The Iron Age 1935-12-12: Vol 136 Iss 24

Owned, Published and Copyrighted CHILTON COMPANY (Incorporated) Executive and Publication Chestnut and Sts., Philadelphia, Pe. MUSSELMAN, President FRITZ FRANK, Executive Vice-President Vice-President FREDERIC STEVENS, JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary CHESTNUT AND S6TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, FRITZ FRANK, President VAN DEVENTER LACHER Managing Editor Emeritus News Machinery Fiske Chicago Cleveland Washington Pittsburgh Detroit Boston —December 12, 1935 They Did Not Wait for the Lightning.................. The Pressed Metal Washington News Statistics Metal Working Activity. Construction and Equipment Buying Products Advertised ..... 116 Index Advertisers. BAUR, General Advertising Manager DIX, Manager, Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF Emerson Findley. 311 Union Bidg., Cleveland B. L. Herman, 675 Delaware Ave.. Member, Associated Business Papers Published every Thursday. Hottenstein, 802 Otis Bidg., Chicago tion Price: United States and Pos- Peirce Lewis, Woodward Detroit sessions, Mexico, Cuba, $6.00; Can- Charles Chilton Chestnut W. C. Sweetser. 239 West 30th &t.. New York For Immediate Shipment Ryerson plants Chicago Jersey City Milwaukee Boston St. Louis Philadelphia Cincinnati Buffalo RYE IRON AGE, December 1935 i} | ‘ i? | | | eae ea i} ‘ THE IRON DECEMBER 1935 ESTABLISHED 1855 Vol. 136, No. The Political man can freely and impartially discharge his duties citizen long sup- ported through the payroll political government, long his daily bread comes hand-out from that government, long the amount and character the crop plants, the business does, subject political control, long his operations are dependent contracts financed government money, long his sources credit are controlled political forces, long his home his business subject mortgage held government. There infinitely more danger human liberty being sold for glittering baubles than there its being lost through defeat battle. With the advent the present Administration, led and manned almost entirely men who have never produced dollar's worth real wealth their lives, has come definite declaration that the principles upon which the American nation has been built are failure; that they must cast out; and that for them must substituted principles imported from abroad and alleged new, but matter fact, old human history, truth, the very principles from which our forefathers fled this country. has been repeatedly charged that the reason have suffering and want because have produced too much wealth, and that the way correct the situation destroy that wealth, that may all poor to- gether; has been repeatedly charged that the business man, the leader wealth creation, responsible for the depression, and that the way get out handicap every way possible those who are responsible for producing the things need; has been repeatedly charged that the average man longer able take care himself, that longer capable planning and directing his own life, but that this must done for him govern- ment, through bureaus and commissions appointed politicians. WELLS UTLEY *From address before National Association Manufac- turers, Dec. See Page 37. President, Detroit Steel Casting Co. Because the many requests for reprints editorials appearing Tue Iron the publishers have ar- ranged make such reprints available any quantity desired price representing cost production and mailing. Please address Reader Service Department, THE 239 West 39th St., New York City. 3 3 4 . i rig = - f | i 2 4 * a i the stem the yoke tail strut for airplane the atomic hydrogen welding process. The axle also welded the yoke. KEEPING pace with the rapid advance the aircraft industry, which has resulted the construction stronger, speedi- er, better controlled and safer air- planes, highly specialized indus- try that field, supplying landing gear shock-absorbing equipment, has devised better shock absorbers protect the plane itself from se- vere shocks taking off, landing and taxiing, thereby providing com- fort for the passengers and pilot and preventing casualties and dam- age during landings under most dif- ficult conditions. Alloy steel high tensile strength, atomic welding, expert heat treating, precision machining and plating, combined with engi- neering skill, have all contributed the construction better shock- absorbing struts, outstanding fea- tures which are strength com- bined with lightness. 20—THE IRON AGE, December Important development work airplane shock absorber construc- tion has been done the Cleveland Pneumatic Tool Co., pioneer this field and the largest manufacturer airplane struts. The manufac- ture Aerol struts this com- pany development growing out its manufacture air springs and shock absorbers for buses, trucks and passenger cars, which naturally much more extensive branch the company’s business because the number land ve- hicles compared with airplanes. Atomic Hydrogen Welding Used Welding plays important part the manufacture airplane struts the company’s plant, where not only are end terminals, fittings and brackets joined welding, but the thickness some tubular sec- tions built laminations ap- plied welding. This done Manufacturing Struts PRENTISS Cleveland Resident Editor, The Age ° stiffen the members, increase strength where needed and per- mit the use lighter sections than otherwise would required, that parts are provided with ample strength without any excess weight. Nearly all this welding now done the atomic hydrogen proc- ess, which the company recently substituted for gas welding, except for making joints points which cannot reached with atomic hydrogen torch. For this produc- tion welding stated that the use the atomic hydrogen welding process has resulted better welds and increase speed welding ‘without adding the welding cost. Struts Are Telescoping Cylinders Airplane struts are located be- tween the axles the wheels and the fuselage. These, made the Cleveland company, are tele- ' 1 scoping cylinders. Within outer cylinder piston and valve mech- anism which the more common type are actuated compressed air and oil. When the wheel strikes the ground the blow transmitted the