The Iron Age 1934-12-20: Vol 134 Iss 25

nel nds ely are lies hen THE IRON AGE December 20, VAN DEVENTER Editor 1934 G,. L. LACHER Ww. W. MACON T. H. GERKEN Managing Editor Consulting Editor News Editor F. J. WINTERS T. W. Liprert G. EHRNSTROM, JR. BURNHAM FINNEY F. L. PRENTISS Cleveland CODE 1934 Registration No. A-3:31-0-1590 Pittsburgh Detroit Chicago Editor Emeritus Washington Contents Please, More White Rabbits! Measurement and Diagnosis Gear Noise Wrought Steel Car Wheels Carefully Processed High Speed Features New Sheet Roughing Mill Open-Joint Checkers Blast Furnace Stove Bullard-Dunn Process Cleaning Car Parts New Equipment News Personals and Obituaries Washington News Automotive Industry Markets Construction and Equipment Buying Products Advertised Index Advertisers THE IRON AGE PUBLISHING COMPANY MILLER Machinery Editor GERARD FRAZAR Boston R. G. McInTosH Cincinnati F. J. FRANK, President G. H. GRIFFITHS, Secretary Cc. 8. BAUR, General Advertising Manager PUBLICATION OFFICE: Corner Chestnut and 56th Sts., Philadelphia, Pa. Member, Audit Bureau of Circulations EXECUTIVE OFFICES: 239 West 39th New York, Y., Member, Published every United States and $6.00; $12.00 year. Single Copy Cents. Canada, Cable Address, ‘‘Ironage, N. Y."’ Associated Business Papers ADVERTISING STAFF Emerson Findley, 311 Union Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, N. Y. : H. K. Hottenstein, 802 Otis Bldg., Chicago Subscription Price: Peirce Lewis, 7310 Woodward Ave., Detroit $8.50, including duty; Foreign 56th Sts., Philadelphia, Pa. Ober, 239 39th St., New York on Possessions, Mexico, Cuba, Charles Lundberg, Chilton Bldg., Chestnut W. B. Robinson, 428 Park Bldg., Pittsburgh Sweetser, 239 West 39th St., New York D. C. Warren, P. 0. Box 81, Hartford, Conn Owned CHILTON COMPANY (Incorporated) C. A. MUSSELMAN, President FRITZ J. FRANK, Heecutive Vice-President FREDERIC ©, STEVENS, JOSEPH 8S. HILDRETH, GEORGE H GRIFFITHS, EVERIT B.TERHUNE, WiLLIAM A. BARBER, Treasurer. JOHN BLAIR MOFFETT. Secretary on, als for ee] Full is, the im- av- ase 100 118 to- ent gle Jn- rial cts oth ion ral and rip and ce- THE IRON 20, 1934 Page Better FENCE Any wire product requiring zinc coating better and fabricated more easily when made from Bethanized Wire than when made from any other kind zinc-coated wire. Chain-link fence, for example, shows clearly the service and fabricating qualities this new Bethlehem Steel Company product. Bethanizing makes available for the first time wire with heavy zinc coating that will stand being woven into fence. The galvanizing-after- weaving process was resorted only through the previous lack such wire. Using Bethanized Wire, chain-link fence can made the simpler, better method weaving from coated wire—wire carrying more uniform coating twice the thickness possible gal- vanizing after weaving, giving from two three times the service life. Bethanized coating flexible that does not crack weaving—or from handling shipment and erection. appearance, too, Bethanized Wire surpasses anything its field. Chain-link fence only one the many prod- ucts that are improved manufacture from this new kind zinc-coated wire. few others are illustrated below. Bethanizing per- Bethanized Tele- Thick Bethan Bethanized Wire screen wire ized coatings stand with its smooth sil- smooth bright sur- properties without surface being woven into very finish, makes three long face the wire re- where alloys have cracks and gives strand without excelient mate- the usual hot- sults product been used. longer service. damage. rial for wire spokes. dip galvanizing. added salability. BETHLEHEM STEEL COMPANY General Offices: Bethlehem, Pa. District Offices: Atlanta, Baltimore, Boston, Bridgeport, Buffalo, Chicago, Cincinnati, Cleveland, Dallas, Detroit, Houston, Indianapolis, KansasiCity, Milwaukee, New York, Philadelphia, Pittsburgh, St. Louis, Paul, Washington, Wilkes-Barre, York. Pacific Coast Distributor: Pacific Coast Steel Corporation, San Francisco, Seattle, Los Angeles, Portland, Honolulu. Export Distributor: Bethlehem Steel Export Corporation, New York. THE IRON AGE ... ESTABLISHED 1855 DECEMBER 20, 1934 Vol. 134, No. Please, More White Rabbits! HIS, seems, time when necessary for qualify something said editorially last week. said then that the track had been largely cleared for full steam ahead business, because the magical white rabbits had had their fling. Business men are more afraid legislative and economic white rabbits than women are mice, and for much better reasons. They have guard daily against the entrance white rabbits their own particular businesses; fanciful, untried and impractical schemes for getting rich quick which are clothed enthusiasm and persuasive salesmanship the most attractive and enticing garments. Letting these harmless appearing little pets into one’s shop office has often resulted fatally. The rabbits die, time, but frequently they take the business along with them. Knowing the destructive habits the little white rabbits which plague private business, business whole naturally fears the enormous white rabbits which have been popping out legislative and administrative hats. Just after predicted, week ago, that the national economic white rabbit plague was over, the irrepressible Madam Perkins doffed her tricorn bonnet and disclosed the ears the daddy all white rabbits. program,” she said, “which will provide work for every able-bodied man the United States for the next years.” Madam Perkins did not show the members the New York Board Trade the body this rabbit, which she said would soon forthcoming. But one look its ears was enough send business men all over the country back into their storm cellars. believe that the President doing all that can assure business that need not fear disastrous and impractical experimen- tation. know that business eager act upon this assurance. Knowing and believing these things, must regard Madam Perkins’ premature and silly statement most unfortunate and ill-timed blow Administration aims and business hopes. ness operation extremely important consideration because the annoyance which produced noise. gears are noisy does not necessarily follow that they are in- efficient, for the amount energy re- quired