The Iron Age 1935-01-31: Vol 135 Iss 5

erience and vement results eg. are, appear favor longer how handle effort, the period, mes point asingly final advan- com- the ona with loca- clamp age the when illus- job engi- ressive advan- set-up sizes fg. Co. of Corpn. eferred esting- pay- ‘ord on West- rectors lend of of the ders of cash tion said vidend, ites as West- the which en- NRA CODE 1935 Ne. A-3:31-@-1500 VAN DEVENTER Editor LACHER Managing Editor WINTERS Editor Emeritus Washington GERKEN News Editor MILLER Machinery Editor T. W. LIPPERT Chicago Cleveland EHRNSTROM, JR. BURNHAM FINNEY GERARD FRAZAR MCINTOSH Pittsburgh Detroit Boston Cincinnati ontents—January 31, 1935 With Apologies Aesop ... Durable Goods Recovery Depends Profits and Con- Grinding Operations Acme-Gridley Parts How Measure and Specify Surface Rustless Steel Production Approaches Peak Level. From Tungsten Powder Finished Carbide Tools Furnace Harden Valve and Clutch Springs New Equipment Washington News Automotive Industry Construction and Equipment Buying Products Advertised Index Advertisers 114 THE IRON AGE PUBLISHING COMPANY FRANK, President GRIFFITHS, Secretary BAUR, General Advertising Manager DIX, Manager, Reader Service PUBLICATION OFFICE: Corner Chestnut and Sts., Philadelphia, Pa. EXECUTIVE OFFICES: 239 West 39th St., New York, Y., Member, Audit Bureau of Circulations Member, Associated Business Papers Published every Thursday. Subscrip- tion Price: United States and Pos sessions, Mexico, Cuba, $6.00; Can- ada, $8.50, including duty; Foreign $12.00 a year. Single copy 25 Cents Cable Address, ‘‘Ironage, N. Y."’ ADVERTISING STAFF Emerson Findley, 311 Union Bldg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, H. K. Hettenstein, 802 Otis Bldg., Chicago Peirce Lewis, 7310 Woodward Ave., Detroit, Charles Lundberg, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. C. H. Ober, 239 W. 39th St.. New York W. B. Robinson, 428 Park Bidg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York D. C. Warren, P. O. Box 81, Hartford, Conn. Owned CHILTON COMPANY (Incorporated) C. A. MUSSELMAN, President FRITZ FRANK, Erecutive Vice-President HILDRETH, GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM A. BARBER, Treasurer. JOHN BLAIR MOFFETT, Secretary ; =. es ' : 10—THE IRON AGE, January 31, 1935 groundhog weather prophet has gone the way many another old, mistaken idea that was accepted more credulous day. Take the notion, once widely held but now swiftly passing, that get sheet able defy rust you must pay fancy price. That’s another myth that has been refuted both modern science and the experience men who use sheets. For years the American Society for Testing Materials conducted exposure tests sheets. This what they found: That all the grades com- mercial steel and iron, copper-bearing steel stands first wide margin re- sistance atmospheric corrosion. Beth-Cu-Loy Sheets are made cop- per-bearing steel. They have from two ETH two and one-half times the rust-resistance ordinary steel sheets, yet cost only trifle more. Wherever rust meets metal —in buildings, and around indus- trial plants, products—Beth-Cu-Loy the sensible, economical sheet \ THE IRON AGE JANUARY 31, 1935 ESTABLISHED 1855 Vol. 135, No. With upon time, man who was journeying through the jungle had the misfortune fall into tiger pit. Being reflective turn mind, his mishap caused him ponder upon the sins and shortcomings his past life, which there were considerable num- ber. Meanwhile, course, although his mind was thus occupied, his hands and feet were engaged trying climb out the pit. This was not easy thing do, since such pits are made with the purpose retaining what falls into them, the course time his mind turned from the reflection upon his past life consideration his future. escape from this resolved, will turn over new leaf and become changed man. will give the poor, provide for indigent relatives, kind animals and treat mother-in-law with respect. will also improve property, plant trees and vineyards and build roads that neighbors who are less fortunate may have work and These thoughts were very intriguing the man the pit, and the vision the benefactor that was become and the good that was going not only eased his mind apprehension, but took away from his more immediate problem getting himself out the hole was in. His physical efforts be- half self-preservation therefore became more and more subordinated the easier and more pleasurable exercise imagination. doubt, after all this intensive long-range planning for the future, might indeed have become great public benefactor, had not been that tiger soon fell into the same pit and ate him up. The moral this tale, any, may that too much long-range planning for the future may not expedient interferes with one's efforts get out AS ae < hole . fou > Recovery Average 1923-1928 100,000 50,000 1924 1925 1926 1927 1928 1929 1932 Steel Sheets—Production (Monthly Compiled the National Association Flat and Rolled teel Manufacturers, representing almost the independent sheet makers. ° 1928 1929 1930 1932 Steel Boilers—New Orders Averages) Compiled the Bureau the Census from reports firms, about per cent the industry. 1928 1929 1930 1932 Malleable Castings—Shipments (Monthly npiled the Bureau the Census, represents re- rts from 130 establishments, covering about per cent the industry. IRON AGE, January 31, 1935 1933 1933 1933 1934 1934 DR. FREDERIC DEWHURST VIDENCE presented pre- vious article appearing the Annual Issue THE IRON istence huge deficiencies cap- ital equipment, buildings and other types durable goods, confirmed the analysis op- erations several additional lines heavy industry. Vertical bars the charts accompanying this article show production ment records during recent years for five important fabricated iron and steel products: steel sheets, steel boilers, malleable castings, woodworking machinery and rail- road track work; four types in- dustrial electrical equipment: over- head cranes, industrial trucks and tractors, industrial locomotives and electrical porcelain; and two basic raw materials, lead ore and zine. Horizontal dotted lines each chart show the average monthly rate operations for the years preceding, but not including, 1929. These