The Iron Age 1936-05-07: Vol 137 Iss 19

vr we MAY 1936 need tell you what forging does steel. Everyone knows means lot tough metal small space. New Departure the forged steel bearing. made one the world’s greatest upset forg- ing plants. NEW DEPARTU Forging machines cost lot money—call for big investments. Just one more reason why you can have confidence any machine which operates New Departure Ball Bearings. The New Departure Manufac- turing Company, Bristol, Conn. Detroit, Chicago, San Francisco. forged steel bearing cy t WAY 1936 4 me Be 9409 4 GAS DOMES FOR SEWAGE DISPOSAL PLANT for the toughest spots REPUBLIC Curious eyes from Maine California are finding Toncan Iron the most unusual places—in gas domes, digestersand sludge agi- tators sewage disposal plants—in chemical plants—in smelters where sulphurous fumes and steam play havoc with ordinary ferrous metals—in acid sludge equipment refineries —in most the tough spots where corrosion takes expensive toll less durable metals. There’s reason for this. Toncan Iron alloy. Iron, refined the open-hearth, combined with copper and molybdenum Where severe corrosive conditions cause early failure ordinary ferrous metals, use Toncan Iron. This building, roofed and sided with Toncan Iron, exposed salt air combined with sulphurous acid, steam temperatures form this alloy that shows the highest and some small amounts sulphuric acid mist. sistance any ferrous metal its price class. For more than twenty-five years, Toncan Iron has been saving money for industries— waging successful war rust-cutting maintenance—improving products. Literature will sent request. Ask for the booklet Path Permanence.” Republic produces plain carbon steel, JOS copper- bearing iron, Toncan Copper Enduro Stainless Steel sheets. Write for full information. 2—THE IRON AGE, May 1936 THE IRON AGE, published every Thursday the CHILTON CO., (INC.), Chestnut 56th Sts., Philadelphia, Pa, class matter November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year Canada $8.50, Foreign $12.00. Vol. 137, No. a \ 4 | 239 WE 4 FR — CHESTNUT AND STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, are agi- mical umes rrous etals. ‘h, st-re- class. ncan ting Owned and Published CHILTON COMPANY (Incorporated) Ask Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH S. HILDRETH, 4. GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary matter No. 19. FRITZ FRANK, President VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Washington Chicago Cleveland Pittsburgh FRANK OLIVER GERARD FRAZAR Detroit Boston Cincinnati Conten May 1936 Plowing Back Forestalls Depletion Depreciation and Corporate Surpluses Machining Buick Transmission Cases Recent Developments Steel Houses Pressure Die Castinas Brass Demountable Containers for LCL Shipments New Equipment Automotive Industry Statistics Metal-Working Activity Rate Activity Capital Goods Washington News NEWS INDEX Products Advertised Index Advertisers Copyright 1936 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service Member. Audit Bureau of Circulations ADVERTISING STAFF Member. Associated Business Findley, 621 Union Cleveland Indexed in the Industrial Arts Index. B. L. Herman, 675 Delaware Ave., Buffalo. li sds Ss Ds ‘ri Published every Hottenstein, 802 Otis Chicago ti *rice: J Sts and tion Price: United States an Pes Peirce Lewis, 7310 Woodward Ave.. Detroit essions, Cuba, Can Charles Lundberg, Chilton Bldg., Chestnut ada, $8.50. including duty: Foreign 56th Sts.. Philadelphia. Pa. $12.00 a year. Single copy, 25 cents. C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh W. C. Sweetser, 239 West 39th St., New York Cable Address, ‘‘Ironage. N. Y."’ D. C. Warren, P. O. Box 81. Hartford, Conn. < | J LANT 4 TO ty, - nes 1.2 PS iy. & NEW, completely modern continuous sheet and strip mill places Bethlehem position meet every requirement industry respect range and size flat-rolled steel products with precise gauge control. These new facilities include all the most recent developments rolling and finishing equipment for sheets and strip, either flat coiled. With steel made under the rigid metallurgical control enforced Bethlehem plants, high standards both finish and physicals are assured. 28—THE IRON AGE, May 1936 MILL bal meet every need for Sheets and Strip Included the wide range products this mill can supply are cold-rolled sheets for automobile doors, hoods, panels and other major body sections, lamp and crowned-fender stock; rolled and cold-rolled strip. The location the new mill, Lackawanna, Y., the Buffalo district, permits excellent service principal consuming areas. BETHLEHEM STEEL COMPANY, Bethlehem, Pa. District Albany, Atlanta, Baltimore, Boston, Bridgeport, Buffalo, Chicago, Cincinnati, Cleve- land, Dallas, Detroit, Honolulu, Houston, Indianapolis, Kansas City, Los Angeles, Milwaukee, New York, Philadelphia, Pittsburgh, Portland, Ore., Salt Lake City, San Antonio, San Francisco, St. Louis, St. Paul, Seattle, Syracuse, Washington, Wilkes- Barre, York. Export Distributor: Steel Export Corporation, New York ; j | | | a ... THE IRON AGE MAY 1936 ESTABLISHED 1855 Vol. 136, No. Plowing Back Forestalls Soil Depletion... prudent knows that must conserve the condition his soil, prosper. cannot expect take continually from his fields without giving back them. That why you see him plowing back the sweet clover, the soy beans and the rank rye. realizes the necessity returning the earth portion the profits that secures from the form those chemical elements that are necessary avoid depletion and insure continual abundance production. The improvident farmer, the contrary, gives thought the future, reaps the entire yield and plows back nothing. His thoughtless policy and practice are responsible for our abandoned farms and for the millions that Uncle Sam must now spend counteract the effects soil depletion. There food for thought this for our legislators who are now con- sidering the corporation surplus tax proposal. Industrial fields, like farm acres, must kept fertile they will become sterile and impoverished. They need plowing back portion the dollar crops that come from them. Research, modernization, replacement, must continue, our industrial