The Iron Age 1935-07-11: Vol 136 Iss 2

~ ARK tley, Inc CHESTNUT AND S6TH STREETS, PA. Sales Offices 239 WEST STREET NEW Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Chestnut and 56th Sts., Pe. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK, President VAN DEVENTER LACHER Managing Editor GERKEN News Editor MILLER Machinery Editor Editor Washington Chicago Cleveland Detroit Boston Cincinnati Americans Choose Choose............... Maintenance Carbide Milling Cutter- Butt Flash Welding Fenders..... New Method Heat Treating Rails Late Returns from Laboratory and Ford Granodizes Lamp Standards for Foundry Statistics Metal-Working Activity. Construction and Equipment Buying 100 Index Advertisers 156 BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau Circulations Emerson Findley, 311 Union Bidg., Cleveland B. L. Herman. 675 Delaware Ave.. Buffalo, Member, Associated Business tien Price: United States and Pos- Lewis, 1310 sessions, Mexico, Cuba, $6.00; Can- Charlies Landbers. Chilton Bide.. Chestnut & 56th Sts.. Philadelphia. Pa. $12.00 year. Single copy, cents. W. B. Robinson, 428 Park Bidg., Pittebursh Sweetser, 239 West 39th New York Abi AY burg. uct. — Vacation Without Worry Off for few days play—and rest. Days too few and precious share with business worries. Orders, production, deliveries—all lined advance—arranged well that they can for- gotten. Parting instructions, call Ryerson when steel needed, take care any emergency that may arise. have the steel—every kind, shape and size, and ship once. More than years steel- service have proved the dependability Ryerson shipments. Write for the Ryerson Stock Immediate Steel. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Buffalo, Cleveland, Detroit, Boston, Philadelphia, Jersey City RYERSON 12—THE IRON AGE, July 1935 SERVICE é | | | | q { ] | THE IRON AGE ... JULY 1935 ESTABLISHED 1855 Vol. 136, No. Most Americans Choose Choose perity and depression. The wear and tear time will cause replacements consumer goods and, limited extent, capital goods, but savings will not risked new ventures unless there rea- sonable assurance security and profit. measure the difference between pros- Saving implies the postponement expenditures from the present some time the future: For that reason, saver can object the principle higher taxation, provided that increased revenues are used reduce the public debt, for only through bal- ancing the national budget that the danger ruin- ous inflation can averted and the security savings assured. And few savers oppose the principle proportion- ately heavier taxation extreme wealth, provided that the purpose reduce the gap between Gov- ernment revenues and expenditures. If, however, the primary aim redistribute wealth from one class the population another, all who have accumu- lated savings have reason become alarmed. Taxa- tion for redistribution would not necessarily stop after its initial application. Wealth, after all, relative what one man may regard moderate accumu- lation may seem like fortune another. Theoretically is, course, possible redistribute wealth taxation. But what the ultimate conse- quences? After wealth has been leveled, where would the savings necessary enterprise found? Soviet Russia, the Government virtually com- mandeers all savings. What does not take taxa- tion obtains the form loans, since all savings must invested State securities. Even what spent for living expenses reverts the Government the sole purveyor goods. the State, barring complications arising from international trans- actions, gets back all that expends. Such system can work, for time least, but entails complete extinction individual freedom. one can control the investment his savings. one can have any choice how much can purchase what can purchase. The Government, and the Government alone, decides what produced. present Russia, the State decides that savings shall into the production capital goods, the consumer must bide his time the hope that the new productive equipment will prove efficient and some future date will with higher stand- ard living. But even when that happy time comes, ever comes, the consumer will have take what the State deigns give him. wants automobile and has saved enough buy one, will forced take the car the Government has produced, provided has turned out enough cars supply the demand. anything goes wrong with the car will have deal with one seller, the Government; cannot threaten trans- fer his future patronage another manufacturer. power politics will probably get service. Otherwise not. reminded recent experience. had tele- phoned member public commission for infor- mation. the midst the conversation hung me. typical example bureaucratic discour- tesy—and there was nothing that could done about it. Human nature cannot different Russia. Power, without competitive responsibilities, inevitably begets arrogance. Ina socialized State the individual has option—as the selection vendors, the purchase goods, the investment sav- ings. all cases must deal with the Government. There are alternatives from which choose. Most Americans will choose choose, when they fully realize that programs, car- ried their conclusions, would condemn them such complete political and economic serfdom. LACHER Managing Editor, The Age IG. testing surface with optical flat the appearance pattern sim- cates surface irreqularities. The exact location these irrequ- larities and their characteris- tics are revealed the hun- dred thousandth part inch. ONE the primary factors our ability turn out masses products that are satis- factory performance the ability create machinery un- usual accuracy. This accuracy has come about methods measure- ment which have cut the tolerances machine tools fractions un- dreamed fifty years ago. the production machine tools few things are more necessary than precision gage-blocks. steel block about one inch length just piece steel, but with proper heat treatment, extremely refined lapping and measuring processes, may finished until the length definitely known one inch within limit one- millionth. Without such instru- ment manufacturing mass basis interchangeable parts would impossible. difficult the mechanical