averages are reasonable measure normal business the past and furnish conservative forecast what may expected the future. Heavily shaded por- tions the bars measure the ex- tent which operations any exceeded the average, while the lightly shaded areas indicate the years when activity fell below normal, the difference between the areas above and below the “nor- mal” line may taken rough measure accumulated shortages, ° ° ° 4 f 4- 4 Ud / a / 600 a a J 30 0 4 (ff A ( \ Profits and Con idence substantial potential demand now exists for the products each these industries. Ob- viously such crude statistical mea- sures can provide assurance future prosperity any industry. New niques and products will continue displace old ones, the past, and infant industries will take the place those whose products have been outmoded have not been adapted changing consumer Some these industries, therefore, may fail attain their “statistical expectancies,” others undoubtedly are destined expand far beyond the “normal” rate operations shown the charts. needs. Taken the aggregate, however, these statistical evidences ac- cumulated shortages reflect the ex- istence potential demand for structures, machinery and equip- ment and other durable goods far excess any that has ever be- fore existed. These latent demands, translated into terms the num- ber months’ operations the average rate prevailing each industry prior 1929 are shown the horizontal bars the large chart (on page 15). Accumulated shortages equivalent four years’ operations the normal rate exist the case residential buildings and freight cars, while least two years’ operations will required make good existing industries studied. Since these industries may considered fairly representative, appears that pro- ducers durable goods are about two and half years behind sched- ule supplying the normal needs the nation. What this means terms future activity clear when realized that make 30.months’ deferred needs would involve operations for entire decade per cent above the normal rate prevailing the past. However, bird the hand always worth several birds the bush. These accumulated shortages Average (1923-1928 1,000000 800000 a 600,000 400000 Woodworking Machinery—Shipments (Monthly Averages) Compiled the iation Manufacturers Wood working Machinery from reports its members varying number from twenty ity-nin 1925 the shipments Average 1926 1927 1928 1929 1932 1933 Track Work—Production (Monthly Averages) Compiled the American and Steel Institute and cove the production all T-rail track pounds per yard and heavier, including all special fabricated track work carbon steel, steel, and other metals for both 4 Average 100000 1923-192 800000 5 600,000 oO wal 4 200 ) 6) 1923 1924 1925 1926 1927 1928 1929 i930 Electric Overhead Cranes—Shipments (Monthly Averages) Compiled the Electric Overhead Crane Institute reports from eleven manufacturers estimated cover per cent the output. THE IRON AGE, January 31, k | 4 . = 3 5 vale ag 4,000 f) 1a? on PENG 1 200¢ OO x ar Laie gta - are still birds the bush. They represent latent, not effective, de- mand; potential business, not ac- tual orders the books. What are Average 1925-1928 1926 1927 1928 1929 1932 (Monthly Averages) pments electri trucks and tractors nin sd fact ymprisina the rater art of > industr 1923-1928 1923 Industrial Electric Locomotives—Shipments (Quarterly Averages) Compiled from quarterly reports the Bureau Census, from nine manutacture comopr na practica 7 entire industry. 1926 1927 1928 1929 1930 193) 1932 Electrical Porcelain, Special—Shipments Averages) Compiled the National Electrical Manufacturers Associa- Statistics special porcelain are from firms producing about per cent all special porcelain. 14—THE IRON AGE, January 1935 1933 1933 the prospects for these deferred re- quirements translated into new business for producers, bigger pay envelopes for workers now 1934 the payroll and jobs for the mil- lions unemployed the heavy industries? Perhaps the most encouraging answer this question found the fact that the process has al- ready commenced. Recovery the heavy industries has been under way for the past two years. all but two these industries, 1933 operations were well above the low levels 1932, with last year’s busi- ness showing still further gains. spite the difficulties and un- certainties the past year, out- put such important products freight cars, lead ore, malleable castings, industrial electric trucks and tractors, steel sheets, steel ingots, machine tools and automobiles, was greater 1934, the second year recovery, than 1931, the second year depres- That 1935 will witness some further improvement the dur- able goods industries can safely predicted even this early date, although the extent recovery will depend largely upon factors outside the control these indus- tries their customers. *Durable goods, whether new factory build- ings, machinery equipment pur- chased industry, new houses, automobiles oil burners bought individuals, involve invest- ment capital rather than charge against current operating expense. These goods are paid for out past savings the form corporate surpluses indivi- duals’ bank accounts, or, more repaid out savings. Purchase capital goods, there- fore, requires the existence adequate supply what Grover Cleveland called “confident credit,” implying confidence the part the borrower that can repay his debt out future profits income and confidence the repaid what loaned, not only money but purchasing power. This assurance does not yet exist. Since new security issues have been negligible amount, obvious that industry has made only neces- sitous purchases capital goods during the past two years, and that these have been paid for chiefly out existing corporate surpluses. Further substantial expansion demand durable goods can not come without rea- sonable assurance increased ins / f / 4 / ) Industrial Electric Trucks and Tractors—Shipments ° 300 / / > / 4 40,000 profits and ready access the in- vestment markets. Although the outlook for profits still clouded with such uncertainties possible increases labor costs arising from further reduction hours work, the threat costly strikes the major industries, and the probability heavier