produce thoroughly loud sound extremely minute compared with the amount energy normally transmitted gears. Because al- most infinitesimal vibration capa- ble radiating noise disturbing magnitude, the accuracy required gearing for quiet much greater than that required me- chanical considerations alone. most gearing applications, quiet- the purpose this article describe briefly variety searches which have been carried out this laboratory for the purpose discovering some the factors which influence gear noise and finding out how measure and diagnose such noises. Our approach the problem has not been gear experts, for have but modest knowledge the theory gearing, but rather, *we have applied these problems our knowledge principles and technique which have learned our training physicists. fact, this work has *Assistant Professor Physics, Uni- versity Michigan. Physicist, Department En- gineering Research, University Michi- Slip Apparatus Under Sound Chamber been carried out the Department Physics, and has been supported various industries through our De- partment Engineering Research. Those phases the problem which the industry supporting the work were interested. Consequently, there are many gaps our knowl- edge which may filled subse- quent work. Nature Gear Noise Sound usually arises from the vibra- tion some object. the case gear sounds not always easy tell just what part the machine really radiating the sound. Gears are usually operated inside housing which filled with grease; conse- quently, there opportunity for air sounds travel directly from the gears listener’s ears; but due variety causes which are men- tioned below, the forces which the mating gears exert each other are not constant the gear revolves, but are varying rapidly. The result these vibromotive forces produce vibration the gears which travels along the shafts, through the bear- ings, into the gear-housing, and other parts the machine. Since the hous- ing and these other vibrating parts Calibration Analyzer, Apparatus Room Fig. 1—Reverberation chamber with apparatus for analyzing and measuring machinery noises. The influence the sound interference pattern minimized the motor-driven steel reflector. 10—The Iron Age, December 20, 1934 EAR noise shown consist vibrations along shafts and through the gear housing other sur- face capable radiating sound. Possible sources such vibrations include errors tooth contour and spacing, eccentricity, tooth deflections, misalinement and de- flection mounting, rubbing fric- tion and pumping oil. addition discussing the na- ture and sources gear noise, the authors outline the methods em- ployed measure the extent some the influencing factors. are contact with air, sound waves are radiated which travel practi- cally every direction. Some parts the housing may vi- brate intensely while other parts are almost stationary. the speed the gear changed, the vibration pattern may shift completely and other parts the housing will undergo large vibration. any point the air near the machine, the sound waves arrive from these various vibrating parts different phases, and sound may also come this point reflec- tion from the walls the room. Thus the sounds arriving given point from variety sources may arrive sound that point, practically cancel each other off nothing. Therefore, the loudness any musi- cal note, such gear hum, varies unpredictable manner from point point. This unequal distribution the sound energy called ference pattern the sound. The interference pattern any change speed which will bring about change pitch. shifts whenever any reflecting surfaces are moved, such the listener himself. This unequal distribution sound energy much with very complex sounds, such speech, Fact vising for beve chine gear separ estab contr \ than side cided lar atten sol chan take two air this patt high wall fron time fron plat patt crop 2 _ > 4 Bands Pre- Microphone ¥ Facts revealed the researches described have been applied de- vising instruments replace the judgment routine in- spection gears. One these for noise inspection spiral bevel gears the matching ma- chine and another for analyzing gear and other noise cream separators. From study 5000-hp. herringbone gear reduc- noise specification was established for practical use contracting for future reduction units the same type. 7 7 than with musical sounds, such gear hum. Two people standing side side and comparing the noises two gears may disagree very de- cidedly because they happen standing different loudness levels the interference pattern. lar difficulty encountered when one attempts measure gear noise with sound meter. The readings vary greatly from point point and are greatly influenced very slight changes the speed the machine the place where the observer standing that becomes necessary take readings large number points and average them order able compare the loudness two gears satisfactorily means air Reverberant Room for Analyzing Machinery Noises our laboratory, surmount this difficulty with the interference pattern when measuring machinery noises placing the machine highly reverberant room with hard walls, shown Fig. The sound from the machine reflected many times from the walls the room and from the motor-driven steel reflector plates, which keep the interference pattern continually shifting. The mi- crophone the sound meter mount- one end the reflector and thereby moves continuously along circular path through the room. The indicating meter arranged re- spond but slowly that average reading obtained, which not in- fluenced the interference pattern. The sound meter provided with tuned circuit that the sound can analyzed into its various compo- nents and the frequencies and intensi- ties each these components may measured. Such analysis often permits the cause the noise diagnosed, and case the machine has several noises, all which must reduced order achieve any appreciable quieting the machine each the noises separately and measure progress the reduction that particular noise means the sound meter. Sound consists pressure varia- tions, which travel through the air, and the magnitude sound may expressed stating the magnitude this pressure variation dynes per square centimeter (one dyne per square