The Iron Age 1935-09-19: Vol 136 Iss 12

CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, Owned, Published and Copyrighted CHILTON COMPANY Executive and Publication Offices, Chestnut and 56th Sts., 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, President J. H. VAN DEVENTER Editor Managing News Editor E.. MILLER Machinery Editor Editor Emeritus Washington Chicago Cleveland Pittsburgh Detroit Boston Cincinnati Importance Fixtures Using Carbide Welded Members New Radial Diesel........... Steel Walls Add Beauty Republic New Equipment ................ Machine Tool Show Personals and Obituaries Statistics Metal-Working Activity. Construction and Equipment Buying. BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAPF Member, Associated Business Papers Emerson Findley, 311 Union Cleveland B. L. Herman, Ave.. Buffale, tion Price: United States and Pos- Peirce Lewis, 1316 Woodward Ave... Detroit sessions, Mexico, $6.00; Can- Charles Bidg.. Chestnut 56th Sts., Philadelphia, Pa. W. B. Robinson, 428 Park Bidg.. Pittsburgh W. C. Sweeteer, 239 West 39th St.. New York D. C. Warren, P. O. Box 81, Hartford, Conn. ada, $8.50, including duty; Foreign $12.00 a year, Single copy, 25 cents. Cable Address, ‘‘Ironage, N. Y."’ - iy General Steel Products steel products, such Bars, Structurals, Plates, Sheets, Strip Steel, Welding Rod, Tubes, etc., are carried stock for immediate shipment. Hot Rolled Alloys S.A.E. 2315, 2320, 2330, 2335, 2340, 2345, 2350, 3115, 3120, 3130, 3135, 3140, 3250, 4140, etc., etc. Rycase (hot Rytense A.A. (hot rolled) Shipment Heat Treated Alloys stock for immediate shipment. Allied lines such non-fer- rous metals, welding rod, babbitt, boiler tubes, fittings, etc., are also Ryco (hot drawn). included. Shears—saws—and specia cuttin cut Resisting Alloys Allegheny Metal (Sheets, Bars, any length special shape. Immediate shipment assured. Plates, Welding Rod, etc.). Cold Finished Steels Std. Shafting, Turned, Ground and Polished, Special Accuracy Stock, Rycase High Manganese Screw Stock, S.A.E. 1020, 1035, 1112, 1120, etc. Tool Steels Ryerson B.F.D. Die Steel. Ryerson Steel Ryerson High Speed Treated Bars, etc. RYERS IRON AGE, September 1935 more than years Ryerson Steel-Service has been meeting the steel requirements industry. Ten strategically located plants make this service quickly available throughout the country. Draw the plant nearest you. you not have the current Ryerson Stock List, write and will glad send you copy. JOSEPH RYERSON SON, Inc., Chicago, Milwaukee, St. Louis, Cincinnati, Buffalo, Cleve- land, Detroit, Boston, Philadelphia, Jersey City il } | ii | | | | | i THE IRON AGE ... SEPTEMBER 1935 ESTABLISHED 1855 Vol. 136, No. Breathing Spells between rounds prize fight, the opponents are allowed one minute inter- vals The purpose these respites based upon commer- cial rather than humanitarian motives. there were rests allowed, the battle would short duration and the customers would not likely get their worth. There somewhat analogous situation the case cat playing with mouse. Instead finishing his job quickly and getting over with, Tom takes pleasure prolonging his amusement and his victim's discomfort. you may have noticed, will worry the mouse nearly into insensibility, then release him and give him spell" until shows renewed signs life, after which the process repeated long Mr. Mouse can take it. The ideal mouse, from the cat's standpoint, would indestructible one, who could stand continual torture without needing breathing spell. is, shrewdly makes allowance for the frailty mouse nature. The ideal pugilist, from the fight fan's standpoint would pair nearly indestructible John Sullivans, who could "go for his sadistic amusement, bare fisted and gory style for rounds more. The ideal opponent and butt for the would indestructible business which could lambasted without let-up for the benefit the voting audience without jeopardizing its tax-paying, revenue producing power. The mouse, who simple creature, probably regards each "breathing the final escape from torment. The prize fighter, higher the scale intelligence, knows that the ing merely prelude another round. What the business man and the industrialist think about political business bait- ing remains seen. They will scarcely, this demagogic age, naive the mouse, who would not easily fooled knew the immutability cat nature. Our President has given good rule for measuring such situations when recommended that judgment formed not promises but upon performance. this basis, how long you think the armistice will last? | 5 itt | i H / ay A j i : Bee 4 2 } ; : i : AS i Fixture Design Important Using IG. vertical head moved inward means cam and roller order avoid interference with the casting. 2—The first operation, performed the right-hand section the fixture, consists milling four ports and pad which are right angles the ports. IRON AGE, September 1935 MACHINE tool fixture design far more im- portant than generally realized, and this especially true when cemented- carbide tools are used. Many shops have had the experience machining troubles which were di- rectly traceable hastily con- economy which eventually proved wasteful. Use carbide cutters offers serious problems the designer has full knowledge the char- acteristics and the potential pos- sibilities this comparatively new cutting material. must remem- ber that carbide cutters will cut faster and that they will give finer surfaces only the work prop- erly supported. This matter rigidity has thoroughly builders who have adequately met the situation. Therefore, with sturdy and rigid machine tools and carbide cutters available better and faster work, there must provided fixtures that fully meet all requirements. These requirements are: Rigidity the fixture; adequate support the part being milled, accuracy both fixture building and the ability the fixture its part accurate duplication, and quick and secure clamping. There are set rules which thickness metal can accurate- determined. One shop which has had much experience with carbide millers arbitrarily weight metal. That is, in. web wall section had been used fixture designed for older production methods, then web about in. thick