taxes, the situation not entirely discourag- ing view the marked improve- ment which has occurred during the past two years. Furthermore, the difficulties involved obtain- new capital appear have been alleviated the announce- ment the S.E.C. its revised and greatly simplified form for the registration new securities. From standpoint the creditor the outlook less encour- aging. Although the dollar has been kept stable per cent its former parity during the past year, there assurance that the pressure inflationist groups Congress will not force further devaluation that the passage drastic inflationary measures over the President’s veto eventually result uncontrolled depreciation the currency. Such possibility not lessened the fact that after five successive an- nual deficits the Federal budget will again fail balance $4,- 000,000,000 the 1936 fiscal year. Short Tons > Short Ton 12,000 10,000 8,000 6,000 4,000 2,000 1923 1924 1925 1926 1927 1928 1929 Lead Ore—Shipments lead ore from the mines the Joplin Avera 1923-1928 (Monthly Averages) from the Joplin Globe. Zinc—Production Data compiled Ameri Residential Freight Cars Industrial Electric ocomotives Woodworkina Machinery Electric Overhead Cranes Electrical Porcelain Electric Motors Malleable Castings ° ° Pig Iron Industrial Electric Trucks and Tractors Power and Centrifugal Pumps U M B E R ° f Fabricated Stee! Plate opera- tions required fill Steel Sheets existing shortages. Ingots Machine Tools and Foraina Machiner Iron, Steel and Heavy Cast Iron Boilers ontniy Avera AGE, January 1932 can Zinc Institute. 1933 district 1933 1934 1934 = et ‘a's ‘ 60,000 Average 2000 10.000 Months | | | | | | | | | } } | | | | | | | | | - | 7 rinding cme-Gridley Parts TYPICAL Acme-Gridley ma- chine has over 1000 separate parts and weighs anywhere from four ten tons, depending course the size. the ma- chine operates high speed must constructed with extreme care for generating unit every sense the word and there- fore cannot duplicate accuracy that not built into it. Accu- racy assured through finishing various parts precision grinding the highest order and several the more important grinding operations are illustrated and de- this article. What might termed the heart IRON AGE, January 1935 FRED JACOBS typical four-spindle Acme- Gridley automatic shown Fig. which illustrates the tool arrangement. Practically all the grinding opera- tions described herewith pertain this important element the ma- chine. excellent example heavy part which must finished accu- rately given Fig. This unit spindle carrier assembled with its shaft, the entire assembly weighing approximately one-half ton. Three diameters the spin- dle and the outer diameter the carrier are finished grinding. The ground spindle dimensions are in. diameter in. long, in. diameter in. long and in. diameter in. long. The ground dimensions the carrier are in. diameter and and in. long respectively. The spindle carrier semi-steel, per cent nickel, and the shaft al- loy steel. The machine upon which the unit mounted Norton gap grinder capable accommodating work in. long, in. diameter over the bed and in. diameter the gap. will noted that the gap accommodates the carrier. The wheel used Alundum, in. diameter, in. face, com- bination grit, grade. The wheel 5500 ft. per min. The work speed ft. per min. About 0.020 in. allowed for grinding. the work held and rotated between centers and the spindle and carrier finished one setting the work, Grinding plays large part finishing the too lide and components. These constitute the the auto- matic. ate TI ° ° in Ca gr 3 Finish- ing three diam the spin- shaft and the periphery the pindle carrier. Thi: assembly one - half ° ° ° obvious that all diameters will concentric, which the result demanded. Fig. shown the spindle carrier mounted for grinding the holes that accommodate the spin- dle assemblies. The spindle carrier question for six-spindle ma- chine take bar stock. This carrier in. diameter and in. long. The holes are ground through both the front and back sections and are in. diameter. The work held and rotated special fixture, the radial distances between the holes being controlled large index plate shown the background. Due the large diameter the index plate, error spacing the holes the carrier can held within small limits. The index in. diameter with six accu- rately spaced holes provided with hardened, ground and lapped steel bushings accommodate the index pin. the illustration shows, the base the fixture has taper slide that accurate vertical adjust- ment possible. The grinder used Heald planetary grinder fitted with Carborundum wheel in. diam- eter, in. face, 303 grit, grade. 3—The set- for grinding spindle seats the carrier. dexing wheel mounted directly upon the spindle carrier shaft. THE IRON AGE, January a 18—THE IRON AGE, January 1935 speed 5000 ft. per min. while the eccentric planetary speed the wheel r.p.m. Ac- curacy the hole diameter, radial distance between the holes, and the dimension from the center the work the axis each ground hole held tolerance 0.0005 in. many instances has been impossible detect any error the ground part. However, limit 0.0005 in. extremely close for work this size and character. Referring again Fig. the front part the spindle carrier are shown two locking blocks let into slots machined accommodate them. The locking blocks receive the lock bolt which secures the automatically indexed from station station. The number locking blocks the carrier course depends the number spindles, there being one block for each spin- dle. obvious that the locking blocks must spaced very accu- rately and this accomplished the grinding operation shown Fig. This operation assures accuracy the spindle carrier location each position within 0.0001 in. understand the prin- ciple involved must borne mind that one side the lock bolt where enters the locking degrees while the other side straight. Thus grinding away slight amount from the locking block, the lock bolt location can altered that high degree accuracy the location possible. Referring Fig. the locking block held special fixture and clamped place two square-head shown the front the fixture. The fixture base two parts, one sliding over the other, the