The Iron Age 1935-08-08: Vol 136 Iss 6

CHESTNUT AND STREETS, PHILADELPHIA, PA. Sales 239 WEST 39TH STREET NEW Owned, Published and Copyrighted CHILTON COMPANY Executive and Publication Offices, Chestnut and Sts., Philadelphia, Pa. MUSSELMAN, President FRITZ FRANK, Executive Vice-President STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK, VAN DEVENTER Editor Managing Editor News Editor Machinery Editor Editor Emeritus Washington Chicago Cleveland Pittsburgh Detroit Boston Cincinnati Contents August 1935 Billet Gauger Controlled Seated Plastics Industry Broadens Its Field................... Steel Parts Carburized Process............ Coating Strip With Copper This Plant Was Struck 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 Bidg.. Cleveland B. L. Herman, ore, Ave.. Buffalo, Vublished every Thursday. Subscrip- H. K. Hottenstein, 802 Otis Bide. Chicago tion Price: United States and Pos- Peiree Lewis, Woodward Detroit sessions, Mexico, Cuba, $6.00; Can- Charles Landberg. Chilton B'dg.. Chestnut & ada, $8.50, duty; Foreign 56th Sts.. Philedeiphis. Pa. $12.00 year. Single copy, Robinson, 428 Park W. C. Sweetser, 239 West 39th St.. New York Ryerson Has the New Alloy Steels Stock—And they Will Ship Today— Steels for Every Purpose— Maintain production schedules and save time, trouble and money concentrating your steel and metal requirements through one reliable source. Ryerson Stocks are complete. They include all the newer alloys, special finish steels and allied metals such copper, brass, bronze, etc. And course you can depend immediate shipment. Ryerson men will glad work with you any special prob- lems. not hesitate call us. The Ryerson Stock List shows hundreds products that are ready for immediate use. you not have copy, write and will send once. Joseph Ryerson Son, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Philadelphia, Boston, Jersey City. Hot Rolled Alloys S.A.E. 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 4140, etc., etc. Rycase rolled, machine straightened). Rytense A.A. (hot rolled, chine straightened). Cold Drawn Alloys S.A.E. 2315, 2320, 2330, 3115, 3120, 3135, Heat Treated Alloys Ryco rolled, machine straightened). Nikrome (hot rolled, cold drawn, machine straightened). Stainless and Heat Resisting Alloys Allegheny Metal (Sheets, Bars, Welding Rod, Cold Finished Steels Std. Shafting, Turned, Ground and Polished, Special Accuracy Stock, Rycase High Manganese Screw Stock, S.A.E. 1020, 1035, 1112, 1120, Tool Steels Ryerson B.F.D. Die Steel. Ryerson "Shock" Steel. High Speed Mill Treated Bars. Ryerson Special High Speed Tool Holder Bits. Permite Leaded Phos- phor Bearing Bronze ft. speed length bars for screw machine production bushings, bearings and parts. General Steel Products steel products such Bars, Structurals, Plates, Sheets, Strip Steel, Welding Rod, Tubes, are carried stock for imme- diate shipment. 4 j { | | | THE IRON AGE ... AUGUST 1935 ESTABLISHED Vol. 136, No. Wealth Destroy Wealth editorial July which the principle ation was opposed. says, part: has taken exception our Redistribution wealth has become imperative restore adequate buying power among the country can truly progressive when the extremely wealthy abuse their power keep the lower classes state quasi-slavery and resort all kinds chicanery evade their lawful responsibilities in- stead assuming their fair share one, least all the writer, will deny that taxes should imposed proportion ability pay, and one can dispute the fact that there are plenty men wealth who have contrived evade their fair share taxes. But selfishness, de- ceit and arrogance the part individuals not condemn whole class. Wealth not evil per se. the contrary, may and often great power for good. Taxes that are confiscatory, i.e., taxes de- signed take wealth away from those who possess because they possess it, are quite different aim from imposts levied for in- creased revenue. The principle confisca- tion, once recognized, would most certainly undermine incentive for enterprise and thrift, and would blight rather pand mass buying power. Inheritance taxes, for example, that would prise from the group which had built might prove calamitous. Wealth not synonymous with the power create more wealth. The so-called profit system really system. Wealth, unless coupled with managerial skill, soon dissipated. Let assume that Henry Ford died and that the inheritance levies were heavy that his properties had sold. there any assurance that the new manage- ment would succeed? Failures the auto- mobile industry have greatly outnumbered successes. the last analysis, real wealth intangible consists the ability, based experi- ence, vision, skill and creative genius, produce commodities services that other people want, and profit. Wealth, represented brick, mortar and ma- chinery, can divided but, without the in- centive that comes from hope for profit and without the managerial excellence that the prospect adequate returns begets, like the human body after the spirit has passed the great beyond. wealth, according the for- mula demagogues, destroy wealth, for without creative power wealth dead the idle manufacturing plant the aban- doned farm. LACHER . J ¥ 3 The Iron Age, New York THE Shorter process, Shorter’s ingeni- ous mechanical adapta- tion the hand-oper- ated torch procedure for obtaining localized hardening, has not only revived the art flame hardening but shows indications becoming firmly entrenched in- dustrial process. Although its use has been largely confined cer- applications known this country. fact, one prominent American concern has been licensed Shorter for sev- eral years and has devoted consid- erable its energies broad- ening the scope operations and minimization the operat- ing difficulties. Although the American licensee has greatly im- proved the and already has 12—THE IRON AGE, August 1935 number installations oper- ation, still felt that additional research should made before public announcement made. This attitude accounts for the dearth information the American trade press about this important new development. reviewing the mode oper- ation Shorterization, one could first consider the most common hardening