piston, which telescopes into the cylinder, building resistance moves and thus cushioning the shock. While each design strut ad- heres similar mechanical fea- tures, each type plane calls for strut different shock-absorbing capacity. Shock absorbers are de- signed meet the requirements each particular design air- plane, and these requirements are developed dynamic drop tests which show the amount energy absorption needed for strut for each type plane. The strut de- signed take care the fixed max- imum load the airplane when the plane landed maximum ver- tical velocity. These dynamic drop tests show inches compression the capacity the strut dissipate energy. Struts Are Made Chrome Molybdenum Steel All parts the strut are made 4130 chrome molybdenum steel. Analysis this steel, which made 0.35 per cent carbon, 0.40 0.60 manganese, 0.040 maximum phos- phorus, 0.80 1.10 chromium, 0.15 0.25 molybdenum and 0.15 mini- mum silicon. The cylinders and pistons are fabricated from seamless steel tub- ing. The shock absorbers range extended length from in. ft. The pistons range from in. in. diameter with wall thickness all metal Lockheed transport plane. TRONGER, better controlled and safer airplanes necessarily call for improved landing gear shock-absorbing equip- ment. The manufacture airplane struts has accord- ingly reached high point perfection. the plant here described selection materials, the use atomic hydrogen weld- ing, accuracy machining and the plating some the finished members play important parts the pro- duction airplane struts the most modern design. speedier, 1/16 in. for the smallest piston in. for the largest. Chemical analyses all steel used are made after reaches the plant. The stock the annealed form which received has tensile strength 90,000 Ib. per sq. in., Brinell hardness 177 180 and Scale Rockwell hard- strength increased subsequent heat treatment 150,000 180,000 Ib. for production work. The hard- ness with 180,000 Ib. tensile strength increased 377 Scale Rockwell. While the chrome molybdenum steel has been brought higher tensile strength heat treatment, not found practical use material having tensile strength excess 180,000 Ib. per sq. in., because the difficulty machining and the necessity cut- ting down the feeds and speeds cutting tools. The steel cut length, after which rough-machined. These machine operations include turning, shaping, milling and grinding. From 1/16 in. in. thickness metal left for subsequent removal after heat treating correct ir- regularities caused distortion. Advantages High Welding Temperature Welding with the atomic hydro- gen torch follows the rough-mach- ining operation. The welding re- quirements are rigid, most welds must non-porous withstand the pressure oil and air. The weld- ing rod that used the same analysis the steel that being welded. With the higher tempera- ture the atomic hydrogen flame, which 6000 7000 deg. compared with gas flame tempera- ture 3500 deg. F., the metal brought the fusion point more rapidly than with the gas flame, welding done more rapidly, and the heat more localized, not hav- ing time radiate into wide area when the gas flame used, The excess hydrogen gas forms shell around the flame, preventing the air from coming contact with the molten metal and thus prevent- ing oxidation and the scaling effect causes. Dirt does not get into the metal, and smoother and better welds are produced, which have greater strength because burning the welds prevented the exclusion oxygen. Atomic hydrogen welding for this class work proving satisfac- tory from the standpoint costs. While the welding cost per inch greater than when the gas welding process was used, the increased speed welding, stated, offsets the higher cost operating the 4 7 3 q 4 3 4 | ¥ x pis : é | ~ 4 J atomic welding equipment, that the welding cost approximately the same when gas welding used. Heat Treatment Follows Welding The parts are heat treated after welding increase the physical properties. This done Homo electric furnace. Most the work heated 1650 deg. being kept the furnace from min. The parts are quenched oil and drawn around 800 deg., depending the degree hardness required. The tubular members are placed vertical position both the heat- ing furnace and quenching tank reduce the danger distortion. The work sandblasted after heat treatment and before finish-ma- chining show surface conditions defects that have developed dur- ing heat treatment. Surfaces previously given rough- machining operations are then fin- ish-machined take out the distor- tions caused during heat treating. these machining operations, which include turning, grinding and WENTY-FIVE more required joining the members the main leg strut for Burnelli transport plane. 22—THE IRON AGE, December 1935 HIS shows the mechanism the retractable landing gear bi-motor Lockheed Electra, transport plane made the Lockheed Aircraft Corpn. some milling, 1/16 in. in. excess metal left the surface during the rough machining opera- tion removed. The increased hardness the steel after heat treating necessitates reduction per cent the speeds and feeds the machine for the finish- ing operations. The cylinders and pistons are ground the outside and inside, although there ex- ception this procedure that some the pistons are not ground the inside. During the grinding operations 0.008 in. 0.010 in. metal removed. Bearing surfaces and bores are held 0.0005 in. the finish grinding operation. Very Thin Sections Are Precision- Ground Precision grinding the tubular walls the cylinders and pistons | i he 4 4 7 | > are rather difficult grinding opera- tions because the amount sur- face ground, the necessity maintaining uniform wall thick- ness and the thinness the wall which makes necessary handle much the work arbors during grinding. Some the cylinders and pistons are in. long and about in. diameter and are ground externally their entire length. The wall thickness some these long tubular sections when finished less than 1/16 in. The cylinder mounted two centers and ground externally Norton grinding machine. Then and ground internally Heald machine. grinding very thin sections only 0.0003 in. metal removed during each pass the grinding wheel. Broaching Struts the Spline Type Broaching operations that are — particular interest because the length the cuts, the thickness the wall and the the steel are performed making recently developed struts the spline type. These are two designs. One has spline the inside the cylinder extending the full length that the piston travels and small male spline the piston head. The this type shock absorber for Seversky airplane landing gear other model has short spline with- the terminals are welded the piston the main and tail strut. grinding the outer sleeve for Lockheed Electra transport plane. Tubular members in. long and with finished wall thickness 1/16 in. less are ground this machine. THE IRON AGE, December 12, 1935—23 4 ¥ . 