soil kept from becoming barren and depleted. Our industrial fertilizers are not sweet clover and rye, but dollar profits. These have been plowed back provident manufacturers the past conserve industrial fertility. Abandoned plants, like abandoned farms, are the result improvident policy which neglects this. unwise legislation should deprive the possibility thus plowing profits back into our industrial fields, the time may come when the soil production and employment will depleted. this should happen, Uncle Sam will have spend billions restore our producing power, just spending hundreds millions restore our barren acres. ity, San Wilkes- General Manager, National Machine Tool Association 7 < Chae , > . AC... York a Depreciation and Corporate the previous article attention was called the fact that the book often greater than the realizable value the time the asset re- placed. This book loss represents depreciation which has actually oc- curred, and which would have been charged against the asset the actual life and the realizable value had been known the time the depreciation rate was set. This book loss should never charged against the future asset, but should charged either profit and loss, fund set for that very purpose. probable that most corpora- tions charge such book losses, espe- cially when large, surplus. this done, simply means that past profits have been overstated the extent that past depreciation charges were inadequate. Federal taxes have, course, been paid these apparent profits. The net result that surplus reduced what would have been past depreciation charges had been ade- quate, less the amount the taxes which have been paid the ap- parent but unreal profits. Industry Should Not Itself the proposed changes cor- porate taxation are made, will even more important that depre- ciation rates should high enough bring the book value asset down the realizable value the time the asset replaced. the past corporation with sufficient surplus could charge any book loss due asset replacements sur- plus, and merely lose the amount the tax which had been paid this amount apparent but profits. corporations are taxed undistributed profits, these ap- parent profits will either taxed used build surplus, else 30—THE IRON AGE, May they will distributed divi- dends. they are used build surplus, presumably the tax will much higher than the present tax. they are paid out divi- dends, the corporation will that extent returning capital under the guise profits, and may the October 31, 1935, is- sue THE IRON AGE, the author discussed De- preciation Fallacy, Tending Obstruct the Replacement Obsolete Equipment." Proposals levy tax the undistributed profits cor- porations suggest phase the depreciation problem somewhat similar that dis- cussed the previous article; namely, what proportion present corporate surpluses result from overvaluation obsolete plant and equip- ment? the present article the author shows that every corporation should immedi- ately take steps get the an- swer, its own case, that important question. Such in- formation will great value even the present method taxing corpora- tions continued, and much greater importance the proposed changes are made. for the corporation se- cure the necessary funds when re- placements should made. There would seem only one way for corporation protect itself. Depreciation charges should all times adequate. But the problem charging adequate de- > digs preciation during the life equip- ment not easy one solve. This especially true under the new Federal regulations governing the charging depreciation. These new regulations specifically provide that taxpayers must sustain their depreciation claims through proof that these claims are not excessive. careful study all assets, determine their future useful life, the only solution; because this the only way taxpayer can secure Federal approval depre- ciation rates which are adequate. Under the present regulations the taxpayer may use high rate desires, provided can satis- the Bureau Internal Revenue that the asset will replaced the end life that corresponds this depreciation rate. the case most taxpayers will prob- ably necessary initiate rather extensive replacement pro- gram, equipment are adequate. little equipment has been re- placed during the depression that many taxpayers are finding dif- ficult convince the Bureau Internal Revenue that their depre- ciation rates should not reduced. result depreciation rates are being reduced many cases. But actual depreciation entirely in- dependent depreciation charges, and where these depreciation charges are inadequate there which may much more painful the proposals tax undistrib- uted profits are enacted into law. Your Surplus May Not What Seems would very interesting could know just what part the present surplus our corpora- tions really fictitious, the sense that represents past profits which were merely apparent profits - AS ? 4 = — Wi % urpluses ° ° PAUL NORTON, JR. Professor Industrial Engineering Virginia Polytechnic Institute because depreciation charges were inadequate. probable that many corporations are carrying their books assets items plant and equipment which are hope- lessly obsolete that they are really without any value. Much this plant and equipment idle, and some will never again operate. Not only should corporations make regular studies all their assets, but they should examine with particular care those assets which are not now being used, determine whether likely that these idle assets will ever again used. decided that they will not again used, the sooner they are disposed the better. discussing depreciation the fact that the total all future depreciation charges paid cut the time the asset purchased often overlooked. Depreciation really fully prepaid operating expense, although capitalized for convenience. desirable that depreciation charges should spread uniformly over ucts the asset, and neither necessary nor desirable that the book value any time during the useful life the asset should equal what the asset would bring sold. But the owners depreciating assets should not con- sider that they are charging ade- quate depreciation merely because their depreciation