procedure—the simple furnace heating and bath quench- ing operation. The more common steels and certain types iron are heated throughout above their respective critical points, there- after quenched and drawn. quired, the treater has recourse heating prior quenching for rolled fabricated parts. This differential heating can obtained furnace manipulations or, less commonly, hand heating with blowpipe subsequently followed quenching. the latter prac- tice the human element major factor and erratic hardness figures often result, even the hands skilled workers. few years ago Shorter intro- variation the familiar hand- process, and experimental results were encouraging that interest was immediately revived. Latterly, widespread adoption the procedure the heat-treating fraternity has become certainty. The shorter process essentially mechanically operated acetylene blowpipe which traverses the object hardened pre- hardening coarse-struct ured partly malleableized iron specimen the Shorter process. 2—Structure iron from the Shorter hardened diameters and 100 diam- eters (right). The hardened surface seen essen- tially martensitic, and then follows transition through troosto- martensite the The black nodules are temper carbon. 4] 1 H } } Old Method Surface Hardening Mechanized Process Gains for Treating Alloy and Plain Iron and Steel—High Skin Hardness Obtained determined speed. Quenching effected coordinate jet water (or air or, some cases, nitrogen) which follows immedi- ately behind. Simple though the set-up ap- pears, there are number vari- ables which must regulated and coordinated nicety assure satisfactory results. few may named. The blowpipe must usu- ally designed for the work hand, i.e., the width localized hardening, the shape the article being treated, the type steel iron, ete. multi-head blowpipe almost invariably used order secure rapid and well-distributed heating. The flame must have con- stancy and predetermined energy assure the desired depth hardness. The between the blowpipe and the cooling jet must determined and set, and the pressure the cooling jet suitably determined, then main- tained constant value. These latter variables must also then tied the analysis steel iron being treated. Thus, evident that each Shorter installation calls for indi- View 570 diameters structure flame- hardened iron sur- face. (b) Normal ma- terial. Note the amount and arrange- ment pearlite. Taken 100 diam- eters. Typical pearlitic area nor- mal iron prior its Shorter hardening treatment. Note the coarseness the structure, resolved 570 di- ameters. Prints read left right. vidual experimentation and con- trol. particularly adapted production problems, where very large number identical objects are hardened given area particular depth. Considering the variables just described being satisfactorily regulated for ations, interesting examine the results obtained independent plant investigations. This process hardening, for England has been applied great variety machined parts, and such parts thereby have shown greatly im- proved service records. Large quantities Diesel engine cams have been treated, also have been pulleys, track wheels, slides, retort doors and frames, crank- shafts, and many other parts. For gears too large for quenching case hardening, provides means whereby wearing surface from 450 700 diamond Brinell can obtained. Since parts treated undergo little distortion, also valuable for medium-sized work, while for shear wear resis- tance and general capacity, the process fills very wide and useful field and rivals the practice case hardening. important gas company the North England previously used ordinary pinions oper- ation where the abrasive action coke was very severe. These pin- ions never lasted more than three months. flame-hardened pinion, however, has lasted months and service with little sign wear. company the same district uses elevator spur wheel which generaliy was withdrawn from service four months due wear. Shorter- ized gear has now been use for months and currently shows little indication serious wear. More detailed experimental re- sults are, however, greater value. First considered here will cast iron. Gray cast iron can treated provided that 0.5 0.6 per cent combined carbon present. Therefore pearlitic cast irons respond Shorterizing. obtain surface, however, the iron must such mixture that when rapid cool- ing effected will respond THE IRON AGE, August { 4 | H t and harden off. Some types foundry iron not readily respond —at any rate, not greater depth than, say, 1/64 1/32 in., and this depth will give little ser- vice; good chilling iron also hardened thicknesses in. are sometimes obtained. One iron, hardening depth approximately in. the Shorter process, has been examined the Oxygen Co., Ltd. should pointed out that the iron investigated this case was incompletely malleabilized iron and not ordinary cast iron. The speci- men examined was approximate in. square section, and etched view showing the depth the two Shorterized surfaces shown Fig. This for showing locations micro- graphs reproduced Figs. 3(a) and sample drillings from the center the specimen (away from the Shorter treatment) had the following chemical composition: 0.34 per cent silicon, 0.11 per cent sulphur, 0.043 per cent phosphorus, 0.19 per cent manganese, 0.93 per cent combined carbon and 1.78 per cent graphitic carbon. The Short- erized surface hardness was found 488 Brinell, and Scleroscope readings varied between and 100. This specimen was thoroughly examined under the microscope, and the locations several the views are shown Fig. Fig. was taken diameters and shows the structure from the hard- ened surface inward. The Shorter- ized surface seen essen- tially martensitic, and then follows gradual transition through troosto-martensitic the normal IRON AGE, August 1935 youn 4—Structure the left-hand (see Fig. unhardened edge, showing the amount ferrite diminishes further from the edge toward the center the specimen, although some pearlite present with the ferrite the edge. Taken 100 diameters. The black nodules are temper car- bon. Fig. also shows the same view 100 diameters—the same condition exists shown