3 ; ay { i - for airplane strut. LEFT keyways in. long are rough- broached internal spline for new type shock absorber Oil- gear horizontal broaching machine, the piece being mounted fixture. the cylinder and long spline the piston. Ten keyways 10% in. long are rough-broached spline with Oilgear hydraulically operated horizontal broaching ma- chine with keyway broach having teeth. The tube mounted indexing fixture for rotation after each the ten cuts. The tube supported mandrel having slot through which the broach moves. After the rough- broaching, the mandrel removed and the splines are finish-broached with round broach having ten rows broaches with teeth and with which all the finishing-broach- ing done one operation. Dur- ing the roughing broach 0.1525 in. metal removed and during the finish-broaching 0.050 in. This broaching practice applied broaching the long spline. For splines shorter lengths and cylinders smaller diameters (CONTINUED PAGE 94) 24—THE IRON AGE, December 12, 1935 od | ABOVE ANUFACTURE fab- ricated composite dies and punches from torch-cut tool steel and machine steel plate described briefly this paper, presented Mr. Janiszewski the recent fall meeting the American Welding Society, cago. Construction, heat treating and advantages these dies, the largest appli- cation which for ing operations, are outlined. WHEN the die builder confronted with the problem building blanking die, always should his desire incorporate long life, quality, simplicity, safety, and economy manufacture the construction, and yet provide for salvage value the event change design obsolescence. Attempts the past produce dies having these advantages have not been successful including all the foregoing. After years development and experiment, our company fected process manufacturing composite punches and dies which embody these valuable character- greater degree than heretofore. Our method based Blanking Dies JANISZEWSKI President, Superior Steel Products Corpn., Milwaukee ° primarily the ease and accuracy with which shapes machine and tool steel may cut oxyacety- lene machines, that they can nested and welded together with- out expensive fitting. Components Torch-Cut From Plate The construction these fabri- cated composite punches and dies illustrated Fig. The die may any shape and practical- any size suit the require- ments. The inner section the die and outer section the punch have rectangular bar cross sections and are cut from tool steel plate oxyacetylene cut- ting machine. The outer section the die and inner section the punch are machine steel, also cut out with the machine torch. Airco-DB Oxygraphs are used for this work our shop. Cutting the inner tool steel section fabricated composite die with oxyacetylene cutting ma- chine pictured Fig. will noticed that the operator guides the hand tracing device around the outline drawing placed the work table. The machine cutting torch, mounted the same bar the tracing devicé, describes motion identical with that the latter, thus cutting out the desired shape. variable speed motor drives the tracing device, permitting correct adjustment cutting speed suit any thickness being cut. The thicknesses tool steel and machine steel used the die and punch are determined the thick- ness the stock blanked and the number pieces required. The punch may niade with solid center with opening the machine cteel, whichever best suited the need. Members Joined Welding The die assembled insert- ing the tool steel ring strip through the ‘machine steel sup- porting member and fabrication gether all around. The tool steel ring strip for the punch placed around the machine steel supporting center and welded similar manner. Note particularly the enlarged view the welding welding extends through the entire thickness the machine forming homogeneous unit both machine and tool steel which indestructible. Actually, these composite dies and punches constitute adapta- tion the use the most modern arts first cutting dissimilar steels with the oxyacetylene torch and then joining them welding produce complete fabricated composite unit. The use the machine cutting torch makes THE IRON AGE, December 1 be 2 ; Ring Die -Weld trating the construc- tion fabricated composite punch and die. The inner sec- tion the die and the outer section the punch are torch- Weld cut from tool stee! Section through A-A Machine Center possible cutting closely the re- quired shape, with but approxi- mately %-in. stock allowed where finish required. typical example composite die and punch shown Fig. The punch (above) appears before the finishing operation. The die appears after the roughing cut has been made, ready for fitting the blank size. They are designed for blanking 5/32-in. thick stock. Machining and Hardening Operations Both punch and die are fur- nished annealed and with all sur- faces ground flat. Layout can made quickly from template blueprint and machining started once. Because the allowance but approximately in., the ma- chining operation fast and eco- nomical. Naturally many hours are saved compared with drilling otherwise cutting the die and punch from solid block tool steel. After machining the proper size, both the fabricated composite punch and the die are hardened the regular way. This procedure hardens the tool sections, but the machine steel supporting mem- bers remain relatively soft. The steel used for these dies and steel. hardens water 1450 deg. F., and produces extremely hard cutting edge (about Rock- much 100 deg. overheat