The Iron Age 1935-02-28: Vol 135 Iss 9

239 West 39th St., New York Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. ©. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President Vice-President FREDERIC STEVENS, JOSEPH HILDRETH GEORGE H. GRIFFITHS EVERIT B. TERHUNE ERNEST C. HASTINGS WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK, President VAN DEVENTER Editor Managing Editor News Editor Machinery Editor Washington Chicago Cleveland FINDLEY Editor Emeritus Pittsburgh Detroit Boston Cincinnati 28, 1935 Reconditioning Locomotive Driving Wheel Sets Late Returns from Laboratory and Close Limit Machining Automotive Pistons. Finish Helps Metal Products Meeting Mining and Metallurgical Engineers Personals and Obituaries Automotive Industry Washington News Construction and Equipment Buying Products Advertised 112 Index Advertisers 132 Cc. S. BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Emerson Findley, 311 Union Bidg., Cleveland B. L. Herman, 675 Delaware Ave., Buffalo, Member, Associated Business Papers N. Published every Thursday Subserip H. K. Hottenstein, 802 Otis Bidg., Chicago tion Price United States and Pos Peirce Lewis, 7310 Woodward Ave., Detroit sessions, Mexico, Cuba, $6.00 Can Charles Lundberg, Chilton Bldg., Chestnut & 3+ 1 > la: 3856. incteding 56th Sts., Philadelphia, Pa. *s C. H. Ober, 239 W. 39th St.,. New York $12.00 a Single copy 25 Cents W. B. Robinson, 428 Park Bldg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address Ironage, N. ¥ D. C. Warren, P. O. Box 81, Hartford, Conn J res? : 4 tae = “ay 4 a oy 4 we outstanding has been the service rendered Bethlehem fastenings for high temperatures and pressures, that they deserve mark. They have it—in the “X” that pressed into the face all Bethlehem Treated and Oil-Quenched Nuts. That “X” found nuts that are being subjected temperatures 1050 deg. and pressures high 1840 highest working pressures the United States. appears fastenings used many leading makes industrial high-temperature equipment. usually identifies the combination Bethlehem Treated, Oil-Quenched Nuts with Studs made Su- pertemp, Mayari 4140, Bethlehem Alloy Steels for High Temperatures. These Studs maintain their shape and strength in- definitely under high temperatures and pressures. Bethlehem Treated Nuts and Bethlehem Oil- Nuts are hot-forged from carefully con- STEEL 8—THE IRON AGE, February 28, 1935 trolled high-carbon open-hearth steel, and heat-treated the proper temperature fit them for the intended service. Exhaustive tests made after prolonged heating show their structural stability, high strength and free- dom from distortion. They “freezing” and “galling.” Where it’s hot, Bethlehem Studs and Bethlehem Treated Oil-Quenched Nuts, marked the are the matched fastenings use. There are many applications which nothing else will do. are remarkably resistant Bethlehem District Offices are located Atlanta, Baltimore, Boston, Bridgeport, Buffalo, Chicago, Cincinnati, Cleveland, Dallas, Detroit, Houston, Kansas City, Indianapolis, Milwaukee, New York, Philadelphia, Pittsburgh, St. Louis, St. Paul, Washington, Wilkes-Barre, York. Pacific Coast Distributor: Pacific Coast Steel Corporation, San Francisco, Seattle, Los Angeles, Portland, Export Distributor: Bethlehem Steel Export Corporation, New York. a N ‘ be | ¢ istant ehem 4a “a many dgeport, as City, wis, St. Coast onolulu. THE IRON FEBRUARY 28, 1935 ESTABLISHED 1855 Vol. 135, No. Not Default general impression has been that need not worry much about the passage 30-hour week bill, since the President and others the Ad- ministration are believed oppose it. Over-confidence this may costly. There doubt but that industrial experts have fully advised the Administration the damaging effects public interest which would ensue from such suicidal measure. The business press our country has also been active showing that enactment this sort would automatically lower our now depressed standards living and penalize every consumer through inescapable price rise approximately per cent. But the fate this proposal well that the new Wagner bill will ultimately rest the hands Congress, not the Administration. And the American Federation Labor, not finding comfort administrative circles, has turned its big guns upon members our national legislature. There surmise this statement. The information comes directly from members Congress, who state that while organized labor now leaving stone unturned present them the case for the 30-hour week, those who oppose have given them little convincing argument evidence rebuttal. Congressmen are apparently somewhat case-hardened the presentations made organized business groups, although they seem lend sympathetic ear the pleas labor lobbyists. possibly may that industry not "'selling its goods" sufficiently far down the line. that may, the case the 30-hour week proposal, most effective supplementary rebuttal would through individual letters sent Senators and Representatives. Many who read this editorial are position explain, clearly and simply, just what curtailment working hours, with the maintenance present weekly pay, proposed, would their specific costs and therefore must their sell- ing prices they are stay business. Evidence this kind pointing the effect upon consumers and based upon individual and specific cases, much more convincing than any generalized presentation. suggest that you are position assemble such facts, you once and present them your Senators and Representatives. must leave stone unturned, big little, prevent economic catastrophe through default individual effort. p — << j = a4 i ~ Special Equipment tor Reconditioning McCALL HEN locomotive driving wheel set recondi- tioned, the tread and flange both tires, the journals the axle and the bearing surfaces the crankpins must turned, and addition, the journals and crank- pin bearing surfaces must bur- nished. considered ad- vantageous perform these opera- tions without removing the wheels from the axle the crankpins from the wheels, machine tools special design are required. and fian =< IRON AGE, February 28, 1935 The treads and flanges are turned simultaneously driv- ing wheel lathe similar the 90- in. Niles machine shown Fig. The