diameters. Fig 3(a) shows the martensitic structure magni- fication 570 diameters. Fig. 3(b), magnification 100 diameters, shows the normal (unhardened) material. The vari- ation the amount arrange- ment pearlite (the combined carbon retaining portion) should noticed. Fig. 3(c), cation 570 diameters, shows typical pearlite area the normal (unhardened) materiai. should realized that the structure very coarse resolved well 570 diameters. Fig. shows the structure the left-hand unhard- ened edge (see “key” photograph Fig. 1); the amount ferrite —_ edge toward the center the specimen, although some pearlite present with the ferrite the edge. This latter condition, the presence temper carbon, and the chemical analysis establish this material partly malleabilized iron, quite probable that the hardened surfaces originally had the same structure for the sec- tion shown Fig. With this mind, the high hardness the Shorterized surfaces even more remarkable. Alloy React Favorably Regarding the applicability the Shorter process alloy cast iron, the report Mond Nickel Co., Ltd., Millbank, London, may cited. The iron examined this company analyzed 3.17 per cent total carbon, 1.60 silicon, 1.07 nickel and 0.16 chromium. The combined carbon was determined both the soft body the iron and the hardened surface. The figure found for this the body the metal was 0.72 per cent and the hardened face (after Short- erizing) was 0.85 per cent combined carbon. Hardness determinations were made the ordinary Brinell method and also the Vickers diamond hardness machine. the ordinary method the hardness the body the cast iron was found 245, whereas the hard- ness the hard face was 504. The Viekers diamond hardness the Shorterized surface was found 558, the soft body being 224 232. The junction between the two structures showed uniform the hard layer. individual read- ing 595 was obtained this hard layer. these figures are IG. structure the al- loy cast iron prior treatment. The view the left 100 diameters and the one the right 100 diameters. ‘ converted equivalent numbers, they will found 230 throughout the soft body—and 500 525 the hardened layer. Microscopic examination the specimen showed the body this particular iron having normal pearlitic structure with perhaps tectic. There was very sharp line demarcation between this structure and the skin structure, the latter showing matrix martensite. this matrix there are patches corresponding with the phosphide eutectic, which shows structure indicating that incipient fusion has taken place (the phos- phide eutectic melts about 980 deg. C.). The polished section the hardened portion showed traces porosity which might possibly again indicate incipient fusion the phosphide constituent. There was indication sur- face cracking oxide penetra- tion the hardened skin. Not that surface cracks cannot result the operator not careful. But modicum skill will cancel this danger. Likewise the surface after treatment smooth and unaltered appearance. Thus this flame process considered superior method heating locally. the latter method, the surface some- times mottled roughened due actual melting portions the surface. Everest, the Mond Nickel Co., Ltd., has reported this paper that the opinion that the Shorter process sur- face hardening can success- fully applied alloy cast iron ordinary cast iron. fact, view the greater uniformity the former, Mr. Everest would an- ticipate improved results the use the alloyed iron. Moreover, Structure section alloy iron. The left-hand view shows the struc- ture from the hard- ened ward; taken 100 diameters. The right- hand view that the hardened sur- face, taken 200 diameters. rather excess phosphide ~« Han cle re d 5—Alloy cast iron bar in. diameter, surface hardened halfway around means the Shorter process. This etched view shows the depth hardening, which measures about in. For more detail the structure this iron, see Figs. and with the small amounts alloy additions which are normally em- ployed this class materials, would recommended that al- teration should made the usual heat treatment. should emphasized, how- ever, that the favorable statements made here concerning Shorterized alloy iron apply only irons hav- ing small quantities added al- loys commonly used for improv- ing the general quality iron castings. The remarks not ap- ply special irons the corro- sion-resisting non magnetic types. Another alloy cast iron which re- acts very favorably Shorterizing Mark special die-cast iron made Stokes Centrifugal Castings Co., Ltd., England. This iron an- alyzes 2.21 per cent silicon, 0.045 sulphur, 0.74 phosphorus, 0.795 manganese, 1.07 nickel, 0.42 chro- mium, 0.41 combined carbon and 2.60 graphitic carbon. Fig. may seen etched section bar this analysis which has been hardened half-way around the Shorter method. The depth the hard band this case approximately 1/16 in. Firth hardometer was em- ployed for hardness measurements, using diamond indenter under 120 kg. load. The Shorterized sur- face tested 470 Brinell numbers, whereas the normal hardness the untreated section was found 228 Brinell. Fig. shows the normal struc- ture this alloy iron both high and low magnifications. These two views demonstrate that both the pearlite and graphite are fine and that network iron-iron phos- phide eutectic exists certain areas. effect the Shorter treatment from the surface inward mar- structures essentially. The iron- iron phosphide eutectic network very pronounced the troosto- martensitic area. microphoto Fig. shows the hardened structure near the sur- face the bar. Normalizing Value Despite the large degree hard- ening which the flame treatment gives this iron, cracking any kind was found during thorough examination. should noticed that the Shorterized section (see Fig. left) the network iron-iron phosphide eutectic rather prominent compared with the hardened structure. good study for the future would ascertain the effect this struc- tural arrangement, the iron- THE IRON AGE, August ned / j ' i + ; i 4 a ° phosphide well known hard and brittle. must appreciated that when cast iron hardened the me- chanical properties such tensile and compression values are de- creased, and