achievement securing accurate flatness and parallelism the sur- faces such block, the problem increases difficulty when necessary, addition the flat, parallel surfaces, attain given length within one-millionth inch. The process still further when complete series blocks must produced pro- gressive increases size, incre- IRON AGE, July 1935 Light Waves 2—Parallel cate absence surface testing with light waves, the inspector esti- mates the millionth part while measuring ex- actly the hundred thou- sandth. ments one ten-thousandth inch. Since the kind steel used gage-block has much with the final success the work, extreme care must exercised its selec- tion. Many experiments have been made the Bureau Standards and gage manufacturers de- termine the formula that offered the important qualities perma- nence and stability. Carbon steel and chromium steel have proven most satisfactory. One manufac- turer uses chromium steel con- taining about 1.20 1.50 per cent chromium; from 1.00 1.10 per cent carbon; from 0.20 0.40 per cent manganese; not over 0.03 per cent phosphorus; and not more than 0.03 per cent sulphur. Such steel resists wear and corrosion and, properly heat-treated and sea- soned, free from changes size and shape. durability and permanence are im- portant factors making gage- blocks, the heat-treating process important and critical operation. The smallest variations condition structure may ruin the blocks. The stabilizing treatment must controlled within narrow range largely responsible for the perma- nence the finished gages. Owing thermal expansion, material standards length can 3—By interposing standard and part tested between two optical flats, the difference dimen- sion the two can de- only correct their nominal sizes one particular tempera- ture. Therefore, machining parts accurate dimensions must determined what tem- perature the sizes shall agree with the figures specified. The measur- ing instruments should adjusted suit that temperature, commonly known the standard tempera- ture, temperature adjustment. America, deg. Fahr. the standard general practice the engineering industries. While impossible avoid some contrac- tion and expansion the blocks with changes temperature, once size fixed temperature, will 4 4 ‘a 5 | 4 ‘ 4 | ‘ Precision Measuring usually return that size when subjected the original tempera- ture. matter how accurate pre- cision gage-block may begin with, useless standard un- less retains its original ac- curacy. Changes which ordinarily would unimportant are very serious blocks made obtain range dimensions varying only 0.0001 inch. Here, er- rors few millionths cannot tolerated. And now the question is, how know that these gages are cor- 4—Method checking ball diameters cylindrical surfaces means optical flats. rect within one millionth inch? The possibility the use the wave-length monochromatic light natural standard measure- ment was first pointed out Fizeau 1864. stated that ray light, with its extremely small but perfectly regular undula- tions, could considered natural micrometer the highest perfection and was eminently suit- Michelson worked out method determining the number wave- lengths certain monochromatic light the length the standard meter. His was the first success- ful attempt refer standard length natural phenomenon. this phenomenon optical interference that forms the basis linear measurements terms wave-lengths light. Most have noticed the iridescence drop oil float- ing water. The tiny rainbows that appear are due light wave interference. When light waves strike surface they are reflected, and when two surfaces are close together, such the top and bot- tom oil film, light waves are reflected from both surfaces, but because the distance greater the second surface, the reflections interfere, producing bands color instead white light. Light waves possess the necessary properties fundamen- tal units length, the most im- portant which are constancy, reproducibility, accuracy mea- surement and ease application. Because they vary length dif- ferent color sensations are received the eye. When two trains waves from one point source, fo) EVERETT MELSON Lomb Optical Co. having traveled different paths, fall upon point the retina, the resultant amplitude vibration de- termines the brightness. they are “in step” maximum brightness results. But the troughs one arrive with the crests the other, destructive interference takes place, resulting darkness. the two that the difference path some whole number wave lengths, then the waves will reach the eye phase. Measuring Optical Flats the use optical flats light waves are utilized testing plane surfaces. take two perfectly flat pieces glass, preferably quartz, and lay one upon the other, touching one edge but slightly separated the other, wedge- shaped film air will formed between them. the surface be- ing tested irregular, the pattern assumes the appearance con- tour map, shown The position ard number lines show the exact location and character- isties the surface irregularities. the surfaces are absolutely flat alternately colored bands will ap- pear parallel and straight. The distance between the surfaces the first dark ring approximately (CONTINUED PAGE 42) 9 — 5—The small prism the right about one-eighth inch largest dimension. The angles are within ten seconds specified value. THE IRON AGE, July f l, t Practical the Maintenance CARBIDE tools are rapidly finding favor machine shop prac- tice. For many appli- cations these tools, various com- positions base metals, have brought about radical changes practice and machine design did the advent high-speed steel. Development still progress, and while use old story types cutter grinders are fitted with exhaust These machines must capable doing accurate work and they must properly maintained. fan. ° SUITABLE lapping plate can made cast-iron disk into the face which diamond dust hammered. IRON AGE, July 1935 ° FRANK CURTIS Research Engineer, Kearney Trecker Corpn., Milwaukee many shops that have made wide applications, nevertheless there are innumerable shops that have only few carbide cutters and count- less others where their use merely contemplated. char- acteristic all equipment there