The Iron Age 1935-08-01: Vol 136 Iss 5

FRANK, VAN DEVENTER Editor Managing News Editor Machinery Editor Emeritus Washington Chicago Cleveland Pittaburgh Detroit Boston Cincinnati 239 WEST STREET NEW YORK, Hot Weather Briefs............. Determining Weights Washers and Late Returns from Laboratory and Statistics Metal-Working Activity............ Construction and Equipment Buying............... BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau Circulations ADVERTISING Member, Associated Business Papers Emerson Findley, 311 Union Cleveland Published every Thursday. Subscrip- Hottenstein, Otis Bidg.. Chicage ra tion Price: United States and Pos- Peirce Lewis, 1318 Woodward Ave., Detroit Charlies Landberg. Chilten Bidg., Chestnut & ada, $8.50, including duty; Foreign 239 West 39th New York Executive and Offices, Cable Address, Warren, Box $1, Hartford, Conn. Chestnut and 56th Sts., Philadelphia, MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS. Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS. EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN MOFFETT, for and ication SHEETS seaming, the duct qualities Bethlehem -work other uses that require forming GALVANIZED Galvanized Sheets speed fabr and keep the work costs low. grade sheet known Beth-Cu- products made from sheets, duct bendin easy- THE IRON AGE AUGUST 1935 ESTABLISHED Vol. 136, No. Weather Briefs Scripps-Howard newspapers, staunch defenders the New Deal and whose intellectual. menagerie includes such stal- wart conservatives Heywood Broun, Harry Elmer Barnes, General Johnson and John Flynn are editorially urging the President concentrate and finish one thing before starts too many others. They emphasize the political danger inherent delaying the ex- penditure the $4,800,000,000 fund which was intended put everybody to. work be- fore election day. $4.8 billions dollars even throw them away. Assuming that one man, given the task, was able throw away one dollar each sec- ond and could keep that pace for hours day, would take him 555 years dispose the entire sum. Naturally recognized that cannot wait that long for recovery, but even with three men charge the dollar disposal will admitted that the job small one. Nature sometimes helps out worthy cause, however, emphasized news item which appeared last week: Lakewood, J.—One New prominent eighty acre lake—which took two years make, van- ished after its dam broke and gal- lons water flowed into the Meterdeconk More these self-liquidating projects what America needs today! perfectly fair, one must examine the evidence both sides subject. That Nature may not altogether cahoots with the Government dollar spenders hinted the set back gave them, also last week, connection with the bountiful harvest the prairie states. This made plenty oppor- tunities for jobs private payrolls but few takers could found, recipients relief preferring remain sitting their back porches that they would sure home when the R.F.D. postman came with the Government relief check. several Western states were compelled suspend the dole order that workers might in- duced accept private pay. The weather too warm point moral, but least can draw conclusion. working both for and against the pork barrel boys, Nature has least given evidence neutrality concerning the New Deal. i| A Lv Volume 1300 meters 0.345 the second standard blast furnace designed the Soviets and adopted the conference blast furnace engineers Leningrad 1934. All measurements are meters, and the effective volume 1300 cubic meters. PRIOR the world economic crisis there was tendency increase the volume and daily productivity blast fur- naces. During the last years the productivity blast furnaces has increased two-fold and the period from 1914 1928 the daily 1.86 Furnace volume per ton pig iron 1927 1928 1929 1930 12—THE IRON AGE, August 1935 Develooments productivity large-sized Ameri- blast furnaces rose from 500 750 tons. the year 1927, ac- cording the information given Mr. McKee, blast furnace No. was blown Jones Laughlin Steel Corpn. the Ali- quippa Works America. This furnace had hearth diameter ft. in. (7.47 meters) and effective volume equal 943 cubic meters. The daily average pro- ductivity this furnace reached 1006 tons for whole year, and this high productivity, according Mr. McKee, was due the abrupt increase hearth diameter, which exceeded feet (0.915 meters) that the largest hearth built that time. Thus, the year 1927 was the be- ginning new period devel- opment blast furnace practice 2—Average coefficient ization furnace volume for all So- viet blast furnaces. Note how the unit volume per pig iron produced consistently declines during recent years. 1.35 1932 1933 1934 pig iron output Soviet Russia rose from five years. required years for the United States achieve this same rise, and England required years. The U.S.S.R. engineers are constructing the largest blast furnaces the world, and the efficiency these and was marked transition regular daily average productiv- ity equal 1000 tons. Following the successful per- formance blast furnace No. mentioned additional 1000- ton furnaces began appear both America and Germany. Blast furnace No. the Jones Laughlin Steel Corpn. was then reconstructed. Its hearth diameter was increased 8.27 meters and its effective volume thus became 1125 cubic meters. These increases size resulted lift the daily productivity 1200 tons. Germany 1928, the daily average production blast fur- nace No. the Thyssen firm reached 1100 tons basic Bes- | 5 4 | | | | | | | | | | | | | | | | | ; | € | 4 | ‘ | | | | | | | ; | | | } ‘ i | | | | | | | | | | | } | | | : 4 Blast Furnace the SUSLOV Mtallurgical Engineer, Grosny, furnaces approaches the best American and German prac- tice, despite lack ore sintering plants and good qualities coke. The author herein sketches the growth Soviet blast fur- nace practice, presents the current status the indus- try and reviews what may expected the U.S.S.R. semer pig iron. This furnace had hearth diameter 6.5 meters and volume 827 cubic meters. Blast furnace No. the Dort- mund Union firm had 6-meter diameter hearth and volume 870 cubic meters and also possessed 1100-ton daily productivity. Al- blast furnaces No. and No. sen, each had volume equal 830 cubic meters and were capable producing from 1000 1100 tons basic Bessemer pig iron daily. The blast furnace the Tata Iron Steel Co. British India had the highest average daily pro- duction, namely, from 1200 1400 tons. This furnace had hearth diameter 7.47 meters and vol- ume 813 cubic meters. The purpose mentioning here- the records some the larg- est blast furnaces point out the highest daily production any blast furnaces the world. 