will still produce fine grain struc- ture this tool steel and hard die. This makes unnecessary IRON AGE, December 1935 2—Cutting tool section die with oxyacety- lene flame cutting machine. The tracing device hand around the out- line drawing the work table. depend the extreme accuracy calibrated pyrometers harden- ing. The amount shrinkage can closely estimated, being vir- tually uniform 0.001 in. per linear inch size. Distortion. Corrected Without Grinding commonly known, tool steel has tendency change its shape distort during hardening. solid tool steel die, these changes may corrected only grinding, greater amount stock must allowed providing for the change distortion. the fabricated composite die, the distortion which may occur during the hardening process can corrected with relative ease squeezing stretching without damaging it, thereby restoring the proper shape and size. Sharp cor- ners long projections need longer feared where fabricated composite dies are used. With the latter there danger that the die will cracked hardening, the tool steel reinforced and held the machine steel supports surrounding and welded it. The same refers fabricated com- posite punches. the illustration (Fig. shows, drilling for mounting screws and dowels both die and punch located the machine steel section the composite con- struction. the machine steel re- mains soft this work may done after the die and punch have been hardened and finished. This eliminates the inconvenience lo- cating these holes, with solid tool steel die. The necessity lap- ping dowel holes assure good fit avoided. Furthermore, the screw holes may drilled either the die shoe the composite, whichever most suitable. Adaptable Alteration When the engineering depart- ment company effects change the product, the outcome fre- quently that one more new dies will required. Sometimes existing dies can altered suit. However, these are the solid steel type they must reworked and rehardened, usually resulting inefficient and unsatisfactory die. the other hand the dies are fabricated composite con- struction, the die maker can re- move any section them without annealing, fit redesigned section and secure place with screws and dowels short space time. Thus the alteration may made retaining the qual- One Piece Machine | One j . | ity the fabricated composite die minimum cost. case obsolescence, solid tool-steel dies are either scrapped entirely stripped down and much the tool steel saved appears warranted. Whether not actual saving can ef- fected most cases doubtful. Fabricated composite dies which have become obsolete, however, often can cut apart and the us- able sections remounted without annealing new die shoe, to- gether with some new other salvaged sections form satis- factory new die. This practice effects considerable savings ma- terial. addition, even greater amount saved because less labor required convert the obsolete composite die sections into new die, retaining the same time the original quality. More than this, when mounting these obsolete sections, new screw holes may drilled either the die shoe composite order avoid old holes which otherwise would cause interference. Thus the possible salvage the old die shoe also effected. Suitable for Forming Dies While the greatest application these fabricated found blanking dies, there are many forming operations for which they are also suitable, not only from the standpoint simplicity but due their inexpensiveness well. These cases come light with greater frequency users be- come more familiar with the fab- ricated composite dies savings material and labor costs effected building them. Fig. illustrates another type fabricated composite die and punch for blanking automobile spring covers, shown the top the picture. This die considerably larger and more complicated than the one described. In- deed fabricated composite dies almost any size and intricacy de- sired can constructed. They are, anything, less subject limitations than other types. Inspection this die will re- veal that the tool insert does not all the way the bottom the 3-in. thick machine steel sup- porting member, but fits into re- cess the latter and fillet welded all the way around. This indicates further possibilities the fabricated composite type 3—Typical fab- composite punch and die de- signed for blanking 5/32-in. stock. The before the finishing operation, and the die appears after the roughing cut, ready for fitting the blank size. 4—Fabricated composite punch and die for blanking automobile spring covers. The tool steel insert does not the bottom the porting member, but fits into recess the latter and fillet welded all around. construction when good engineer- ing practice indicates departure from the method shown previously. Advantages Summarized conclusion, the principal ad- vantages fabricated composite punches and dies may sum- marized follows: composites save from per cent the net cost building. 2—The consumer pays for less ma- terial, does not buy holes excess material because odd shapes. 3—-Highest quality punches and dies are obtained lower cost. 4—Practically anything required shape size can secured. fabricated com- posites usually are made from the factory the second day after receipt order. sized fabricated com- posites are shipped the next day after order received. 6—A minimum machining hours required finish composite punches and dies, because their closely cut shape. element risk eliminated practically impossible crack com- posites. can corrected with- out expensive grinding. 9—Composite die cutting edges are harder, because the use high- grade water-hardening tool steel. 