are two problems involved, ap- plication and maintenance. This article sets forth some the prac- tical aspects the maintenance carbide milling cutters. the first place few words about care shipment. The car- bide tips must protected against the possibility being chipped. Mishandling may also result damage the brazing that binds the carbide tips the cutter. The inference must not drawn that these tools are particularly deli- cate, but like any fine tool they should receive the attention that consistent with their cost and the quality work that ex- pected from them. They should packed tightly. Generally stout softwood boxes are satisfactory. the case milling cutters the bottom the box often fitted with layer heavy felt. The carbide tips rest the felt during shipment and many cases the user saves these boxes, the cutters being placed them for safety | q § 4 j 4 4 a RY | | | | i | | handling them and from stor- age metal shelves. The matter storage involves safe-keeping because the cost; further, carbide cutters are usually best segregated from other cutters unless all tools are handled men who thoroughly understand the characteristics the carbide equipment. Many shops that are now com- ing use carbide tools start with operation here there and cautiously buy the minimum requirements. the start often not practicable buy grinding equip- ment that will satisfactory, and consequently tools must turned intervals the seller for resharpening recondition- ing. From the practical point view every installation should have extra set cutters. When only one cutter purchased, there naturally will lost time when regrinding necessary. Close-Limit Grinding Required When the use these tools has advanced the point where possible maintain them the shop, real study must given the type and characteristics the grinder purchased. Rigidity, strength and ease operation are three the prime necessities. Con- stant wheel speed and therefore ample power are recommended, be- cause speed lag causes excessive wheel wear and lengthens the time necessary uniformly sharpen set blades. Whether supplied regular special equipment the grinder that used for milling cutters should have mounted it, sturdy man- ner, indicator that can ad- justed two planes. Spindle end- play must eliminated, and the spindle must rigid. few words, the grinder that used for carbide cutters should Carbide Milling Cutters capable sharpening blades limit in. Some manufacturers give spe- cial attention the removal dust means wheel hood and exhaust system with air filters. One theory that dry grinding the spark must travel far enough from the wheel that will addition precautions relating care ship- ping and storing, this article gives considerable mation the grinding and lapping carbide milling cates, deals with the prob- lem maintenance, dis- tinguished from application. picked the suction and re- moved from the area where will damage ways and bearings and destroy the accuracy the ma- chine. Seals not always prove effective and many owners insist that grinders oiled daily and stated intervals taken apart, washed and cleaned. (CONTINUED PAGE 46) not grind the outside diameter not grind the with the the whee/ When new set blades mounted cutter body- grind the outside diameter cylindrical machine, When resharpening Grind Face cuthng There objection eage Grind the faces the cutter sharpening Heel Clearance Diameter @Corner Exert light pressure and move cutter transversely across the average iron, malleable ground average work. will be found When radi US cannot-* angles will sati sfactory wheels frequently Tuis sheet essential for properly grinding carbide milling cutter. THE IRON AGE, July 4 \ aZ/ \ Pontiac Uses Special Machines Butt WITH the development sweeping fender lines, with deep crowns and long skirts, its six-cylinder and eight-cylinder pas- senger cars, the Pontiac Motor Co. finding more economical and practical make its front fenders two pieces welded together rather than one piece stamped out single steel sheet. Prob- ably the outstanding achievement connection with this job the butt flash welding the outer and inner sections the fender, each in. long, the welding being done with such perfection that the flash burr ground off and prepared for the enamel coat without any soldering being necessary. The right and left inner section the fender drawn one oper- ation triple-action toggle press from 19-gage steel sheet 43% in. rectangular shape which tapers down width in. the trimming die the stamping part the die. The outer left front section and inner left front section then are flash welded special Taylor-Winfield Corpn. ma- chines, four which are used for this purpose. These machines are similar construction body panel welders. The main base frame carries stationary slide which dies and locating and clamping fixtures are mounted. Directly line the movable upsetting slide which mounted the other half the fender. The movable slide driven 5-hp. motor with variable- welding machine which joins the two parts the front fender sec. Clamping arms are hinged that they can raised stamp- ings are placed the welding dies made special aluminum bronze castings. 18—THE IRON AGE, July 1935 speed drive operating through gear reduction unit the cam- shaft. Clamping arms are heavy, rigid construction and are hinged the rear the machine that they can raised while the stamp- ings are being placed the dies. The hinges are carried vertical slides, are the latches the front end the machine. Hence, when the two stampings are po- sition welded, air cylinders either end exert downward pull simultaneously until the weld completed, when the pressure re- leased and the arms ascend for the next loading. Welding dies are made spe- cial aluminum formed the contour the fen- der. Uncommon accuracy re- quired the dies, the reason that, with normal commercial varia- tions the sheet stock, any inaccu- racy tends throw the abutting sheets out line. The re- sult would de- fective welds welds which are difficult finish. The dies are made three seg- ments, the center section being fixed the clamping arm proper. each end the center section the other segments are carried slides, being provided air cylinders attached