wheel set mounted centers the headstock and tail- provided with rapid power traverse along the bed 10-hp. motor. When positioned, the tailstock clamped the bed with powerful electric clamps. Both headstock faceplates are driven 50-hp. motor, the large internal gears each being driven compound gearing from pinions which are keyed heavy shaft the bed. The wheel set rotated equal- izing driver dogs fastened each faceplate. serrated face each dog bites into the outside face the tire, and means wedges, the biting action increased the cut becomes heavier. Cored openings both faceplates for the ges are turned simultaneously this 90-in. driving wheel lathe. crankpins permit the wheels located close the faceplates. This shortens the height the driver dogs and increases the ri- gidity the drive. Two too] rests are properly lo- cated for turning operations both wheels. Tur- rets are furnished which the different tire turning tools are lo- Feeds are provided from the driving mechanism means ratchet arms. calipering de- vice the rod extending over the faceplates enables the operator size both wheels equal diam- eters. push button slow down the motor speed useful when hard spots are encountered tires which have been service. Fig. shows Niles 90-in. loco- motive axle journal turning lathe. wheel set without tires shown for the purpose The wheel set mounted cen- ters the headstock and tailstock i is a d a 0 r Vv ocomotive Driving \Wheel Sets and rotated from the faceplate clamps one the wheel spokes jaws clamping the crankpin. cored space the faceplate, eccentrically located weight radially adjust- able This weight set off-center equalize the effect the counterweights cast driving wheel centers. aid obtaining the correct position, ammeter connected the line the driving motor and placed the headstock. flow current will indicate the proper lo- cation the adjustable weight. The faceplate driven belt its from jack- shaft the rear. The jackshaft driven belt from 15-hp. motor the headstock. The drive arrangement may seen the rear view, Fig. Two tool rests, mounted stand between the wheels, are provided with tools simultaneously turn the two jour- ACHINE tools designed facilitate the recon- ditioning locomotive driv- ing wheels without removing the wheels from the axle the crankpins from the wheels are described this article. They include able for small well large shops, and equipment for wheel sets three-cylinder locomotives, the design which has complicated wheel set reconditioning. nals. Burnishing rollers are then placed the tool holders burnish the journals. Feeds are obtained from the drive mechanism. Cross feed provided for facing the hubs the wheels. Some locomotives are built with trailer wheels under the hind the drivers. The diameter these wheels usually larger than the largest car wheels, but smaller than the driving wheels. The ma- chine suitable for turning inside journals these trailer sets, and often furnished with outside journal turning attachment, some the trailer sets have journals outside the wheels. This attachment may seen Fig. When not use tilted off its seat, shown, means turn the wheel set end for end the lathe machine both outside journals. Feed the attachment obtained from extension the regular feed shaft. Both Crankpins Turned While Mounted Wheels Fig. shows Niles 90-in. quar- tering and crankpin turning ma- 2—Turning journals 90-in. locomotive axle journal turning lathe. i THE IRON AGE, February 28, i + | in ne is e- to O- ER n- > 4 tomy “igs chine for simultaneously boring the crankpin holes each wheel, for turning the outside diameter both crankpins while mounted the wheels. the radial cen- ter lines the crankpins each wheel make angle deg. with each other, the machine called quartering machine. The crankpins may positioned the wheels two different ways. the pin the right-hand wheel (either wheel being placed the right-hand wheel) deg. advance the pin the left- hand wheel the wheels are rolled forward from the observer, the set said have right-hand lead. the pin the left-hand wheel leads, the set has left-hand lead. There are not many loco- motives arranged for left-hand lead. While some the older 12—THE IRON AGE, February 28, 1935 types quartering machines were designed for operations wheel sets with either lead, all the new machines have been built for wheel sets having right-hand lead. The wheel sets are placed the machine with each journal resting V-block. The V-blocks are adjusted vertically until the wheel set lines with the centers the machine. Rotating tool heads are mounted both ends the machine. The one the left-hand end located below the center the machine and adjustable vertical plane through the cen- ter suit the eccentricity the The head located front the center the machine and ad- justable horizontal plane through the center. tool head rotated 5-hp. motor IG. Crank turning operation left-hand wheel and boring oper- ation hand wheel. The machine 90- in. and crankpin turning and provided with feed and power rapid traverse. After the wheel set centered, rotated until the crankpins line with the tool heads. then securely clamped position, and the pins are turned with two revolving tools mounted tool holders the tool heads. The tool heads have recesses which are deep enough provide clearance for the longest crankpins. Bur- nishing rollers may substituted for the cutting tools when the pins are burnished. When new wheel centers are pressed axle, the holes for the crankpins are bored. Boring bars are inserted the too] heads and are provided with inboard sup- ports the castings which support the V-blocks. These supports have adjustment the same direction 1G. 4—Boring crankpin hole with quartering attach- ment journal turn- ing lathe. no fe the tool heads. The left-hand end the machine Fig. ar- ranged for pin turning and the right-hand end arranged for poring. The boring bar for the left-hand tool head temporarily placed the center supports. Machines Designed for Smaller Railroad Shops large railroad shops, all the machines described can kept busy. However, the smaller shops with less work the problem different. provide suitable ° IG. 5—Turning crankpin with quartering attach- journal turning