would se- lected for use with carbide cutters. usual thing cast metal pre- ferred, although some successful ti i | : i} 7 } | | ag | ° “ i 4 | al | ° ° Carbide Cutting ools fixtures have been built welded steel sections. Any material placed the design give the required rigidity will prove satis- factory. The matter the cost fix- ture due extra weight metal should not enter into consideration because with proper design entirely possible many instances obtain well milled surfaces that result substantial savings subsequent operations. For ex- ample, there have been instances where grinding operations have been eliminated with resultant sav- ings labor, power, and burden. well milled also re- duce scraping time and labor. analyzing the cost many fixtures quite evident that material cost constitutes but small portion the total cost. Engineering, la- bor and burden are far the largest portion expense. the amount material doubled, the total cost fixture may in- creased only per cent or, ex- treme cases, much per cent. The increase investment quite small, yet its importance lies the fact that insufficient strength may result failure, are often directly traceable hastily con- ceived fixtures and false economy designing them, especially when cemented- carbide tools are employed. such fixtures and two exam- ples good design are out- lined this article Mr. Curtis, authority this branch machine shop practice. against success with desirable added weight. Clamping time matter relative importance. For instance, part which requires sec. for the actual milling operation can probably well afford sec. for loading and clamping. However, part requires sec. for milling then special study must given YO \ Ag \ ° ° FRANK CURTIS Research Engineer, Kearney Trecker Milwaukee. ° ° clamping devices which will cut the time the minimum. al- ways attempt reduce the loading time proportion the reduction cutting time. These figures give idea what hap- pens when trying use clamping devices with carbide cutters that were suitable for other types cutters. two more parts are milled the same time the de- signer must give attention quick loading the part which enters first. This time saver because the feed can started sooner. most cases there ample time load the second and subsequent pieces while the cut being taken the first piece. general rule, because high speeds and fast cuts, cast- ing must given support more places when carbide cutters are used. All tendency for must eliminated. For instance consider, for example, channe! section standing its legs and milled across the end. Experi- ence has proved that deflection the web back will result poor surface unless means are taken support the web. not 3—Two manifolds are mounted this fixture and cuts are taken three planes only two which are right angles each other. THE IRON AGE, September 19, H “ ” Cylinder Block Oil Pan 4—The various operations this cylinder block and oil pan are handled to- gether; that is, one block fixture and one pan fixture are used simultaneously. 5—This double fixture holds one cylinder block and one pan.. This the set-up for the first operation. Note massiveness fixture construction. 20—THE IRON AGE, September 1935 sufficient clamp the part merely near the legs. This men- tioned because with many similar jobs end supports only have been sufficient for the slower feeds and speeds high-speed steel cutters, but when the rate cutting in- creased additional center supports are definitely needed eliminate chatter. Spring plungers and supports can often added after- thought trouble develops, but with careful study these can incorporated the original design. Then, too, they can often actuated combination with other clamps that additional efforts are needed adjust and lock them. Fixture for Holding Manifold excellent example fix- ture for holding manifold per- form two operations shown Figs. and this part there are four ports line that must finished, also pipe flange which angle the ports, and carburetor pad which must finished vertical miller. The fixture designed hold two manifolds that the cutter the horizontal spindle can finish the four ports one manifold and the pipe another. The vertical cutter catches the pad the set-up which the four ports are milled. See Fig. The first operation performed the right-hand section the fix- ture which provided with three fixed points one which indi- cated which the manifold rests. The center ports are sup- ported two spring plungers, which are locked means the hand knob, Additional clamp- ing obtained means the floating jaw clamp shown and the clamp, The latter slides over the work and actuated the cam, The stud, used with this clamp floating type and ar- ranged lock additional spring plunger, the same time. This plunger supports the work direct- under the pad which milled the vertical miller. Inasmuch the vertical cutter cannot follow straight line be- cause interference with the casting necessary feed the cutter into the pad relation table travel. This accomplished means cam, The vertical head sliding type and means cam roller and the cam i} | G Y Za __ 4 4 | \ the head fed inward the cor- rect position. The second operation formed the left-hand section the fixture which provides for mill- ing the exhaust pipe flange which angle the ports. The work located from three finished ports and the pad which right angles the ports. The manifold held two clamps. The clamp hinge type and can with- drawn facilitate loading. When brought into clamping posi- tion, the head the bolt, turned shown. This clamp operated means cam which engages pin which bears against the heel the clamp. This clamp the extreme left. Another cam- operated clamp which op- erated the handle holds the work solidly against fixed stop very close the portion milled. Engine Block and Oil Pan Fixtures Another Example Good Design Another fine example fixture design afforded two-cylinder gasoline engine block and oil pan. Fig. shows general dimensions the block and pan and also shows the surfaces milled and the sequence operations. The ma- terial cast iron and the depth cut varies from 3/32 in. All surfaces are milled. The various operations the cylinder block and oil pan are handled