the clamping arms. struction neces- sary because the weld line semi-circular con- tour and the pres- sure necessary hold the stock the dies cannot sh. | | a ° i f | Weld Fenders secured with pressure one direc- tion only. The upsetting slide faced with hardened and ground steel wear plates and provided with take-up adjustments compensate for wear. All bushings and pins are hardened steel, which used prevent undue wear parts sub- ject hard service and help maintain accuracy over long pe- riod. Thus the life the machine increased and the cost upkeep lowered. Each welding machine equip- ped with two 300-kva. pancake-type transformers with water-cooled copper secondaries connected parallel the die terminals give even distribution heat through- out the length the weld. Each transformer has eight-step volt- age changing regulator adjust the heat suit the job. The the trans- means aux- iliary switches actuated fan cam the camshaft, which operates spe- cial tactor arranged with four poles, two poles being used for each transformer. This arrange- ment the con- tactors assures the current be- ing turned and off the two transformers si- ly. The motor operated button con- trol, being stopped auto- matically the completion welding ONTIAC front fender stamped two parts, out- and inner sec- tion each which in. long. The two are welded perfectly that the flash ground off and the fender pre- pared for the enam- coat without sol- dering being neces- sary. The capacity each machine 100 welds hour. Actual time per weld sec. After the two parts the fender are welded, the flash removed inside and outside means portable grinders. Special precau- tions insure the safety the opera- tor who grinds off the flash the inside the fender; wears protective mouthpiece, goggles, cap, leather apron, and gloves. The outside surface the fender polished with hand tools metal finishers, the fender resting wooden buck platform cars oval conveyor during this opera- tion. and left inner section fender drawn one operation triple- action toggle press. the trimming die the stamping cut half shear which part the die. THE IRON AGE, July New Method Heat- special normalizing process developed the Illinois Steel Co. for use the produc- tion rails resulting prod- uct greater ductility and resis- tance impact, and with far greater resistance wear and end batter. Also importance the anticipated elimination the conditions which give rise trans- verse fissures and other serious in- terior defects. Investigations described this article have been carried out the laboratories and the rail manu- facturing plant the Illinois Steel Co. under the supervision the writer and Beers the Gary Works metallurgical organization, consultation with the metallurgi- cal staffs the other rail-produc- ing subsidiaries and the personnel the research laboratory the United States Steel Corpn. What Tests Showed One the first investigations made was determine the cause rail breakages low atmos- pheric temperatures. Impact tests were made standard full-size rail test pieces rail drop test- ing machine various tempera- tures between plus deg. and minus deg. These tests de- veloped that the impact resistance rails decreased rapidly with the temperature, especially with high hardening properties such are required the pres- ent-day rail specifications. This investigation covered over 2000 full-size impact tests and required about two and one-half years. After this investigation had been completed another investigation was made determine so-called “transverse fissures” interior progressive fractures could pro- duced new rails through repeat- stresses approaching the yield strength the steel the rails. 20—THE IRON AGE, July 1935 This investigation resulted valu- able information that showed that transverse fissures could produced various transverse lo- cations about the middle the rail head, depending the place the application the load the top the rail. Failure the rails under the low temperature tests and under the fatigue tests began the coarser grain struc- ture the interior the rail heads and spread the surface. Taking Advantage War Experience Based these findings, in- vestigation was planned develop means refining the grain struc- ture rails thermal treat- ment. Many the investigations made controlled cooling and other thermal treatments ord- nance and munition materials pro- duced during the war period re- vealed means eliminate interior ruptures found alloy and car- bon steels large sections. Interior ruptures found steel that time were given the name “flakes,” account their ap- pearance. They were small and were evidently formed through cooling stresses which were such magnitude split the grain structure the steel passed through the brittle cooling ranges. They were, this respect, related interior ruptures called “shatter cracks” which were later found the interior rail heads. the close the war several processes treating rails were tried with the object view im- proving strength and quality. These investigations included con- showing the loca- tions Brinell hardness determina- These figures may interpreted the data shown Table Note how the hardness drops the lower part the rail, and also greater distance from the end the rail. 1G. 2—The hardness data shown Table correspond the points this Rails like analysis were tested normalized condi- tion and reqular hot-bed cooled condition. There more qradual change hardness for the normalized rail. F | I | trolled cooling, reheating and quenching various quenching mediums, with subsequent drawing stress relieving special methods normalizing. Quenching and Drawing Tried investigating the quenching and drawing process was found that the rails would have re- heated before they were cooled into the so-called “brittle ranges,” and that the quenching operation should not longer than carry the center the head slightly be- low the critical range order tain the best results ductility and prevention “thermal rup- tures.” Rails produced this process were high properties and impact resistance. However, the estimated cost equipment and operation for the production quenched and drawn rails was found high, and this process thermal treatment did not appear