the best cut- MAURICE RESWICK Engineer, Lubricating Department, Standard Oil Co. New Jersey ting medium, but since, they have been displaced gradually other forms cutting oils, particularly those the sulphurized types. The objection lard oil compounds their inherent susceptibility becom- ing rancid, developing objectionable odors, and their low resistance bac- terial growth, which might lead skin infection the operators. Mineral lard oils still have, how- ever, legitimate field application. For example, the manufacture small size parts for clocks, watches and instrument making, where pre- cision and quantity production are involved, mineral lard oils are prefer- red. When working brass and bronze, the use sulphurized oils may re- sult discoloration and staining. Mineral lard oil available the market finished compounded form several grades, depending the viscosity the base mineral oil and the percentage lard oil. The percentage the latter may vary from per cent. Mineral lard oils light viscosity produce film the work pieces which assists inspection. The close tolerances the manufactured parts well the tight-fitting bearings the machine Fig. Types and Use fre thi int the lec toc bir dis sul act tic PIECE tra bir off addition outlining the func- tions good cutting oil, Mr. Reswick describes briefly the char- acteristics and uses five com- monly-employed varieties, includ- ing sulphurized and soluble emulsifying oils. His discussion the latter includes suggestions re- lating the checking strength, straining and filtering, and the prevention skin infections. vv require relatively light oil that free from gumming, and that rich lubr