centimeter equals 0.0000145 ound Pressure Level decibels above 0.0002 bars 100 per sq. in.). The magnitude this pressure variation called the sound pressure. The sound pressure your ear when you are listening sounds conversational loudness about one dyne per square centimeter. The least sound pressure which audible 1000 cycles 0.0002 dynes per square centimeter. The loudness sound the strength the sensa- tion which that sound will produce the average normal ear and may expressed the sound pressure the 1000-cycle reference tone which produces the same loudness the sound question. But for variety reasons, having mainly with the characteristics the ear itself, scale sound pressure expressing loudness. The units such scale are called decibels; zero decibels just audible sound, while 120 decibels painfully loud sound. The loud- ness the sounds our every-day experience lie between these limits. have, therefore, scale terms which the loudness sounds can expressed and which defined with sufficient precision that acous- 1000 10000 per second Fig. 2—Equal loudness contours for the average human ear, showing the amount pressure variation the sound wave required produce equally strong sound sensations different frequencies. All points lying given curve have the same loudness. The Iron Age, December 20, vel ic- ti- i] | | 70 | Pill | 0 | | } | | 40 | iz 0 | | | 500 tical engineers can reproduce each other’s measurements with practical accuracy. Sounds having equal sound pres- sures are not equally loud, the loud- ness depends upon the frequency well upon the sound pressure, indicated the curves Fig. general, the ear more sensitive higher frequencies, greater sound pressure being required produce equal loudness lower frequency. Factors Influencing Gear Noise Sometimes possible achieve gear noise reduction decreasing the number teeth the speed opera- tion that the gear hum lower frequency which the ear less sensitive. Furthermore, the gear housing less efficient radiator low frequency sound, small objects not radiate long sound waves ef- ficiently. Remembering that gear noise con- sists gear vibration which has trav- 12—The Iron Age, December 20, 1934 T Nn Ist Revolution Graphite) 240 280 320 360 Secondary Displacement Gear, min.ofarc 360 ABOVE Fig. 4—Graph second- ary motion, that is, the difference actual angular position the driven gear and the theoretically po- sition. LEFT Fig. 3—Stand for measur- ing the secondary motions worm gear carrier under load. some surface the machine capable radiating sound, let con- sider some the possible sources gear vibration. These are: 1—Errors tooth contour tooth spacing 3—Tooth deflections 4—Misalinement and deflections mountings 5—Eccentricity 6—Rubbing friction 7—Pumping oil the tooth contour not theoreti- cally correct, the tooth spacing not uniform, the teeth deflect considerably under load, the gears are not held proper aline- ment, then the driven gear will not move constant angular speed when the driving gear running con- stant speed. These tween the place where the driven gear should and the place where are called secondary motions. Second- ary motions are thus angular gear vibrations. Drive -2nd Revolution (With Graphite) 600 640 680 720 Angular Displacement Pinion,deg. Another source gear vibration the rubbing friction the teeth, come into contact and the op- posite direction they out con- tact. The rubbing friction influ- enced the roughness the teeth and the nature the lubrication, which itself depends some extent the number teeth which are instantaneously contact. The pumping action the squeezing oil from the space between the teeth some cases important source gear vibration. Any these secondary motions forces, which recur each time tooth comes into contact, will give rise periodic gear vibration resulting gear hum. these vibrations could confined the gears themselves and kept within closed housing, would result, but usually possible for these gear vibrations travel through the metal parts the ma- chine and reach comparatively large surfaces which are capable radiating sound. The gear noise thus very much modified the vibra- tion transmitting characteristics the machine itself, point which well worth keeping mind when de- signing machine. Sometimes the gear itself may resonate modify the vibration which trans- mits the housing. Measurement Secondary Motion see there existed secondary motion such nature pro- duce the sound which had been ob- served, set rear axle automobile gears was mounted shown Fig. such manner that they could turned slowly under moderate load, the angular rotation the pinion and gear being measured accurately divided circles with ver- niers. The difference between the actual position the driven gear and the theoretical position, the pinion utes (one minute here equals Relative Velocity of Secondary Motion abou were set rota odie seco erro trici peri mon muc pect hav men obse The are “ma twe tati toot neo con nois the: tion tact pac equ tity opp wel and | | ~ i! Relative Velocity of Secondary Motion Ww Harmonic Pinion Revolution Fig. analysis secondary motion graph Fig. showing large 11th and 22nd harmonics due secondary mo- tions having tooth engagement frequency and second harmonic thereof. about 0.0011 in.), showing that there were secondary motions this gear set amounting about 0.005 in. difficult see these curves any secondary motion having the period the tooth engagement (33 deg. rotation the pinion), this peri- effeet masked irregular secondary motions, due perhaps errors tooth spacing and eccen- order discover this periodic secondary motion, these curves were traced over with har- analyzer, which yielded the re- sults shown Fig. There were teeth the pinion and the eleventh harmonic pinion rotation shows much larger than any the other harmonics. One would therefore ex- pect this gear set give gear hum having the frequency tooth engage- ment and such note was actually observed when these gears were run. The other harmonic components which are shown would contribute mainly the general roughness and the “marble sound” the gear. The twenty-second harmonic pinion ro- tation the second harmonic the tooth contact frequency and itself important noise many instances. Measurements Tooth