movement being controlled screw. the front the fixture shown knob for turning the screw and the dial graduated give close settings. Thus pos- sible control the amount re- moved grinding within close limits. ABOVE LEFT IG. 4—Accuracy within 0.000! in. indexing se- cured taper grinding one side each locking block. LEFT 5—Grinding the top sur- faces the T-slots the main tool slide. The fixture held and magnetic chuck which located Sharpe surface grinder. The wheel used this operation taper- face cup, in. diameter, in. face, Alundum, 1946 grit, grade. peripheral speed the rim 4000 ft. per min., which ample for operation this kind. this simple grinding method extreme accuracy the lock bolt location each locking block assured. The part arranged for grinding Fig. main tool slide. This unit made from high-carbon steel forging, heat treated, and provided with The slide illustrated in. long and in. diameter. slides over the spindle carrier stem shown Fig. being actuated acam. The tool holders locate over the tapered portions the slide each side the T-slots. The operation shown Fig. consists grinding the flat surfaces over the T-slots. the illustration shows, the work held mag- netic chuck. The machine abrasive machine tool grinder fit- ted with cup wheel in. diam- eter, in. deep, grit, grade. The wheel has surface speed the rim 6000 ft. per min. Care must exercised this opera- tion have each finished surface equidistant from the axis the part these ground surfaces are used for locating the piece for the next operation, Fig. shown the tool slide arranged for grinding the beveled surfaces the sides the flat surfaces previously ground. the illustration shows, the work held special angular fixture, locating from two flat surfaces previously ground. The part held place clamp each end, while the fixture located magnetic chuck. This machine Norton sur- face grinder capable taking work ft. long and in. wide. The machine fitted with three chucks placed end end. The wheel Alundum, in. diameter, in. face, combina- tion grit, grade, and operated surface speed 4000 ft. per min. Great care must exercised this operation make sure that the ground surfaces are equidistant from the axis which assure inter- changeability the tool holders — interior surface of e-harde clutch 7—Finishing THE IRON AGE, January 6—Grinding the beveled surfaces the T-slots ‘ 2 2 the completed machine. The lim- its this work are 0.0005 in. The machine question almost constant use employed for finishing flat surfaces diver- sity parts, large and small. Due its chuck range, ft. in., can accommodate number parts one setting. The operation illustrated Fig. consists finishing case-hard- ened machinery-steel clutch gear. diameter and in. deep. this operation the part faced, the in- ternal diameter finished and the bottom the hole faced one setting the work. The piece located wringing onto stub arbor which locates the head- stock spindle. This machine Heald internal grinder fitted with Alundum cup wheel, in. diameter, in. face, grit, grade. The wheel operates spindle speed 10,000 r.p.m. while the work three surfaces one setting the work, the bottom and outer surfaces are parallel and square with the bore, which essential requirement. Referring again Fig. the parts shown the extreme right are finger holder spools. They are made chrome-nickel steel, heat treated and contain the mechanism for operating the collets that grip 20—THE IRON AGE, January 1935 the bar stock. The groove the spool engages with shoe the feeding position and the shoe re- leases the mechanism permit the stock fed forward against stop. Fig. shows how the spools LEFT IG. grinding fin yer hole spool, BELOW IG. 9—An ex- ample grind- ing finish long and slender work. The job drive shaft, in. lona. are ground internally. This par- diameters plainly shown one the spools the work table the machine. The smaller portion in. diameter and in. nie a operation applied long. The remainder the spool has internal diameter 13/16 in., this portion being in. long. Due its construction, this piece lends itself readily locating for three straps locating the groove which brings the back the work against three locating surfaces. After the work positioned ap- proximately, the operator trues indicator. Then the strap bolts are set firmly enough hold the work securely for grinding. This machine No. Heald internal grinder fitted with Alundum wheel, in. diameter, in. face, grit, grade, oper- ated surface speed 5000 ft. per min. The work speed r.p.m. Both internal diameters are finished one setting the work which assures their being concen- tric and the tolerance 0.0005 in., which close for internal job this size. good example comparatively long, slender work grinding shown Fig. This part drive shaft 101 in. long overall, the largest diameter being in. The other dimensions fin- ished grinding are in. diam- eter in. long, in. diameter in. long, in. diameter in. long, in. diameter 25/32 in. long and in. diameter 13/32 in. long. number instances. This shows the cam roll studs. finishing this shaft many diameters possible are ground one setting the work. The work held between centers and driven dog one end the usual way. Also the work sup- ported two backrests, one which shows illustration. The machine used Norton indrical grinder capable accom- modating work in. diameter and in. long. this case the machine utilized over ca- pacity since the work 101 in. the illustration shows, the tailstock projects ways for about one-quarter its length. The wheel used Alundum, in. diameter, in. face, combination grit, grade, operated surface speed approximate- 5500 ft. per min. About 0.020 in. allowed for grinding and the grinding tolerances are 0.0005 in. many instances, however, the finished shafts not vary 0.0002 in. from the desired size. Centerless grinding employed for finishing number parts. Fig. 10, the operation consists finishing eam roll studs. These are case hardened and have ground portion in. diameter in. long. The operation shoulder grinding, that the work cating the work slide and bringing the feed and grinding wheels together means hand-actuated lever. The machine used Cincinnati centerless grinder fitted with Alundum wheel, in. diameter, in. face, 1960 