together; that is, one oil pan fixture and one cylinder block fixture are used simultaneously. Three sets fix- tures are needed and the operations require two 10-in. cutters. The first operation the cyl- inder block consists milling the top and bottom surfaces. Work located from the crankshaft bore and the cylinder head end rests two adjustable pins. Along the lower side the cylinder-block fixture narrow table which target gage may set obtain correct height the pins which are adjustable and down the hand knob which directly below the cylinder block. See Fig. usual thing when this adjust- ment once made checks are nec- essary only infrequent intervals. The cylinder block drawn into position hook bolt which operated from self-locking clamp shown the end the fixture. Four heavy-duty spring plungers support the crankcase end. These a 7—Sketch showing clamping oil pan for operation No. 8—On the second operation both sides the cylinder block and one side the oil pan are milled. THE IRON AGE, Seprember 19, { Fic. stop bars used locate crankshaft bores. Four jacks support each piece. EES 9—The cylinder block held firmly two clamps which are located the bridge the fixture. plungers are operated through single hand-knob. The cylinder clamped means large over- head bridge which has two swivel clamping blocks attached it. digress here for moment might well point out that fixture more less ordinary de- sign would probably nothing more than cradle with several straps hold the casting down. The clamping time would waste- ful and thought would have been given adequate support the crankcase end which after all deep channel section that needs adequate support not only the legs but the web back. The oil pan, which milled the same time, requires only the finishing the front face. The work located from the rough bore. The open end supported two heavy spring heavy cast-steel hinge clamp used fasten the piece securely the fixture and overhead bridge clamp used insure the piece being rigidly held place. handling this operation the oil fixtures are fast loading and clamping. Only one handle used for the pan side and two handles for the cylinder block side. 22—THE IRON AGE, September 19, 1935 pan loaded first, then the table feed applied and then the cyl- inder block fixture loaded. The feed in. per min. Second Operation The second operation the mill- ing both sides the cylinder block and one side the oil pan. The oil pan located from the previously milled joint face and alined two spring plungers which fit into the rough crankshaft bore. The work held place two heavy strap clamps. These clamps are tightened means large pilot wheel the top the fixture. spring plunger used support the center portion the surface being milled. Referring Fig. which shows the oil pan clamping devices, clamps and are sliding type and can withdrawn, shown dotted permit loading and removal the workpiece. After oil pan placed into the fixture, both clamps are set inward the clamping position, then the hand- wheel tightened. This brings action the link causing the clamp bolt pull the clamp downward. The heel this clamp rides the hinged plate that the pin strikes the work, against the button Continued turning the handwheel, then tightens both clamps securely. One motion only required locate the work endwise, well clamp it. The cylinder block located two hardened plates and, shown, rests up-side-down the pre- viously milled cylinder head face. Alinement obtained means two spring plungers which enter the rough cored cylinder bores. End clamping means two spring plungers the right-hand end and sliding bar the left- hand end, which are operated through self-locking clamp. The work held firmly place means two clamps, located the bridge the fixture, that are operated pilot wheel. The port face milled 4-in. tungsten-carbide cutter, and the opposite side milled 12-in. tungsten-carbide cutter. Approxi- mately in. material re- moved and feed in. per min. applied. Third Operation The third operation consists milling both ends the oil pan j t} — | | | and cylinder block. Both fixtures are the quick-operating type. The oil pan inserted the fix- ture until flange the opposite side strikes stop, which provides end clamp then engaged. This works through pinion and rack, caus- ing the swiveling clamps each end clamp against the work. This the operation single handle, the device being quick, fast, accurate, positive and de- pendable. The cylinder block fixture also quick acting. The block slides two hardened plates against stop. The handle the lower right engaged, causing two sliding blocks force the work that the cylinder head face bears against two hardened plates. This motion through racks and pin- ions, running through the fixture the opposite side. The operator then engages the upper handle which causes the heavy clamp the bridge contact the work and clamp securely place. Only two motions are required. Two 10-in. cutters are used. Insulating Refractory Concrete NEW hydraulic insulating re- fractory concrete known In- that takes the place fire brick and insulation combined poured refractory furnace lin- ings, boiler baffles, etc., has been developed the Quigley Co., Inc., West Forty-fifth Street, New York. This new development said possess the unique properties interlocking crystalline minerals forming cellular heat-insulating, heat-resisting, high load-carrying, and low permeation refractory. Also, because its low heat stor- age, and low thermal conductivity when poured form lining baffle, the boiler furnace becomes more sensitive automatic con- trol, saving fuel and increasing output. makes mono- (jointless), air-and-gas-tight furnace linings. stated that Insulcrete does not shrink after being poured furnace wall boiler baffle, ft. dry state weighs Ib., and after mixing with water, poured and allowed acquire 4 q <i handle the lower right causes two sliding blocks force the cylinder head face against two hardened plates. This motion obtained through rack and pinions. Close study the above fixtures reveals ample weight meta] and its proper distribution. Clamping devices are strong and positive and hydraulic set for hr. cu. ft. dried weighs Under continuous operation 2500 deg. furnace temperature the expansion contraction said negligible. Insulcrete mean tempera- ture 1100 deg. has thermal conductivity 3.13, stated, compared with first quality fire- brick which the same tempera- ture has thermal conductivity 8.16. 