1931, due the world eco- nomic crises, further attempts increase the volume and productiv- ity blast furnaces were stopped America. This action came about even earlier date Germany. Rates Doubled Prior 1918 the largest coke blast furnace Russia was cap- daily production pig iron tons) Soviet blast fur- for the eleven months 1934 (curve A). furnace volume cubic meters per ton piq iron curve for the same period. ing the average 4—Total Soviet pig iron produc- tion millions tons. The output 1913 equal 4.2 million tons. Dur- ing the revolution the production pig iron practically ceased. able producing only 400 tons pig iron separate days. How- ever, the present time there are several furnaces existing this country with daily productivity ranging from 800 900 tons. Moreover, blast furnaces No. and Works, Ural District, have shown average daily productivity equal 1000 1080 tons. These fur- 23.8 295 Month THE IRON AGE, August if Table and Effective Volume Soviet Blast Furnace During the Period 1928 1934 Total Number New and Re- Volume constructed Blast Furnaces Put Operation Total New Volume and Re- Blast Blast Blast all Soviet constructed Furnaces Furnaces Furnaces Blast Blast With With With Furnaces Furnaces Volume Volume Volume Thou- Thou- Less More More Total sands sands Than 800 Than1000 Number Cubic Cubic Cubic Cubic Cubic Meters Meters Meters Meters Meters Furnaces Table First and Second Typical Blast Furnaces Effective volume cubic meters..... Diameter hearth (meters)......... Diameter belly Diameter stock line Diameter great bell (meters)..... Height hearth (meters)........... Height air tuyeres (meters)....... Height bosh (meters)............. Height cylindical belly (meters).. Height conical shaft (meters)..... Height cylindrical shaft (meters).. Effective height furnace (meters).. Full height furnace (meters)...... First Type Second Type (1930) (1934) 3.06 3.2 82% deg. 28.50 The section the first typical blast furnaces, 1930, was designed for the southern district U.S.S.R., for use with Krivoy Rog, red hematite iron ores and Donetz coke. naces have hearths 7.62 meters and volume 1180 cubic meters. Furnace No. located the same works, with 1220-cubic meter vol- ume, capable producing 1148 1200 tons daily. Furnaces No. and No. install Kuznetzk Works possess volume equal 828 cubic meters, while furnace No. has volume corresponding 1180 meters. The development the blast furnace industry U.S.S.R. was stopped during the Civil War and 1923 there were only three fur- operation the southern and central districts the Soviet Union. The rehabilitation the blast furnace industry did not be- gin until 1925. Table has been drawn from data published the Soviet press. This table shows the increase 14—THE IRON AGE, August 1935 the number furnaces and the to- tal volume all newly constructed, reconstructed and restored fur- naces during the period 1928 1934. Also may seen from this table that with the growth the number furnaces placed oper- ation, the effective volume and pro- ductivity the furnaces increased. 1930 the State Institute for Designing Plants de- signed and adopted the first typical blast furnace construction with effective volume 930 cubic me- ters. the present time nine such furnaces have been construct- and placed operation, and now planned build five addi- tional furnaces this size during the period 1935 1937. The designing, construction and operation these furnaces have served good training for So- viet blast furnace engineers. necessary note here the impor- tance construction and exploita- tion the first typical furnace Soviet practice. enabled the en- gineers foresee and eliminate certain defects discovered its construction during the building the additional typical furnaces. The introduction large-sized furnaces with volume 930 cu- bic meters gave favorable results, served pave the way for the transition blast furnaces having volume equal 1180 cu- bic meters and average daily productivity ranging from 1000 1100 tons. addition, the neces- sary experts for their operation were trained. Owing the insufficient supply high-grade coke required for the operation such large-sized fur- naces, the sudden switching from 400 500-ton furnaces furnaces designed for producing from 1000 1200 tons caused many difficul- ties arise. The use meter fur- naces, naturally, made necessary improve the production and quality coke required. Thus the gradual transition the master- ing larger-sized furnaces was prepared for advance. The installation and operation blast furnaces designed McKee Co. the Magnitogorsk Works, Ural district, and Freyn Co. Kuznetzk Works, West Si- beria, played especially impor- tant role the progress blast furnace practice the Soviet Union. The operation these fur- naces proved the possibility con- structing blast furnaces with daily output equal 1200 tons and more. Following the successful work furnaces No. and No. with volume 828 cubic meters, fur- nace No. was installed Kuz- netzk Werks. This latter furnace has volume 1180 cubic meters. the Magnitogorsk Works, the average daily output furnaces No. and No. with volume equal 1180 cubic meters, runs high 1000 1100 tons. Furnace No. with volume 1220 cubic me- ters, reached 1148 1200 tons the course four months. The raised output Magnito- gorsk furnace No. explained the elimination defects discov- ered furnaces No. and No. namely: (1) The thick-walled bosh | | | | | | | | | | | | | | | | | j | | | | | | | | | | | 7 i | | | | } i a | 1 with American bronze cooling plate system was replaced thin brick work (lining) and water cooled cast iron plates, designed for the protection the plate the bosh. Similar im- provements made the tuyere zone. (2) The diameter the furnace belly was increased from 8.380 9.00 meters, causing the volume the furnace increased from 1180 1220 cubic meters. Second Typical Blast Furnace The successful use typical blast furnaces with volumes run- ning high 930 cubic meters and 1180 cubic meters gave occa- sion further increase the volume blast furnaces. 