with regard this would interesting determine how much this effect concerns sur- face-hardened cast iron. Inasmuch tempering treatment about 300 deg. restores and even im- proves the tensile and compression properties hardened cast iron without great loss hardness, should value make com- parative tests bars the sur- face-hardened condition and simi- lar bars after tempering. Naturally lot depends the cast iron put. dealing with iron cast certain shapes, could value conduct nor- malizing stabilizing treatment about 500 600 deg. with the object removing distrib- uting casting internal stresses before surface hardening carried adjust the rate quenching dur- ing hardening suit the anal- ysis the cast iron being treated. normalizing treatment follow- ing Shorter surface hardening could easily incorporated the flame-quenching set-up. Two blow- pipes could employed, first hot torch heat the iron above i, Hard produced Shorter process martensitic structure Gradual change zone showing martensitic structure with envelopes normal structure the 8—Showing the effect flame-hardening treatment plain carbon steel. Taken diameters. The normal structure the iron coarse— the steel was originally not properly normalized condition. the critical point, after which the water jet. Finally cooler torch would follow again heat the surface desired tempering temperature, after which the iron ean air cool room temperature. number other alloy irons Brinell Hardness Eight Different Irons Before and After Shorterizing Treatments Chemical Composition Graphitic Phosphorus .......... Hardness Before Iron Iron Iron No. No. No. No. 0.64 0.74 0.69 2.09 2.30 2.00 2.08 0.56 1.58 2.26 1.82 1.01 0.07 0.48 0.16 Nil 0.076 0.36 0.10 0.24 0.114 0.086 0.114 0.123 0.077 0.069 0.096 0.073 0.843 0.850 0.915 0.630 292 269 253 367 450 450 472 518 Brinell Hardness Tests Fight Different Alloy Cast Irons Before and After Shorter Flame-Hardening Chemical Composition Hardness TABLE Iron Iron Iron No. No. No. No. 0.96 0.49 0.49 0.76 1.92 2.61 2.58 2.35 1.42 1.91 1.92 2.43 Traces Nil Nil Nil 0.11 0.064 0.064 0.022 0.106 0.105 0.106 0.083 0.138 0.465 0.458 0.071 0.722 0.678 0.890 350 241 235 223 560 472 450 441 TABLE Iron Iron Iron Iron No. No. No. No. 0.49 0.49 0.96 0.76 2.61 2.58 1.92 2.35 1.91 1.92 142 2.43 0.064 0.064 0.11 0.022 235 241 350 223 450 472 560 441 Iron Iron Iron Iron No. No. No.7 No. 0.74 0.69 2.09 0.64 2.00 2.08 0.56 2.30 2.26 1.82 1.01 1.58 0.48 0.16 0.07 0.36 0.10 0.24 0.076 269 253 367 292 450 472 578 450 16—THE IRON AGE, August 1935 | | | 9—Effect the Shorter process hardened and tempered alloy steel. surface; martensitic structure produced the Shorter process transition, showing troosto- martensitic structure structure and This view diameters shows the change-zone between the as-received sorbitic structure and the hard surface martensite. readily respond flame hardening. Eight cast Meehanite alloy-iron bars were Shorterized the rough condition. After the surfaces were ground for hardness testing, the Brinell numbers shown Table were obtained. Note the large in- crease hardness each case. The results obtained with eight other types alloy cast iron are shown Table The Brinell numbers designated “after Shorterizing” naturally apply only the hardened surfaces, the body core the iron un- affected the Shorter treatment. All the foregoing has applied plain and alloy cast iron. The Shorter flame-hardening method just applicable carbon and alloy steels. Consider carbon steel analyzing 0.18 per cent sili- con, 0.038 sulphur, 0.031 phos- phorus, 0.68 manganese and 0.48 This steel finds use the making gears, and the teeth such gears Brinelled only 190 prior heat treatment. Following Shorterizing operation, the faces of: the gear teeth Brinelled 630. The microphotograph Fig. shows the normal condition this iron, the transition zone and, finally, the structure the hard surface produced flame-hard- ening. Many alloy steels respond the Shorterizing treatment readily does plain carbon steel. One alloy steel thoroughly tested had composition 0.173 per cent sili- con, 0.049 sulphur, 0.031 phosphor- us, 0.65 manganese, 0.36 carbon, nickel, 0.96 chromium, 0.30 molybdenum and 0.02 vanadium. This steel Brinelled 350 the hardened and tempered (as re- ceived) condition. Following surface hardness was raised 506 Brinell. micro-photograph show- ing the transition between the normal and hardened surface may Two Germans, Holler and Zorn, also have studied the flame-hardening steel, and reached the conclusion that the most suitable range carbon con- tent the steel 0.4 0.6 per cent. Other conclusions were that the manganese content exceeds per cent, the steel must han- dled more carefully than one with, say, 0.5 per cent, and the distance between the blowpipe and the cool- ing jet must increased order make the quench less drastic. cent has practically influence the hardenability the steel, but increases the wear resistance. Steels with per cent chromium can successfully treated this process; with great- amounts, the metal must avoid fissures. Doctor Swinden the United Steel Cos., Ltd., also has examined numerous plain and alloy steels and has stated that entirely satis- (CONTINUED PAGE 95) TABLE Effect Shorter Surface Hardening Treatment 0.4 0.5 Carbon...... Nickel-Chromium ...... Chrome-Molybdenum Nickel-Chromium-Molybdenum ...... Nature Hardened Surface Type and Composition the Steel Hard- Total Man- Shorterized fected Troostite, Carbon ganese Nickel mium denum Surface Inches Martensite Etc. 0.46 0.69 783 0.128 0.076 0.052 0.42 0.71 1.05 782 6.108 0.084 0.024 0.39 1.59 0.31 773 9.111 0.092 0.019 0.39 0.56 1.52 1.16 770 0.108 0.080 0.028 0.36 0.60 1.13 0.31 726 0.096 0.012 0.36 0.70 3.34 0.20 710 0.123 0.086 0.037 0.32 0.56 2.56 0.72 0.42 650 0.135 0.120 0.014 THE IRON AGE, August , q : § } } asta ‘ McCALL THE removal seams and other defects from the surfaces steel billets properly con- dition them for the subsequent roll- ing operations subject im- portance all manufacturers rolled steel products. While hand chipping with pneu- matic tools widely used billets small cross section, the larger billets are now successfully and economically deseamed mechan- ical