rates are the same those which have been suf- ficient the past. large part our present equipment will end (CONCLUDED PAGE 103) THE IRON AGE, May by Trunnion Fixtures Feature Machining Buick Transmission Cases ILLUSTRATING the trend combining set- ups and machining op- erations automotive parts the new equipment in- stalled Buick Motor Car Co., Flint, Mich., machine the trans- mission case for the Model Buick ear. great deal floor space has been saved and the total num- ber machine units required has 32—THE IRON AGE, May 1936 FRANK OLIVER been reduced almost one-third through the use special-purpose machinery, which the principal common characteristic seems the use multi-station drum-type fixtures employing either one two work positions. The fixtures operate either horizontal vertical plane. the 2-position machines, the work semi-finished the first set-up and then placed the second stage the same fix- ture for the final operations. One the principal advantages this method tooling the fact that single operator can effect load two stations without moving from his position. Further- more, simply adding spindles the heads, additional holes can drilled tapped bored the second set-up with only slight additional cost the orig- inal investment, compared with what would required sep- arate machine purchased, completely equipped with hydraulic heads and the usual auxiliary equipment. this particular transmission case line, there are number diverse units which il- lustrate various machine tool build- ers’ ideas how these jobs should performed, and interesting note the various points view represented the design such special-purpose, multi-tooled equip- ment. Altogether, there are fourteen machine set-ups required the Buick transmission case. Fig. shows the first set operations the rough casting wherein the main bearings are rough bored and | ° ° then semi-finish line-reamed. There are provided two Greenlee 2-way horizontal boring machines, each with identical set-up. the shows, trunnion-type fixture operating vertical plane used with hand clamping the piece. The casting lo- cated against adjustable set screws one side and hardened stop plate one end. For the rough boring operation, multi-tooth bor- ing tools come from both sides the hydraulic heads. The third station blank, and the fourth station the main bearing holes are line-reamed cutters carried single boring bar the right- hand hydraulic head. There are pilots ahead each tool. Positive registration the trunnion fix- ture assured bar carried the right-hand unit head that passes through pilot the trun- nion frame and thence through substantial locating holes the fix- ture itself. the photograph examined, will seen that there dust collector hood behind the fourth station which carries gray iron dust away from the operator, who ordinarily stands front the loading position. This feature common most the boring and drilling units this particular bor- ing and semi-finish line reaming per- formed this two- way hydraulic ma- chine with 4-station trunnion fixture. line and has resulted greatly improved working lumination also improved this practically dust-free atmos- phere. The second operation simple press which the main bearing bore spotfaced inside the front end. From there the casting placed Davis No. drum- type miller for rough and finish milling the front and rear ends, leaving 0.020 in. for later finish- ing operation. The piece located horizontal floating arbor en- gaging the main bearing bores and locked against this arbor pressure pins extending through the fixture itself. Pressure these pins actuated through spring pressure chain mechanism which will described later. unit used for this particular op- eration and production 100 units per hour. Another drill press op- eration follows which the main bearing holes are chamfered. Later these same bearings are finish line- reamed couple drill presses. between these operations, small slot broached the piece. Finish facing operations the end are illustrated Fig. which shows modified lathe with spe- cial carriage the rear actuated mech- anism. The carriage itself yoke-shaped casting which gen- erous sized shaving tool bits are carried angle. Attached the top this same carriage angular plate which supports the hood for the dust collecting system. can seen, the hydro-pneu- matic mechanism actuates the car- and pinion-and-rack together, six machines have been adapted with this special carriage and the production each ap- proximately units hour. Since the work directly sup- ported arbor the finished bearing bores, the set-up assures accuracy the over-all length the case and also that the faces are exact right angle the bore. Drilling, countersinking, ream- ing, tapping, counterboring and chamfering operations are com- bined the next set-up, shown Fig. The particular machine which these various operations are performed 2-way, 4-headed combination Natco drilling and tapping machine. has 8-po- sition automatic mechanical index- ing trunnion-type fixture with pot- type holders for the part. now the practice the design THE IRON AGE, May 1936—33 a tag j d | a = ABOVE 2—Hydro- pneumatic mechan- ism and special rear carriage perform double end facing operation modified lathe. RIGHT 1G. While the casting clamped pot-type holder this eight-station trunnion fixture, drilled, reamed, countersunk, cham- fered and tapped. Note the dust collec- tor hood. 34—THE IRON AGE, May many these special-purpose ma- chines, the base single welded steel structure and standard hy- draulic and tapping heads are mounted thereon. The right-hand hydraulic unit equipped with cluster box containing spindles, while the left-hand hydraulic unit has cluster box containing spindles. The right-hand unit arranged with automatic time de- lay, reverse and positive stop. All spindles are mounted bearings and have ment. The two tapping heads are mounted independently the hy- draulic units and are attached di- frames which support the trunnion fixtures. Drive for both sets tapping heads through single reversing motor. The right-hand head contains four spindles and the left-hand one five, each arranged with individual lead screw feed. The machine interlocked prevent