1934 the State Institute for Designing Metallurgical Works de- signed blast furnace typical construction having effective volume 1300 cubic meters. This design was examined and subse- quently adopted the conference Soviet blast furnace engineers held 1934 Leningrad. The differences between the first typical furnace and the second are shown Table II. sketch the sec- ond typical (standard) furnace shown Fig. The thickness the furnace lin- ing (brick work) was designed follows: 1.5 meters for the lower part hearth, 1.15 meters for the lower part the shaft (stack), 0.805 meters for the upper part stack (shaft) and 0.345 meters for the bosh and cylindrical belly. Sixteen tuyeres are used, each with diameter equal 175 225 mm. regards the hot blast Cow- per stoves, three for each furnace were found sufficient. The surface each Cowper stove equal square meters and the capacity the Freyn gas burners was high cubic meters per the Soviet standard air blow- ers are capable producing from 3200 3400 cubic meters air per minute, the Soviet blast fur- nace engineers assume that the new typical furnace will provide average daily output equal 1000 tons with coke consumption less than ton per ton pig iron, using charge having con- tent equal per cent. When the content the charge goes per cent, the aver- age daily output should run high 1300 1400 tons with coke Table Volume Per Ton Daily Productivity Pig Name Plant Average 1913 Petrovsky ......... 1.93 2.13 Average Type Furnace 1933 Soviet coke furnace. 1.60 Soviet blast furnace Average 1933 Average June, 1934 1.33 1.15 1.54 1.55 1.29 1.76 1.38 Jan. Feb. March April May 1.50 1.41 1.38 1,29 1.89 1.87 1.82 1.92 Table V—Furnace Volume Per Ton Daily Productivity Blast Furnaces Constructed According American Design Magnitogorsk Works 1934 March April May June Blast furnace No. volume 1180 cubic meters 1.28 Blast furnace No. volume 1180 cubic meters.. 1.80 1.24 furnace No. volume 1220 cubic meters.. 1.15 1.04 1.27 Blast furnace No. volume 1176 cubic meters.. 1.09 1.04 1.08 1.15 Works 1934 Blast furnace No. volume 828 cubic meters.. 1.36 1.26 1.09 Blast furnace No. volume 828 cubic meters.. 1.39 1.4 1,12 1.08 Blast furnace No. volume 1180 cubic meters.. 1.39 1.87 1.09 1.07 Table Vi—Average Hot Idle Time Soviet Blast Furnaces (in Per Cent) During 1934 Coke blast 5.85 Charcoal blast furnaces..... 3.01 Feb. March April May 4.73 3.65 2.04 6.43 Table Coke Per Ton Pig Produced Magnitogorsk Works............ Makeevsky Stalinsky Average 1933 Average June, 1934 0.953 0.920 1.130 0.966 1.079 1,107 1.001 consumption less than 0.9 per ton pig iron. considering the burning and destruction phenomenon which has been observed the lining bosh, belly and shaft the Magnito- gorsk blast furnaces No, and No. the conference previously men- tioned found obligatory have shaft brick work made con- tact with the steel plate shell shaft. addition this, was found necessary provide the bosh with brick work (lining) 345 mm. thick and continuous steel plate jacket order avoid the burn- ing brick work noticed the bosh and lower part the shaft which was supported bracket rim. For the protection the jacket the bosh and belly, was pro- posed the conference place water-cooled cast iron plates (flat plates with steel tubes fer cooling water inserted them) between the brick work and steel jacket. was also found necessary raise the columns and bracket rim meters order provide the cylindrical part the belly with wall 345 mm. thick, thus ensuring the durability brick work the shaft supported the bracket rim. was acknowledged that the bronze cooling plates placed the shaft brick work according American practice did not justify themselves and consequently was decided the future install not more than four rows bronze cooling plates directly above the bracket rim. considering the great trans- portation difficulties caused the close spacing blast furnaces and THE IRON AGE, August Table Volume Per Ton Daily Production Pig Jan. aie straight-line layout the fur- naces (for example, Magnitogorsk Works McKee Co. design, and Kuznetzk Works Freyn Co. design), was concluded the conference that the furnaces should spaced 120 125 meters apart. relation the layout the blast furnace plant, was also de- cided that should analogous that existing the American plant Gary the Illinois Steel Co. Such layout was recognized more convenient for furnace operation, and addition this permits the construction new furnaces without disturbing the operation old ones. Effective Volume Utilized The coefficient utilization the effective volume blast fur- naces is, other words, the fur- nace volume per ton daily pro- ductivity, value reversible daily productivity per unit fur- nace volume. Along with the de- velopment volume and produc- tivity Soviet blast furnaces, there has been improvement carried out for the utilization effective volume the latter, and interest point out the progress reached this respect the present time some Soviet iron works comparison with the pre-war period. Table III shows the great improvement utiliza- tion furnace volume since the revolution, and the more recent im- provement the average monthly coefficient utilization furnace volume for all coke and charcoal furnaces presented Table IV. necessary note here that during the pre-war time Russia, none the furnaces using coke blast ever possessed such coeffi- cient utilization furnace vol- ume the average value for coke blast furnaces reached May- June, 1934, that is, 1.26. The yearly change average co- efficient utilization furnace volume for all blast furnaces exist- ing the Soviet Union shown Fig. may observed from the diagram how this value keeps systematically decreasing with the years and finally reaches 1.35 1934. The change average coefficient utilization furnace volume and daily production pig iron (ayerage per month) the Soviet Union 1934 are shown Fig. June, 1934, the average monthly utilization coefficient all the iron 16—THE IRON AGE, August 