means. compete with the hand method, machine must not only built with highly sensitive control, but must, addition, have means for quick and easy loading, clamping, unclamping, rolling over and ejecting the billets. The Niles Tool Works Co. has recently built new billet gouger designed meet all these re- quirements. Fig. shows the ma- chine the erecting floor and Figs. and show after instal- lation large steel mill. The machine has many improvements IRON AGE, August 1935 ovements Billet Gouger over previous units Putnam de- sign, which have been use many mills for number years, and will handle billets in. machines have been built for billets larger section and greater length. The billet held that the sur- face being conditioned inclined angle deg. This per- mits the operator readily view ONSTRUCTION and op- erating details im- proved machine for ing seams and other defects from the surfaces steel billets the larger sizes are given this article. One operator seated the head end can load, clamp, turn over, deseam, unclamp and eject the billet from the ma- chine without moving from his seat. controls the table movements with his feet and tool movements with his hands. inspector sta- tioned beside him marks the defects the surface worked passes by. gouger erecting floor. the surface while seated his po- sition, and also aids the chips. The housing the machine massive casting tongued and grooved integral extension the bed. its upper portion, ways are planed for the tool-slide saddle angle deg. The tool slide arranged with two tool holders separate clapper boxes. One tool has flat face for strip- ping and the other has rounded edge for gouging seams. These tools are spaced that either one may used across the entire face the largest billet without inter- ference from the other. bring either tool into cutting position, merely necessary traverse the tool-slide saddle amount equal the distance between the two tools. The ways the housing where the saddle slides, and the ways the tool-slide saddle where the tool slide slides, are lined with renewable hardened steel plates. Bronze plates are attached the mating surfaces the sliding parts. Separate motors geared directly nitrided screws provide move- ment the tool-slide saddle along the housing ways and the move- ment the tool slide transversely across the tool-slide saddle. Con- trol handles each the opera- ui | . | | ° ° ° ‘ ° ° | | ‘ | | | | tor’s hands start and stop these motors and select the direction rotation. The table driven hp. planer-type, reversing, adjustable- speed motor, through reducing gear unit and helical bronze pinion meshing with forged steel rack. This type drive, which similar that used worm- driven planers, particularly ad- use heavy and frequent ribs the bed where the loads are heaviest. The table movement controlled the operator’s feet double walking-beam type foot treadle. Pressure from his right foot causes the table move the cut direction and pressure from his left foot moves the table the reverse direction. Removing both feet from the treadle stops the table. The amount foot move- ment determines the speed the table. tion view show- ing loading plat- form and me- chanical billet The dis- charge skids are ground, The in- dex members for turning the bil- lets are attached the loading platform. The table slides two flat tracks with flanges cast their sides which form troughs for the table lubricating oil. Each way the bed protected specially treated canvas belt, which extends the full length the bed and passes through suitable cored open- ings the table. The belts lie flat the flanges adjacent the tracks and suitable flanged roll- ers are guided through the table. Springs each end the belts Controlled Seated keep them taut for all positions the table. The tracks the bed are lined with renewable hardened steel plates, and the mating sur- faces the table are lined with bronze plates. Holddown clamps each side the bed prevent the table from lifting when heavy cuts are being taken. Two chucking and manipulating units are arranged that they may located advantageously for the particular length billets handled. They are held place bolts engaging clamp members tee slots the table and also stop pins. Two torque motors, fitted with electric load brakes, are ceiling mounted the underside the chucking and manipulating mem- bers, and are electrically synchron- ized. the transmission power, spline shaft extending along the back the table employed that the manipulating arms will operate perfect unison. Power from the spline shaft passes througk two pairs worms and wheels and pair pinions and racks attached slide member carrying the gripping jaws. The racks attached the grip- ping jaws extend and mesh with other rack pinions attached the manipulating arms. The upper pinion, visible Figs. and attached the manipulating arm. The arms are caused make the necessary angular movement (CONTINUED PAGE 36) i i ‘ 4 | 4 STATEMENT obser- vations operating executives the plant one the foremost instru- ment makers where Carbo- loy tools have been increas- ingly used. NCLUDED the engineering values ascribed tungsten cemented carbide tools for metal guarded users and which has direct relation use small lots work requiring extreme accu- racy assembled product. The ability cemented carbide tips, and tools formed shapes, retain “keen” cutting edges, more and more calls for their use where tool-security, from keen edge viewpoint, highly impor- tant. This because experience has taught that maintained accuracy this class work involves non- removal tools from the time job set until completed total quantity. “Keen-edge,” factor tool- security, can specified sharp edge which free from any evi- dence irregularities when checked under glass. The tools referred particu- larly meet this requirement under stated conditions, that their cut- Accurate Hole Boring with Tungsten Cemented Carbide Tool. ting edges may sufficiently main- tained operation, this class work, stoning rather than grinding and sharpening. This maintained condition can held without tool removal from holder and the resultant disturbance “set-up.” must not, however, con- cluded that tungsten cemented