The Iron Age 1936-09-10: Vol 138 Iss 11

10, 1936 casi Enduro Stainless Steel Oil Country Casing and Line Pipe Electrunite Boiler and Condenser Tubes Conduit Republic Steel CORPORATION GENERAL OFFICES-*- CLEVELAND, OHIO 1 | : PHO your products BRAND BRONZE vor Rugged construction alone not enough. Real protection assured only passes the action test. Press down the shackle—listen for the sharp, snappy, business-like click that means perfect functioning the mechanism within And springs, big and little, are the motive power behind the vital inner mech- anisms which are responsible for the successful operation the simple padlock, the massive bank vault and practically every machine and device regardless its size. Everything depends the perfect operation these springs and the small parts which they ac- tivate Elephant Brand Phosphor Bronze springs, round and flat, are being specified for countless applications where dependable the advantages this enduring metal. THE PHOSPHOR BRONZE SMELTING 2200 WASHINGTON AVENUE PHILADELPHIA, a * INGOTS FRITZ FRANK President VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco Sales Offices SANDERSON ROUNDTREE, JR. ALLISON Toronto, Ontario Birmingham, Ala. Newark, 239 WEST 39TH STREET NEW YORK, CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Owned and Published CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Pa. C. A. MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-Pesident JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS, WILLIAM Treasurer JOHN BLAIR MOFFETT, Secretary EDMONDS St. Louis TURNER Buffalo Con 10, 1936 Poisoning the Wells Lathe Cutting Monel Metal. Flexibility Press Layout Evaluating Shop Jobs the Point System Tool Engineering and the Society Tool Engineers Vibrations Set Power Hammers Machinery Exports 1936-1937 Crobalt Enters National Cutting Field Automotive Industry Statistics Metal-Working Activity Rate Activity Capital Goods Washington News NEWS CONTENTS Copyright 1936 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations ADVERTISING STAFF — Emerson Findley, 621 Union Bldg., Cleveland Indexed the Industrial Arts Index. and Chilton Bldg., Chestnut 56th Sts., Philadelphia, Pa. tion Price: United States and Lewis, 7310 Woodward Ave., sessions, Mexico, Cuba, $6.00; Ober, 239 39th St., New York ada, $8.50, including duty; Robinson, 428 Park Pittsburgh $12.00 year. Single copy, cents. Sweetser, 239 West 89th St., New York Cable Address, Warren, Box 81, Hartford, Conn. p d d ° | J dge Towers huge tonnages, den Gate Gol The towers the Golden Gate Bridge, tall 65-story buildings, are pro for purposes requiring special for ordinary everyday find Bethlehem excep- lly satisfactory source plate supply. 1es physical propert appl bably the most spec- ions, you tacular structures ever built plates. ike this, involving Whether for projects 32—THE IRON AGE, September 1936 | | - | ESTABLISHED ... THE IRON AGE ... SEPTEMBER 10, 1936 Poisoning the Wells the strangest delusions the New Deal its belief that can advance the interests employees opposing the interest employers. Interests and rights are two altogether different things. laborer steel mill automobile plant, have right fair wage for full and satis- factory day's work. The stockholders who have financed company have right fair return the money they have invested. And the management company has right fair wage for management and supervision. far these are concerned, there room for distinct differences opinion the relative shares which may considered ethical from the social standpoint. All these social and ethical from the practical standpoint are subordinate the fact that you cannot divide pie that hasn't been baked. You can debate length whether