10—Any thickness material that blanked with solid tool-steel dies can blanked with composite dies also. composites can altered required without reharden- ing, and can salvaged lower cost. THE IRON AGE, — ‘ _ | « ; = HIS the article which won second prize our recent Modernization Con- test. While told inter- esting fictional manner, based entirely upon fact. The presented are based upon actual results obtained. was late the afternoon when William Kennedy, general man- ager the Universal Products Co., leaned back his chair. “It’s shame fellows!” remarked with air perplexity. “Here are, faced with pros- pect business revival, and orders increasing rate that will soon reach our present ca- pacity. But costs too much manufacture considering the 28—THE IRON AGE, December 12, 1935 prices can get for our product. Since 1929 have taken many machines out service, avoid buying new parts, that our actual capacity only about one- half what was. should carry out the modernization plans made 1929 but all our figures show will cost much now thought would then.” “It looks that way, but still don’t believe Charlie Hood, the plant manager, replied. “George, why you think will cost all this money bring our plant date?” George Johnson, the chief en- gineer, replied slowly, “There are several reasons. you know, operations require special machin- ery every process. cannot write manufacturer and ask him quote.us standard machine. had design and develop them ourselves. the concerns LESLIE BRYANT that built our machinery the past, find only few are main- taining more than skeleton or- ganization. Those that have quoted say their high prices are due the fact that their labor costs have gone up. They can only employ men when they have jobs, they have big labor turnover. The estimates provided our own shops are higher than the outside prices. The boys blame ob- solete and worn out equipment.” “You mean say that get lower equipment prices, either have buy new equipment for our own shop, solve other shops’ labor problems for them?” de- manded Kennedy. “That’s about it. not favor trying solve other plants labor problems, but would like have Mart and Harry tell their side the story.” Turning the phone called the shop have the two men come the office. few minutes Martin Web- ber, the master mechanic, and Harry Underwood, the machine shop foreman, came in. The prob- lem had been discussed the En- gineering department, were ready tell their story. Not Wait for the When Rising Costs Burned Their Fingers This Plant’s Officials Turned Modernization for Rescue can’t reduce these esti- mates for building this machinery want,” demanded Kennedy. “We should build them for less our own shop.” “It isn’t our machines any more,” expostulated Webber. weren’t allowed spend any money repairs from 1930 machine that can accurate job even twice the time formerly took.” “Yes,” added Underwood, “and are still trying use about half the machines bought dur- ing the war for that government contract.” “And used that made our machines out cast iron and soft steel. Now the engineers want us2 welded steel construction and alloy steel parts. The machines have simply won’t the same time. I’ve asked for new equipment but have always been told, can’t afford now. Can’t you get along without it’?” Webber was getting out all his defensive armor. Kennedy flushed, “Yes, Webber, made that statement several times, but still would like shown how new equipment would reduce our costs. Who has done that way?” Underwood Suggests Visit machine tool salesman told the other day that the machine shop superintendent the XYZ Steel Co., Steelville, has put lot new equipment, and that ought see how has been re- ducing costs.” Underwood sug- gested. “He seemed think would have no.trouble getting him show what has done. over there and see.” have heard that Dick Brown was doing real job over there,” was Charlie Hood’s reply. can arrange it. Dick Brown and used play football together down State, and know would glad tell about it.” for the group spend the day the XYZ machine shop. Dick Brown met them the train, and escorted them the plant. “Charlie,” jibed Dick, believe you are turning gray above the ears. costs have anything with it?” “Yes, probably,” Charlie smiled ruefully. “We are all worried about the special machinery need. can’t afford pay have built, and can’t afford build our- selves. hope you can give some light.” “We have reduced our costs. It’s long story, Charlie. Suppose the baleony where can get general view the shop.” They were soon standing bal- cony overlooking the main part the shop where the heavier machin- ery was located. orderly layout planers, large lathes, radial drills, boring mills, gear cutters and slotters met their view. Ma- terial was neatly arranged front the machines. Definite aisles were marked out, and everything seemed its place. their backs they could hear the hum activity the lighter machinery the shop. Blue Chips Catch Eye Harry’s eyes kindled watched vertical boring “Look, Mart, how that fellow hogs into that piece steel.” Mart nodded. watching that planer. Those are the first blue chips I’ve seen long time. And look the size them.” Kennedy turned Dick Brown. “How you make your machines run like that when ours always break down when insist that they speeded up?” “When came here five years ago had the same problem. knew what machine tools could do, but every time tried some- thing broke down. first attempts sell the management new equipment did little but lay foun- dation for the time ‘after turn the wrestled with the problem for about year, took some the slack, but made little real progress. Then had fire the other end this bal- cony. in. gas line broke, caught THE IRON AGE, December 1935—29 Pee | ‘© 4 f q { q 4 on 3 | | 4 ‘ a fire, melted in. air line, making beautiful cutting torch. was brought under control, but not until two lathe beds had been cut half. There was nothing but replace them.” “Our purchasing agent would have brought all the second hand machinery dealers this end the State,” broke Webber. “We did have that problem,” smiled Dick. “But had some clean cut examples the savings that could made with new equipment. The manufacturers backed estimates with guarantee per- formance. was allowed purchase two new lathes with the tool equipment wanted.” “Were you actually able show the savings you predicted, asked Charlie with interest. Example Furnished Good Argument saw that did get re- sults. Not only the first few days, but every day for months. meant lot hard work seeing that there were always jobs worked on, that the men had proper tools, that there were complete instructions for doing each job, and the proper feeds and were used. After three four months had all the arguments needed for that verti- cal boring mill that Harry watch- ing. This