1935 the Soviet Union varied from 1.08 2.01. The operation the blast fur- naces located the Magnitogorsk and Kuznetzk works, constructed according American design, of- fers special interest respect. The data these operations are shown Table necessary note that both the above-mentioned iron works are operating easily reducible Magnitogorsk iron ore and Kuz- netzk coke which has sulfur con- tent equal about 0.5 per cent. The data Tables III are based the data published Soviet Metallurgy, No. 1934. several the best months the first half year 1934 the co- efficient utilization several the Soviet blast furnaces reached 1.04, which considered the usual average value for large American furnaces. There were many furnaces where this value reached 1.11 1.13 with- out any preliminary preparation iron ores, while the southern district the U.S.S.R. the ore loss flue dust reached per cent and often per cent and more. the future, after having switched screened and sintered iron ores, the utilization furnace volume many Soviet furnaces should greatly improved. interesting note here that the lowest coefficient utilization furnace volume for large fur- naces reaches 0.873 (usually average coefficient 1.05) American practice and 0.75 Germany. According the data given above, the coefficient utilization furnace volume the U.S.S.R. somewhat higher than that ex- isting America and Germany. the same time must taken into consideration, examining the utilization volume Soviet furnaces, that the natural condi- tions blast furnace smelting dif- fer from those America; namely, the coke obtained the southern parts the U.S.S.R. (Donetz quaritity ash (10 per cent) and sulfur (1.5 2.5 per cent) than that used America. such cases, reduce the sulfur content pig iron the blast fur- nace process must carried out high basic and refractory slags with high melting point and con- tent varying from per cent. Meanwhile, the American slags are less basic and have lower melting point. known that highly basic slags may cause irregular op- eration furnace and scaffold the furnace hearth, demanding high- coke consumption. The second circumstance causing difficulties arise the work Soviet blast furnaces the fine- ness Krivoy Rog iron ores, espe- cially rich ores mined the south- ern district the Soviet Union which have high content SiO. (especially poorer iron ores). Krivoy Rog, red hematite iron ores, The average characteristic these iron follows: The quantity fines (lumps from mm.) ranges from per cent. Due the great quantity fines these ores there con- siderable loss ore flue dust. Usually this quantity not less than per cent and often reaches per cent and sometimes more. 1935 there was only one ore sintering plant existing the Soviet Union, namely, the Dwight Lloyd system located the Kerch iron works. 1935 new sinter- ing plant was completed with 2000 tons daily the Kerch Iron Works and another plant with capacity 1000 tons daily Makeevsky Iron Works. Thus, the fineness ore and lack screening and sintering the latter has handicapped the more intensive utilization furnace vol- ume, proposed place additional large ore sintering plants op- eration and the follow- ing years, and sinter per cent the total Krivoy Rog iron ore charged into blast furnaces. Pig Production the total Soviet produc- tion pig iron corresponded 10,500,000. metric tons, which twice much that produced 1930. The growth pig iron pro- duction the more clearly demonstrated Fig. The great growth pig iron production was achieved not only introducing large-sized blast furnaces but considerably im- proving the work reconstructed j | { | i | j ; | | j | | § | | | | | | | i { q 4 q } | i | | | | | | | | | | | | | | | | ; i } | | | | | | | H | | | } | { and restored old blast furnaces. This may seen from Figs. and which depict the decrease av- erage coefficient utilization volume all Soyiet blast furnaces during the period from 1928 1934, During the time the first Five- Year Plan radical reconstruction tons Pig iron production 1922 1929 1934 5—Total pig iron output the leading producers. Note the drastic drop American production and the consistent rise production. all old blast furnaces the Soviet Union was accomplished. The reconstruction consisted the following: Installation new turbo blow- ers with capacity 1500 3100 cubic meters per minute. Equipping many old blast furnaces with modern devices for charging raw material the fur- nace top. Installation the first casting machine for pig iron 1931. During the following three years more pig casting machines were manufactured and installed. Over per cent the pig iron now cast means casting machines. Almost all the furnaces with volume exceeding 400 cubic me- ters have been equipped with ladles higher capacity for transporta- tion pig iron and slag. Reconstruction storing places for raw material (ore and coke). Improvement quality coke. Improvement the organization labor and qualification all the working staff engaged blast fur- nace plants. investment large amounts money the blast furnace in- dustry. All the above-mentioned fac- tors served basis for the con- siderable growth pig iron pro- duction. the present time such effective means for improving the operation and production furnaces, such sintering iron ore, have not been fully introduced. may seen from Fig. that 1934 the Soviet Union came sec- ond the world pig iron produc- tion, greatly surpassing its pre-war production, which was equal 4,200,000 tons 1913. According the State plan, 12,500,000 tons pig iron are produced 1935 and 16,000,000 tons 1937. interesting note that the growth pig iron production the limits 4,000,000 10,000,- 000 tons (metric) has been reached the U.S.S.R. during the period 1929 1934 years), the U.S.A. during the period 1885 1897 (12 years), Germany dur- ing the period 1896 1905 (15 years), France during the pe- riod 1910 1928 (18 years), and England during the period 1865 1910 (45 years). spite the great increase production pig iron and steel, the Soviet national economy still greatly need metal. 