Contact Factors was mentioned above that the average number teeth simulta- neous known the tooth contact factor, might influence the noise affecting the lubrication and thereby changing the rubbing fric- tion. one our clients was in- terested the influence tooth con- tact factor the load-carrying ca- pacity the gears, have built equipment for measuring this quan- tity, although have never had opportunity measure its relation- ship the noise produced. The gears were mounted matching stand and alternating current amp. Ny nyo Angular Position Pinion,degrees 180 200 260 Fig. 6—Determination tooth overlap. Most the time the load carried one tooth only. ny Ww Voltage Nw Angular Position degrees Angular Position Pinion, degrees Fig. 7—More tooth overlap than Fig. but the load still carried one tooth only, part the time. Note the differences between teeth the length time the load carried. was passed between the gears, most this current flowing through the teeth, and only small fraction going through the stand. coil was wound around the base each pinion tooth such manner that whenever cur- rent was flowing through tooth, small alternating voltage would generated the coil surrounding that tooth. vacuum tube amplifier and indicating meter connected this coil thereby served indicate when the tooth came into contact the pinion was slowly rotated, the angu- lar position the pinion being meas- ured divided circle. Fig. shows some the results which indicate that there much less tooth overlap than usually ex- pected spiral bevel gears. When these same gears were different adjustment, the overlap was shown Fig. where two teeth divide the load for part the time, but there are always times when one tooth only carrying the entire load. should also noticed that different teeth carry the load for different lengths time, due errors tooth spacing and tooth contour. carefully lap- ping the gears under certain load and testing them under this same load, was possible have two teeth contact all the time and three teeth part the time; but this was very critical condition which disappeared soon the load the stand was slightly changed, due slight deflections the stand. Instantaneous Areas Tooth Contact any one instant, the teeth not touch over their whole surface, but merely along line contact which sweeps across the surface the tooth during the cycle engage- ment, thereby marking out the wiped area which ordinarily observed when gears are painted and run to- gether. get idea the posi- tion and length this line con- tact, tooth one the gears was painted and then brought into contact with the mating tooth the other gear different parts the cycle tooth engagement. Fig. shows series photographs the tooth contact line, traveling tooth. Such data are useful studies lubrication and loading. Measurements the Roughness Gear Teeth One the factors which influences that part the gear vibration which comes from the rubbing friction the tooth roughness, quantity which difficult determine and difficult express numbers. have built instrument called the profilograph for measuring gear tooth roughness. The Iron Age, December 20, 1934—13 eeth, The urce S or ooth ould sible avel ma- vely bra- de- the ion lary ob- bile rate the ver- the and nin- Fig. 8—Showing how the instantaneous contact area progresses across the face the tooth during the cycle engagement. Tracer. Point Tracer Surface ABOVE Fig. 9—Showing the principle the Pro- filograph, ment for determining the roughness gear teeth and other sur- faces. Fig. 10—Profilograph roughness spur gear teeth. 14—The Iron Age, December 20, 1934 The principle this instrument illustrated Fig. sharp diamond tracer point mounted the block which sup- ports the mirror and hinged beam light reflected from the distance, thereby obtaining sufficient amplification that very small angular motions the block can recorded. This tracing system supported arm which hinged the end the arm being supported the pilot point, which rests polished gear tooth standard profile. This pilot surface and the unknown sur- face are simultaneously pulled along underneath the pilot point and tracer point that the spot light the drum indicates the small differences between the shapes these two sur- faces, and thereby gives magnified record the roughness the gear tooth. The assembled instrument shown Fig. 10. Typical results spur gear teeth, cut gear shaper, are shown Fig. 11. Each trace covers from the base the tip the tooth and the vertical magnification such that every detail curve can repeated, shown the first three curves Fig. 11. The last four curves show that the detailed rough- ness and the tooth contour are con- siderably different different teeth the same gear. The profilograph not limited recording the roughness gear teeth, but can used for making rough- ness curves even the most highly polished metal surfaces variety shapes. For example, Fig. shows the wide variation rough- ness between the cylinder bores 1933 production cars. These records are placed upon instrument means which three roughness numbers 7 y ‘ are als ths the Tooth Repeated Graph Gear Tooth Tooth Loudness-Equivalent Decibels above 1000 Cycle Threshold Graph Fig. 11—Profilographs the roughness spur gear teeth showing the accuracy repeating records and the differences roughness and contour between teeth the same gear. 200 400 800 Frequency per second Fig. 13—Acoustic spectra different gear sets measured the matching stand, showing that the relative importance the harmonics different for the different radiated directly from the gears themselves but that most came from one the webs the match- ing stand considerable distance from the gears. was also found that the gear hum did not consist single frequency but was composed fundamental and second har- monic whose relative proportions varied from gear gear, shown Fig. 13. was then necessary determine the relative importance Fig. 12—Profilographs showing the variation roughness production these various components when the cylinder bores different makes 1933 cars. gear was operating car, and for this purpose measurements gear noise were taken cars running the road and also car which was are determined which represent not ness gear noise can determined set