equipment for these shops, has been necessary build driving wheel lathes with journal turning and quartering attachments, and design the journal turning lathe that the additional operations boring the crankpin holes and turning the pins can performed. Fig. shows 90-in. Niles jour- nal turning lathe arranged for single quartering operations. The spindle mechanism with its 5-hp. motor and feed mounted bracket the front side the tailstock. hori- zontally adjustable the bracket suit the eccentricity the pin, the center the spindle being horizontal plane through the cen- ter the machine. boring bar with inboard support the journal turning rest used bore the crankpin hole. The same machine and attach- ment arranged for crankpin turn- ing illustrated Fig. ro- tating tool head similar the one used the quartering machine fastened the spindle and its bearing supported bracket mounted stand the bed. When the machine furnished with outside journal turning attachment shown, the attach- ment swung out the way its air cylinder and the bracket mounted the base for the at- tachment. When arranged for these opera- tions, the journal lathe vided with adjustable and clamping provisions those the quartering machine. These features may seen Fig. When the journal turning lathe arranged for single quartering operations, necessary turn the wheel set end for end. indi- suspended vertically below the headstock spindle used line the hole pin the wheel next the headstock and insure that the hole pin the other wheel the proper loca- tion quartered. Lathe Equipped for Double Quartering and Pin Turning The journal turning lathe shown Fig. equipped for double quartering and crankpin turning. additional quartering spindle with its 5-hp. motor and feed mechanism mounted vertical ways the headstock under the main spindle. The quartering spindle adjustable the vertical plane through the center the machine. During quartering oper- ations, the spindle passes through clearance hole the faceplate. inboard spindle support provided the bracket which supports the V-block. The rotating tool head for turning the pins held bearing which supported bracket mounted the bed front the faceplate, Obviously, when the machine arranged for these operations both the headstock and tailstock must adjustable along the bed. They are provided with rapid traverse from individual 5-hp. motors, and are clamped the bed powerful eccentric clamps. When set for double crankpin turning, nec- essary use extension centers, shown Fig. line the wheel set. The pads the back side the tailstock Fig. are provided for mounting the same bracket that supports the quartering mechanism the front side. When mounted this position, the quartering mechanism turned end for end, but suitable for boring and turn- ing the spindle extends from THE IRON AGE, February 28, etre! fies eel er- ort ave ion with turn- . both ends the attachment. This provision made case should necessary quarter wheel sets with left hand lead. Three-Cylinder Locomotive Design Complicates Reconditioning During recent years number three-cylinder locomotives have been built. The design these locomotives has complicated the reconditioning the driving wheel sets. The crankpins these sets are 120 deg. apart instead deg. number quartering ma- chines old design have been equipped with deg. filler blocks which one the quartering mechanisms mounted increase 14—THE IRON AGE, February 28, 1935 the angle. quartering machines late design have been arranged for operations 120 deg. Journal turning lathes have however, with deg. filler block used with the quartering mechanism the tailstock. Fig. shows this block position. The parts are accurately fitted and lo- cated with dowels that either deg. 120 deg. operations may performed. The inboard sup- port for the boring bar also pro- vided with deg. block shown the illustration. Another deg. block necessary the base support the rotating tool head when turning the crankpin. The unit the rear Fig. the upper part Micro ment 30-deg. filler block operation 120 grinder mounted the machine for grinding crankpins. The third cylinder the loco- motive central the wheels, and its center line in- clined angle from the hori- zontal that its driving rod will clear the axle the front wheel set when attached central crank the axle the second wheel set. turn the journals this crank axle necessary re- move the standard tool rests and their base, and substitute low base with high tool rests pre- vent interference with the sides the central crank. One these tool rests may seen the ex- treme left Fig. 7—Journal turning lathe with quartering attach- inder locomotive wheel sets. ~ 4 pis. & Rear view of irnal turning lathe arranged for double quartering operations ° ° ° tr 4 li. art, q 4 te A 7 7 New Tungsten Carbide Tests 2000 Vickers URING the last decade scien- tists have constantly searched for hard and still harder ma- terials. But for practical purposes hardness not the only requisite. metal must tempered with some degree ductility. Various grades tool steel first appeared the market and were followed even harder cemented carbides. Recently the Norton Co., Worcester, Mass., diamond-hard boron carbide. This material has many valuable appli- cations abrasion resistor, but ate Returns rom and Mill LIPPERT The Age, New York its usefulness other lines lim- ited some extent its fragility. Still another hard material being developed this country. The hardness this tungsten car- bide (not cemented) transcends that cemented carbide, its duc- tility exceedingly promising, and its reaction experimentation has led the belief that even further improvements can made. The laboratory developing this newest cast tungsten carbide having difficulty securing satisfactory grinding wheel for shaping into desired forms. Fig. shows test made this new material disinterested laboratory. The impression that diamond pyramid under kg. load Vickers machine. This impression gave hardness 2000 Vickers, compared with about 1300 for certain cemented carbides and 930 for hardened tool steel. can seen that the material cracked from the corners the impression, indicating that somewhat brittle. However, not unduly brittle for its hardness, for poorly nitrided