George, representing Labor, should get per cent slice the pie per cent slice. But that does not get George anywhere. wants pie, not percentage. That where the distinction comes between rights and interests. There can differences opinion rights and percentages, but ordinary common sense tells that the interest all groups make the pie larger and against the interest all groups make smaller. This plain and very practical point overlooked the New Deal. has dealt its legislation and administration, well its politics, with rights and percentages not only the exclusion common interests but their detriment. promoting and abetting labor warfare and class antagonism, its vicious attack upon big business which bakes most the pie for George, its repeated efforts cripple and handicap the progress and future industry through injudicious taxation surpluses, the piling unprecedented national debt through unheard ex- travagance, the New Deal, ostensibly defender labor's rights, actually enemy labor's interests. acting like the Arab chief who poisoned the wells order away with his enemy, overlooking the fact that both and his own tribesmen had other source water. Vol. 138, No. — | 24. | J ¥ i ; f | WHILE there ex- tensive literature the cutting metals, prac- available the cutting the various copper and aluminum alloys Monel Since Monel Metal extensively used alloy, believed that information the lathe cutting this metal would value industry. The experiments discussed this paper were carried out under the direc- tion Deale, executive sec- Committee Metal Cutting Data. The investigation may divided into three main parts, namely, (1) determination the effect cut- ting speed tool life. (2) the effect feed tool life, and (3) the effect depth cut tool life. Power measurements were also taken for most the tests reading voltmeter and ammeter placed the power circuit. Hot forged Monel Metal rounds, rough turned diameter ap- proximately in., and in. long were used these tests. The chem- ical analysis this material was: Carbon, 0.12 per cent; sulphur, 0.005; silicon, 0.07; manganese, 0.81; iron, 1.16; copper, 31.21; and nickel, 66.49 per cent. The Tensile properties determined from trans- verse tests were: Tensile 95,000 34—THE IRON AGE, September 1936 far known, nothing having direct experi- mental basis has been pub- lished the relations be- tween cutting speed, tool life, tool shape, depth cut and feed when machining Monel Metal. For this reason the accompanying partial re- port lathe tests this ex- tensively used copper-nickel alloy should afford data use- able machine shops gen- erally. Although independently conducted, the tests here re- ported take place part larger investigations the broad field metal cutting. One such that sponsored the American Society Mechanical Engineers, which put the cutting metals engineering basis. Part this project the setting basic mathematical ex- lb. per sq. in., yield point 78,000 per sq. in., elongation in. 23.0 per cent, reduction 55.5 per cent. Brinell hardness varied from 207 the center 224 the outer surface. One Tool Shape Used The tool bits were high-speed steel the 18-4-1 type, in. square. Analysis the tool steel follows: Carbon 0.78-0.83, manganese 0.20-0.25, phosphorus 0.025 max., sulphur 0.03, chromium 3.50-4.00, tungsten 17.25-18.25, and vanadium treatment was follows: Temperature Time Operation (Min.) Atmosphere Preheat .... 