chassis dynamometer. only the amount the roughness but and controlled. this way was found that miles hour, the second harmonic was the loudest component the gear also the character the surface. nn imagine line drawn through the roughness curve such level that per cent of. the time the metal and per cent air. An- other line drawn such level that lies per cent the metal. The distance between these two lines called the medial roughness and measures the average magnitude the roughness the surface. The height the average peak meas- ured the difference level be- tween the per cent line and the per cent line and called the peak roughness. Similarly, roughness measured from the per cent line the per cent line. These three numbers roughness any surface speci- fied drawings, and samples from production can measured see they are meeting With the aid this equipment, there- fore, the effect gear tooth rough- Production Inspection Gears and Diagnosis Gear Noise have found possible many instances build instruments which would replace the inspector’s judg- ment the routine production in- spection gears. most such cases, standard commercial sound meters, which are available the market, would not satisfactory, cause the difficulties taking measurements the midst shift- ing interference pattern and because investigation usually discloses that gearing application certain pitches sound are particularly im- portant, and the sound meter must built especially give proper weight the different components. For ex- ample, were given the problem building instrument which could used noisy factory for inspect- ing spiral bevel gears for noise the matching machine. was first found that the gear noise was not The Iron Age, December noise, while miles hour the fundamental was the loudest compo- nent. The matching stand was therefore sound meter which could measure separately the fundamental and sec- ond harmonics, and separate limits were maintained these two com- ponents the sound. The inspector thus watched two dials, and the hand either dial passed the red line, that gear set was sent back for repairs. the sound meter was ac- tuated the vibration the web the matching stand, was not influ- enced general factory noise and soundproof rooms were necessary. Cream Separator Noises Studied Another problem involving the in- spection and diagnosis gear noise was that cream separators, noise analyses which are shown Fig. | ar ec FUNDAMENTAL BOWL NOTE Separator SECOND HARMONIC BOWL NOTE > ! Separator LOW-GEAR NOTE Separator HIGH- GEAR NOTE (1097~) +10 Noise Rating Relative Separator No.1, decibels Separator Fig. 14—Relative importance four different noises five cream separators, showing that Separators and had been rejected for different noises although the inspector was not aware this. 14. The noise these separators consisted low gear note from the spur gears, high gear note from the spindle worm, and note, due the bowl being out balance. Any one these sources noise might particularly loud given separator and cause its rejection, while the inspector was unable tell listening which was the source the trouble. The repairing re- jected separators, therefore, involved promiscuous changing parts un- til the separator was quieted. But after these noises had been analyzed, Fig. 15—Sound measuring equipment set the factory for routine inspection cream separators for noise. cate which separators should rejected but also the cause the noise those which are rejected that repairs can made logically. Not only does this equipment indi- LEFT Fig. 16—Sound mea- suring position for measur- ing noise gear whicl noise shoul the repai guess +10 4 a Pe: hal 16—The Iron Age, December 20, 1934 was possible build sound meter which would measure these different noises separately, and would thereby indicate not only which separators should rejected but also indicate the source the difficulty, that repairs could carried out straightforward manner, without This special sound meter, installed the testing booth, shown Fig. 15. Another problem undertaken was the measurement absolute and reproducible units the loudness 5000-hp. gear reduction units which connected two turbines direct these units was excessive, the user wished write noise specification which the manufacturer would have meet supplying future units. Each unit consisted large her- ringbone gear, which was engaged two pinions different diameters. These gears gave off number notes which analysis proved harmonics the rotation frequencies the pinions and were not tooth engagement frequencies. cated errors indexing rather than errors tooth contour being the source the noise. measuring these notes, was necessary take ber positions the microphone, due the presence the inter- ference pattern. Readings taken similar microphone positions the different gear units placed the dif- ferent machines different order loudness, that only the average reading significant. From the meas- urements taken was possible specify units, which can repro- duced years later, the loudness the gear noise which the operator will accept from the manufacturer. The specification the gear noise physical units has thus been accom- plished and the human element elim- current generator. the noise the average reading large num- inated. ANZIG, the far-famed Polish Corri- dor, the ultimate destination this mirror-finish stainless steel sheet, which believed the largest ever made the United States. product the Central Alloy Division the Republic ures 230 in. equipped streamline train. this picture the 900-h.p., 12-cylinder, V-type Diesel engine, and its directly connected gener- ator, are being lowered into position the chassis the power car. Low swung and generator, which have combined ate smoothly higher speeds around sur- fleet. Three newly designed Pullman zing sleeping cars are the train which will service between Chicago and the Pacific Coast, reducing the Union Pacific schedules The Iron Age, December 20, 1934—17 { Wrought Steel Car ARNEGIE wrought steel wheels are heat treated produce the company’s well-known “rim- toughened” wheels. They are heated large Stevens furnace with ca- pacity for wheels two parallel rows. The wheels are moved through the furnace motor-driven me- chanical