case will crack the same manner even with less hardness. The status this mate- rial will determined the near future when additional tests are made compare the characteris- tics this and other similar products under actual service con- ditions. Stainless Steel Has Low E.M.F. Seawater two dissimilar metals immersed seawater are connected either actual contact with each other THE IRON AGE, February 28, = : 4 Ne ill > ° ° ee ock |. ve 7 >. third conducting material, there flow current from one metal the other. This flow accompanied solution cor- rosion the negative metal. This corrosion, however, not confused with any corrosion the metals might suffer independently result seawater attack. The possibility serious cor- rosion arising from this cause the case widely differing metals used aircraft, particularly ma- rine aircraft, led investiga- tion potential differences Willstrop (England). The tendency this electrolytic corrosion occur dependent the potential difference between the metals when immersed seawater. his experiments Mr. Willstrop used invariable against which each metal was tested, instead attempting measure the differences between various metals directly. The actual e.m.f. between any two metals given the difference their respective potentials against the standard. all the metals tested the po- tenial was negative against the standard. Hence comparing the the metal giving the higher value the two will negative and will tend corrode the event electrical contact while exposed seawater. few test results are follows: Potential Against Standard (At Deg. C.) Volt, Average Austenitic stainless steel 0.20 Monel metal. 0.18 0.21 Aluminum bronze...... 0.26 Duralumin ... 0.78 Cadmium (plating).. 0.82 Aluminum 0.90 Magnesium alloy....... 1.59 With some alloys, particularly stainless steels the 18-8 type, steady potential not attained even after long immersion. Since the result seems fluctuate, this might accounted for periodic changes passivity. Duralumin samples take many hours attain steady potential. the case magnesium alloys the effect con- tact with stainless steels very marked. When these two metals are connected and immersed seawater the magnesium alloy cor- IRON AGE, February 28, 1935 rodes completely away days. When not connected the al- loy suffers little change after six days. Inasmuch stainless steel has very low comparative poten- tial, rarely suffers from this type corrosion. But contact with other metals may greatly accelerate their corrosion. Oval Converter Has High VER since Kelly developed the Bessemer converter 1847, the form this important steel-mak- ing unit has undergone many modi- new cast tungsten carbide cemented) tests harder than certain yrades cemented carbides. This pyramid impression the new material. The diamond was slightly clipped, thereby the irreqularity one corner. fications. this country the bodies converters are often cylindrical shape. Recent experiments Germany, however, have shown that converters with oval cross- section show higher efficiency. Thilo Heyden recent issue Stahl und Eisen discusses investigation the wear lining and the change shape two types converters during cam- paign. One converter was oval cross-section and the other circu- lar, shown Fig. This same figure shows the progressive wear the lining the two converters. Consider the oval converter the left. After melts making 695 tons metal, the lining was position after more melts, after more melts, and after and additional melts, and respectively. the be- ginning this converter had vol- ume 810 cu. ft., and after the 308 melts the volume was cu. ft. the right Fig. are shown results similar tests the con- verter with circular cross-section, After melts making 733 tons, the wall was after more melts and after 105 and subsequent melts the wall was and respectively. the be- ginning this converter had vol- ume cu. ft., and after the 247 heats the volume was 1050 cu. ft. evidenced the plan views, the wear the linings was not uniform over the whole circumfer- ence; was much greater the back than the belly, and this caused displacement the reac- tion space toward the back. was also found that flow conditions were influenced the same sense much more strongly the oval than the cylindrical form. Dur- ing each campaign, graduated charges were blown the be- ginning and end the life each bottom order discover the con- nection between the charge weight, time blowing and blast consump- tion the one hand and the di- mensions and shape the interior the converter the other. comparison the results showed that the oval converter operated more satisfactorily. The observa- tions also showed that the determi- nation the circulation cross-sec- tion must based the greatest surface the reaction space. the article the author dis- the relationship between blowing time and the consumption dolomite. Also reviewed are the relationship the converter height the conditions within it, and the mechanical processes taking place inside during the passage the blast. Slush Casting PROMINENT English maker shoe lasts now casting this product from aluminum unique manner. The same pro- cedure applicable any thin- wall casting, using either alumi- num some other non-ferrous metal alloy. core required, the mold being constructed two more portions which can readily opened and assembled into one piece. When closed the mold may held together some simple met arm rm Cc. 1] r c 0 i 1 I 1 | I clamp. The molten aluminum, some other alloy metal, poured into the mold through inlet until the mold completely filled. The filled mold thereupon immediately tilted turned over empty through outlet hole. Thus all the metal not solidified removed from the mold, and the thin-skin casting produced the chilling the mold may re- moved and subsequently trimmed and finished. apparent that the tempera- ture the mold, rate filling and time lag before emptying, all reg- ulate some extent the thickness the casting. The inlet should sufficient size enable the mold filled rapidly and easily, but preferably limited dimen- sions prevent the flow back metal collected the riser lead- ing from the outlet. The inlet and outlet both should situated the joint between the mold sections. case the metal