1600 Hardening 2400 8-10% Tempering 1100 240 Only one tool shape was used throughout the tests, which was follows: deg. side rake; deg. front relief; deg. side relief; deg. end cutting edge angle; deg. side cutting edge angle; nose radius in.; deg. back rake was produced the tool holder. All tests were run “dry.” heavy-duty, cone driven lathe with swing in. and dis- tance in. between centers, j Fic. | | | | | F | i i 7 | ¥ | 4 MELVIN MATSEN Montana State College, Bozeman, pression that will establish the relation between cutting speed, tool shape, depth cut, feed and tool life under cut. The experiments Mr. Matsen, carried out co- operation with the A.S.M.E. sub-committee metal cut- ting, provide data that per- mits comparing the tentative ing quite different character- istics. But addition their use connection with studies the general field cutting, the data here pub- lished should immediately useful current shop prac- tice. The tools are shape that approximate general use, and the range relationships for cutting iron feeds and steel with those ob- tained cutting metal hav- and meet ordinary shop require- ments. was used. was equipped with adjustable speed, hp. direct-cur- rent motor that any possible speed could obtained within the range. order ob- tain smaller feeds than the gears the lathe permitted, new set feed gears was made. elim- inate friction far possible the tail center, new center, hav- ing ball and roller bearings, was built. proved very satisfactory. Fig. shows the set-up the ap- paratus. special tool-holder (Fig. 2), designed and built the author, proved effective that was very rigid and allowed slippage the tool bit. was similar the tool-holder used French turning steel, that two bits, one in. square and the other in. square, may held place the same time, thus allowing the use trailer tool necessary. The main body the tool-holder one piece steel, the top piece being held place six cap screws. The tool bits are placed their respective grooves and held place set screws. the end each groove bolt with lock nut which backs the bit, thus preventing slippage. Since deg. back rake was desired the tool bits, the tool-holder was made give this rake; thus back rake was ground the bits. The tool bits were carefully ground sharp edge. The nose radius was ground hand con- form standard templet. After grinding, the cutting edge and face were honed remove any burrs. was not necessary use the trailer for any the tests herein described. The cutting speed was measured the uncut portion the log with the aid tachometer. This was checked the r.p.m. and diameter the log. Depth and Speed Checked Frequently assure uniform depth cut and cutting speed, the two were checked frequently during the test. Before the actual cutting began test, the lathe was allowed run for several minutes until the power reading showed constant value. The tool life was determined close observation the cutting edge the tool during the test. For feeds less than 0.015 in. per revolution was found that the THE IRON AGE, September 10, 1936—35 | Mont. OOS O_O A L____£€£ i ee tools failed nose abrasion. Fail- ure the cutting edge could observed begin the outermost part where the cutting speed was the greatest and then proceed in- ward. Feeds greater than 0.015 in. caused the tool fail cratering. was observed times that the tool bit would require cutting edge Monel Metal, TABLE Tests Determine Effect Cutting Speed Tool Life. (Feeds 0.0033, 0.0284 and 0.0132 in.) Cutting Corrected Depth Speed Correction Cutting Tool Life Feed Cut Test (ft. per min.) Factor Speed (min.) 295 0.965 285 0.0033 298 965 297 0.0033 3/16 300 0.965 289.8 1.13 0.0033 3/16 296 0.965 286 1.23 0.0033 3/16 225 1.041 234 6.33 0.0033 3/16 237 1.041 246.9 6.18 0.0033 3/16 246 0.965 237 4.00 3/16 251 0.965 242.1 10.25 0.0033 239 1.029 246 0.0033 3/16 18 236 1.029 242.2 4 95 0.0033 3/16 232 0.960 6.25 0.0033 3/16 286 0.960 274.2 5.60 0.0033 302 290 2.41 0.0033 3/16 305 0.960 298 2.07 0033 3/16 302 0.960 290 1.63 3/16 261 0.960 251 0.0033 3/16 256 0.960 246 2.85 0.0033 3/16 254 0.960 244 2.08 3/16 29 260 0.960 250 3.00 0.0033 3,16 256 0.960 246 6.00 3/16 222 1.046 232 11.25 0.0033 3/16 223 1.046 8.75 0.0033 3/16 216 1.046 226 11.25 0.0033 3/16 222 1.046 232 6.25 0.0033 36 222 1.050 233 5.18 0. 