the indexing fixture before the heads are the cor- rect position, also prevent the heads from rapid traversing for- ward before the fixture locked place. Each head provided with separate push button control, but the entire unit cycle may con- trolled from single push button station. LEFT 4—Reamer bars are mounted permanently this rotating fixture and are rotated through special Buick-design clutches. BELOW clamping pins pro- truding through the mandrels are actu- ated means spring-tensioned endless chain partly wrapped around the drum fixture this continuous milling machine. chines performing these operations and each scheduled for com- pleted parts hour. Several single unit operations follow, such reaming the idler Millholland machine, which there are two units, and drilling and tapping the oil filler hole the side the case heavy-duty drill press. rather unusual ar- rangement employed for ream- ing the idler shaft, countershaft and rail holes previously drilled the Natco unit. special Buick has been adapted 2-way hydraulic head ma- chine. can seen the il- lustration, Fig. the reaming tools are permanently carried the fix- ture itself and need not handled and out the machine, except for sharpening. This feature, to- gether with the fact that the bars are standing still except during the actual reaming operations, has increased the cutter life about three times. Two identical ma- chines are used and there are two separate set-ups each. one, the idler shaft, countershaft and rail holes are semi-finish reamed and the second set-up the idler shaft and countershaft holes are finish reamed well the rail THE IRON AGE, May 1936—35 ic 3 pe holes. operation, the hydraulic heads are advanced the clutches engage the tool spindles which are returned spring pres- sure when the heads drawn. Location the work accomplished pilots which en- gage the main bearing bores when they are actuated the hand levers shown top the fixtures. Ordinarily series operations this kind would call for two sep- change reamers with bayonet hold- ers for drive. Another milling operation second Davis drum-type miller fol- lows. Like the many other special- purpose machines the line, this particular machine has drum- type rotating fixture with two work stations each position. there are twelve stations, this means that there are castings loaded the machine one time. Production 100 finished units per hour. The main operation rough and fin- IRON AGE, May ish mill the cover face, and for certain transmissions side boss milled, using the right-hand head. will noted the photo- graph, Fig. that the transmis- sion cases are loaded mandrels engaging the main bores, the man- drels being radially disposed, far the drum fixture con- cerned. From the loading position steel guides loosely hold the work 6—Details construc- tion the work clamping mechanism used the Davis the lower part Fig. Thus the event that any par- ticular casting does not seat prop- erly, undue pressure built the clamping pins, since the springs merely give relieve the load. Cutters for the cover face are in. diameter and are the inserted-blade type with Stellite tools for the roughing cut and Equalizer Bar place for part the revolution until the clamping pins come into action. The line drawing, Fig. gives better idea the construc- tion the clamping mechanism which actuated endless chain. will noted that the drawbar that pulls down the clamp- ing pins attached cross- member which has protruding piece shown “A.” This actuat- ing member engages chain, which partly wrapped around the drum fixture. Tension the chain maintained through sprinz-backed idler which can high-speed steel tools for the finish cut. Cutters for the boss the side the box are in. diame- ter, and are carried huge cast- iron housings with bronze sleeve bearings. The cutter spindles them- selves are mounted roller bear- ings and each unit head mounted quill providing for end-wise adjustment under micrometer con- trol. The purpose this construc- tion provide extreme rigidity that deflections under load are insignificant. add further cutter life, smoothness the main drive assured using worm | | } | ! | ! | | | H | | | | | | | | | | | | ' | i | | | 4060 ' | | | Cla MpINng — L ! | (| il | i! | \ yt ! | | hil q | | | and worm wheel the final drive the drum fixture. End-wise lo- the drum maintained two large ball thrust bearings, one mounted either end the drive head. Another pair Natco 2-way drilling and tapping machines take the piece after leaves the miller. Here again drum-type fixture employed using two work-loading stations each the four posi- tions. can seen Fig. the transmission case again lo- cated mandrel which engages the main bores and clamped through simple bar and hand nut arrangement. The photograph also shows the sheet steel ducts the dust collecting system which has been attached the right side the trunnion fixture support. Like the other Natco machines, this one has single-piece welded steel base and two self-contained hydraulic units. There are also two tapping heads driven through single re- versing motor and attached direct- the stanchions supporting the trunnion fixture bearing. The right-hand hydraulic unit has roller bearing spindles and the left- hand unit, seventeen. Each unit arranged with automatic time de- lay, reverse and positive stop. Tap- ping units have twelve spindles the right-hand head and nine the left head, each with individual lead-screw feed. The entire unit interlocked the machine can- not start until the fixture = 7—Another type vertical trunnion fixture, with two work positions each station. This Natco machine has two heads and lead- controlled ping units both ing the trunnion bearings. THE IRON AGE, May 1936—37 > : 3 = Unit push button control provided, well single button for cycle con- trol. Operations this machine include drilling, countersinking and spotfacing combination, spot- facing alone, reaming and tapping. Net production completed pieces per hour for each the two machines. the case the other units mentioned above, after the piece has gone around once removed from one man- drel and remounted the other, after fully completed piece re- moved from the second mandrel. Two rather unusual