does not flow out with sufficient rapidity, its exit can hastened introducing compressed air the mold through suitable inlet. This procedure almost necessary when high-melt- ing point metals are used. com- plicated molds several such air passages can used obtain the desired wall thickness various sections the mold. Naturally the air passages leave apertures the casting, but these points may located parts the not required solid. Uses Concrete Patterns LEADING English maker bath tubs employs concrete blocks preference wooden pat- terns obtain the sand impres- sions. ordinary concrete block suffices for the purpose taking the outside impression the bath, but the block which has act the capacity the core inner side has specially made, in- asmuch must withstand the effects the molten iron, and not out shape for succeeding castings. iron box, not unlike tub shape, but open the top and bot- tom, lowered over the ordinary concrete block and sand rammed hand. The top the box represents the bottom the tub. Pins are fitted the bottom the concrete block that when the iron box lowered the latter lies exactly position and requires further adjusting. The iron box with the sand impression the outer dimensions the tub then raised crane and lowered onto the special concrete block, which has previously been coated with plumbago black molding sand. Pins are also fitted this block the iron box fits with accu- racy. Although the pins cause the molds lie exact position, the Non-Choking Hot-Blast Stove Checkers CHECKER design for use blast furnace stoves must pos- sess several important characteris- tics, namely, heating surface, gradual increases deflection prevent dust chok- age, and maintenance velocity and turbulence effects order 2—Change the shapes two types converters during campaign. The converter the left has oval cross-section, and the right one circular form. Both types are eccentric. efficiency. depth which the iron box low- ered can varied the discretion the molder order make thin thick wall section. The molding boxes are discon- nected while the cast tub still dull red-hot condition. The sand emptied out and used over again for the next day’s molding. The tubs are left standing position top the inner block until the next day, after which they are in- spected and weighed quently dressed means grinding wheel and sand blasting. Slight cracks are often welded to- gether and the completed tubs are then enameled. The oval converter displays secure maximum heat exchange. The original Duoflex checker sys- tem apparently had all these quali- ties, but after long lengths op- eration was found that dust col- lected excessively the top and middle zones. The original design had top zone straight brick, middle zone curved brick, and bottom zone made brick still another curvature. Chokage was found the junction the straight and curved zone. Fig. there shown modified Duoflex design wherein all the zones are made curved brick. believed that this will eliminate chokage. This modified design should also THE IRON AGE, February 28, val ion ace ro- mi- ore one c 3—Modified design Duoflex checke Heating cased by 64 Length increased Gases say 2280 Middle Zone Heating Surface Brick Used increased Length increased 2000°F Bottom Zone Heating Surface Brick U ed increased by 20% Velocity Restored for blast furnace stoves. This maintains velocity, and such not clog wher handling dust increase the efficiency well eliminate dust collection. All four walls each passage each zone are curved, and the curvature accentuated further each the lower zones. The cross-sectional area progressively restricted each zone, and there compen- sation for the decrease velocity caused reduction volume the gases they transmit their heat the checkers. Thus the original velocity maintained each zone, and the gases leave the bottom checkers 1600 deg. the same velocity they entered the top 2280 deg. The in- Depth Gage Disk Microscope Clamp of den gases. creased length travel provided this Duoflex system insures the same time interval for complete system using straight checkers throughout. This latter system would have decreasing velocities the lower zones. This checker system finds par- partially cleaned gas which may contain 0.5 1.5 gm. dust per cubic meter. claimed that stove this type constructed brick in. long form passages in. and exposing sur- IG. 4—English wear testing machine. The specimen mounted the clamp which then moved press IRON AGE, February 28, 1935 the material against rotating face 150,000 sq. ft., will give efficiency high another stove having 150,000 sq. ft. sur- maintained passing the gases through the stove. Wear Resistance Determined New Machine jor factor selecting suitable materials for machine parts, equipment, and considerable effort has been expended pro- duce machines measure this characteristic reliably. new in- strument this kind the Skoda-Sawin machine marketed England, and illustrated Fig. Metallic articles often not re- sist wear proportion their strength hardness, for hardness indicates durability against wear only materials having the same composition and heat treatment are compared. substantially different materials are contact they should individually tested determine their relative ability resist The Skoda-Sawin machine can make test five minutes with sufficient measure probability units volume the impression thousandths cu. mm., which has been attained after specified number revolutions (3000) Widia (cemented carbide) disk. The disk works specified load (23 and circumferential speed (675 r.p.m.). impression caused the disk does not dam- age the surface the tested article. Fig. clearly shows the prin- ciple the machine. The disk supported two bearings con- nected yoke. The weight acts this yoke, through lever which swivels around fulerum and through rod which slides bushings. The lever connected depth gage. mo- tor the base the machine turns the disk means flex- ible shaft. The test piece liquid per cent potassium di- chromate distilled water), which also carries away the chips formed under the disk. shown the photograph Fig. the test piece clamped universal vise, and prior the Zone ¢ q jers 7 7 ‘ ] by sil all ¢ de ing Widia disk. ive ler lr- ses test the specimen brought accu- rately parallel with the periphery the disk means spirit level. After the test the gage de- termines the depth and micro- scope can swung over mea- sure the width the impression. These values are used with ac- companying table determine the wear resistance. The slightest change the composition the cooling liquid has considerable in- fluence the results. Therefore, the machine can used stand- ard test blocks determine the relative efficiencies lubricating oils, emulsions and solutions used cutting liquids. tests soft materials are carried out, the duration the test can short- ened and the results converted the normal number revolutions 3000, which has been fixed for the tests hard surface pieces. 