practical the production rails from Rails JOHN BRUNNER Manager, Department Metallurgy and Inspection, Illinois Steel Co., economical point view except for special severe service require- ments. The controlled cooling process was further studied and developed its application rails, and the temperatures which interior rup- tures may develop rails were determined. Hardening the ends rails air blast applied the time the rails reached the up- per limit the critical thermal range was also developed. While this method treatment, car- ried out thoroughly, eliminated in- terior ruptures, lacked the most important feature, namely, the re- finement the grain structure, which required resist the im- pact stresses which the rails are subject under rapidly moving loads, especially low tempera- tures. The controlled cooling process was also found de- ficient uniformity that the outer rails protected hoods boxes cooled more rapid rate End Rail Tin. from End Rail Brinell numbers show the variation hardness normalized rail, both the distance from the end increases and measurements are taken greater distance from the Note how the extreme end the rail the hardest. Rail analysis 0.73 0.73 Mn, 0.033 and 0.24 Si. Chicago. than the rails toward the middle the charge. Special Normalizing Process Developed special normalizing process was found the most promis- ing that refined the grain structure and within the proper ranges cooling, prevented the formation “thermal ruptures” “shatter cracks.” applying drastic cooling, re- heating and final cooling, was demonstrated that even under such adverse conditions the damage the steel through stresses the rail head would minor. The process could, therefore, all times regulated that internal stresses would reduced mini- mum and thermal ruptures entirely prevented. manufacturing rails this process, the rails, after they are rolied, are not allowed cool through the brittle ranges until after they have passed through the thermal treatment and have obtained grain structure sufficient ductility resist the cooling stresses without rupture. Rolling and stresses produced the rail mill are reduced minimum this process. further prevent stresses, controlled slow cooling applied. the further development this process, hardening the ends the rails before the final cooling was added, thereby producing quality rail which best covered the general requirements rail- road track service, both safety and resistance wear. Limited Air Cooling Followed Reheating This special normalizing process consists air cooling the rails after they have left the mill until they reach temperature, the interior the rail section, slightly THE IRON AGE, July cooling n r e 307 302 255° 269 TABLE TABLE Brinell Hardness Determinations Hardness Data Three Types Normalized Rails for Normalized and Hot-Bed Cooled (Location points are shown Fig. Rails Distance Brinell Hardness From Locations Shown Fig. ses Showed End Rail 0.75 0.92 Location alysis s 2 3 4 5 6 i d 8 Mn, 0.034 P, Number =0.85 311 321 302 293 302 269 255 302 386 293 293 262 248 Normalized Rail 364 364 364 340 321 321 321 286 =0.78 321 332 332 321 302 302 293 262 255 311 311 311 293 286 293 269 255 255 255 375 379 375 340 325 321 304 300 Hot-Bea 332 340 318 321 288 269 269 321 321 321 293 300 300 275 Average 259 below the so-called “thermal criti- cal range,” and before they have reached the thermal brittle range. They are then placed furnace slightly above the thermal critical range. The rails are held the furnace until the entire rail section has reached uniform temperature. After they are taken out the furnace, blasts compressed air are applied through special nozzles the top the rail head both Er ends for sufficient length time obtain the hardness desired these particular locations. Hardness Controlled Air Quenching Rails normalized have hardness close that the hot- bed cooled rails, which aver- age about 260 Brinell. more explicit designation the hard- ness values shown Fig. which may interpreted the data shown Table Also, the difference hardness normal- ized and hot-bed cooled rails like analysis shown the data Fig. and Table II. the compressed air quenching, the hardness the ends between 375 and 400 Brinell the top the rail the ends. From that point, the hardness decreases the regular hardness the rail head distance from in. along the top the rails and from in. downward IG. order determine equal stress lines, the end rail section was first machined and then 5—This rail head has been cut apart means band saw. cutting The rail head then was divided into compound kept the rail cool. Lengthening contracting individual diamond- diamond-shaped sections, shown here. shaped sections gives indication stress distribution. 22—THE IRON AGE, July 1935 | t t § | | | t 3 | | | | | + H along the ends the rail sections. These distances can regulated demarcation +0.005 Ib. per sq. in. compression zone between the hardened part 9,000 per sq. in. compression and the unhardened part. There +0.0025 in.= 7,500 Ib. per sq. in. compression is, therefore, plane zone along Ib. per sq. compression +0.0015 in.= 4,500 Ib. per sq. in. in.= 3,000 Ib. per sq. in. compression place service. Another demon- +0.0005 in.= 1,500 Ib. per sq. in. compression stration the extreme hardness =neutral zone the rail end may seen in.= 1,500 Ib. per sq. in. tension 3,000 Ib. per sq. tens Fig. Note also how the hardness 0.0015 in.= 4,500 Ib. per sq. in. tension decreases gradually the distance in.= 6,000 Ib. per sq. in. tension from the rail end and from the rail surface increases. This process can regulated automatically throughout that TABLE the human equation, subject er- Results two companion rails, one “B” rail from ingot and the other rors, can eliminated and thereby “B” rail from ingot 13. One rail was special normalized and the other was cooled the hot bed. uniformly treated product ob- eat Number Speci- Number Cent Elongation per Inch Testing the Results 0.80 The method which equal stress Normalizing 1.85 first, machining and grinding the discontinued ends the rail uniform sur- 0.80 ension the rail. The rail head 2.40 then divided into number Twisted—Test discontinued diamond-shaped sections and 0.75 the sawing operation. diagram sawed rail shown. Through 1.90 released from each other and the 0.80 compression stresses showed 2.30 the part the rail head which had discontinued tension stresses shows contrac- 54031 B-13 0.75 Sections were separated steel 0.75 trok 9 9 9 piece would drawn back its 0.73. 