1934 the yearly consumption metal per every one man population was approximately kg., whereas 1929 the corresponding con- sumption U.S.A. reached about 518 kg., 240 kg. Germany, and, 235 kg. France. Although the world economic crisis decreased the consumption metals these industrial coun- tries, the Soviet Union still far behind average consumption metal. view this, still greater development pig iron Soviet Union the future. The data Table show that the hot idle time Soviet blast furnaces considerably more than that American blast furnaces. June, 1934, the hot idle time all Soviet blast furnaces varied from 0.14 16.18 per cent, re- lation the calendar time. The consumption coke per ton iron produced various steel works shown Table VII. this brief article the author has described only some facts the recent progress made Soviet blast furnace practice and had intention give complete informa- tion this question. Wire Men Formulate Attractive Program Wire Association will hold its meeting and exhibition conjunction with the Ne- tional Metal Congress Chicago, quarters the association the Congress Hotel. Registration, annual meeting and directors’ meeting will held Sept. 30. The subsequent sessions will consist technical meetings open the public and two special meetings restricted association members. informal dinner will Among the papers and addresses presented the technical sessions will the following, ac- acording announcement from the program committee: “Acid Cleaning and Han- Rods and Wire,” Frederick Westphal, superintendent, wire mill, Sheffield Steel Co., Kansas City, Mo. “Grain Size and Its Influence the McCarthy, metallurgist, Spencer Steel Co., Buffalo, “Industrial Relations Applied the Wire Industry,” Kempton, director industrial relations, Ameri- can Steel Wire Co., Cleveland, Ohio. “Cold Heading Wire,” Sey- mour, metallurgist, Youngstown Sheet Tube Co., Youngstown, Ohio. “Tests and Testing,” Kel- metallurgist, Continental Steel Corpn., Kokomo, Ind. “Modern Acid Handling Methods Lower Pickling Costs,” Hoover, assistant manager, Sales Division, The Goodrich Co., Akron, Ohio. “The Grain Size the Physical Properties Copper Drawing and Annealing,” Dr. Barker, M., metallographer, General Electric Research Laboratories, and laboratory, Wire Dept., General Elec- tric Co., Schenectady, “Hard and Soft Copper Wire,” Rudolph Schatzel, superintendent, General Research Laboratories, Gen- eral Cable Corpn., Rome, THE IRON AGE, August | | | | Facilitate Determining Weights any estimate costs ma- chinery parts, one the most complicated calculations de- termining the weight the wash- ers and disks involved. The area the hole must found squar- ing the radius and multiplying This must subtracted from the area the washer without hole formed the same 15 16 Directions for Use Place rule straight edge across the inside diameter scale (A) and the scale (B) and read Then swing the rule around the point found scale (C) through the thickness scale (D) and read the number pieces per pound scale (E) the weight per 1000 pieces scale (F) ow Inside Diameter (A) 18—THE IRON AGE, August 1935 manner. After multiplying the ‘result the thickness and then weight steel per cubic inch, the weight per thousand pieces. Finding the reciprocal figure gives the number pieces obtained per pound. All these calculations can determined instantly means the charts shown herewith. rule placed across the inside diameter scale and the outside diameter scale The rule then crosses scale the correct area the washer. swinging the rule around the point found scale that goes through the desired thickness scale the weight per 1000 pieces can read directly scale 0.800 0.750 0.650 160 150 130 2065 1 0.300 é SO 14 0.200 55 0.150 2409 $09 6 0.050 Outside Area Number Diameter Pieces per Pieces (B) (F) } | i | | | | i } q 4 | | } 4 . | | | | | { | j | | { 6 | | | | | and the number pieces per 100 Ib. seale The charts can constructed within any range desired. One those reproduced herewith covers washers the sizes ordinarily dealt with actual practice, while the other gives more accurate read- ings for the smaller washers, below in. outside diameter. Directions-for Use Place rule straight edge across the inside diameter and the outside diameter scale (B) and read the area Then swing the rule around the point found scale (C) through the thickness and read the number pieces 100 pounds scale (E) the weight per 1000 pieces scale For more accurate calculations washers small diameters, (A) and (B) can considered 0.9, etc. This requires that two places pointed off scales (C) and (F) and two ciphers manner for larger washers and two decimal places pointed off scale (E) All figures shown are inches, but scales (A) are square feet and the values scale (F) should multiplied 144 and scale should divided 144 Washers and Disks The figures shown are inches, but scales and are read feet, will square feet, and the values scale should should divided 144. Either the charts can used for larger smaller washers and disks than those shown. For ex- ample, scales and can 30 20. Area Diameter (C) (B) Se ° ° ° EUGENE CALDWELL General Manager, Wrought Washer Co., Milwaukee ° This requires that two decimal places pointed off scales and and two ciphers added scale like manner for larger washers scales and can considered 100, 90, etc. This requires that two ciphers added C-and and two decimal places pointed off scale Number Weight per Pieces per Pieces (F) THE IRON AGE, August | 100 = DA i & /4 2.085 160 = | 2409 Inside Diameter (A) THE 9—Machine for inspecting gears under conditions approaching those actual operation. The device charts all errors combina- tion and makes permanent red line record, from which possible determine the magnitude and loca- tion various inaccuracies. THE devices described the previous part this paper are intended primarily for checking individual elements gear teeth, independent other elements. Such devices are especially useful for checking original designs, when during various stages manufacture check individual elements desired. close study the action gear teeth will reveal that there always more than one tooth af- fecting the operation mating pair gears, that careful check the individual elements does not present complete pic- ture. individual tooth element check does not indicate what effect certain error one tooth will have another tooth. Inspection all errors com- 20—THE IRON AGE, August 