62% per cent better insulator and has less than half the heat storage firebrick, which makes saver both fuel and time. Insulerete recommended for all types heat treating furnaces, flues, pot furnaces, boiler walls and baffles, ovens, open-hearth re- generators, stack linings, doors, soaking pit covers, malleable iron annealing furnaces, producer and blast furnace gas mains, oil refin- ing furnaces, galvanizing tin fur- naces, The relining exist- ing furnaces with the new material, stated, will pay for the cost the improvement many times over the first year used based the saving cost fuel. Small gas forging, wire ing, heat treating furnaces, etc., special attention has been given supporting the castings that ad- vantage can taken the full value carbide millers. may cast single piece. Gas- fired Insulerete-lined furnaces, asserted, attain working tem- perature one-third the time and operate approximately 100 deg. higher temperature than ordinary fireclay brick furnace. Chromium Steels Are Reviewed Majesty’s Stationary Kingsway, London, has just published comprehensive book chromium steels edited Richard Henry Greaves. The vol- ume for the most part review published information the constitution, treatment, mechanical and physical properties plain chromium steels, presented such able and interesting metallur- gists and engineers. provides, accessible form, numerical data extracted from hundreds sources and contains critical sur- vey methods chemical analy- sis applicable chromium steels. Some hitherto unpublished work the research department, Woolwich, also described. THE IRON September 19, } A ae § ¥ 1 ‘ f ABOVE peel- erecting floor. BELOW pushed through ting tools the entering side age until the dis- charge aqe. the cutting tools the discharae side carriage. Parallel- charqe bed are shown the foreqround. ABOVE 3—Billet pulled through 24—THE IRON AGE, September 19, 1935 | — gy N 4 | eels Round Billets A\n Hour McCALL eter are turned in. the rate 480 tons hr. the machine here de- scribed, which designed for turning the surface unstraightened billets length. Two unskilled oper- ators easily handle the ma- chine, one operator the hydraulic feed and air clamp valves and the other the controls. THE surface round billets which are used the manufacture seamless steel tubing must carefully conditioned produce good product. there are many invisible cracks and checks concealed under the scale, advisable completely re- move the scale from the billets. This operation performed the Putnam billet peeler, which shown the erecting floor Fig. Figs. and show in- stallation views. This machine rapidly turning the sur- face, uniform depth, from un- straightened round billets. The term “uniform depth” means that the centers gravity the rough section and the finished section approximately coincide, the cut following the camber the billet. has been found that taking cut in. deep, reducing the di- ameter in., practically all the surface defects are removed. The machined surface smooth and such texture that any re- maining defects may readily de- tected. Billets in. diameter and ft. length are handled the machine shown the illustra- tions. Equipment has been built, however, handle billets great- lengths. The machine fitted with cen- tral cutter-head securely bolted and keyed the bed. The entire tool- holder assembly and may quickly removed and new tool holder placed the machine when the cutting tools be- come dull. Necessary provision for accomplishing this change in- cluded the design and consists hinged mandrel attached the right hand, discharge side, carriage. This mandrel may swung into position with its axis coincident with that the tool holder. moving the carriage, the tool holder pushed out from the cutter head and removed the loading crane. second tool holder with sharp tools placed the mandrel and drawn into the seat the cutter head. Fig. shows the self-contained tool hold- removed from its seat and sus- pended the hinged mandrel. The tool holders are arranged for six cutting tools in. in. The tools are clamped and adjusted the tool holder before placing the machine. gage, pictured Fig. used properly set the tools cut the required di- ameter. The tool holder driven two large keys, diametrically opposite, and the thrust taken against shoulder the hub the cutter head gear, only two bolts being used keep the tool holder posi- tion. pair tool holders fur- nished for each inch billet di- ameter. Internal adjustment the tools provides for fractional diameters. 3-to-1 adjustable speed motor, rotates the tool hold- through herringbone reduction unit and herringbone pinion and gear the cutter-head. The gear the cutter-head runs large bronze-lined taper bearing having adjustment for wear. Thrust the bronze track the inner face the main housing. hard- ened steel ring, fastened the face THE IRON AGE, September 19, 1935—25 igi tia he : 7% ; suspended mandrel being removed from cutter head. Duplicate tool holders are furnished for each range billet sizes. One set tools being sharpened while the other use. the gear bears against this track. Massive feet are provided the main housing for bolting the bed. These feet are carried well the tendency the cutter-head tip, due the feeding pressure. Provision made keep the lubri- cating oil from leaking out and likewise prevent cutting com- pound and scale from entering the head. Two carriages are mounted the bed, one each side the central cutter-head. The left-hand carriage, shown the foreground Fig. carries the entering side grip. After the billets are placed skidway the mill crane, they are picked the loading crane with the special hooks shown Fig. The billet placed position with one end resting the lower jaws the entering side grip, and the. other end the ad- justable V-block the front entering side the cutter-head. The upper jaw counter- weighted hinged member operated wedge and pneumatic cylinder provide ample opening for plac- ing the billets the