milling op- erations follow group two 24-in. Cincinnati hydraulic 38—THE IRON AGE, May millers. One the set-ups il- lustrated Fig. both set-ups the purpose mill bosses inside the case, operation formerly performed spotfacing opera- tion drill press. From the position shown the photograph, the table rapid traverses the right until the center the boss coincides with the center the tool spindle. Then the head itself stroke. The head then backed out and fed face the opposite boss inside the case. can seen, the casting supported half-tilted position and held pilots that engage the main bores. The front pilot inside bosses ordinarily performed drill press ac- complished this milling machine set- combining table and head tra- verse. advanced rack-and-pinion mo- tion through the hand lever. These milling operations complete the ma- chining the piece which need only the power washer be- fore being sent final inspection. Practically all the machinery this line new, although few units were rebuilt take care the design modifications the pre- vious models. the retooling, spindle equipment has been thrown out, and floor space has been con- siderably conserved, enabling the same department take trans- mission work other General Mo- tors units, such Pontiae and Oldsmobile. | | RIGHT REFABRICATED from basement roof, this five-room Mesker Co., 424 South Seventh Street, St. Louis, Pine Lawn, suburb St. Louis, was viewed 8000 persons dur- ing its construction. Of- fering non-standardized designs, the company leaves determination shape, number rooms and interior and exterior finishes the architects pective home-owners. Approximately tons steel used this house, which has side walls plates and makes use steel This company can build five-room house with full basement, com- pletely equipped and ready for occupancy, for cost the pur- chaser $3,500. RIGHT BEAUTIFUL country setting enhances the charm this modern four-room bungalow constructed Ameri- can Houses, Inc., 480 Lexington Avenue, New York. Framed steel, and with steel-reinforced roof and floor, this type house requires from tons steel and sells for less than $5,000. new plan has been introduced whereby local dealers will provide substantially all the equipment going into each house, while the frame, joists and shell the structure will continue fabricated the factory. Not only will good will and cooperation obtained from the local dealers this plan, but flexible price will made possible due the difference conditions throughout the country, and the type equipment selected the individual owners for their particular homes. LEFT Twentieth Century Home, pre- cision-built the Corp., Milwaukee, for less than $4,000 erected, and provides six rooms and bath. There are two large bedrooms, each having the modern sys- tem cross ventilation; living room; dining room and well-equipped kitchen and heater room. The home may had with without basement and with two types roofs—either hip flat. Steel framing and trusses give the Twentieth Century Home its structural strength. The type construction recognized fire-safe and vermin, ro- dent and termite-proof. THE IRON AGE, May 1936—39 3 } DIE casting the cop- per-base alloys ex- ceeded importance today, far die castings are concerned, only the alloys which and aluminum respectively are the primary “base” metals. Brass alloys have far the highest strength and hardness any the die-casting alloys and are comparable some respects forged alloys simi- lar composition and even mild steel wrought form. They are ductile, having elongation per cent, with reduction within the same limits. Cer- tain the alloys are rather diffi- cult machine, but others are fairly free machining, though less than the zinc-base and alumi- num-base alloys. Brass die castings can made within closer dimensional limits well thinner sections and more complex forms than brass sand castings and forgings and are often used place these. Thus possible produce brass die castings small moderate size with sections 1/16 in. less thickness and hold dimensions within plus minus 0.005 in. per inch less when required, though wider limits may result naturally lower cost. Die castings zinc base and aluminum base can held within closer dimensions and can made thinner sections well much larger size. Brass die castings are commonly used only cases where their physical properties and relatively high re- sistance corrosion are particu- larly desired. This, however, pro- vides wide field utility. Brass alloys are considerably more difficult cast than alloys lower melting point. For this rea- son (which among those making for higher cost) casters who make all types can relied upon recommend brass only when its superior properties best serve the 2—Miscellaneous brass die castings including ball bearing retainers and machine elements. The ring for soap dispenser, lower left corner, can opened almost straight without fracture, indicating high ductility. te 40—THE IRON AGE, May 1936 APID commercial strides during the past few months warrant review production possibilities they now exist connection with pressure die casting, in- volving light-color alloys ing basic metal other than aluminum and zinc. these strides two funda- mentals are main factors; ex- perience, which the die caster continues perfect purpose hand. special form machine required for “pres- sure casting,” sometimes termed, brass. The metal not forced into the die true liquid hardware parts die Such parts are almost strong high bras: anneal Pressure Die not uid die cast mild all elements his mechan- isms; and research, through which the products the steel maker more measurably resist the element die- heat damage. Names alloys herein mentioned are not new; they do, however, serve iden- tify group activity increasingly important branch industrial effort. form are the alloys lower melting point. first ladeled into pressure cylinder semi- molten form and quantity slightly greater than required brass, some being for use refrigerators. annealed steel, and have high ductility and HERBERT CHASE, M.E. ° ° fill the die. then forced into the die plunger actuated hydraulic pressure generally within the range 2000 3000 lb. per sq. in. The plunger size may