1935 Methods for METHOD checking gear tooth errors combination rather than separately described this abstract the paper, continued from THE IRON AGE July Study the action gear teeth will reveal, pointed out, that there always more than one tooth affecting the operation pair mat- ing gears; and tooth element check does not indicate what effect cer- tain error one tooth will have another tooth. Oper- ation the machine de- scribed based the prin- ciple that errors gear tooth elements cause either velocity changes tions center distance. bination more nearly meets the de- mands manufacturing require- ments, because more ap- proaches the actual conditions ob- tained when the gears are op- eration. Fig. shows inspection machine known the Red Liner, deriving its name from the red- line chart gear inaccuracies which produces. Its operation based the principle that errors gears affect their center dis- tance relation when the gears are brought into intimate contact and rotated. One gear, generally mas- ter known accuracy, held the driving spindle, the latter be- bracket. The gear tested held fixed stud, fixture, de- pending upon its design. Errors the gear being tested impart movement the ful- through multiplying lever ar- rangement, operates pen, which contact with constantly moving paper chart. This device charts all errors combination and makes permanent record. possible analyze the charts produced, and detect and deter- mine the magnitude and location various inaccuracies. The mul- error 0.001 in. the gear represented 0.200 in. the chart. Lack Continuous Action the teeth pair mating gears are not sufficient length, have other defects, which will prevent continuous action, then the gears will fail transmit uniform motion. Fig. shows chart gear the teeth which have been shortened such extent that continuous action not obtained. Note the peculiar characteristics the line. Action interrupted each tooth passes through mesh, causing jagged peak and then constant “building up” until action again ceases. Uneven tooth spacing, generally called errors circular pitch, pro- duces characteristic chart, Fig. This particular gear was cut with cutter, each alternate tooth which was purposely ground off from its true spacing position, re- sulting the line shown. Note that there are jagged peaks, equal | | | q | q | > | | } | | | | | | j | | } } | | | { | | | | \ | | | i | Checking one-half the number teeth was compared. Here have Slight errors pressure angle the gear. jagged peaks equal the number produce chart somewhat similar teeth the gear. This error was line curve. Variations Pressure Angle purposely exaggerated, making the Lack concentricity the pitch Fig. shows chart gear “peaks” higher than cirele common error which the which varies pressure angle would normally the case with Red Liner clearly records. Fig. from the master against which slight errors pressure angle. shows chart gear purposely REO LineR- for Automatic Gear inspection - The Fellows Gear Shaper Co., Springfield, Vermont es FIG. gear the teeth which have been shortened that continuous action not PEO LinER— for Automat Gear inspection— The Fetlows Gear Sheper Co. Springfield. Vermont FIG. chart produced uneven spacing. THe REO for Automat Gear inspection The Fetlows Gear Shaper Co Senngteid. Vermont FIG. 12—Chart gear that varies pressure angle from the master which compared. The error wes purposely exaggerated, the peaks being higher and than normally. THE IRON AGE, August it if 4 j | H | | 4 i | THE RED LINER-— For Automatic Gear Inspection— The Fellows Gear Shaper Co.. Springfield, Vermont. FIG. 13—Chart gear cut about 0.004 in. eccentric. cut about 0.004 in. eccentric. Note that eccentricity causes the re- corded line depart from the datum line one revolution the gear being inspected, reaching the maximum deviation when half way around the gear. There difficulty locating fillet interference, causes series abrupt departures from straight line shown Fig. 14. this case the cut gear was purposely made too shallow that contact took place the fillet be- fore the profiles could come into intimate contact, causing the gears alternately: come together and spread apart. Charts Cut, Hardened and Lapped Gears addition recording tooth errors, the inspection machine shown Fig. also presents accurate picture the condition the contacting tooth surfaces. Fig. shows three charts the same gear three different con- ditions, namely, “green,” hardened, and lapped. The upper record the green gear, which was cut the gear shaper without any par- ticular pains teken obtain ex- treme accuracy; fact this would represent average gear. The accumulative error does not exceed 0.001 in. The tooth surfaces are not extremely smooth and there are slight errors circular pitch. This, however, would prove sat- isfactory gear could used without being heat treated after cutting. While extensive studies have been made producing steels for making gears, still impossible put gear the fire and have come out the same condition that went in. Distortion, al- though some cases slight, still takes place, and the second rec- ord Fig. shows, this particu- lar gear did not improve any when placed the fire. Almost invariably gears swell during hardening. The two points the teeth which the greatest distortion takes place the fillet and top the booth. The fillet usually rises and the top the tooth thickens, which the Red Liner indicated combined interference and pressure angle variation error. Before this particular gear was put the fire, the accumulative error was 0.001 in. When came out the fire, this had grown in., that the tooth action was not smooth when the gear was the “green” condition. lapping this gear Fel- lows gear lapping machine, using internal gear type lap, was possible bring the gear back its original accuracy shown the lower record, Fig. 15. Not only has the accuracy the gear been improved, but the tooth surfaces are considerably smoother, assur- ing that this lapped gear would operation than would the case with the “green” hard- ened gears. Fig. the readings this gear the three conditions are placed the one chart for com- parison. will noticed that ec- centricity practically the same amount the green and lapped gear. There is, however, some im- provement in*smoothness tooth surface, and decided improvement all respects over the hardened gear. The charts previously shown were all made spur gears. Heli- cal gears properly cut and (CONTINUED PAGE 94) THE RED LINER-— For Automatic Gear Inspection— The Fellows Gear Shaper Co., Springfield, Vermont = FIG. 14—Fillet interference causes series abrupt departures from straight line, shown this chart. 