jaws. There are three serrated jaws, one mount- hinged member, and two mounted adapter plate the main casting. The jaws slide tapered pockets the adapter plates, that the torque increases the billet, the jaws slide the taper 26—THE IRON AGE, September 1935 and grip proportionately tighter. When the chuck closed the pneumatic cylinder and wedge, suf- ficient pressure set the billet insure the jaws sliding the tapered slopes when the cut starts. The opening and closing the jaws controlled air valve, placed convenient posi- tion for the operator. set adapter plates and jaws provided for each size billet handled. The carriage feeds the billet through the cutter-head hy- draulic pressure. The entering side feed cylinder placed between the ways the bed, its plunger being directly the carriage. The push back cylinders are fast- ened one each side the enter- ing carriage, their plungers thrust- ing against the bed, next the cutter-head. the peeled end the billet emerges from the discharge side the cutter-head, gripped the jaws mounted the right- hand discharge side carriage. The lower jaw member actuated small air cylinder and nor- mally its lower outer posi- tion, well clear the billet emerges from the cutter head. When the air valve opened, this lower jaw member first runs up- ward into contact with the billet. The hinged member containing the two upper jaws then descends, and these jaws are mounted adapter plate, this plate will revolve its seat until both upper jaws are contact with the work. evi- dent type grip will find and clamp the billet whatever position may due its out straightness. therefore not nec- essary stop the cutter and release the enter- ing side grip be- fore closing the discharge side grip. When the billet gripped the jaws the dis- charge side car- riage, the jaws the entering side carriage are re- leased carriage returned the loading position rapid movement through the push-back cylinders. The gripping jaws are opened sufficient amount clear the hot saw fins the end the billet. The discharge side carriage fed hydraulic pressure and pulls the billet through the cutter-head. soon the billet clear the cutting tools, the feed movement the carriage may changed rapid movement until the billet clears the cutter-head and will roll down the skids the discharge carriage when the jaws are re- leased. The discharge side feed cylinders are fastened one each side the discharge side carriage, their plungers thrusting against the bed, next the cutter-head. The push-back cylinder placed between the ways the bed, and its plunger connected directly the carriage. set adapter plates and jaws provided for each size billet handled. Fig. shows peeled billet pulled through the cutter-head the grips the discharge side carriage. When the grips are re- leased, the billet will roll down the skids the discharge side the cutter-head and the discharge side carriage. discharge bed skid- way provided receive the bil- lets. the discharge bed usual- made quite long, important that the billets not start down the skids skewed position. prevent this, set air-operated | ; a { | | | | | | | | | i | | | i | | if 4 | | | | paralleling stops are mounted near the machine the discharge bed. The stops project between the skids and are pulled down, after the billet has rolled against them, air valve placed position con- venient the operator. Figs. and show the hinged mandrel which used change the way and held the rear the discharge side carriage. The front and rear ways the bed are covered with renewable hardened and ground steel wearing plates. Bronze plates are attached the mating surfaces the car- riages. large rectangular open- ing provided the bed under the cutter-head through which chips and cutting compound fall into pit the foundation. The chips are removed conveyor, and the cutting compound re- pumped the tools motor- driven pump. Two unskilled operators easily operate the machine its max- imum capacity, one operator the feed and air clamp valves and the other the crane controls. cutting speed ft. per min. and feed in. per tool, in. per revolution the cutter head (there being six tools), easi- maintained. in. diameter billets, being turn- in. diameter, approximate- 5740 ft. 480 tons are easily handled hr., leaving liberal time allowance for changing tool holders, set tools stands three four hours before be- coming dull. billet peeler new design now being developed the Niles Tool Works. the machine handle long billets, the carriages ° RIGHT 5—Gage for setting tools cut the required diameter. The arms fit the tool-holder and the tools are set disk proper size. al. th 4 will moved along the bed electric power avoid the neces- sity using long hydraulic cyl- inders. Each carriage will moved along the bed nut separate screw. Each screw will speed motor driving through speed reducer. very likely that the carriages will moved electric motors all future machines regardless the length the billet. feed long billet through the cutter-head necessary grip several times with both the en- tering side and discharge side car- riage. being fed either carriage, the other carriage traversed back the position where new grip may taken. LEFT 6—View show- ing for handling tool hold- ers when swuna out the way the side THE IRON AGE, September é j % “4, i j 4 4 > a t Composite Rolls* Review Typical Designs Use ing shapes and light sections unusual dimensions cost- item modern rolling mills. the case rolls for heavy sections, such rails and structurals, sev- eral passes are provided sin- roll and the whole length the barrel used, which precludes any marked economy the turning and machining the rolls. The situa- tion altogether different rolls used for rolling small shapes and sections, which are usually rolled double-duo small three-high mills, only one pass being made be- tween each pair rolls. Each pass being independent the other fa- cilitates rapid adjustment the rolls and permits small errors calibration readily corrected. The replacement defective rolls and interruptions rolling pro- gram are, moreover, infrequent mills this type. long possible work with open passes, the cost turning roll determined solely the size the section required. Thus roll