grit, grade, operated surface speed 5000 ft. per min. Repair parts for old style ma- chines involve the manufacture aluminum bronze bushings which preceded the anti-friction bearings These parts must setup used today. ground very accurately. for internal grinding spindle bushing shown Fig. 11. The £ aluminum bronze bushing used old style automatic THE AGE, January oe planetary-type grinder fitted with Alundum wheel, in. diameter, in. face, grit, grade, operated surface speed 5000 ft. per min. The planetary speed the wheel about r.p.m. The work shown place 127/32 in. long with in. nole. This good example planetary internal grinding and assures round, straight hole. The operation grinding the outer diameter old style spin- dle bushing shown Fig. 12. This part has two surfaces finished grinding each in. in’ diam- eter and in. long. The work located expanding arbor and driven dog one ‘end. The machine used Norton cylindrical grinder fitted with Alundum wheel, in. diameter, in. face, combination grit, grade, operated approximate speed 5500 surface ft. per min. illustration shows, the ting down the screws not The work speed r.p.m, This with parallels that the ap- distort the work. However, com- accurate operation the toler- proximate correct center locating paratively light pressure suffici- ance for variation from the given assured. approximate loca- ent hold the work place se- size 0.0005 in. and the same limit tion, that with 0.001 satis- curely enough for this operation. applies concentricity between factory because the outer diameter finished locating from the in- The machine used Heald the hole and the outer ner ground diameter. The work clamps shown, being understood that care must exercised set- 5 13—Grinding external ameter tapered bearing Sharpe No. universal grinder ar- ranged for finishing the outer diameter old style taper bear- ings. These units are machinery steel, case hardened, and are in. diameter the large end with 20-deg. taper each side. The inner diameter ground pre- viously internal grinder. The (CONCLUDED PAGE 82) 22—THE IRON AGE, January 1935 of tr m ze ng Fig. II IKE all practical problems, sur- seems certain that the most im- portant are the size and shape the irregularities which are the roughness the surface. Several means have been sug- gested for rating surfaces, and these will discussed presently, but the author’s knowledge there only one method measurement which gives essential data the sizes and shapes the irregulari- ties everyday units, namely, the inch. This instrument called the Profilograph’ because enables one make enlarged sur- face profiles. Briefly, consists Developed the physics laboratory project undertaken for the Timken Roller Bearing Co., the Department Engineering Research. Additional development the instrument was made connection with project for the Ingersoll Milling Machine Co. Profilograph Measures Rough- ness Finely Finished and Ground Automotive Industries, Aug. 1933, page 204. urtace Finish and How Can Measured A\nd Speci ABBOTT Research Physicist, University Michigan instrument for tracing over the surface with very sharp dia- mond point, and magnifying and recording optically the movements the point obtain enlarged record the profile the surface. The instrument has been described ent paper the sizes and shapes surface irregularities are de- scribed briefly the basis in- formation obtained with the Pro- filograph, after various methods rating roughness are problems finish. Characteristics Surface Finishes IG. shows profilograms the surface irregularities three typical finishes The out- standing feature all three sur- faces clearly the extreme blunt- IZES and shapes surface irregularities, deter- mined means the Pro- are described briefly and various suggested methods rating surface finish are reviewed paper, which was presented Mr. Abbott the annual meeting the Society Automotive Engineers, held Detroit last week. The Profilograph illustrated and described article "The Measurement and Diagnosis Gear Mr. Abbott and Prof. Firestone THE IRON AGE Dec. 20, 1934, page 10. ness the irregularities. each the width hill valley from times its height, and this seems general all surfaces mea- sured. The instrument easily capable recording much sharper curves, and since there trace such irregularities, con- cluded that the essential irregu- larities surfaces are very dull. This fact should borne mind when talking about “bending over peaks,” This dullness per- haps more easily understood when one thinks the difficulty main- taining tools which are sharp terms tenths thousandth. second feature machined surfaces the wide range the size the irregularities. rough boring operations and the like, the profile may have depth 0.004 0.005 in., while finely finished parts such piston pins, gages, ete., the irregularities may the order five millionths (0.000005 in.), factor nearly THE IRON AGE, January 1935—23 x > 1 7 q f aft 7 4 eet) = } 4 = Nigra, . = ee ink. 1000 between coarse roughing and fine finishing operations. Extreme Range Shape Profiles third feature surfaces the extreme range the shape the profiles. This probably expected from the ease with which various operations can recognized inspection the sur- faces. many surfaces two the irregularities are alike, and the inch profile. For this rea- son records the type shown one feed mark diamond Fig. are slight practical value because they cover too small length specimen. This difficulty overcome gearing down the recording drum the Profilograph that the profile compressed horizontally factor perhaps so. This makes all the ir- regularities appear times sharp they are, but, since they are initially dull, still pos- sible distinguish the individual wiggles. has been found that about in. trace suitable obtain good rating most sur- faces, and fine finish operations still shorter trace sufficient. some surfaces profile curves are very irregular; others they are very regular. some the profiles are essentially Jat with occasional scratches, while others are essentially flat with oc- peaks. most machined surfaces, valleys are larger and more prominent than peaks, but some the peaks and valleys are al- most identical size and shape. course, the irregularities are more closely spaced the finer finishes, and peculiarities form exist almost every different type EK. J. Abbott and F. A. Firestone. Mechanical Engineering, September, 1933, page 569. 