22—THE IRON AGE, August 1935 | J | ee ees | 4 j | | | | | | | | { | | } | | | | H | | j j Pressed Steel Boats Made Without Stem Stern Posts RESSED steel boats are being constructed without keel, ribs, stem stern posts the Gil-Boat Co., Holland, Mich. Sheets are first cut pattern and then rolled the form tube, Each tube then broken three places, the center break forming the keel. These formed sheets are again matched pattern and the bow, also cut pattern, welded place. The stern assembled the same manner. The three seats are air tanks and therefore the boat practically unsinkable. should noticed that these seat tanks, welded place, form the only ribs bracing the boat. Speed boats are built with three curves the bottom. 11-ft. boat this type weighs only lb. will plane easily with 3-hp. motor and at- tain speed miles per hr. Other sizes this design, equipped with 16-hp. motor will attain speeds from miles per hr. THE IRON AGE, August i The sheets are first rolled cylindrical form. Each cylinder broken three places form keel and bilge. Bow, stern, and tank seats are welded plece. Returns A\nd new developments noted this week the author method worked out this country for testing the homogeneity steel balls electrically. English using aluminum the evaporation process producing mirrors cited, new method developed for jointing aluminum which similar soldering. The results German experiments nickel-aluminum magnet steel and, also, the development plating bath produce absolute black chromium plate are other highlights recorded. Dead Black Chromium Plate RIGHT nickel has already won prominent place the plating industry, finding particular appli- eation various types con- sumer products and decorative motif for modern offices and fur- niture. equal importance for the same purposes the development black chromium plate having finish similar gun metal, 24—THE IRON AGE, August 1935 alloys which imitate the nearly black tarnish copper-alloy gun metal. additional interest the plat- ing industry are the new types chromium plate which have “ab- solute black body” finish. solu- tion producing this type surface cent ‘issue Chemiker Zeitung. The electrolyte calls for 0.52 0.83 formation copper wire during successive drafts through die. From left the been reduced three draws from in. 0.57 in. diameter about per cent re- duction each case. Die opening about dea. LIPPERT The Iron Age, New York Ib. per qt. acid and 0.8 1.2 per cent acetic acid, but sulphuric acid. The bath oper- ated more than amp. per sq. in., and kept below deg. system ‘water cooling. The black plate can applied directly mediate coat bright chromium plate. the undercoat nickel plate, must free from oc- cluded hydrogen and from internal stress order secure satisfac- tory black plate results. Wire Deformation During Drawing EVERAL years ago Taylor and Quinney (English) investigated the deformation wire during drawing dividing copper wires longitudinally and scratching net- work lines the inner sur- faces; the two halves were then put together again and carefully drawn through die. study the lines, following drafts vari- ous amounts, gave indication the displacement the wire parti- during drawing. This work was mostly confirmation pre- vious investigation copper rods the German, Siebel. The work the Englishmen, however, had one defect that the wires were drawn back through the dies, thereby deforming the drawn part degree. Siebel has just issued re- port study wire deforma- tion supplement his study changes occurring rod, In- stead using solid die, uses split die, thereby facilitating the removal the wire any time | | | | | i } | { | q | | | | { | 1 | for examination. network lines were scratched the inner surface the wires means razor blade, previous experi- ments. The appearance these lines, following successive reduc- tions per cent, shown Fig. apparent that the distor- tion the cross-section rapidly diminishes with successive draws, and finally the changes shape are merely due the lateral contrac- tion and longitudinal extension, with entire absence strain. Siebel suggests that the de- crease displacement the outer zone the wire with successive drafts can attributed the dif- ferent degrees work-hardening the outer zone and the core; consequence, contrary the case mechanically homogeneous material, the outer zone offers greater resistance the subse- quent displacements during the fol- lowing drafts. his study the deformation the scribed lines, Siebel has determined the principal direction deformation wire during drawing. ° ° ° Jointing Aluminum Alloys NEW method jointing alu- minum alloys without the dan- ger injury the metal involved welding processes has just been simple and analogous solder- ing, except that flux any kind required. The material used the process known Alusol, and will join aluminum cast, roll- ed, sheet, tube form, well Hiduminium, Duralumin, Birma- bright, with strength equal that the unjointed material. claimed that Alusol withstands corrosion the result process used its manufacture, and not affected aging. also un- derstood that aluminum tube bracket this process, the steel bracket surface first tinned with soft solder; such joint will stand pull approximately tons per sq. in. Test Internal Structure Bearing Balls DDED uniformity ball bear- ings has recently been made possible unique electrical test- ing unit which reveals de- fects and gives indication the microstructure the steel without injury the surface the it- 2—Testing the internal structure steel balls magnetically. The operator placing ball V-shaped notch where forms one arm Wheatstone bridge. unbalanced bridge indicates internal flaws. self. This equipment, shown Fig. operation the plant the Fafnir Bearing Co. Balls tested are simply ro- tated two small electrical con- tacts the