0033 3.16 232 1.050 243.8 9.00 0.0033 206 1.164 240 0.0033 209 0.998 34.02 0.0033 208 1.090 13.01 0.0033 212 1.090 231 9.97 0.0033 3/16 42 210 0.998 209.8 10.81 0. 0033 3/16 201 1.164 234 0.0033 237 0.908 215.6 16.61 0.0033 241 0.986 238 13.70 0.0033 3/16 47 242 0.903 218.5 14.81 0.0033 3/16 50 213 0.976 208 17.50 0.0033 3/16 51 213 0 976 208 21.38 0.0033 316 214 0.980 210 23.51 0.0033 3/16 55 135 0.917 124 2.95 0.0284 3/16 127 0.917 116.4 2.88 0.0284 3/16 122 0.980 119.8 2.78 0284 118 0.980 116 4.06 0.0284 118 1.010 119.2 2.33 0.0284 115 1.010 116.1 0.0284 3/16 107 0.980 105 0.0284 62 107 1.050 112.3 4.33 0.0284 3.16 63 107 1.050 112.3 4.40 0.0284 3/16 64 105 1.127 118.2 3.25 0.0284 3/16 65 104 0.954 99.0 7.85 0.0284 3/16 66 105 0.954 100 10.25 0.0284 316 67 103 0.992 103 7.83 0.0284 3/16 93 100 0.934 93.4 13.28 0.0284 3/16 112 1.030 115.4 3.10 0.0284 3/16 108 1.030 111.2 0.0284 3/16 0.934 89.6 0.0284 3/16 162 0.975 158 3/16 162 0.995 161.2 7.07 0.0132 3/16 162 0.990 160.3 7.35 0.0132 3/16 151 1.005 151.9 10.88 0.0132 3/16 177 0.971 172 4.88 0.0132 3/16 176 1.005 177 3.47 0.0132 3/16 174 1.000 174 3.65 0.0132 3/16 175 0.971 170 3.60 0.0132 3/16 151 1.110 5.00 0.0132 3/16 153 0.970 0.0132 3/16 153 0.990 151.8 11.75 0.0132 3/16 36—THE IRON AGE, September 1936 phenomena observed the cutting steel. For practically all large feeds and depths cut used, was ob- served that the chips came off the form large spirals which be- came smaller diameter the tool became dull. Before the break- down the cutting edge the chips curved pieces. Considerable trouble was encountered turning with small feeds that the chips would tend curl about the tool and wedge between the tool-holder and the re- volving Monel Metal round. determining the effect cut- ting speed tool life depth cut 3/16 in. was used throughout with feeds 0.0033 in., 0.0132 in. and 0.0284 in. with variations cutting speed and tool life. Table shows the results tests run the above mentioned feeds. Relationship Between Speed and Tool Life attempting derive mathe- matical relationship between cut- ting speed and tool life, the cutting speed was plotted against tool life log—log coordinate paper keep- ing the feeds separate. From the curves thus obtained the following 2—A special tool-holder was em- ployed for the lathe cutting tests. found: ........ Feed 0.0033 in. ........ Feed 0.0132 in. ........ Feed 0.0284 in. speed ft. per min. tool life minutes. ; ? | | | Cutting Speeds for Wrought Monel Metal Based Tool Life Min. METAL CUT TOOL (pictured below} per cent Side Cutting Edge Angle Yield Point per sq. in. Back Feed In. per Rev. 0.002 0.004 0.008 /64 1/32 1/16 Depth Cutting Cutting Cutting Cutting Cutting Cutting Cutting Cut Speed Speed Speed Speed Speed Speed Speed 262 209 168 139 118 104 1/16 223 179 144 104 205 163 138 110 192 153 124 103 These calculations, based part the data Mr. article, are published courtesy the Special Research Committee the Cutting Metals. Nose Shape lathe tool used Matsen monel metal cutting experiments. i | | j | ; | t | - | | . } ‘ J | | Using these approximate rela- tions, was calculated for each test point. Using the values thus obtained for each single feed one set, tabulation was made accord- TABLE 2—Results Tests Run Various Feeds, with Depth Cut and Cutting Tool Depth Speed Life Feed Cut 227 0.00474 3/16 7.05 0.0464 3/16 225 0.00474 3/16 223 3/16 103 0.0264 3/16 105 10.25 3/16 162 8.30 0.0132 3,16 151 0.0132 3/16 TABLE 3—Results Tests Run Various Depths Cut and Constant Feed Cutting Tool Depth Speed