contrivance which lifts the wheels one row, moves them each forward the distance one wheel, and sets them down. Another part the device then raises wheels the other row and moves them for- ward similar manner. While one part the contrivance moving wheels forward one row, the other part moving back the distance one wheel underneath the other row. The movement the wheels slow enough insure their being heated the proper temperature. Every means provided heat the wheels uni- formly. Twenty thermocouples are provided different locations the furnace record the temperature and keep uniform throughout. Instan- taneous readings may obtained any location pressing the proper button dial recorder. The wheels are usually heated temperature 18—The Iron Age, December 20, 1934 EAT treatment produce the Carnegie wheels, machining oper- ations vertical car wheel lathe and special double boring and facing machine are outlined this concluding part Mr. article, the first installment which was published THE IRON AGE Dec. 13, page 12. The prac- tice described that currently employed the Carnegie Co., the production “wrought car wheels. between 800 and 820 deg. (1472- 1508 deg. F.). the wheels are ejected from the furnace, they are picked overhead crane and loaded the ro- tating machine shown Fig. 12. One wheel may seen mounted the ma- chine. The wheels are rotated contact with bottom roll, the adjust- able side rolls serving guides. Only the rim contact with the water, the water level being set cover the the inside edge. The wheels are ro- tated contact with the water fora length time dependent upon the tion the rim. The machine set automatically remove the water from contact when this time has ex- pired. light indicates the crane operator that the hardening operation complete. The wheels are removed from the rotating machine the crane and per the degree hardness that specified. This amount varies with different customers and for different service, but commonly ranges between 310 and 340 Brinell. The draw-back temperatures range between 375 and 475 deg. (707-887 deg. F.). The draw-back furnace duplicate the heating unit, the rotating machine being located between the two fur- naces. Every fifth wheel from the draw-back furnace tested for hard- ness Brinell machine. After heat treating, the wheels are sent the machine shop for machin- ing. The first operation performed the heavy-duty Niles vertical car § heels| wheel tical dle cylind dially the side faces the incre tight the head agair tor. belov twice form roug are Fig. tread . Fis i 7 Carefully Processed wheel lathe shown Fig. 13. ver- tical rod the center-line the spin- dle connected the piston air cylinder. pulled down air pressure, wedges serrated jaws ra- dially against the inside surface the hole the hub. Additional air pressure causes these jaws pull the wheel downward and forces the flange side the rim against the serrated faces driver dogs the table the machine. the driving power increases, the dogs grip the wheel tighter. The wheel centered with the centering roller the right-hand head and held transversely clamps against the inside the rim which are held place wedges. The table rotated 75-hp. mo- tor. The spindle gear, which just below the floor approximately twice the diameter the wheel. forming tool the right-hand head roughs the flange and tread, which are finished forming tool the Fig. 13.— Machine for turning flange and tread, and facing the outside surface hub and rim. ing machine for toughen- ing the rim. left-hand head. The finishing cut started shortly after the start the roughing cut. Facing tools the heavy vertical bar, face the outside surface the hub. Power feeds with automatic trips are used these op- erations. Rapid power movement the vertical bar provided 1-hp. motor. auxiliary head with ver- tical and horizontal hand adjustment used face the outside the rim during the other operations. pneu- matic crane loads and unloads the wheels. Fig. shows the location the large spindle gear, the air cylinder for clamping the wheels, the wheel clamps and driver dogs, and the cut- ting tools. Hubs Bored and Faced Special Machine The next machining operation performed the special Ingersoll dou- ble boring and facing machine shown McCALL Fig. 15. This machine used bore the holes through the wheel hubs and face the inside surface the hub. The boring spindle, which mounted stationary unit the center the machine, driven 75-hp. mo- tor. Wheel-holding units the same design are mounted each end the bed and are horizontally adjustable along the bed hydraulic pressure. 15-hp. motor each unit drives the Oilgear pumps. The wheels are load- and unloaded trolleys and hoists, fresh wheels being position load soon the finished wheels are re- moved. The wheel automatically centered between two V-shaped clamps which close horizontally against the tread the wheel. the same time, clamps each side are swung around vertical axes and contact the flange side the rim and clamp the wheel squarely against the jaws. The centering and clamping operations are performed pressure. » “4 = — The Iron Age, December 20, 1934—19 the rom ora ater rane tion the and that with rent veen and hine fur- the ard- are hin- med car Fig. 14.—View showing powerful drive vertical wheel lathe. Boring bars and facing heads ex- tend from each end the boring spin- dle. Each wheel-holding moved along the bed hydraulic pressure and started forward with rapid approach until the wheel nears the boring tool, when the movement automatically changed the boring feed. When the hub face nears the facing tools, the movement auto- matically changed feed suitable for facing. This movement continues until the proper amount removed from the hub face, when the movement automatically stopped and the wheel permitted dwell momentarily un- til the facing cutters complete their operation. The wheel-holding unit then automatically returned the loading position with rapid return movement, and the wheel The centering, clamping and un- clamping the wheels arranged the same continuous automatic cycle with the feed and traverse This cycle started the movement one lever. Each wheel-holding unit independently operated. Fig. shows wheel mounted one the units, with the boring bar