V-shaped notch shown front the operator. light beam moving over ground-glass reveals whether not the balls come within previously de- termined standards. balance inductances be- tween three known values and the ball tested, similar prin- ciple the balance resistances obtained with Wheatstone bridge, provides the basis the test. Since the balls have been previously checked for size within limits 0.00005 0.0001 in., settings are made the basis constant mass for each size ball. Experiments have shown that in- ternal flaws, soft centers, excessive decarburization and other varia- tions microstructure result definite changes the readings obtained. Since hardness also de- pends upon microstructure, the electrical measurements give indirect check this factor well. Correlation the results ob- tained with metallographic ex- amination, hardness tests and the like provides standards for produc- tion tests. Nickel-Aluminum Magnet Steel Investigated RECENT report the Archiv presented data number ex- periments performed sand-cast nickel-aluminum magnet Samples such thickness that the cooling rate the most favorable show maximum values for coercive force and remanence. Heavier thicknesses may used without decrease the coercive force the aluminum content increased from per cent. The in- crease aluminum content has lit- tle effect either the remanence maximum The report states that the nickel content best kept about per cent, and only when increased rem- anence required should the con- tent permitted drop per cent. Deficient coercive force and remanence thick-sectioned mag- nets can best increased heat- ing 1100 deg. and then cooling The properties thin-sec- tioned magnets, however, are im- proved tempering 700 deg. for from hr. Water quenching and tempering are recommended when coercive force 250 350 and the highest possible remanence are desired. method heat treatment will give simul- taneously the maximum values coercive force and remanence cor- responding correct cooling con- ditions after casting. Therefore, advisable adopt the begin- ning the most suitable dimensions for the castings giving atten- tion the design. Also was found that carbon has much less influence the magnetic proper- ties than had previously been be- lieved. THE IRON AGE, August 1935—25 | q | 3 | > 3 | Modern standard steel lookout tower the Cloquet forest experiment station, Carlton County, Minn. ALL timber resources the United States are being drawn into closely-knit system forest protection, vital part the attempt save the nation’s watersheds from irretrievable ero- sion damage. Based recent tests and experience the great West- ern forests, system high steel lookout towers now being ex- tended not only the National forests, but through State, County and even private forests. Realizing that all efforts pre- vent ameliorate the dust and 26—THE IRON AGE, August 1935 Steel Towers water erosion must prove fruitless present watersheds are not thoroughly protected—and, fact, extended over burned and lumbered areas—the cooperation all own- ers important forest lands, both governmental and private, has been obtained States, and standard specifications for suitable steel towers have distributed the Forest Service, United States Department Agriculture. Citizens Conservation Corps labor, combined with local metal artisans many communities, already work some the end 1936 several hundred the new type towers will have been added supplement the 3000 odd towers all kinds already functioning. specifications now use the California, Oregon and Wash- ington forests, certain items are described, for reasons clarity, with the name standard manu- facturer, but made clear, too, that all responsible may bid the items, and that there bidding prejudice the use such descriptive nomen- clature. Towers Have Maximum Height 120 Ft. The greatest height the new steel towers has been set 120 ft., but sections may deleted meet the requirements specific locations. tower mountain top, for instance, can construct- with section two, while one reach the ultimate 120 ft. Experience the great forest fires 1934, which men lost their lives the various fronts, revealed that the extremely hot air from great fire rushes up- ward, cold air from aloft pushes into the vortex velocities reach- ing 115 miles hour. Hence, the new towers are designed accom- modate minimum wind pressure TEEL lookout towers have been standardized the Government and many will added those now use nation-wide cam- paign reduce forest fires. Conservation our wood supply important but minor motive. Floods, droughts, erosion and dust storms have brought home the with dramatic force the im- perative necessity pro- tecting our forests from further destruction. 100 miles hour—a little vari- ance from normal steel tower safety limits, since great pres- sure not usually encountered low altitude. anticipated that where there are county forestry departments, costs will divided about they are Los Angeles County, Cal., which considered standard set- up. Here, the county defrays the cost the towers, while the C.C.C. absorbes the labor costs. Where there are C.C.C. units available (which not probable, since where there are important forests there are almost all cases C.C.C. camps), the county will take over labor costs well. private forests, about the same rule will prevail, but C.C.C. men will available for this ser- vice even private forests, since the get complete pro- tection forests possible, the shortest possible time. Prefabrication Required Therefore, bids may called for, States, counties private owners, parallel Federal usage. The standard specifications are the result long experience | = ' | | | | | | | | | Our Line Defense Against Floods, forest work, and therefore bids towers differing design even detail can not considered. The bidders are required furnish all structural steel shapes; metal sash glazed with clear double-strength glass; sheet metal rivets and bolts (number required plus per cent), including bolts for fastening down the cab flooring, landings and stair tread; anchor bolts and reinforcement bars for footings; and two base plates for 1-in. pipe with provision for attach- ing corner angles cab make one more complete towers specified. The