0.92. Phos 0.034. Sul 0.028. Sil 0.23. original position. The sections which represent the part the rail head which had been compression before saw- ing elongate, and the sections was then measured microm- given Fig. and may inter- which represent the part the eter attached weight resting preted the data Table III. rail head which had been tension the rail end and the microm- Note the greater strains the before sawing contract, leaving eter adjusted for readings the used rail. the sections the rail head change length the different While these sections are not unequal length the change sections. this manner the stress small enough fully show the caused through releasing the lines new rail and rail maximum and minimum stresses stresses. after four years service were the rail head, they are made Each part the sawed rail head determined. These figures are practicable and their THE IRON AGE, July | | : | stress lines new rail (left) and rail after four years service (right). These figures may translated into stress figures the data given Table Ill. 24—THE IRON AGE, July 1935 7—Diagram showing the dis- tribution initial stresses hot-bed cooled (upper left), slow- cooled from 600 200 deg. right), and normalized rail (bottom). The numbers indi- cate length increments and corre- spond the stresses Table The normalized has the lowest initial stresses. 8—Stress lines hot-bed cooled rails before use left), after service one month {upper right), and after service six months (lower). These fig- ures may interpreted the data shown Table Note how the stresses increase during service. indication the approximate lo- compression and tension the rail head. Fig. are shown three diagrams giving the distribution initial stresses ordinary hot-bed cooled, slow- cooled and normalized rails. The numbers indicate Stresses given Table III. Note how the initial stresses are mini- mum the normalized rail. The stresses ordinary hot-bed cooled rails increase during ser- vice, shown Fig. This increase for ordinary rails may compared normalized rails comparing Fig. with Fig. comparison the permanent set and elongation normalized and hot-bed cooled rails given the data Table IV. The greater ductility and resis- tance impact will tend elimi- nate most the weaknesses found rails service, especially low. temperatures, such broken bases, square breaks, transverse fissures, End battering, which limits the life the rail service, and which source vibration, noise and wear rolling stock, retarded minimum the special hardened ends. The slightly greater hardness the lower part the head the ends the rails where the joint bars bear against the rails, reduces the wear the rails this point. large number American railroad systems test tracks the rails produced this method thermal treat- ment. These tracks are being closely observed, and the wear and battering measured and compared with hot-bed cooled rails, and few cases, with slowly cooled rails. The United States Circuit Court Appeals for the seventh cir- cuit recently handed down de- cision the case the Cleveland Crane Engineering Co., Cleve- land, vs. the Richards-Wilcox Mfg. Co., Aurora, which the de- cision the District Court the Northern District East- ern Division, was sustained. The District Court held that the patent suit, held the Cleveland Crane Engineering Co., was in- valid and that the Richards-Wil- cox Mfg. Co. had not infringed the patent. The patent suit in- volved the use monorail track current conductor. | 6.0015" 0.00/57 70.00! -0.00/"" | ~O 00 905" 4 | UA \) 0,002 0005” 20 the older engineers could turn time back the days when they entered the profession, and could draw picture the conventional machine shop, would see first glance mass transmissions through the full length the shop with belts countershafts and more belts from the countershafts individual machines. would see large number machine tools generally grouped types and appearance slightly different from each other, but even types and sizes there would not great variety observed. Such old friends the planer and shaper, the engine lathe, the drill press and radial drill, the knee-and-column type milling ma- chine and the Lincoln-type miller, few. universal grinding machines and: some tool grinders, were the normal equipment those days. Instead the grinding machines, would observe few speed lathes and for the production gears milling machines with index heads, some primitive gear cut- ting equipment. Operating these machines, were, almost exclusively, trained mechanics capable oper- ating any machine the shop, each selecting speeds and feeds the best knowledge and judgment, generously using the “squirt can” lubricate the machine and care- fully operating the machine avoid spoiling the work, damage the machine, accident him- Environment Changed The parts thus produced were made after drawings, ances and fits were left the sound judgment the operator. the same shop those days, found SOL EINSTEIN Chief Designer, Cincinnati Machine Co., Cincinnati NSTEAD relatively few types and sizes machine tools, old, modern shops require standard, semi- special and special machine tools undreamt-of variety and multiplicity sizes. This diversity re- quirement has brought prob- lems the machine tool builder, have improper care machine tools, and the tightening tolerances. Consulting service, usually gratuitous tooling prob- lems, commented upon, and plea made for closer cooperation between users and builders machine tools. This article from paper presented Mr. Ein- stein the semi-annual meeting the American Society Mechanical Engi- neers held Cincinnati, June ~ rows and rows which fitting and some other operations were performed manually. The mechanics those early days are many cases the pioneers the machine tool industry. Instead the relatively few types and sizes starfdard and conventional machine tools, find today standardized, and special machine tools