time was little easier, and also got that radial drill over there. One machine led another, until now have replaced nearly two-thirds our machine tool equipment. The last four years have worked harder than ever worked before, but was fun after started going places.” “How much did you reduce the time for some the operations you do?” asked Harry. “Can you point out some examples?” “Sure thing,” Dick replied, turn- ing machine near him. “On this No. Warner Swasey turret lathe are doing job weight stops that formerly did engine lathe about hour each. now make lot ten two hours. The actual time per piece six minutes, and requires about hour set the machine.” didn’t know you could run turret lathe such small lots,” Charlie Hood exclaimed. thought you had have least hundred pieces make them pay.” “We run them lots six pieces where the set time less than 30—THE IRON AGE, December 12, 1935 hour. have found our work here that set time impor- tant item. set job quickly the operator must spend most his time putting tools and setting the cuts. You can’t have him hunt- ing attachments tools.” “Do you grind the tools for your men?” Webber asked. “All our tools are ground the central tool room. common practice grind milling cutters and special form tools the tool rooms, but when put Sellers’ tool and drill grinders had quite edu- cational problem our hands. had the men convinced this time were trying help them, soon put the idea across. The time required for hand grinding frequently depends upon the man’s social obligations. developed series standard tools and grind them all machine. You can machine grind tool from one six minutes where hand grind- ing requires from ten thirty minutes.” “Here this in. Lodge Shipley engine lathe are turn- ing roller hr. and min. The year old lathe that the fire destroyed took seven hours.” “Over here this in. Gould Eberhardt shaper are doing slide bearings hr. each that used take hr. old in. shaper had. believe was least ten years old. Some our machine tool records were rather hazy.” Stepping the rail again pointed the vertical boring mill again. “That piece that vertical gudgeon for the end pipe roll. the in. engine lathe the best ever did was one every hours and frequently did worse. That little Italian down there turning them out regularly min. apiece. That in. Bullard vertical turret lathe.” “How did you know you could get these results before you bought the machines?” Kennedy inquired. Estimates Helped had pretty definite ideas de- rived from past experience, but get some moral support sent some blue prints few typical parts some the machine tool manufacturers. They sent some excellent detailed estimates that are big help selling the idea. Their forecast performance generally very accurate you run the machine recommended. They not attempt estimate set time, that frequently has local factors beyond their control. The taking preliminary time studies may aid arriving savings made, although not favor its use that manner except when you want window dress your argument.” “How these machines handle some the newer and tougher steels that have been developed?” asked George Johnson. “We want take advantage some the properties the newer steels, but our machines slow down painfully when try use them.” “The machines have bought were obtained with just that mind. true, some the tougher alloy steels will slow the machine down some. another angle problem though. Have you ever considered specifying material basis its machinability, and doing more heat treating? There real saving tween the two points view. When machine alloy steels our cutting tools give more trouble than our machines.” They spent several hours moving about the shop studying the ma- chines, the layout, the toolroom, the method despatching work, heat treating and other features. Somewhat tired they stopped Brown’s office look over some the production records and costs. Still Room for Improvement “Do you consider your shop completely modernized, Dick?” asked Charlie this point. “No, there are several positions our line-up that are weak. was the Machine Tool Show Cleveland recently, and believe those boys have been busy. Practically every exhibit had some- thing new offer you stopped and looked for it. Many the new features were self evident. going apply some soon can.” “This shop looks No. me, wouldn’t know where start improve it,” exclaimed Mart. “One problem that looks good this: Our company sells cold drawn flats and frequently get orders for odd sizes. Where the quantity ordered the delivery time does not justify special dies draw the next width larger, bring the stock over that long } i 7 | i | i | | | i } | ~ ° planer you saw and stand the stock edge fixture and plane size. That in. ft. planer has worked kind work per .cent the time for the last years. saw Sellers planer Cleveland cutting both the forward and return strokes. can cut our time half that job. would get the same size machine. have planers the shop now, and be- liev2 could take out two and install one.” “How would you figure your sav- ings this machine, Dick?” Char- lie inquired. haven’t figured this machine out exactly because wrote for quotations yesterday, but here are some rough figures jotted down that tell the story: Present machine hour rate in. ft. .... $2.45 Present machine hour rate Total rate for two 4.50 Cost new planer ........ 30,000.00 Yearly depreciation ........ $1,500.00 Daily depreciation (275 day Hourly depreciation hour Proposed machine hour rate Hourly savings ..... 