section the shape shown Fig. la, only the shaded portion Fig. need turned from the upper roll and portion from the lower roll, the rest the barrel re- maining unusued may turned for other open passes later. the other hand, closed pass cut for the section shown Fig. 1c, the whole length the barrel must turned, which not only consider- cutting rolls for the roll- *Report Cramer the Verein deutscher ably increases the machining costs but makes rolling costs much great- than when using open passes. reduce these costs using only few closed passes dispense with them altogether not prac- ticable with certain sections, with some sections open-pass roll- ing rendered difficult and the time adjustment made long that whatever saved turning and machining costs more than discounted the increased costs rolling. Efforts Reduce Costs Where passes are provided along the whole length the barrel, pro- vision may made for the subse- quent use that part the barrel not immediately employed, but the first instance the high cost turning roll must met. Several Section Pass FIG. shape (a) required, with open (b) and closed passes necessary. methods have been evolved re- duce roll-making costs, but without much success. Thus eight similar closed passes are provided along the barrel, when only one re- quired, the hope that repeat or- ders may enable the seven extra passes utilized. repeat or- ders are placed, the cost making the roll sufficiently spread over warrant the first high cost, but usually the demand for small sec- tions special shape too small permit full use made the extra passes. The first cost may reduced providing only one closed pass along the and series blind passes which can later cut the required shape. practicable plan followed here make the width the blind passes progressively greater, mm., where seven blind passes are provided. third method cut the closed pass one end the barrel and leave the rest its length available for subsequent- cutting open passes required. The cost making roll this type less than the two previ- ous methods, but apart from the high first and subsequent costs these methods possess various seri- ous drawbacks and introduce number difficulties actual roll- ing. The disadvantages these meth- ods have led the evaluation “ring rolls,” comprising rings mounted the rolls, such rings FIG. 2—Attachment roll ring with nut and key. FIG. 3—Shrunk-on roll ring. 28—THE IRON AGE, September 1935 } it i | | eal | | } 7 Pass | i q | b, a, Z t being width sufficient for cut- ting the pass required with proper allowance for the edges. Thus, for the pass shown Fig ring width required. These rings are secured the roll barrels various means, typical examples being shown Figs. and Fig. the roll ring secured laterally the barrel the nut whose diameter must the same that the roll neck. Nut which right-handed left- handed, according the direction rotation the roll, secured the bush and the key the other side lies the collar the roll bearing. The roll ring driven the roll through the feather key. using this form attachment, the bore the ring must accurately machined and make good fit the roll barrel. Owing the heat developed during rolling, the ring usually loosens gradually, and this the main disadvantage this type, and which also precludes the use chill-cast rings. Ring Shrunk High Temperature These disadvantages are over- come the arrangement Fig. where the ground coned ring shrunk the ground coned bar- rel, which thus dispenses with means for securing and driving the ring. Laterally, the ring also bushed and keyed. But prevent the ring loosening getting hot rolling and slipping under high rolling pressure, essential shrink the ring fairly high temperature, which again prevents the use chill-cast rings. suit- able steel for these rings man- ganese steel 1.2 per cent. and about 0.5 per cent. special hydraulic stripper also required for removing the ring from the barrel after use. Further improvements are in- corporated the design shown Fig where the barrel made two parts, securely keyed to- gether after the roll ring has been mounted position. the diame- ter the barrel, owing its sec- tional design, can made smaller than the diameter the roll neck, more durable chill-cast rings can used than the two previous methods. the other hand, high-grade chrome-nickel must used owing the reduced diameter the barrel. the side the ring bushed and keyed. The FIG. single-roll composite rolls. ring does not run slack easily this arrangement the previ- ous ones, the heat evolved does not reach the center the ring quickly owing its greater width. Also, the four driving keys counteract slipping. The use rings reduces the machining the passes minimum, and the work entailed purely determined the dimen- sions the shape required. Re- dressing also limited the roll ring, and does not embrace the bar- rel. The cast the individual rings comparatively small, al- though the provision barrel with rings throughout its length would cost more than dressing and machining the roll itself. Mills which roll large quantities shapes and sections have adopted the use ring rolls from con- siderations economy, and have put with their various draw- backs. the other hand, other mills rolling only tonnage shapes still employ the direct dressing and machining the rolls. Recent Type Ring Roll more recent type ring roll, designed Hermann Irle, G.m.