such that the pressure the metal forced into the die 15,000 20,- 000 per sq. in. This makes necessary lock the die under ex- treme pressure. The strength and rigidity heavy machine are therefore required. other re- spects the die-actuating mechanism may similar that used machines for die casting aluminum zine. using metal the melting point rather than liquid metal, the temperature the metal entering the die lowered, and this important consideration respect die life, for the higher the tem- perature the metal, the shorter die life, other things being equal. This one important reason why die casting with brass not ° progressed more rapidly. has been necessary, well difficult, develop dies which will stand the temperatures involved, usu- ally 1600 1650 deg. F., well find alloys which can cast below the latter temperature. These problems have been the sub- ject prolonged research and de- velopment the plants the Doehler Die Casting Co., and espe- cially its plant Batavia, Y., where its brass die castings are produced. The development has long since reached commercial stage, however, and brass die cast- ings are produced Batavia production basis, where high 50,000 casts are made from die before must replaced. There now use, for example, die which pistons approxi- mately hour-glass shape are pro- duced for hydraulic braking sys- tems the rate 8000 per day. (CONTINUED PAGE 103) 3—Pipe fittings and valve parts, well the other small brass die castings shown, are strong and dense and have high corrosion resistance. They are produced within close dimensional limits and require little machining. They are also smoother. THE IRON AGE, May ion in- es- Containers for the great problems railroad management the more efficient handling less-than-carload merchandise freight. Joseph Eastman, Fed- eral coordinator recently predicted the combination and concentration the less-than- carload, express and car-forward- traffic, which would handled much more heavily loaded cars shock-proof construction and moved passenger train speeds. also forecast the development intermediate service, between the present less-than-carload and carload service, means the use containers carried flat cars. These, thinks, will light- weight construction, uniform types and capable interchange between all railroads and between railroads and motor trucks water carriers. Freight containers admittedly of- fer the best solution this prob- lem. average weight about 200 per item representative common freight shipments and would included with separate charge for each item. readily seen that 4000-lb. shipment any shipment 10,000 Ib. the separate freight items can very well included one freight con- tainer with resulting economy time and billing expense. container widely used the railroads today that the L.C.L. Corp., 230 Park Avenue, New York. This company, which has been occupied designing, building and licensing containers for more than years, has made available five general types: Mer- chandise containers, bulk contain- ers, air-activated containers, coal containers and refrigerator con- Merchandise Containers The first these, the merchan- dise container, being designed par- ticularly for the less-than-carload shipment has capacity which varies from 7000 12,000 lb. according type. has capacity 426 cu. ft. and pro- 42—THE IRON AGE, May 1936 vided with supporting straps that may lifted from the car into place the car means guides and slots that each con- tainer firmly held place and REIGHT containers which may demounted from the railroad car truck alongside have been studied the railroads for years. Many different solutions have been worked out, some the railroads themselves and others private organiza- tions. The subject has been stimulated the interest Joseph Eastman, coordinator tion. This article points out some the advantages widely-used container de- veloped the L.C.L. New York. the possibility side sway other constructed and 16-gage steel, inverted braces giving added strength. carload consists six these containers which may handled two ways: First, for transporta- tion from one shipper one con- signee when the shipper has suf- ficient tonnage warrant the use container; and second, when consolidators who substitute them- selves for the individual shipper consignee gather large enough number small packages load close the maximum the con- tainer and act distributors the point destination. When individual shipper uses container may loaded his place business, locked his own lock wishes, sealed the truckman and then taken the railroad car. arriving its destination the consignee’s truck picks the container and carts his place business where unlocked and unloaded. the case consolidated con- tainers, used freight con- solidating companies, these oper- ators have equipped themselves with stations their own and have facilities for loading containers and switch the cars and containers di- rectly and from such stations. either case labor cost the railroad entirely eliminated that the containers are loaded and unloaded the shipper advantage this system that claims through loss are very largely done away with, due the fact that the container cannot opened while the car, and prior either locked sealed. There can be, therefore, pilferage tran- sit, and the locks and seals are unbroken there positive proof that the shipment intact. Another type merchandise con- tainer provided with legs addi- tion lifting hooks top and rides drop-side container car. Each section hinged the floor the car that will swing out- ward and downward, filling the space between the side the car and platform that the container can moved the platform lift truck and placed truck trailer. This provision was made for the benefit terminals not equipped with cranes, where the volume business not sufficient justify the heavy expenditure necessary for such facilities. The benefits the L.C.L. mer- chandise container can summed presenting economies and ad- vantages which appeal the ship- per, consignee, and the railroad and present the unique feature for railroad reduce its rates voluntarily under new method transportation the same time getting more money out the re- ( ‘ ‘ | ‘ | ‘ ‘ Than-Carloa duced rates than the rates com- monly force for handling less- than-carload merchandise. Rates and Weight Minima These benefits, unfortunately are only theoretical since rather un- satisfactory condition exists today where the containers are use. The minimum shipment that can sent container the New York Central Railroad, which largest single user the L.C.L. Corp. products, 6500 east Buffalo, and 4000 lb. west Buf- falo. Since these figures were an- nounced, use the merchandise containers has decreased consider- ably. Few small shippers freight 6500 lb. merchandise one time, but since they have pay for that amount when the containers are used, whether they are shipping that much not, they naturally use the old method. West Buf- falo, where the 4000 lb. minimum would probably meet with the satis- faction most shippers, the Inter- state Commerce Commission raised activated containers operation. 