and facing head the foreground. Wheels which are machined are rolled in. larger diam- eter than the finished size; in, metal left each hub face for fin- ishing. metal left for finish the rim face the rim thickness has tolerance in. The wheels are rough bored smaller than the finished size. The finish boring done the railroad shop. All Operations Carefully Supervised Every operation carefully super- vised trained metallurgists, and all furnaces are equipped with recording pyrometers. Complete records are kept all operations. The wheels are inspected after rolling before any machine work performed. Any wheels showing unfilled portions mechanical defects, are set aside for machining. Wheels showing these con- ditions are sent the machine shop and sufficient metal removed re- store the wheel the proper contour dimensions. Wheels machined un- der dimension allowed the specifi- are scrapped. Freight car wheels are not rule machined, but furnished with contour tread Fig. 15.—Double machine for boring the hub, and facing the inside surface the hub. 20—The Iron Age, December 20, 1934 and essal size, car sign Thes whee havi weal the Ame chan simi are the call Co., ing Sout descr clear Roof spec Twe serv mot« ploy: ll i stru tabl Fou 0 latic and of n Size Vv Day ve and flange rolled and faces hub n forged. All wheels are rough bored. un- heir All wheels are given final close inspection and the exact size the marked each wheel. not nec- urn essary have all wheels the same ped, size, but when shipped they are mated pairs. large percentage the freight car wheels are manufactured de- nts. sign allowing one period service. 1ent These wheels are known “one-wear unit wheels.” This light-weight wheel having 1%-in. rim thickness. One- the wear wheels are not reconditioned after removal These wheels are scrapped when worn ined the condemning limits set the am- American Railway Association, Me- in. chanical Division. fin- Fig. 16.—Close-up view car wheel mounted the boring machine. Wheel-hold- passenger car, tender truck and ing unit approaching the boring bar and facing head. similar wheels for high duty service are These wheels are wheels are worn the tour, care being taken see that shed multiple-life type with rim condemning limit the wheels are placed service metal wasted machining. the Some designs wheels, standard wheel lathe, the wheels This operation repeated whenever including those under Pullman cars, remaining the axle. The tread and the wheels are removed for wear, slid for 3-in. thickness rim. When flange restored the standard con- flat spots service defects. ised per- all trical measuring and protective apparatus. ling NEW TRADE PUBLICATIONS Technical details illustrated with schematic are drawings and photographic cuts. Size, 8% in. eels Pipe Borden Co., Warren, Ohio. illustrates the belt and its construction. Chart any Condensed catalog, pages, with cuts and de- contact degrees. Tables speed ratios, Any scriptions ratchets, cutters, threading equip- pulley diameters, V-flat belt sizes and center Mfg. Co., 1929 No. Buf- ment and power unit drive. distances, relation hp. groupings fum Street, Milwaukee. ae covering a range from 5 hp. to 300 hp. Gen- Predetermined productimeter, counters, oper- for Washer Mfg. eral data and calculations for special drives. ation recorders, standard devices for each Co., Milwaukee. Specifications schedule cover- Examples problem solutions. Size, in. industry. relay and hop ing Government standards. in., pages. electric counters for alarms, prevention, con- trol and effortless operation. Metal Cleaner.—Magnus Chemica] Co., four South Avenue, Garwood, N. J. Small folder Oxy-Acetylene Apparatus and Paint Spray un- descriptive of Magnusol and its uses as a metal Equipment.—The Alexander Milburn Co., 1416 Control Units. Roller-Smith Co., Bethlehem, : cleanser. West Baltimore Street, Baltimore. Catalog. Pa. Catalog No. 8, loose leaf. Switchgear, cifi- Cutting and welding torches, interchangeable metal clad units, central panels, switch houses, car Temperature Limit Furnace tips, pressure regulators and gages, manifolds Six sections devoted unit types ned, Roofs.—Leeds Northrup Co., Philadelphia. and accessories and supplies, paint and lacquer and descriptive each. Twenty-four pages, Application Bulletin, No. 58-116. sprays, air and gas purifiers, portable and car- in. in. devices and their installations, including bide lights. Size, in. in., pages. Co., Bristol, Conn. Booklet entitled Can Electric Motor Imperial Elec- type K-66, speedmatic wood saw. Specifications service rendered applying the company covers, in. ploying motors. Four pages, in. i im. with Glentretions. Weight Tables of Tubing.— The Timken pressor Co., Easton, Pa. Bulletin No. 157. Steel Tube Co., Canton, Ohio. Pamphlet Describes units, operation and construction Deming Co., Salem, Ohio. Bul- devoting one page explanation and formulae, details, using photographic, arrow indicated, letin No. 4150. Announcing eight pages two colors, tables, fractional illustrations. Twelve pages, in. in. trifugal pumps. Tables covering types con- and decimal, covering round steel tubing, hot structio metal specifications. Performance Sheared Plate and Pressed By- es showing capacities, heads and motors. Products Steel Corpn., Coatesville, Pa. Bul- presse snhapes 2 stee . ac © order. Inc., Oakland, Cal. Bulletin details, instal- Welder Metals Co., Inc. Descriptive the lations, applications, photographic illustrations product, illustrations types and Expansion Inc., Louis- and price lists, covering closures for all types Motor generator tables, gasoline engine and ville, Ky. Bulletin dealing with the design machinery which bearings are important. belt drive units. User list and company offices. and fabrication expansion loops made with Size, in. in. Size, in. in., pages. Tube-Turns and straight lengths pipe tubing. Included chart means which Rubber Mfg. Co., Air Circuit Co., loop dimensions can quickly determined Dayton, Ohio. Catalog No. 100. Describes and Bethichem, Pa. Catalog No. loose leaf. Elec- without involved calculations. The Iron Age, December 20, High THREE-HIGH roughing unit for sheet mill offered the last word equipment its kind was introduced steel plant executives