20-Ft. Rolls Brinell 450 ECENTLY foundry received order for hollow roller cast- ings ft. long. The outside di- ameter was in., the inner hole tions cailed for surface hardness 450 The composition selected for this job had the elements necessary for successful hardening, namely low carbon and silicon, and sufficient alloy content produce initial hardening effect “as cast.” The complete analysis was total carbon 2.90 3.20 per cent, silicon 1.30 1.50, nickel 1.75 2.25, and chromium 0.60 0.75 per cent. was necessary rough-machine the castings prior heat treat- ment; therefore they were softened heating about 1300 deg. for hr., which brought the hard- ness down 200 BHN. pos- sible avoid this sub- stituting approximately 0.30 per cent molybdenum for amount chromium, making the metal “as cast” slightly softer but not decreasing its ability harden heat treatment. The heat treatment consisted bringing the castings 1550 deg. two steps; the first warming them gradually 950 deg. F., then speeding the heat- ing 1550 deg. with soak that temperature. The cast- ings were quenched oil and tem- pered the range 450 650 deg. some cases the hardness ex- ceeded 450, but was reduced this figure elevating the temper- solder. The physical properties ing temperature. the alloy are those materials having specifi- cations D.T.D. 166-A and D.T.D. shapes with ease, although inter- mediate annealing may neces- sary such manipulation com- plicated. The annealing tempera- ture about 780 deg. C., and the alloy can quenched water air-cooled. Annealing does not cause scaling have any effect the surface except dull the polish slightly. British air ministry speci- fications D.T.D. 232 (hard) and D.T.D. 237 (soft) have just been published for new non-ferrous alloy nickel, copper and This alloy was developed William Gallimore Sons, Ltd., Sheffield, England, and ex- pected them have great future for radiator tubes and other tubing account its strength and the strong joints made when soldered. This alloy can soldered and welded with ease, strong joints be- ing made with the usual grade “A” tinman’s solder. The electrolytic not liable fatigue season cracking, and one those “neu- tral” alloys answering well con- For certain applications the al- loy likely compete with stain- less steel which resembles, being white color and readily polished. Extensive tests seawater have shown that there corrosion junction with the lighter alloys the metal itself the joints such duralumin and the various made with grade steels. Editor's Note: This series observations which, strangely enough, are exactly what they purport be. other words, they come from the daily diary real prominent executive the metal-working industry who prefers remain anony- mous author. “The and bul can and does who Che and service. anxious mother, disheartened mad Che church. When, when will the religion, politico, THE IRON AGE, February 28, Hex > < ble ro- i his ent act ted fon fied 1SK. oad 32 MA am- sted rin- con- & : & rum hich r is hine di- hich med RECISION boring equip- ment arranged for the diamond turning pistons with elliptical and tapered skirt limit 0.0005 in. the major and minor diameters and the taper: and set-up for single-point finish boring cylinders unusually close limits are de- scribed this article, which Point Boring Cylinders and Diamond Turning presented Mr. Wise the annual meeting the Society Automotive Engineers, held Detroit, Jan. 14-18. many problems con- fronting automotive engine manufacturers has been the production pistons the limits called for their blueprints inso- far the elliptical and tapered form the skirt concerned. Grinding has been employed, but recently precision horizontal bor- ing machine (Figs. and has been adapted for this work, and with this equipment possible produce the necessary cam shape ellipse shown the accompany- ing drawing (Fig. and the same time turn the taper the skirt. 20—THE IRON AGE, February 28, 1935 Automotive Pistons Fig. shows standard Ex-Cell- Junior double-end precision bor- ing machine equipped with suitable fixture for turning two pistons elliptical and tapered and turning two diameter ring lands the same operation. this machine the diamond turning pistons ac- complished with follower riding that has the desired form produced. This operation similar pantographing opera- tion. The elliptical tapered cam mounted the flange nose the F Ic. |\—Preci- sion boring machine ar- ranged for turn- ing two aluminum pistons one operation. spindle and carries rectangular driver, which fits and centralizes be- tween the pin bosses the piston. The piston placed over the tangular driver and pilot locates the open end the bore. The driver designed hold the pin bosses proper relation the cam shape, that the elliptical form will always have its major diameter right angles the wristpin bosses. the case split skirt piston, the driver carries two spring expanders for support- in or the cal jor the Close Limit and Cylinders ing the skirt adjacent the slot against the pressure the cutting tool. the piston located centers, its dome end supported tail- stock having live precision bear- ing center. the piston located the bore the open end and against the face the open end the skirt, then spring clamped draw-bar used for holding the piston with pin through the pin bore. This draw-bar may re- leased while loading either hand-operated lever hydraulic cylinder actuated pressure from the main hydraulic unit the ma- chine and controlled hand