4 the rate until was cheaper continue shipping the old way. Thus two forces are working against themselves—in one section, the rates are satisfactory but the minimum too high; the other section, the minimum tory but the rates are too high. Un- til this condition corrected generally believed that the use merchandise containers will lit- tle increased. For Bulk Shipment The most popular container li- censed the L.C.L. Corp. the drop-bottom container for shipping bulk. typical example the use this type for the shipment one year 300,000,000 bricks were transported New York this method. Each container holds 3000 bricks which are loaded directly the kiln and then placed the car and shipped destination. arrival, the container lifted crane, brought into position over the truck body, dropped down Freight Shioments within foot the floor the truck and the bottom slowly opened the same crane, without actually setting the container down. This permits the brick slide out with- out concussion, breakage, strange may seem, being less than from barge This proc- ess takes less than four minutes, compared many times that when done hand. From the standpoint rail- road the handling brick container cars presents many ad- vantages. The time element alone make their use profitable since car 36,000 bricks can un- loaded less than hour continuous unloading taken, compared average whole day unload box car the saving time, container car units carries considerably more bricks than does ordinary box The bulk containers with drop- These are constructed and steel and are built pressure vessels, con- sisting cylindrical shell with hopper bottom and dished head, all welded together. through in. pipe line. Cement being discharged compressor being used. ¢ THE IRON AGE, May 1936—43 > ¢ e it is 2 |- - e a in n l- Ss e | r = e f \- A r | = bottom are also used carry chrome ore, dolomite, coke, cement, magnesite, ferrochrome, ferrosili- con, bauxite ore, manganese, silica sand, pebble lime and molding sand. The lime container differs from the others that equipped with waterproof top and bottom. Here again, economy time the most valuable factor since whole car 120,000 lb. lime can released hour, whereas un- loading the usual box car load around 40,000 slow, labori- ous and expensive operation. Steel Plant and Foundry Uses Steel companies have found the use the drop-bottom container advantageous transporting fer- rochrome, ferrosilicon, fluxing lime, dolomite and other similar mate- rials. Among those making use this type container are the Youngstown Sheet Tube Co., Re- public Steel Corp., nois Steel Corp., Inland Steel Co., Bethlehem Steel Corp., Great Lakes Steel Corp. and Crucible Steel Co. America. Foundries find that using the drop-bottom containers coke may lifted directly from the car 44—THE IRON AGE, May ROP-BOTTOM lime con- tainer operation. This container equipped with waterproof top and bottom, but otherwise identical with the brick container. Note that the pressure the two chains controlling the bottom doors has been released allowing the lime force open the doors its own weight. crane, carried the top the cupola and emptied part the charge, reducing handling costs and saving much time, well avoiding breaking the coke excess. Contractors favor the drop-bot- tom container for cement, which conveyed directly from the mill the contractor’s bin without loss material danger weather dam- age the container designed for complete protection from the elements. using this system, there difficulty cleaning out all the cement often the case with hopper cars, and pit underneath the track which means expense and inability operate inclement weather unnecessary. Expensive and troublesome con- veyor systems carry the cement from the pit the bin other receptacle are also not needed when containers are employed. The drop-bottom container con- sists corrugated sheets cop- per bearing steel 3/32 in. thick, welded steel frame. The drop- bottom mechanism very simply constructed. Chains running through pipes opposite ends the container are fastened rings the top that cranes may oper- ate them, and separate into two tions the bottom, one controlling function the drop-side container truck may now transport the container truck loading dock where carried the impossibility container each bottom door. When the chains are held taut the doors remain closed, but when the pressure re- leased, the doors open. Either overhead caterpillar crane course necessary when drop-bottom containers are em- ployed. Air-Activated Units Another means moving cement and other similar pulverulent mate- rials has been provided the containers, which are loaded bulk the mill and are equipped that unloading accomplished air pressure. The controlling mechanism for dis- charging the container air compressor, which contractors the con being | | | j ontainer ontainer ontainer l- from the car across the platform the the consignee. This photograph also shows being opened while the car. usually have one more, thus causing additional expense above that operating the com- pressor. The containers are air- tight and weather-proof, loss incurred through dust blowing, and any desired quantity may per sq. in. required the compressor for ordinary materials. 