undreamt variety and great multiplicity sizes meet mod- ern requirements, and some cases the fancy the individual user. The operator serving these ma- chines generally not the mechanic the earlier days, but specialist trained handle this particular type ma- chine, and quite often produce only particular type work piece. The machine itself with its powerful drive, its simple com- plicated tooling and intricate mech- anisms, Greek letter him. The shop itself divided into vari- ous functional elements and de- partments, sometimes grouped similar operations and other times into line production into this greatly changed at- mosphere that the machine tool manufacturer supplies his product. Tool-Room Machines Capable Variety Work For the tool room where, most cases, single pieces any shape size are produced, the machines must suitably designed for pro- ducing this large variety work pieces. They have uni- versally applicable, and operable under extreme range conditions Frequently number attach- ments greatly increase their utility. Control and operation these types machines are generally greatest convenience ‘and handiness, and modern tool-room equipment capable shaping work pieces high degree accuracy and very satisfactory time. Accuracy the parts produced the tool room the fundamental require- ment any industrial establish- ment. Gages, cutting tools, boring bars and fixtures are precision in- struments. They cannot check duplicate higher degree ac- curacy than theirs, The modern tool-room equipment with its slide dimensions, its rigid frames THE IRON AGE, July ° ° ° and its ease operation fulfils accuracy demands modern in- dustry. That such modern equipment sometimes does not show still more favorakly regard time-saving compared with older models, lies the fact that too much time has spent chucking the work piece the machine for the ma- chining operations. Standardized chucking and clamping equipment for tool-room operations would this setting-up time and with such improvement the tool-room methods could obtained modern tool- room equipment obtained hourly and daily with modern manufactur- ing equipment. The amount energy and ingenuity which the machine tool builder has put into development this type equip- ment should met with more con- structive response and cooperation from the user the full utilization its productivity. The inventory statistics pub- lished the American Machinist metal-working equipment, machinery particularly used the tool room show that replacement such equipment has not been any- where near line with replace- ment equipment for manufactur- ing purposes. Analysis the pos- sible machines used tool rooms from these inventory statistics in- dicate that more than per cent the equipment tool rooms over years old—certainly not equivalent with the tremendous development which has taken place the design this type ma- chine tool. Production Equipment Design and Building Problem The American ventory metal-working equip- ment indicates that per cent practically all the machine equip- ment this: country over years old having increased from per cent 1925 and per cent 1930. While unquestionably the years depression have retarded the replacement antiquated equip- ment, can positively stated that such standstill develop- ment production machinery has not taken place. The and manufacture such production equipment one the biggest problems the machine tool builder faces today. asked build 26—THE IRON AGE, July 1935 machines for the tool room which also frequently have used for small quantity manufacturing. The ease manipulation and set- ting-up such machines makes this type equipment especially suitable for this class work. The machine tool builder further asked build machines for quan- tity manufacture medium high production and natural that such machines have dif- ferent from the general utility ma- chines. They should have semi completely automatic cycle, and the work the operator should confined solely the chucking and unchucking the work. addition these two types machines which standard and can produced quantity manufacturing basis, the machine tool builder asked build high production machines semi-standard nature; that say, machines which are partly made standard units and part special mechanisms meet in- dividual requirements. also has build high-production, semi-spe- cial tools, which are machines special design but using few standard components, and finally has occasionally meet require- ments for completely special chines. From One Extreme the Other The demand for these various types machines did not develop the order mentioned; the con- trary, was jump from one extreme the other. When in- dustries started get large manufacturing basis, they departed from the standard machine tool and saw their only salvation the highly specialized machine. These machines, however, had and have the disadvantage being designed for specific operation and pro- duce specific part only, and they become obsolete soon change the part for which they were de- signed takes place. overcome this problem, ard high-production manufacturing machines were developed and their design lately the unit type construction has made possible the assembling various these units into different components with the result that semi-standard machine tools semi-special high-produc- tion tools can produced today composed more lesser degree from standardized units. productivity compares satisfac- torily with the special machines above mentioned. Requirements Studied hardly necessary call at- tention the amount study and development cost the machine tool builder put solving the problem here discussed. Years practical experience combination with thorough field study are necessary obtain true picture the requirements the various industries into which the proposed the opposite page, take pleasure presenting his many friends the working industry August Tuechter, president the Cincinnati Bickford Tool Co. This week marks the fif- tieth milestone Mr. Tuech- business life, and wish him many happy re- turns the day. machines have fit, and the de- sign such machine and com- ponents multiplies problems and costs. The machine tool manufacturer any particular