foot-operated valve. Fixture Carries Turning Tools and Cam Follower The fixture carrying the turning tools and cam follower mounted the machine table proper. provided with hydraulically-op- erated cross-slide for moving the tools into the turning position IG. 2—Single-end precision boring machine for turning two tons without centers. WISE Ex-Cell-O Aircraft Tool Corpn., Detroit the start the cycle and for quick return from the piston the end the cutting stroke. Thus the tools dragging across the finished surface the piston the return stroke are eliminated. The diamond tools are position away from the work during the loading and unloading operations, thus eliminating the chance accidentally damaging the turning tools. The follower which engages with the cam, and the diamond tool for turning the skirt elliptical and taper are mounted member which oscillates about centers sup- ported the cross-slide and backed spring which pro- vided the proper tension for the follower contact the cam. The two tools for turning the ring lands are held rigid tool-block, which also mounted the cross-slide. Ahead the cam follower spring tension wiper for keeping the surface the cam clean that the follower will make proper con- tact throughout the entire length the cam. Each the three tools has individual micrometer adjust- ments for accurate setting. Coolant Delivered Proper Point the turning operation essential that coolant delivered the proper point the piston throughout the entire cut. Tubes with series holes are placed above each piston, which provides complete flushing the work and tools during the turning operation. The coolant carries the chips the THE IRON AGE, February 28, aoe | ae + 2, Nex - Ag? Re py { i 3—Close-up view the turning units and fixture, showing cam for turning the pistons. fixture pan and then into screened settling tank. valve the ma- chine automatically shuts off the coolant the end the cutting cycle and turns just before starting the next cutting cycle. The close-up view, Fig. shows how two turning units are mounted one bridge with the tailstocks mounted the bridge the op- posite end. The turning units are heavy-duty flange-type Ex-Cell-O spindles with balanced driving motor mounted directly over them. The units and tailstocks are provided with fine cross adjust- ment each bridge for accurate alinement. Each tailstock sleeve lapped fit its bracket and operated longitudinally means rack and pinion through horizontal bar the bottom the bracket. This bar has vertical member which connected the end the tailstock sleeve. this member moves the tailstock sleeve forward, under spring tension for clamping the pis- ton and provides positive return the sleeve. adjusting and stop provided the vertical member that the tailstock the closed position exerts the proper tension the dome the piston. standard jig lock operates the rack and pinion and holds the tail- stock sleeve the closed position. One Operator Runs Two Machines The production obtained per ma- chine per hour, with one opera- tor running two machines, loading the one machine while the other turning. 22—THE IRON AGE, February 28, 1935 The Ex-Cell-O precision boring machine used for this piston turn- ing operation standard all re- spects except for the fixture and the cam arrangement the front each spindle nose. hydrau- lically operated and the movement the table and fixture operat- from the main hydraulic system the machine. The accompanying sketch, Fig. shows the ellipse and taper the piston. Advantages the diamond turning include better finish, which gives greatly increased bearing con- tact between piston and cylinder walls and thereby reduces initial wear. Turned pistons can pro- duced with greater accuraey, due the lower tool pressure; and the greater uniformity size and Held Norma/ Diameter Elipses much IG. 4—Sketch showing how the el- lipse and taper are turned the aluminum pistons. form obtainable. Diameter limits can held closer than previous methods, being possible hold 0.0005-in. limit the major and minor diameters the ellipse. 0.0005-in. limit can also held the taper, and the edges full T-slot are cut clean and not rounded off. Oil consumption the engines and cold “slap” are reduced, the latter due closer fitting; and time saved selec- tive fitting the respective cylin- der bores, because uniformity piston sizes. Single Point Boring Cylinders Another recent development importance engine builders the single-point finish boring cylin- der blocks. the past, most firms used reamer before the honing operations. has been found that during this reaming operation, one more flutes the reamer become dull, the wall thick- nesses vary, due core shifting, there will tendency produce wavy uneven hole the fin- ished cylinder block. Because these holes are not round and straight, most engine manufactur- ers leave large amount stock removed during the honing operations. most cases, the hone follows these uneven out-of-line holes, although they partially cor- rect this unevenness. believe are safe saying that almost impossible correctly hone hole far alinement con- cerned unless this hole round, straight and free from taper before the honing operation performed. With machine for single-point boring the cylinder block, eight holes can bored one operation. tolerance 0.0003 in. for out round and diameter hole can maximum 0.001 in. for parallel- ism throughout its entire length with the center-line the crank- shift bore. Uniformity Important The machine illustrated Fig. designed for boring four holes each two V-type cylinder blocks. The material these blocks grade cast iron (nickel iron) with Brinell hardness 180 240. great deal the suc- cess this single-point tool cylin- der boring operation due the iron, which not uniform struc- ture and harder than 240 Brinell cannot machined without great } 4 | ' A oles 1ese suc- the ruc- deal trouble the limits re- quired. feed 0.007 in. per revolution used this machine, but feed adjustable meet individual re- quirements. Stock removed the diameter ranges from 0.012 0.015 in. The difference between these limits makes appreciable dif- ference the finish bored hole, and allows more liberal limits for previous operations. The sizes any the