1.37 Interest $30,000 per A\nother for HIS weather-proof tennis net, Allegheny manufacture, made stainless steel drawn wire, woven into chain link fab- “There probably greater sav- ings than that, because use night man that machine quite frequently, and have not con- sidered it. “In studying the route our parts travel through the shop find have quite bit work that planed first and then bored the horizontal boring mill. The parts are mainly bases, housings, bear- ings, frames and similar pieces. When looked the Gray Milling planer saw wonderful oppor- tunity eliminate some the set-ups required these parts. You can mill and bore both hori- zontally and vertically, and some drilling where would save extra operation and moving the piece. imagine the cost figures would very similar those the planer just showed you. going take keen operator take advantage all the possibili- ties the machine. have been surprised the number jobs boring mill, that take longer set than they machine. And when you save set-up that work you save three four hours shot. Then, too, there are many jobs that you can mill faster than you can plane. “We have considering grinding method finishing work our shop. present not great deal it. But some > ric the Page Steel Wire Co., Monessen, Pa. The net not only of- fers unusual features utility, but also practically eliminates “fluke” the grinding operations saw convinces can much more it. not have all the data want present, but think will make the plunge six months so. You know hard start new method machining and get going right, but our fellows are used adapting them- selves newer conditions, and that half the battle. “Do you know that after had put few new machines and got them operating the way they should, there was decided improve- ment the operation our older machines. seemed that even man could not run one the newer machines, got thrill out working beside one.” There was more discussion, and then the Universal Products Co. group thanked their host and hur- ried their train. After dinner very little was said. All were deep thought. Mr. Kennedy finally spoke, “Well boys, for some reason feel better.” “Well, Mr. Kennedy, what Dick Brown has done, believe could do,” was Harry com- ment. you feel that way, Harry. you think you could see through the finish, and not satisfied with half-way job?” try.” Steel tennis services and return shots. Its resistance weather conditions also permits remain exposed without damage during all seasons. THE IRON AGE, December j : 7 ; ~ 4 4 | 4 ~ | ° BLEAKNEY* the February, 1922, meet- ing the A.I.M.E. New York, Messrs. McQuaid and Ehn presented paper “The Effect Quality Steel Case Carburizing Results.” that pa- per for the first time was enunci- ated the theorem that the harden- ing steel influenced not only the methods employed but the quality the steel itself. contribution profound impor- tance the metallurgical knowl- edge steel, aroused country- wide discussion and little con- troversy. the whole, American metallurgists accepted the authors’ conclusions, and number spe- cial carburizing steels which ap- thereafter undoubtedly owed their origin the work McQuaid and Ehn. That work opened new ave- nue thought and stimulated line investigation which may said have culminated the grain size symposium held the National Metal Congress Octo- ber, 1934. May 1922 Ehn discussed the same subject before the Iron and Steel Institute. Its reception England could not described enthusiastic. The discussion which provoked varied from the mildly skeptical the frankly incredulous. Hatfield prob- ably expressed the opinion the meeting when said (as reported the Journal the Iron and Steel Institute) that “the experimental evidence for the conclusions arrived was not contained the paper. that was quite satisfied. instance referred the first conclusion the summary, which Mr. Ehn suggested that soft spots were due oxide dissolved the steel. They were not. They were almost invariably due in- different hardening.” the years that have elapsed since McQuaid and Ehn first postu- *Metallurgical Canada. the Iron and Steel In- stitute, 1919. No. pp. 469-560. French: The Quenching Steels, pp. 28, 29, 92, 96, 97, 98, and 112. Edgar Bain: Factors Affecting the Inherent Hardenability Transactions American Society for Steel Treating, November, 1932, 390. Engineer, Ottawa, 32—THE IRON AGE, December 12, 1935 View diameters specimen quenched oil from carburizing pot. Reheated 1400 deg. and quenched water. (Right) View 1000 diameters undissolved carbides the soft surface layer seen the left-hand picture. Soft Spots lated the influence quality upon the hardenability steel, some details that work have required modification. instance, our present conception the influence grain size the properties steel may traced the work Hardy, then chief metallur- gist the Timken Roller Bearing Co., published THE AGE for Dec. 20, 1928. But while many the ideas inspired the work McQuaid and Ehn have been modified since, one cannot fail impressed with the extent which time has substantiated the essential soundness their conten- tions. And when realized that Dr. Hatfield’s discussion Ehn’s paper probably expressed the opin- ion all metallurgists that time, better appreciation the revolutionary nature their work made possible. The foregoing quasi-historical note must serve the writer’s apology for discussing now, after many years, one item the brilliant array data and conclu- sions contained that paper. work exhaustive, comprehensive and detailed, difficult not skim casually over some unempha- sized but significant point while concentrating the main line the argument. suggested that such point was contained Ehn’s paper before the Iron and Steel In- stitute May, 1922. discussing the influence hardening maxi- mum carbon content the case said, “In few instances case- hardened work with high carbon content, has even been found that the surface layer correspond- ing with the hypereutectoid zone was almost whereas the deeper layers corre- sponding with the eutectoid zone consisted uniformly hard mar- tensite. This condition makes still more difficult harden ab- normal steel which, already mentioned, has tendency build higher carbon case than nor- mal steel, and can safely stated that even with steels very ab- normal types, the presence excess carbon (10.5 per cent more) necessary condition for the complete development soft surface the hardening.” Two Factors Influence Hardening That this point has not received the attention which its significance warrants indicated the fact that reference was not made either the discussion McQuaid and Ehn’s paper New York } | IG. Fully martensitic case obtained quenching oil from car- burizing pot. Photo taken diameters. (Right) The same martensitic case Hardened Steel the discussion Ehn’s paper London. not suggested that the fact itself not widely recog- nized and accepted. Even before the findings McQuaid and Ehn