car- bide tools are “cure-all” for al! metal cutting inaccuracies. Yet well established that the ma- terial presents means for ac- complishment desired results, and when planned avoidance every type tool abuse incor- porated tool-handling system which properly supervised its execution. The system must in- clude every tool-handling and use, both within and without the tool crib. Tool sharpening thor- oughly informed employee, one only possible, important safe- Under such planned attention, tungsten cemented carbide tool wil! hold its size and shape and good condition perform re- quirement-meeting manner. The engineering theory back this shop practice is—give something definite and sure that treated that will fail only under unknown condition. Any application lesser theory will tend prove that these modern tools are expensive luxury rather than profitable investment. Used for Aluminum Today, aeroplane accessories and other precision devices, well the manufacture many delicate measuring and timing mechanisms, aluminum, drawn and cast forms, being in- creasingly employed. This type production seldom large quan- tities but cutting edge difficulties é H | | | | i } . } | { ’ persist because silicon content the metal. Here the maintain- ing keen cutting edge diffi- cult and less importance, while surface speed, because ir- regular shapes forces created when motion, may either major minor importance. other words, speed may utilized sacrificed deference cutting edge maintenance. any work this class much depends upon tool shape and tool mounting. Rigidity, the train machine elements back the tool, essential. Clearance angles must such take from the cutting-tool edge little its support possible. The em- ployment 1200 ft. per min. not, overlooked gaining 0.0005 in. aceuracy round irregular shaped parts and the same condi- tion may prevail the milling flats. This speed connection with the elimination subsequent work grinding operations. The necessity for particular rate speed nil, while cutting-edge se- curity vital, Producers the class work under consideration are after tool security. The an- swer tool security always— How often necessary grind? Given proper machines, often with special design features, plus tool security, quite possible get the accurate results required for instrument work manufactur- ing basis. one-man tool grinding, such considered best this class work, there one rule from which said there should devia- tion—The grinding wheel should never lose its contact with the tool until the final stroke pass the wheel. should not clear the tool any point before the grind- ing work the tool completely finished. Otherwise, tool distur- bance the cutting edge the tool. Engineering knowledge, within the organization which use the tool, essential. Such knowledge cannot bought from the seller except basic This statement casts reflection upon the present method tool distribu- tion but, rather, indicates that the use cemented carbide tools its infancy and that until certain definite ground reached, profit- able use must based upon de- tailed engineering knowledge material and cutting-tool action under specific conditions which set the limit profitable use within shop. Such limitations are largely determined both organ- and Their Relation Small-Lot Work ization provision for proper tool and employee ability make profitable use such provi- sion. Back these must right machine design. Obviously, the de- velopment these proper shop conditions matter supervi- sion and not one seller’s con- tract obligation. Nor should any prospective user expect that the seller will supply him with any- thing other than fundamental in- formation, gained during the rela- tively short period time that the material has been use. con- nection with the material there most useful field accurate small-lot production. Using Tungsten Cemented Carbide Tools for the Milling Accurate Flat Surfaces. J Plastics Industry Broadens Field ° PRENTISS Cleveland Resident Editor, The Age ANUFACTURERS molded plastic prod- ucts, which the General Industries Co., Elyria, Ohio, one the largest, are improving their technique and broadening their range the trend toward larger products cash register drawer, made the Elyria company, which measures THE plastic molding industry continually seeking broaden its markets developing new applications for its products. Recent activities that direction ° Although plastics are competitive with iron and steel, their manufacture calls for considerable steel, well machinery. new market for equipment has been opened the perfection extrusion method molding thermal plastic material which the hot plastic compound will forced into dies. are centered considerable ex- tent making much larger plastic products than heretofore have been produced. addition, plastic molding products recently have be- come competitors glass for use lighting fixtures and some extent interior trim building construction. Lenses for dome lights for least one make automobile are now being made plastic material, which also has replaced glass lighting fixtures some railroad cars. Production large globes plastic material for dome light- ing fixtures the latest develop- ment this particular field. Mold- ing these necessitates open top but otherwise the design does not differ from that glass globes. claimed that much light will pass through lighting fix- ture globe made white plastic thin sections through white glass and the light weight the former compared with glass highly advantageous. change appears imminent 350- ton semi- automatic hy- draulic presses which the pre- formed molds are pressed their final shape and then baked. ‘ | | | j ° ° ° 2 the method molding which promises production methods this indus- try, which present following practices that have been pretty well standardized. This promised the development extrusion method molding thermal plastic material under which the hot plas- tic compound will forced into dies, the being virtually similar that making die ings. press manufacturer has developed machine for this extru- sion process, orders for which have been placed several makers plastic products and some these machines placed opera- tion shortly. Cash