line has serve the various industries, one dealing with small integral parts such typewriter, sewing and adding ma- chines; second one producing himself generally does, medium- sized parts like the automobile industries; and finally the industries which make the large parts such railroad equipment, printing presses, power plant equipment, Thus, even the machine tool builder confines himself limited line products has manufac- ture machines relatively large number styles and sizes meet the demands his customers. obtain picture what extent various types machine tools have developed might mention here that more than dozen different. | t 2 { 4 4 | q | | AUGUST TUECHTER, Drawn John Frew for The Age 4 4 d 3 3 | q J 4 ME € ¥ | } i | { q . ( | 5 | | = types lathes, some different types milling machines and over different types grinding ma- chines are produced today this country various manufacturers, and that practically all these various types machines are built multiple sizes. Every year brings such new machines the market, and new methods and ap- plications add continuously this large list machines. The life design these individual ma- chines has for various reasons be- come shorter and shorter which results the tremendous and costly problem keeping his ma- chines date. Add this the development and utilization new mechanisms such electrical and hydraulic controls, and you have picture one phase.of the problem that the machine tool builder has meet. Improper Care Problem Another serious problem which the machine tool builder faces in- directly the improper care machine tools large number shops. Machine tools produce chips and often use cutting coolant; dur- ing the cutting operation these chips are spread not only over tables and slides, but also over other parts the machine. astonishing indeed, how little care often exercised the operator and shop management keeping these machines clean and thus not only maintaining the intended ac- curacy the performance, but also avoiding problems the form break-downs, blame for which fre- quently put upon the shoulder the machine tool manufacturer. Machine tools are general pre- cision machines. maintain the accuracy machines and products, adjustments tool and work sup- ports occasionally required. Such are provided most machines, but they are too often utilized only after damage done tool work. Machine Tool Builder Consultant Tooling The modern machine tool manu- facturer the consulting engineer industry its various tooling problems. the years gone industrial establishment needed machine tool they made their own selection size, style and make, and the deal was closed. Today with the tremendous specialization the machine tool, the production department plant sends the part, drawing the piece machined, the various ma- chine tool manufacturers and them for recommendation the best methods machining. In- dustry thus obtains from the ma- chine tool builders, expert opinion their production problems and avails itself this free service. This service not only requires thorough study the individual operation involved, but also com- parative time studies all possible methods, consideration fixture and tool problems, and large number cases study the piece machined its pos- sible resistance against strains, and its possible behavior during and after the cutting operation. Selec- tion the most advantageous material for the cutting tool, such high-speed steel, stellite tung- sten carbide, another concrete problem. And finally the method holding and clamping the work piece requires considerable study. Mechanical, pneumatic fluid pressure clamps are available and the production requirements, well the nature the work and the type operator, must dictate their proper selection. The design fixtures and cut- ting tools involves not only such considerations, but also complete moved and, course, the nature the material the work piece. Variance either these factors might detrimental the satis- factory performance the in- tended equipment. Quite frequently also the performance certain operations particular type machine might simplify elimi- nate certain previous operations, and therefore sometimes dif- ficult get true picture the problems involved. These are just some high spots the free service the machine tool builder called upon give. Benefits from Cooperation Quite frequently the design individual part machined does not lend itself all, only with certain limitations, particular machining operation specified type machine tool. the sad experience every foundryman that the castings designed can only molded with considerable difficul- ties, all. This due lack knowledge foundry practice the designer. similar lack shop experi- ence lets the designer produce pieces which can machined only under great difficulties not all, certain advanced types ma- chine tools. The average designer, although might have had shop experience his early days, has not kept himself fully versed with the development new methods and new machines. Sometimes change the design the part question suggested the ma- applicable for machinability his product, and sometimes such sug- gestions are gratefully Quite frequently, however, num- ber reasons make such change design such late date un- desirable and less advanced method because the usefulness, utility and applicability the modern machine tool was not known was not thoroughly un- derstood and appreciated. this respect, closer cooperation between machine tool builder and the engi- neering staff machine tool users would mutual benefit. Tightening Tolerances Adds Problems stated previously, olden times tolerances and finishes in- dividual parts were left most cases the expert judgment the machine operator the foreman. Today have every modern shop quite elaborate system tolerances for the various fits, and besides, considerable attention paid the desired surface finish parts. specify tolerances and limits our drawings and the trend these tolerances con- tinuously toward closer limits. In- terchangeability parts and closer uniformity product makes such narrower limits desirable. Such closer tolerances not only eliminate some cases hand fitting where, due the nature the mechanism, clos