24—THE IRON AGE, January 31, 1935 IG. | Prot jrar ot surfaces in true pr larities. Magnification The profilo operation. fact, most oper- ations can recognized almost easily from the profilograms from the specimens. Figs. and typical surfaces. Specification Roughness would desirable the roughness surface could specified single number that surface could rated No. No. finish. first thought seems that number giving the height the profile would serve this purpose, but inspection the profiles actual portion showing bluntness of irregu surfaces proves that such not the case. From the standpoint wear, surface which tially flat with occasional scratches obviously far superior one with prominent peaks, even one which saw-tooth contour, even though they may all have the same total depth profile. After examination the profilo- grams practically all the usual machining and finishing op- erations, was decided that the best approach specification the rate which the bearing area the surface increases upper part the profile moved. Measurements were made the increase bearing area with depth number pro- filograms, and the following speci- fication devised the basis these measurements. was found that most the peaks sur- face are removed when the bearing area per cent, and that when the bearing area per cent, only the deeper valleys remain. Accordingly, surface defined terms three heights, fol- lows: Peak Number.—The height be- tween the per cent and per cent bearing area. Medial Number.—The height between the per cent and per cent bearing area. Valley Number.—The height between the per cent and per cent bearing area. All three numbers are given inches, preferably inch for convenience. The per cent and per cent limits were chosen minimize the effect single prominent irregularity. This specification takes account the horizontal spacing the ir- this, appears that the number times the profile curve crosses the per cent bearing area line good rating. This method speci- fication, and the reasons underly- ing it, are described more fully previous Surface Waviness addition the finely spaced termed the “roughness,” many sur- faces exhibit another type regularity which have called “waviness.” general, the roughness and waviness sur- face are the same order ver- tical dimension (up 100 mil- lionths inch for finishing oper- ations), but the horizontal spacing the waviness much greater— the order tenths inches, more. Fig. shows some typi- cal examples waviness. The due “feed marks,” “chatter” and other causes. Obviously, one actually realize the benefits smooth surface, the waviness small enough that the bearing area determined the roughness rather than the waviness. ap- pears that waviness important many familiar operations. present seems that the best way specify waviness give the height and spacing the waves. For example, millionths inch high, and 1/16-in. spacing. Practical Methods Rating Finish HILE the method measur- ing and specifying finish just outlined apparently leaves little desired concerning data the lar ly, dit rec pre ca | an its in ra m p n n F a pore; and Cc, finish hone. \ \ 7 size and dimensions the irregu- larities, has one drawback, name- iy, time (that is, cost). While ad- ditional development will certainly reduce the cost records from the present value several dollars each laboratory basis, ap- pears the author that the minute dimensions involved demand deli- cacy instrument, adjustment and manipulation which precludes its immediate application rou- tine factory inspection. With this briefly the various methods rating finish which have been sug- gested, together with brief state- ment the advantages and dis- advantages each. Microscopic Examination.—Ordi- nary microscopic examination slight practical use because one primarily interested the height the irregularities, while the mi- croscope gives plan view, and hence does not yield definite nu- merical values. the magnifica- tion great enough bring out millionths inch, the field view small that usually only viewed once. Small depth focus another drawback. using different lighting, one can obtain almost any kind picture wishes. Hence this method little use settling arguments. Profile Microscopic Examination. method has been devised for illuminating small area sur- face and viewing essentially grazing incidence with This very simple method for comparatively rough surfaces, such boring and the like, but not sensitive enough for finishing oper- ations where smoothness really factor. specimen carefully copper plated, the surface, and the cut carefully polished, the profile can ex- amined microscopically, and photo- believed that this the best method studying the details the shape any single irregu- larity, assuming that the shape properly preserved the prepara- tion the specimen. one uses, ein neues Mikroscop zur Ober- Sonderabdriich auf Zeiss Nachrichten. Heft Juli 1934. “Microscopical Examination Sawyer. Appendix paper cited Note 6. a record covering about in. the specim profiles obtained, and are not intended with given operation. The one ata partial hone; reamed; worn automob and 3—Protilograms several snd shape irregularities. Magnif typical surfaces showing differences size ation: Vertical, horizontal, 30X; the ens. These records illustrate the sort indicate the relative smoothness obtainable ile cylinder; bore; burnished; say, 1000X measure the vertical yards records obtain suit- able average. This method laborious that seems reasonably sure that will used only special laboratory experiments. tempt has been made rate the roughness surfaces the rate which pencil lead worn away when drawn over the surface certain speed under given pressure. Usually the mounted the end dial gage that the wear thousandths indicated directly. The author has never had opportunity com- pare readings made this method with profilograms the surfaces THE IRON AGE, January 3!, 1935—25 9 | \| | i af £ e 2 | question, and hence has defi- nite information. have been in- formed that, while seems give fairly consistent rating, leaves much desired. Electrical