Register Drawer Made Plastic Among the largest manufactur- ers plastic products the Gen- eral Industries Co., Elyria, Ohjo, which has one the best equipped plants for molding plastics and one the leaders developments that field. large plastic recently made this company drawer for cash register 14% in. dimensions and in. deep. The lower half the steel mold required for mak- ing this drawer weighs 1000 and pressure 350 tons used molding the drawer. housing for meat chopper another large part that made plastic material. During 1934, when other indus- tries were lagging, the Elyria com- pany put $75,000 worth new machinery equipment. Large Variety Molded Parts Made large variety molded prod- ucts are made the plant ranging size from pieces in. long in. diameter the cash register drawer, which one the largest molded parts that has far been made. Molds are made with single cavity for large pieces 100 cavities for the smaller. Three grades molding ma- terials purchased the open mar- ket are used. These are Tenite, cellulose acetate material, Bakelite and Durez, which are phenolic molding compounds, and Plaskon and Beetle, both urea materials. Molded products are held the usual commercial tolerances plus minus 0.005 in., but much closer OLDS are made the hobbing process when the quantity parts molded warrants the mak- ing molds this way. Under the pressure 100C-ton hydrau- lic press ened steel hob forced into the lank, producing the die cavity that then ma- chined, hardened and highly pol- ished. The metal screen the hobbing press protect the operators should the hob break while being pressed, into the die blank. limits are maintained the cus- tomer requires it. Work being produced with wall thickness thin 1/32 in. Very intricate parts are produced for mechanical purposes. thermostat valve hous- ing with both internal and external threads interesting example. The plastic molding industry has created valuable market for the makers machinery iron and steel. addition press and other mechanical equipment used plastic molding, the Elyria plant has tool and die department equipped with large amount machinery and also uses great deal light machinery its finish- ing department, mostly for remov- ing fins from the work. The smooth, lustrous finish the molded parts requires very accu- rate and finely finished molds, and die makers are especially trained for that class work. Molds are made the hobbing process when the production piece sufficiently large war- rant the use that method. hob that duplicate the object molded machined from special tool steel, which hard- ened after machining, and this serves master die for making duplicate The use hob when once made assures the accu- racy all the molds dies made with hob, errors due the human element machining mold cavities are The hobs are stored that case accidents the molds they may used for making new molds. The cavity the mold formed hydraulic press 1000-ton capacity rated with 100 per cent over-load, and pressure 1500 tons frequently exerted press- ing the hob into the blank pro- duce the die. The blanks are made low-carbon machine steel. For dies that are machined instead hobbed machine steel used. For the hobbing operation the blank placed heavy ring ft. diameter and about in. thick prevent the metal from spreading out under the powerful pressure the hob. When oval blanks are used make molds, spacers are inserted fill the space between the blank and inner the large ring. The cavity, after being formed (CONTINUED PAGE 43) THE IRON AGE, August | { t 4 4 4 | | | | | | | | e ir : — } } carburizing furnaces are used the Electric Auto-Lite plant carburize clutch pinions, clutch bodies and clutch housings. Clutch bodies are given case depth 0.028 in. Steel Parts A\re Process UCH time, money and thought have been spent devising cheaper, quicker and better ways carburizing steel parts. number methods have been evolved. One the best employs retort muffle with gas carburizing medium. Some- times city gas used. The Elec- tric Auto-Lite Co., Toledo, Ohio, however, utilizes combination raw natural gas and city gas that has been reformed, and with great success. Electric Auto-Lite the second largest maker automobile start- ing and lighting equipment. Its main plant Toledo housed 24—THE IRON AGE, August 1935 huge building. many parts call for special metallurgical and physical properties that separate heat-treating division necessary. Among the furnaces special note this division are the batch-type gas carburizers. These furnaces, which there are three, eliminate the packing parts carburizing material, they are the full muffle type and employ gaseous medium. Using method known the Eutectrol process, they were developed and built the Surface Combustion Corpn., Toledo. The work carburized consists primarily clutch pinions, clutch bodies and cluteh housings. Clutch bodies are made from S.A.E. 4620 steel, weigh each and are given case depth 0.028 in. produce this case they are heated and held 1700 deg. for hr. while being subjected predetermined atmosphere gas This cycle consists (1) (reformed gas) flowing through the muffle rate cu. ft. per hr. for definite time, (2) natural gas cu. ft. per hr. for definite time, and (3) both and natural gas the same rates for the balance the cycle. The rate carbon penetration, 1700 deg. F., 0.012 in. per hr. (CONTINUED PAGE 48) | { | } { Coating Strip with Copper For Ford Rod Bearings the manufacture copper- lead bearings for connecting rods V-eight cars, the Ford Motor uses process which copper-lead cast continuously steel strip, which turn formed half circle and ma- chined size. This work, the rate 5500 bearings day, done the Rouge plant Dear- born, Mich. Due the design the Ford connecting rod bearing, desir- able have steel back sup- port for whatever bearing materia! used. Low carbon cold-rolled strip steel, 0.068 in. thick and 21/16 wide, first channeled make flanges for bearings, ordinary rolling machine being used for this operation. After be- ing flanged, the steel strip 1.886 in. width. The steel strip passed down through copper-lead bath coating furnace and held tem- per cent chrome metal coating pot, the heat zone being