tools coming contact with the finish bore the cylinder the spindles are withdrawn from the bored hole. The fixture had longitudin- ally indexed for the next boring position, which represents the dis- tance between the two cylinder bores. The blocks clamped and unloaded automatical- ly. The complete cycle automatic. the mechanical construc- the rear the machine the floor line. “low pressure” hy- draulic system used. Emergency hydraulically-operat- valves are provided that the slides can reversed, should any portion the machine become jammed each slide can automat- ically returned without causing damage. This single-point precision cylin- der boring machine bores un- 5—Front view eight-spindle, cylinder-block boring machine. individual holes are held within 0.0002 in. each other. boring 1/16 in. diameter hole, spindle speed 525 r.p.m. employed. The single-point tools are tipped with tungsten carbide, and production eight-cylinder V-type blocks hour obtained. Many difficulties had over- come using machine this type for boring cylinders. All spin- dles had accurately alined the bore and had come stop the end the down-stroke the slides. Accordingly the machine was designed that hydraulical- operated mechanism brings all boring tools alinement the end the boring stroke, that when the fixture automatically oscillates back 1/82 in., there chance tion the machine, the spindles and alining assembly rest slide having one and one flat way, and are under full pressure lubrication. These slides are extremely long and are heavily ribbed reduce minimum any vibration that may enter the machine. Boring spindles are the sleeve projection type, using four standard Ex-Cell-O precision bearings. They are driven two V-belts with individual motor for each spindle, thereby eliminating jack shafts and other mechanisms which might cause vibration. The spindle brack- ets, are bolted the slide the machine and have horizontal ad- justment. The motor used for driving the main hydraulic motor and pump usually close accuracy, only 0.0005 0.0007 in. being left the bores for honing against 0.002 0.004 in. generally left with the former method reaming, etc. leaving this small amount stock, with uniformly round and straight hole, naturally, the production limits the finished product will held more exacting tolerance, and the same time eliminate the rough honing operation now done most engine builders. the type eight-cylinder block, alternate cylinders were bored, and our opinion that this plan method will used the future for boring cylinder blocks, because gives the machine builder opportunity equip his machine with large, rugged spindles. THE IRON AGE, February 28, 1935—23 \re out can gth nk- = nell Finish Metal Products Sales Designing for Profits HERBERT SIMONDS the metal working industry de- sign may have its primary objective reduction cost in- enough these two factors often are unwittingly combined. design- attempts better the appear- ance metal product, say pencil sharpener, generally turns simplification, that is, the use fewer parts and fewer angles, and result this the manufacturing cost the article frequently reduced and its main- tenance simplified. This most welcome state af- fairs occurs most often when article being redesigned. the original design the demand un- certain and the his desire risk little possible tooling charges will often led put out design which, while economical for the first few thou- sand parts, may highly extrava- 24—THE IRON AGE, February 28, 1935 important feature design metal prod- ucts the nature the finish and therefore discussion some principles industrial design seems appropriate this series metal finishing. Whenever two products are otherwise equal, the one that looks more attractive the purchaser will bought first and when the demand insufficient for both, the maker the more attractive item may stay business and the maker the other bankrupt. The accompanying article describes some the work industrial designers and tells the small manufacturer how can adopt few the principles successful de- his own plant. gant the demand warrants mass production. typical example this sort carry-over original design point extravagance shown the two illustrations old and new pencil sharpener. The new sharpener designed Raymond Loewy has many advan- tages other than improved appear- ance. avoids collecting dust, more rugged, and mass pro- duction basis less expensive make than previous models selling the same class. built relatively few zinc die castings. The die casting is, fact, good medium for the redesigning established parts. hard zinc alloys has sound structural value and readily takes most finishes. Davis the New Jersey Zinc Co., who has devoted much atten- tion design metal products, states: “The subject design usually includes finishing characteristics well form and contour. Nickel plating one the most common finishes and found three chief forms—bright nickel, brush nickel (Butler finish), and black nickel. undercoat nickel base for any the usual metal plates, as, for bronze, silver, platinum and gold. rich bronze finish used success- fully one manufacturer sun lamps. i a \ ° ear- lust, pro- ling ngs. rood zinc alue ten- icts, ally ckel mon hief ckel ‘kel. for as, sun “Some unusual effects are secured die cast parts contrasting lac- quer and plating. die castings when well made with polished dies have smoother finish than which are machined all over any usual com- mercial process.” Someone has said whenever are equal point utility and price the one that looks most attractive the purchaser will bought first, and when the demand sufficient take but one, the maker the more attractive item stays business and the maker the other goes bankrupt. From this easy realize the growing im- portance industrial design and also the reason why the recent de- pression focused attention this particular field activity. The foundation upon which the successful industrial designer must build his own career thorough knowledge the properties the material has work with. Such knowledge fact distinguishes the newer profession from that older one occupied essentially with decorative effects and well exempli- fied artists employed pottery manufacturer