Pick-Up Method. Several investigators have drawn phonograph pick-up across sur- face, and used the generated volt- age measure the rough- The voltage was measured means amplifier and elec- tric meter. This single value ob- viously cannot give all the infor- mation which can obtained from profilograms, but the author the opinion that this the practi- cal instrumental method for rou- tine inspection. However, some the outfits have been assembled without proper appreciation the electrical factors involved, and opinion that such instru- ments should regarded spe- cial-purpose devices, developed for specific inspection after compari- sons with profilograms, and suit- able adjustments the electrical circuits assure proper agree- ment. They should not used for Survey Surface Quality Standards and Tolerance Cost Based 1924-30 Precision Grinding Prac- actions, A.S.M.E. (1931). Paper No. MSP-53-12 26—THE AGE, January 31, 1935 pte + c Fic. waviness we rougnne the ns. The record bore; small waves about general rating purposes without check. Visual Comparison with Profilo- graphed Standards.—The old “eye and method judging finish often leads one far astray trying compare different types operation, as, for example, ground, lapped, and faces. cannot depended upon for this purpose. the other hand, one has several specimens given operation, as, for ex- ample, grinding, varying de- grees roughness, they can unerringly placed the correct order roughness ordinary in- spection. This immediately sug- gests method checking finish which both economical and ac- curate. When one making preliminary decisions regarding finish obtained different opera- tions, different machinery, settle argument, the answer profilograms selected specimens. For routine inspection, visual com- parison made between the pro- duction finishes, and the standard specimens the particular opera- tion question. Means are now available that surface finishes can measured and specified terms the di- mensions and shapes the irregu- larities, which are the roughness and waviness the surface. Suf- ficient profilograms have been made indicate something the com- plexity the problem, and prove the necessity more than one number for specifying rough- ness that account can taken the character the surface, well the size the irregulari- ties. set three numbers has been devised which appears sufficient for specifying most fin- ishes use today. For routine checking finish appears that visual comparison with standard specimens, and spe- cial-purpose electrical meters are most promising. both cases, they should based on, and cor- related with, profilograms, and the Profilograph used settle all arguments. Additional develop- ment will also improve the Pro- filograph. Two Electric Furnaces Installed Campbell, Wyant Cannon Foundry Co., Muskegon, Mich., has installed additional electric furnace, which rated three tons per hour batch cold melt- ing practice. This foundry spe- cializes largely iron camshafts, crankshafts, cylinder blocks, centrifuse brake drums, ete. The Pittsburgh Lectromelt Furnace Corpn. has four other units this foundry. Three these are rated 1000 lb. per hr. and the fourth will melt tons per hr. The Duraloy Co., New Cumber- land, Va., now installing its third Lectromelt, 500-lb. three- phase unit, which will used for making special heat and corrosion resistant alloys. Chicago Well Attended Chicago chapter the American Society Metals celebrated its president’s night regular meet- ing held Jan. 10. The guest and speaker the evening was Judge John McGoorty, who presented address concerning the control crime. Shepherd, na- tional president the society, also gave brief talk the influence the society and the help the industry. - a W Ww cE nN. m F W h depression over for producers corrosion and heat-resisting steels. 1934, total output such alloys amounted 43,695 tons, compared with 54,949 tons the peak year 1930 and 23,832 tons 1932, which was the least active dustry. From these figures, evident that the rustless (or stainless) steel business has considerable in- dustrial significance. Although the tonnage only small per- centage total alloy steel output, the monetary return consider- ably larger than for equal ton- nage low-alloy steels. Alloys belonging the chro- mium and chromium-nickel groups introduced commercially about years ago for the making cutlery. was soon discovered how reduce the carbon these Steel Production eak LIPPERT The Iron Age, New York alloys point where they could more readily rolled and fabri- cated. quick order, the high- chrome compositions and chrome irons appeared, after which the 18-8 and other chrome-nickel com- binations were offered consum- ers. great many types steels (or nickel base alloys) are now regular commercial and number these composi- tions are practically indispensable for various corrosion resisting applications. Production Statistics Now Available order keep the trade in- formed the status this phase the steel industry, THE AGE has conducted annual production since 1929. These statistics are not obtainable through any other medium. Prior 1933, only about per cent the country’s rustless steel ingot production was reported, and the totals Table for the years 1929 1932 are weighted accord- ingly. For 1933 and 1934, however, every licensed maker ingots but one cooperated the survey. This one producer’s output has been es- timated closely from other allied data obtained THE IRON AGE. Table total yearly produc- tion ingots for each the last six years shown, well complete breakdown analyses. These same data are pictorially presented Fig. The figures show that the 18-8 grade continues first place, with itic steels the chro- mium type second importance, and ferritic chromium alloys occupying third position. This relation reversal pro- duction 1931 and 1932, during which years the per cent chromium alloys were third place, from tonnage standpoint. per cent chromium ably resulted from increased mis- cellaneous demand and cannot attributed particular consum- ing industry. Much the chromium steel, however, goes the automotive industry the form strips sheets. Table large tonnage was necessarily lumped under the gen- eral caption “All Other (Cr. Cr-Ni).” good portion this