in. long. The strip this zone one min. Hydrogen gas diffuses through the coating furnace and deoxidizes the steel strip the zone just be- fore enters the bath. the clean steel strip moves through the bath into the graphite die, the copper the copper-lead mixture brazes onto the steel. The upper part the graphite die 2100 deg. and held the bottom the chrome pot di- rectly under the copper-lead bath, that the die allows certain amount copper-lead pass along with the steel strip. The opening the die the size desired the rough coated strip. The steel, course, coated with copper-lead the size and shape the opening the die. the steel strip, now sur- rounded hot copper-lead, goes through the graphite die, the cold end the die, which cooled water jacket, causes the copper- lead freeze and become solid, thus holding back the hot metal from above. The coated steel, after coming out the cold end the die, passes through friction-pulling rolls and ready cut length. TEEL strip passed down through lead bath coating furnace and held tem- perature 2100 per cent chrome metal coating pot. Below the bath phite die through which the steel, coated with copper- lead, moves. then passes down through friction pulling rolls and ready cut length. The copper-lead mixture the following analysis: 30.00-35.00 Per Cent Per Cent 0.50 Per Cent maximum 1.00-1.50 Per Cent The coating furnace has outer steel shell in. thick, with loose silocel refractory material between the shell and the molybde- (CONTINUED PAGE 47) 4 4 cle. Machine Tool Exports STILWELL Vice-President, The Warner Swasey Co., Cleveland; President, National Machine Tool Builders’ Association the days before the World War, American exports machine tools represented very high share the business the indus- try. one time, for instance, per cent the business our own company came from abroad. quarter century later the pro- portion the industry’s produc- tion which went abroad was sub- stantially less. The volume, how- ever, was still large terms dollars. During the 1926-30 pe- riod, exports industrial machin- ery, reported the Department Commerce, averaged $216,000,- 000 annually. Then came the depression—and machine tool exports dropped 1933. was hoped that with the gradual world-wide revival busi- ness substantial increase ma- chine tool exports would result. But such increase has not mate- rialized any satisfactory extent. true that 1934 exports industrial machinery rose $98,- 349,000—but comparison with the former experience the indus- try, this amount seems small in- deed. the whole, machine tool ex- ports have been the decline for long time—and recently, busi- ness abroad has revived, new de- velopments have arisen which are making increasingly difficult for American machine tool builders compete foreign markets. the face these facts, only natural that hear ex- pressed some quarters the idea that American machine tool build- ers may well resign themselves the inevitable and give the 26—THE IRON AGE, 1935 hope that some future time they may again revive machine tool ex- ports something approaching former levels. not subscribe this idea. Admitting all the difficulties now attendant upon the building foreign trade for machine tools, not believe that the industry afford for moment enter- tain the thought giving for- eign markets. Those who are pessimistic with respect export trade would well remember that, with the de- pression, domestic sales well foreign sales hit the toboggan— that even the face present disadvantages, exports from 1931 through 1934 have constituted ap- proximately per cent the business American machine tool builders—and that the largest 1934 increases industrial machinery exports were made the power- driven, metal-working machinery group composed almost exclusively machine tools. opinion, export trade inherent and integral part the American machine busi- ness and absolutely necessary for the life and progress the indus- try. Certainly, the industry can- not merely sit back and let foreign markets slip away without strug- gle. The proper course action, seems me, analyze the facts, determine the obstacles overcome, and decide what steps, any, may taken toward re- gaining foreign trade, insofar .as that may possible the light changed circumstances today. understand the present situa- tion, necessary review briefly the course machine tool exports during the past years. The peak machine tool exports was reached 1912 and The period was one industrial expansion Europe, and the large demand for Ameri- can tools arose because machine tools American make were vastly superior European construction, design and produc- tivity. Then the war came, and still further added the already large demand. But the war also began teach the British and the Ger- mans how make better machine tools. Previous that time few Euro- pean manufacturers had made ma- chine tools quantities. March 1914, for instance, English plant asked our company figure machines and tools for making 10,000 carbureters. After the figure was handed in, were in- formed that the company had changed its mind—that was not going ahead with the proposition because “the quantity large!” The war started Aug. that year. fall this firm had orders for 4,000,000 fuses, and wanted all the machine tools they could get. This illustrates the manner which the war launched European manufacturers into quantity pro- duction. Before the war was over, was old story. Facilities were immensely enlarged, espe- cially England and Germany. After the war, they naturally had occupy these increased facilities. The vast number machine tools which America had shipped were now released for normal industrial purposes. the same time wages and prices the United States were rising. result, exports machine tools from the United States de- clined very low point. Business Too Good Worry About Exports Coincident with this decline foreign demand there came the 1919 boom this country. The result was that many American manufacturers for the time being disregarded foreign markets and discontinued active solicitation machine tool orders abroad. Re- sale agencies which had been es- tablished before the war had many cases become totally dis- rupted. Mea