were published, Portevin and Gar- vin, classic study critical cooling rates, had demonstrated the influence carbon content upon hardenability steel and had shown that the critical cooling speed increased the carbon con- tent departed either the hypo hyper direction from the eutectoid composition. But the writer has been unable find any critical metallographic examination this phenomenon reported the liter- ature, and hoped that the data and conclusions presented here will interest and value metal- lurgists and heat treaters The successful hardening depends primarily upon two fac- tors: first, the method harden- ing employed and, second, the in- herent hardenability the steel. The latter function the criti- cal cooling rate the steel which turn depends upon its chemical composition and the practice used its production with particular reference deoxidation. The for- mer comprised temperature heating, time during which the steel held that temperature, furnace atmosphere, quenching nie- dium, and degree agitation the quenching medium. The two hardening factors enumerated are largely interdependent, and steel may alloyed that can hardened after adequate heating simply cooling air. the other hand, steel relatively poor hardenability may hardened quenching drastic medium such iced brine, violently agitated spray. obvious that the choice steel and the method which hardened are dictated the necessity obtaining finished product suited the purpose for which intended, the lowest possible cost. Where service condi- tions demand the use alloy steel, hardening rarely prob- lem. the case the large tonnages plain carbon case car- burized steels, quenched into water brine with only moderate agita- tion, that soft spots are most preva- lent. When such occur, there strong implication that the steel “abnormal,” which say that its critical cooling rate faster than that provided the quench- ing medium which, turn, fast enough completely harden the cases “normal” steels similar chemical composition. Neverthe- less, there wealth evidence show that the direct cause the soft spots the presence gas films the surface the When piece red hot steel plunged into liquid such oil, water brine, the liquid volatilized the surface con- tact, creating gas film, which in- sulates the steel and obstructs fur- ther cooling. These films are usual- wiped off the circulation the coolant, escape bubbles, and the critical cooling speed the steel ordinarily sufficiently slow that the momentary presence the gas films does not prevent hardening. But abnormal, partially abnormal, steels, the crit- ical cooling speed may fast that certain points where the gas films persist for appreciable length time, transformation oc- curs temperature somewhere above 900 deg. F., steel soft that point. is, incidentally, interesting obser- vation that the structure such soft spots cannot correctly de- scribed troostitic. Inasmuch transformation, their structure really fine pearlite, defined Bain.’ Two Types Soft Spots Soft spots case hardened steel occur one two types, either penetrating completely through the core superficial layers, underlain fully hardened steel. Accepting Ehn’s statement that “even with steels very abnormal types the presence excess car- bon necessary for the develop- ment soft surface,” follows that the superficial type soft spot must decidedly the more prevalent, since all carburized steels have readily hardenable eutectoid zone. This phenomenon has already been explained be- ing attributable the faster critical cooling speed the hy- pereutectoid surface layer than the eutectoid zone beneath. order reproduce the struc- ture described Ehn, some- what abnormal low carbon steel was carburized bone meal 1650 deg. for hr., quenched from the pot into oil, reheated 1400 deg. and quenched still water. After quenching oil and before reheating for the water quench, sample was cut from the (CONTINUED PAGE 94) THE IRON AGE, December 1935—33 3 q q 4 / 5 EARLY New England mechanics neers must credited the development both equipment for handling sheet metal and methods expanding its usage into new fields. not difficult vision Yankee mechanics devising new ways producing articles for which increasing demand re- quired more speedy costly production methods. The first available record recites that Orziel Wilkinson, blacksmith, that another blacksmith was shear- ing pointed chips from old iron door lock and making them into tacks heading them vise. “punch” press for various sized dies, fastened this oak log with stirrup for the foot and, placing his David, astride this hobby-horse, produced iron tacks. This stated the first “punch” press America. Orziel Wilkinson made another contribution, though indirect one, the pressed metal industry. 1794 built rolling provided source raw material for fabrication his “punch” press. patents, however, were granted for these inventions. The first official record the invention the power press (as the succeeding step after the foot- recorded that July that year patent was granted one Darracutt Boston for power press for copper, etc.” October the same year, McOmber was granted patent for power press. the patents for power presses were 34—THE IRON AGE, December 12, 1935 HATTON granted. presses had doubtless been use some extent during this period. patent was granted 1849 for cotton press and another 1851 for portable hydraulic press but between 1854 and 1870 only sixteen patents were granted for presses this type. But from the beginning and until very recently hydraulic machinery was too slow and expensive fig- ure any extent, save for the heaviest operations. Recent de- velopments speeding them have, however, brought them the aid their mechanically driven with advantage for cer- tain classes work. prob- able that the future will see me- chanical and hydraulic power join the further developments under- way. Early Machine Shops The early New England mechan- ics could not content with either the laborious handwork cutting, piecing and soldering cop- per, brass and tin, with the more rapid production secured step- ping swinging the pedal the foot press. The industry had emerged from its centuries primitive craftsmanship and was calling power its aid (as were a