- b.H., Deuz-Siegen, claims rem- edy the disadvantages previous types, and consists essentially series integral ring rolls, shown Fig. The bottom roll provided with six separate top rolls Os, each which the ring located different point along the barrel. dress the rolls for particular section, the necessary pass cut roll and the corresponding part the barrel that only the shaded portion has machined. The second section provided with pass roll and its correspond- ing position the barrel and along the whole length Thus, for six sections seven rolls are required. More complex ring rolls have also been evolved for three-high and four-high mills, and with two more rings each roll, each ring being dressed and machined according require- ments. The cost turning and fin- ishing the rings reduced the minimum, while there also con- siderable saving roll costs against the old cylindrical rolls. The principal advantage claimed for these new ring rolls that rolls standard composition and dimensions can used, making these rolls suitable for all mills, and not only for those rolling shapes and sections. ‘ - + AA / erro Section A-B FIG. ring roll with four keys. THE IRON AGE, September 9 3 Welde locomotives, power plants and industrial and marine service, the Continental Motors Corpn., De- troit, building 10-cylinder ra- dial two-cycle Diesel engine, which develops 450 hp. 900 r.p.m. light weight essential, the crankeases are constructed weld- steel. They weigh 475 after machining, weight ratio slight- more than per hp. The en- gine itself, complete with all acces- sories, weighs 3900 ratio 8.66 Ib. per hp. Design the welded steel crank- case was developed the Conti- nental Motors Corpn., coopera- tion with Lukenweld, Inc., Coates- ville, Pa., the latter company also fabricating this part. The crank- case made two halves, the sections being split vertically and bolted together the engine as- sembly. Welding done with cov- ered electrodes under insurance procedure control and the finished structure thoroughly furnace stress-relieved. metal specimens deposited with the elec- trodes used fabrication showed use rail cars, switching 30—THE IRON AGE, September 1935 yield point 65,000 per sq. in., ultimate strength 95,000 lb. per sq. in., and elongation in. per cent. The front half the crankcase high tensile Lukens Cromansil RIGHT IGHLY the crankcase are made high-tensile Cro- mansil steel. weight ratio slightly more than per hp. ob- tained. BELOW ONTINENTAL radial Diesel engine with welded steel crankcase and sump and base, also welded steel. Steel Members steel and S.A.E. 1020 carbon steel. The rear half, which carries number bosses, also welded assembly Cromansil steel, S.A.E. 1020 carbon steel, and electric fur- nace stee] castings which were used form the periphery the cam pocket due the intricate contours involved around the rod guide bushing and the bolts tying the two halves the gether. The cast- ings were made units one per cylinder and the entire assem- bly welded into one ring, which inspected and machined be- fore welding into the balance the assembly. both sections the crankcase, tensile Lukens Croman- sil steel was used the main stress members, with carbon steel parts secon- dary importance. i} i tt | i i | 4a} iil 4 4 i} 4 i 3 | ‘cma | | q New The main ring, main web and all the ribs, which aid the transfer the cylinder stresses the main web, are Cromansil steel. mounting the Continental ra- dia] Diesel engines, was desir- able have some form oil res- ervoir carry the lubricant the engine. conventional method in- volved mounting the sump hol- low base, subsequently filling the base with concrete and grouting the entire unit foundation order provide stable mass. Such arrangement, however, would inconvenient that once the unit mounted would dif- ficult unmount and the entire installation would lose much its advantage taking high de- gree permanency. Solution the problem was found combined base and oil sump which weighs 8240 Ib. and which the sump welded stee] plate base in. thickness. The desired mass was thus obtained and the complete assembly base, tank, engine and generator then set down upon nest springs, giving floating mounting and pre- Radial Diesel combination sump and base, the sump welded plate base venting any vibration from reach- ing the building. The unit remains portable, since its mass movable, thick. and the material used obtain the mass can salvaged, because 4-in. plate has value any time. Soaking Pit Trolley Fabricated Welding ELDED steel construction employed the Shaw- Box Crane Hoist Co., Muskegon, Mich., building the soaking pit trolley shown the ac- companying illustrations. 15- ton capacity, this trolley used large steel mill for travel- ing over soaking pits and lifting the covers. One illustration shows the frame. The arched section made 3-in. steel plate. The main girder so-called four-sided box construc- tion, utilizing flame-cut plate with heavy wide flanged dia- phragms inside. These are welded integral with the side members. THE IRON AGE, September 19, > q | 4 i a | | | | 3 ‘is atl | > . The bevel gear box bracket and housing unit completely welded from 1-in. steel plate. The trolley driven electric motors high torque with asbestos insulation and slot insulation mica. The complete trolley with motors mounted place shown the second illustration. The rail gage the trolley ft. in. stated that using the welded construction strong, rigid frame light weight was obtained, and the cost complicated pat- ° ° ° frame this soaking pit trolley shown the pre- ceding page. made 3-in. steel plate, and the main girder, box construction, utilizes flame-cut steel plate phragms inside. The complete trolley with its high-torque electric place above. ° ° terns was avoided. The many sepa- rate parts the steel frame are joined into one integral unit with- out intermediate connecting mem- bers. The illustrations are courtesy the Lincoln Electric Co., Cleveland, whose shielded-arc equipment was used the welding. Steel Walls Add Beauty Republics New York Offices Tom Girdler, president and chairman, Republic Steel said that “the growing adaptability steel new purposes en- able supplant other materials infinite variety fields.” THE IRON AGE May 30, 1935, one indication the “grow- ing adaptability steel new 32—THE IRON AGE, September 1935 purposes,” probably finer ex- ample available than the new New York offices Mr. Girdler’s company the Chrysler Building. All the walls—Masterwalls Hauserman including the strik- ingly handsome entrance doors and lobby, are built entirely steel. For many years the Hau- serman Co., Cleveland, creators movable steel Masterwalls, have concentrated the idea that walls steel are not only thoroughly practicable and far superior various other types inclosing walls and partitions, but actually are far superior from invest- ment cost standpoint. - , 4 — | 4 | | i | | i | | | | | } } Steel manufacturers, heretofore, have been rather indifferent to- the unquestionable and de- finitely proved advantages mov- able