4-in. discharge outlet provided and when desired container may unloaded less than ten min- utes. Unusual physical conditions The are handicap since the discharge transport pipe line may easily adjusted meet conditions arising from elevation distance. container for flour and other foodstuffs similar design and construction the standard steel- type air-activated container, but built Plychrome and will not any way the most delicate food products, according the L.C.L. Corp. The coal container offers meth- for transporting coal directly from mine consumer. These con- tainers have capacity one two tons each and are loaded direct for the consumer the mine. One the purposes the container facilitate deliveries and make possible direct service from car home without the use yard. Even when the containers are stored yard for deliveries how- ever, the use coal pockets, bins, silos and elevators eliminated. this manner there loss coal transit and the consumer sure receiving the product that sent out under the miner’s own seal. The refrigerator container which frigerator car, with the exception the ice bunkers which are the top the container, offers pack- BELOW HREE thousand bricks are about released into the waiting truck. The chains the top the container constitute the releasing mech- anism. When they are let down the weight the load bricks opens the doors. The yoke and the block are controlled the same operator. ers and shippers perishable goods one the most modern methods shipping products re- quiring refrigeration. This unit may loaded the place where the shipment originates and re- frigeration will not broken until opened the consignee. de- sired, products may even held storage these containers. The same car chassis will carry re- frigerator and merchandise con- tainers interchangeably. The six refrigerator containers loaded one chassis may each held dif- ferent temperatures the contents require. Due design, long hauls may made without the necessity re-icing. The containers are fitted with tanks hold brine drip- pings when salt refrigerants are used. The New York Central leases 12,935 containers various types, which number only about half are actual use today. The L.C.L. containers are also use the Lehigh Valley, the Reading, the Baltimore Ohio and other roads. THE IRON AGE, May 1936—45 iv hy ly C- = Production Positive Length Gaging Features Straightening and Cut-off Machines PPROXIMATELY drive crank for gaging feed lengths before cutting knife strikes the wire the operation new “Travel- Cut” automatic wire straightening and cutting machine announced the Lewis Machine Co., 1592 East Twenty-fourth Street, Cleve- land. Stock fed from coil, straightened, gaged length and cut the fly. The cut-off die head which has vertical ways ac- curately machined guide the cut-off knife holder; movement forward with the wire during the cutting operation. The knife operated quick-action cam the fiywheel shaft. The adapta- tion this quick action cam traveling cut-off provides that the wire cut during the cen- tral portion the forward travel the head. This permits the wire, after mechanically tripping the clutch, move forward positive length gage which travels with the cut-off head. The design cut-off head drive allows for low head construction, 46—THE IRON AGE, May 1936 reducing rocking tendency, and un- steel rotary straightener used for finish straightening. The unit straightening die best suited the work and material. All main drive units, including the flywheel and clutch, are fully enclosed oil housings. The cut- off drive mechanism sealed the machine bed, and the cut-off cam and cut-off head drive crank run oil. Force feed lubrication provided; oil pressure sup- plied geared pump driven from the crankshaft, this main- tains film oil the bed ways ° ° LYING shear de- sign the basis operating move- ments which feature the new automatic straightening and cut-off equipment illustrated. ° and floats the cut-off head during its entire stroke. New extension support brackets are mounted rigid steel base, extending from the ma- chine base the full length the extension. Wire brackets are con- structed hold cut lengths away from the machine for removal without interference. “T” shaped gage wire fits the guide bar, supporting the end without clips. Motor mounting within closed steel base with V-belt drive from double step pulley; one set belts driving rotary straightener arbor; and another set driving the transmission. Slid- ing gears are mounted spline shafts and feeds flywheel speeds are obtained transmission levers. Ball and Tim- ken roller bearings are employed ° ° ° rear view below shows the V-belt drive, from electric mo- tor location base, through double step pul- ley. ° and Shop Equioment Thirty-Five Ton Fluid Power Press For Broaching General Utility NEW 35-ton, press, the Oil Gear Co., Milwaukee, Wis., welded steel construction, entirely inclosing all control mechanism, new variable delivery mounted integral motor and pump base. The press base, pump and motor base, side frames, rear wall and yoke are welded into compact unit. frames, internally ribbed, and the rear plate constitute rigid con- nection between the opposing yoke and base units; tie rods and frame bo'ts are eliminated. Reservoirs for both the variable delivery and lubricant pumps are built into the rear the press while open 3 chip collecting chamber with chip basket built the left the base. bore, bottle type, dou- ble acting cylinder, with large bronze bushing the yoke guide the ram, bolted the top the press. Pipe connections are flanged the cylinder. The press was designed for the elimination stress concentra- tion, dne tool marks and sharp corners, rear axle automobile housing. operation, the housing tube placed locating and holding fixture the base and back wall the press; the broach- ing tool, 111/16 in. diameter, hydraulic press shown was designed for special automobile production purpose. however, sim- ple which purpose restrictions and provide shop utility wide variety general right illustrated counter- shaft unit marketed for wide range shop and assembly work. threaded end tube; the op- erating lever pedal de- pressed; the ram moves down, and lubricant automatically flows tool and work for the broach- ing operation. When the end the t