THE IRON AGE, January 1935—27 pet \ bin 3 7 ° ° ° > > ° ° | < e S Annual Production, net ton 60,000 1929 1930 Fig. 1934 productic corrosion and heat resisting ingots analysis for the past six years. ere not chromium group, but the exact pro- portion unknown. future sur- break the “all other” group order that the distribution more complete. Larger Sheet Production breakdown for finished prod- ucts type and composition was completed for 1933 and 1934. These data are shown Table II. The figures give fair indication what products and compositions the consumers are demanding. However, they not represent full coverage the industry, in- asmuch licensed mills sell many thousands tons ingots and semi-finished steels yearly in- numerable plants which fabricate these materials into consumers’ products. practically impos- sible obtain full statistical data from these plants, many which handle only few tons yearly. However, the distribution Table does represent about per cent the total output the country. and the total distribution should conform fairly closely. The predominance sheets over other products expected, when the large demands for sheets from the railroad, building and ex- terior decorating industries are considered. But what really sur- prising the large production bars, which second and almost 28—THE IRON AGE, January 31, 1935 1934 rustless steel ingots shows per cent advance over the 1932 level, which was a low point. and castings and per cent distributions The percentages shown blank, prior 1933 ated analysis. Also the decorative arts use sizable quantities, and the tonnage going into modern furniture ing each year. Tubing about the oldest product made from corrosion alloys. Boiler tubes 0.30 carbon and per cent chromium were production long ago 1922. Strip production fourth place, despite the general assump- tion that strip next sheets general usage. Most the strip tonnage shown Table repre- sents cold-rolled material. Build- ing and decorating are two large outlets strip, and usually cold- surface fine for decora- tion polishing. Drop forgings, forged bars, etc., are included un- All der forgings. More Castings Produced previous years, the sur- veys foundry production rust- less and heat-resisting alloys for 1933 and 1934 were not completely successful. All but seven the li- censed foundries furnished figures yearly output and distribu- tion analysis, and with actual production data from all the other foundries available, was possible arrive the estimated output the unknown seven the basis their capacity produce rust- less and heat-resisting castings. can seen Table that the 1934 output castings was higher than for either 1932 1933, and was almost equal the 1931 production. The 18-8 grade has the largest tonnage the re- ported analyses. This graph gives the annual production equal the sheet tonnages. large proportion bars used for fittings cars, and also distilling and refining equip- ment. the bar group are also listed small rolled sections, which are subsequently cut into many pieces for use small machines and consumer all the bars listed Table are less than in. diameter, large bars are usually forged. Tubular goods occupy third place. Much the demand for these products comes from the brewing, distilling and refining industries. However, the TABLE PRODUCTION OF RUSTLESS OR STAINLESS STEELS IN THE UNITED STATES (1929-1934) (Net Tons) Ingots: 1929 1930 1931 1932 1933 1934 and 8.. 21,074 34,867 14,740 19,620 24,818 per cent (approx.) 14,552 8,821 5,397 2,900 7,401 8,658 per cent (approx.) 10,127 7,995 7,483 6,751 4,969 6,242 All other (Cr and Ni).. 2,950 2,792 2,438 4,312 4,262 3,977 Castings: All other (Cr and Ni) 2,876 3,131 2,264 1,840 1,510 1,690 4,403 4,522 3,22 2,786 2,493 2,874 Grand Total Castings) 53,293 59,471 3,901 26,618 38,745 46,569 50,000 : - \ Vy \\\ Hil} | . | | | i ing as- the ion ler 22. rth rip re- ld- in- tonnages grouped under the desig- nation other” large, amount- ing about per cent the total castings produced. known that much the tonnage under the “all other” classification nickel and chromium. Also included are complex alloys with very high nickel contents, per cent chromium, together with small amounts silicon, iron, titanium, future surveys attempt will made split most the “all other” tonnage castings into several these groups. general business 1935 ful- fills the expectations most prophets, quite possible that the 1935 output corrosion and heat-resisting ingots and castings will reach new high level. How- ever, should pointed out that chromium and chromium-nickel al- loys are encountering increasing competitive pressure alloy steels. For general building obliquely along the overflow edge Arizona Spillway Boulder Dam. The view shows the drum gates lowered posi- tion. These immense steel gates can raised low- ered decrease increase the flow water over the Spillway. Boulder now built height 625 feet above bedrock, and will reach its final height 726 late February, which time can begin store water. TABLE PRODUCTION RUSTLESS STEEL 1933 AND 1934 PRODUCT AND ANALYSIS (Net Tons) Total All Grades (Net Tons) 18-8 Sheets: 9,953 6,617 10,217 6,661 Bars: 1933 8,228 3,3 1933.. 4,14 726 Strip: 1933.. 1,370 1,838 510 Plates 1934 1,451 960 Forgings: 280 Wire: 173 purposes, railroad equipment, etc., the use copper-bearing steels, copper-molybdenum steels, showing signs growing. larger Crand Cr-Ni 1,472 1,628 236 2,199 1,192 165 1,769 2,099 985 2,515 786 1,002 492 2,878 199 210 1,281 222 819 273 1,001 128 391 demand for these types steels will displace some the tonnage the highly-alloyed and Cr-Ni alloys. THE IRON AGE, January 1935—29 ble st- ~ mee li- er 77 > pre g the 4 30—THE IRON AGE, January 1935 Tools ABOVE reduce the powdered metals the exact grain size required, the materials are sieved through series screens progressively smaller mesh sizes. left, the operator placing the sieves the mechanical agitator. LEFT FTER the metals have been reduced powdered form, the exact proportion carbides and ce- menting agents are thoroughly mixed ball mills. material and the ball mill which mixed. Pictorial Description the Carboloy Process Making Cemented Carbide ABOVE pres Ting naik-like, powaered torm pre- tig af A rs? > ; shaped