steel partitions, and many them even now are occupying office and factory buildings where other types partition have been used, and sooner later will have demolished financial loss accommodate in- evitable rearrangement and changes which will have made. The beautiful entrance door rep- resents the last word attractive practical adaptation stainless steel for door construction. Passing through the entrance door one instantly impressed with the magnificently executed treatment the lobby. The walls are finished grained hare- wood with stainless base and cornice, attractively and striking- set off with horizontal bands stainless steel around the room. The rest the entire suite, seven offices, and conference room, has grained finish. The in. all-steel Masterwalls between the various offices are soundproofed rockwool-filled—and are more sound-resisting than tile and plaster wall practically double their thickness. All the exterior walls are wainscoted the same handsome walnut grained finish, are the splendidly executed window em- brasures. installations, all wiring conceal- within the walls, and yet almost instantly available for changes case wire trouble. the telephone room truly unique feature. The new Hauser- man Acoustiwall—a steel partition with built-in acoustical treatment —has been effectively used cor- rect and control the acoustical con- ditions ordinarily such problem interiors this kind. The Hauserman Acoustiwall per- forated metal surface backed with thick pad sound-absorb- ing material. functions identi- cally the same manner perfo- rated metal ceiling treatment. The Acoustiwall, like the rest the in- teriors, has grained walnut finish and the perforations are almost imperceptible. using steel walls throughout its offices the Republic Steel Corpn. when, and should ever decide relocate elsewhere can readily—and with loss whatever Hauserman Masterwalls and load them the moving truck with the rest its furniture for reerection new quarters. tile and plaster similar so-called permanent walls had been used, when the time came for rearrangement mov- ing out the walls would have completely demolished with 100 per cent loss the investment, plus cost removal debris. High-Production Press Suitable for Follow Dies Considerable Length BLISS CO., Toledo, Ohio, has added its line the high- lustrated, which has width in. between housings, adapting use follow dies consider- able length. The machine rated from tons, depending upon the char- acter and duration the load. regularly arranged with mul- tiple-speed variable-speed drive for operating speeds 250 300 strokes per min. for the non- geared machine and 150 175 strokes per min. for the longer stroke geared machine. Long die life—a valuable fea- iad 4 ture where expensive multiple-op- eration tools are used—is attribut- use heavy sections, special gibbing highly accurate type, the double crank construction with heavily ribbed crown, shrunk-in tie-rod frame. Equip- ment high-speed type double roll feeds, substantial scrap shear with blade clearance adjust- ment, spring counterbalance for the slide, and automatic force feed lubrication; also foot-controlled starting mechanism, which em- phasized for efficient production strip feeding and convenience starting and re- starting coil stock. q a high-speed production press, patented new design, adapted for follow dies considerable length. die life attributed use heavy sections. highly accurate gibbing and other THE IRON AGE, September 19, } i : | | | Both New Design and Improved Models Feature Kearney Trecker Line dustrial activity, for more and better controlled production, Kearney Trecker Corpn., Mil- waukee, has entered the field with new milling machines. the field light work and 3-hp. machines feature rapid production, while 3-hp., No. light, plain uni- versal and vertical tool room mill- ers are provided for the require- ments jobs within that field. Model high speed machines now have front and rear control with new model dividing head and new astronomical divider. Hy- draulic feed, with two-way cycle made optional feature bed- type machines. announced that practically the national machine tool in- every machine the entire line both knee and column type ma- chines has been either redesigned supplemented entirely new The new No. manufacturing knee-type, model arouse interest because their “Midget” size. The distance from the spindle center the floor ft. in. Their utility for small parts large quantities. “Midget” machines are built two sizes, powered 1%- hp. motor, and No. powered 3-hp. motor. There op- tional power rapid traverse for table, either 150 300 in. per min. Characteristic, two steel bar over- arms are employed. Both “Mid- get” are equipped with hydraulically controlled screw feed, Production automatic two-way cycle and auto- matic spindle stop. Sixteen spin- dle speeds, the quick change gear box type with three optional ranges, are provided. Anti-friction bearings are employed throughout. No. light, high-speed machines, model for general manufacture and toolroom service light oper- ations are powered with 3-hp. mo- tors and are available plain, universal and vertical types. They have quick-change speeds with two optional ranges. Sixteen feeds have single dial control with three feed ranges. new line model high- speed, wide-range, knee-type ma- chines represents entirely rede- signed line. Duplicate front and rear control provided for both hand adjustment and power feed operation. new safety feature The new model manufac- turing Milwaukee miller shown below for small parts large quantities. Dis- tance from floor spindle only ft. in. The miller pictured the left, the model new high-speed, wide range machine featuring front and real control. \ at a | a j } 34—THE IRON AGE, September 1935 provides positive interlock hand-crank hazard when power feed rapid traverse engaged. Twenty-four spindle speeds are provided one continuous series approximate geometric progres- sion without overlapping. Speed selection made single lever and large direct-reading dial. The lever may rotated either clockwise anti-clockwise. The method selective and not progres- sive when dropping back lower speed. There are feeds con- ti