Nov. Wooster, Ohio. The “rougher” represented Jamshedpur, India, for the Tata Iron Steel Co. had been assembled for testing before shipment and 125 who had gathered for the oc- less than were officials and operators from practically all the well-known sheet and tin plate plants the country. The new mill the result inten- sive study Frank Estep, vice- president, Perin New York, consulting engineer for the Tata company. His requirements detail had been worked out those associated the construction: The Mackintosh-Hemphill Co., Pittsburgh, builder the mill proper, the Wean Engineering Co., Warren, Ohio, builder the mill tables, the Clark Controller Co., builder the electrical control apparatus, and the Flinn Dreffein Co., Chicago, builder the furnaces. The special feature the new rougher the item speed. not only employs mechanized mill tables operating connection with continu- ous furnaces—a modernization com- bination that has done much give single-stand roughing and rolling methods strong economic position the rolled products industry—but has been put under electric con- trols that provide for push-button manipulation. The sequences the furnace, roller table and mill cycles are kept their without possibility dislocation danger. word the mill de- signed rough 12-in. width sheet bars five passes No. No. gage in, say, sec. minimum, that is, sec. from the start the one cycle five passes the beginning the next. Thus comes the claim Iron Age, December 20, 1934 that the rougher will the fastest its kind. was broadly viewed that the com- plete cycle could not reduced below sec., but calculations for roughing pair 12-in. bars weighing 16.5 per linear foot length in. showed 14.468 sec. The trials Wooster, the machine shops the Mackintosh-Hemphil! Co., using cold material, led the belief that difficulty will experienced run- ning rate pair bars every sec. over whole week. Such performance means 1800 pairs per shift hr. Bars 37% in. long will weigh 103.125 lb. per pair, that 1800 pairs represent 82.87 gross tons bars this foot weight roughed the one 8-hr shift. Tata Sheet Developments Briefly Sketched The Tata Iron Steel Co., for some years producer rails, structural materials, plates and merchant bars, entered into the manufacture sheets December, 1924. The sheet mill was laid out and equipped ac- about 1918, consisting single train hot and cold rolls driven from 1500-hp. motor, the mills being two- high with rolls from in. in. The furnaces were con- tinuous for pairs and in-and-out for packs, stoker fired. The mills were hand operated Indian crews under American foremen. fair precentage the product was annealed and shipped black sheets while the major percent- age was galvanized, large part the latter being corrugated. Each the six mills has its own rougher. The greater part the product in. wide and in. long in. wide and 120 in. long, mostly gage and averaging about 23.5. The mills ap- proximate gross tons sheared sheets per mill per 8-hr. shift. India large consumer gal- vanized sheets, gated sheets. 1928 and 1929 the importation galvanized sheets was approximately 330,000 gross tons per annum, which time the Tata com- pany was making about 35,000 gross tons per annum. Beginning with the world depression the imports came down rapidly due primarily the serious condition the jute business. However, 1932 they were still quite substantial into which the Tata company could readily supply. Early 1932 serious consideration was given the increase produc- tion sheets the Tata Works. secure lowest costs increased pro- duction 100,000 tons per annum was indicated but close study the ground the consulting engineers showed that there was immediate market addition that then pro- duced Tata only 25,000 50,000 tons per annum. was therefore decided adopt plan expansion units approximately 25,000 tons per annum each, the first unit installed quickly possible and the second unit market con- ditions warranted. Sheet bars are rolled Morgan continuous sheet bar and billet mill consisting six stands in. and six stands in. rolls. connec- tion with the installation the first sheet mill extension was decided increase the power This was done taking the 2300-hp. motor from the 24-in. mill the sheet mill; transferring the 4000-hp. motor from the 18-in. mill the 24-in. mill; and installing 7500-hp., 93.75 r.p.m. synchronous motor drive the 18-in. mill. strengthening the 18-in. mill the Tata company can roll in. and possible in. wide sheet bars. Sheet mill extension located the north end the existing sheet mill building, starting with the 2300- hp. motor mentioned above and gear reducer, was consist one Speed Features New Sheet all rou cor > ve} Ye wa cre dec ope sta the she wei ave = ‘ enc ave anc son Ins enc anc ar tha nac the wa; spr gal- orru- the per com- the came the quite the ation pro- nnum the neers diate pro- 0,000 efore nsion tons and con- mill and nnec- first mills. sheet notor mill; 18-in. mill and sheet 2300- new one Roughing two-high finisher with mechanical tables and two-high hand roughers served double-width continuous furnaces. The additional equipment consisted conveyors, veyor, and squaring shears, well additional buildings, cranes, pickling and galvanizing equipment and new warehouse take care the in- creased product. Practically all the equipment was bought the United States and months from the decision proceed the roughing mills were started and the finisher started one week later. The entire new hot mill started unit Monday, March 1933, and has continued operate without stoppage date. When the decision was made in- stall the addition was guaranteed gage, would average gross tons sheared sheets per 8-hr. shift. After the mill had been operation eight weeks, the guarantee was raised average 37.5 tons. From March 1933, March 31, 1934, inclusive (the end Tata fiscal year), the mill averaged 38.15 gross tons per shift; and from April 1934, and in- cluding Nov. 17, 1934, the mill has averaged 41.4 gross tons. During 1934 the mill has rolled part all some weeks in. wide and also during other weeks has rolled gage instead gage. During the week ended Feb. 10, 1934, the mill and in. wide gage averaged 49.5 gross tons for shifts including maximum shift 63.45 g