Life Feed of Cut (Ft. per min.) (min.) (In. 276 10.38 0.0033 1/16 250 11.66 0 0033 a 251 12.20 0.0033 220 7.91 0.0033 205 13.18 0.0033 5/16 210 0.0033 5/16 300 8 02 0 0033 1/32 200 0.0033 7/16 TABLE 4—Average Chip Thickness and Length Engagement for Different Cuts and Feeds Depth Length Average Engage Chip Cut ment Thickness 1/32 0.0033 0.091 0.001131 1/16 0.133 0.00155 0.0033 0.202 0.00204 3/16 0.0033 0.268 0.00230 5/16 0.0033 0.00257 7/16 0.0033 0.523 0.00276 3,16 00474 0.269 00330 3/16 0.0132 0 27: 0 00908 3/16 0.0284 0.281 0.01895 3/16 0 0464 0.292 0 02970 ing their absolute position the monel metal round, inches diameter and approxi- mate thirds the log length the headings. The values grouping were then averaged, and this average used indication the machinability the annular ring covered the grouping. average value for all points was obtained base point. This value divided each annular ring average gives factor which was used correction for the indi- vidual values. Each cutting speed multiplied its appropriate cor- rection factor for the ring which occurs gives value basis uniform possible far the metal cut concerned. Plotting the new values cutting speed against tool life, smoother curve obtained than the one obtained from the preliminary values. The follwing relationship then found hold: constant for 0.0033 feed. constant for 0.0132 feed. constant for 0.0284 feed. Figs. and show the curves obtained after the correction factor has been applied the cutting speeds. The average the first two ex- ponents 0.123. appears that for feeds where the tool fails nose abrasion the exponent some- where around 0.123, while for feeds where the tool fails cratering the exponent 0.153. Several tests were conducted different feeds and depths cut. Table shows the results tests run 3/16 in. depth cut and varying feeds, with tool life 8-10 min. Table shows the results tests run constant feed 0.0033 in. and varying depths cut with cutting speeds such obtain tool life 8-10 min. obtaining the relationships for variations depth cut and feed, each cut was reduced length engagement tool with the work and the average According Deale this method much more fundamental than depth cut and feed used investigators. The total length engagement the total length engagement the cutiing edge the tool bit with the Monel Metal round, shown Fig. Table gives the average chip thickness and length en- gagement for several different cuts and feeds. According Mr. Deale the de- sired formula should have the form where the cutting speed ft. per min., the average thickness the chip, the total length engagement, the tool life min- utes, and constant depending the material cut. The value has been previously deter- mined from the equation VM’ TABLE 5—Average Power and Value for Three Different Feeds Depth Cut Cutting Depth Speed Value 0033 298 1.82 9.98 0.0033 3/16 300 1.75 9 45 0.0033 3/16 296 1.74 9.50 0.0033 3/16 225 1.30 9.3 0.0033 3/16 237 1.38 9.42 0.0033 246 1.30 8.54 0 0033 3/16 251 1.39 8.96 3/16 239 1.38 9.35 0.0033 3/16 236 1.31 8.98 0.0033 3 16 232 1.32 9.20 0.0033 3/16 286 1.62 9.15 3/16 302 1.79 0.0033 3/16 305 1.72 9.14 0.0033 3/16 302 1.98 10.60 0.0033 3/16 261 1.49 9.24 0.0033 3/16 256 1.42 0.0033 3/16 254 1.52 9 68 0.0033 3/16 260 1.39 8 64 0.0033 3/16 256 1.65 10.4 0.0033 3/16 222 1.22 8 90 0.0033 3/16 223 1.10 7.98 0 0033 3/16 216 1.28 9.60 0.0033 222 1.33 9.72 0.0033 232 8.44 0033 3/16 206 1.19 0.0033 3/16 209 1.22 0.0033 3/16 208 1.16 9 02 0.0033 3/16 212 1.26 0.0033 3/16 210 1.34 10.30 0.0033 3/16 237 1.20 0.0033 3/16 241 1.52 10.20 0.0033 3/16 242 1.32 8.82 0.0033 3/16 213 1.3 10 20 0.0033 3/16 213 1.16 0033 3/16 214 1.22 9.20 3/16 135 6.85 0284 3/16 127 4.72 6.99 0.0284 3/16 122 4.29 6.60 0.0284 3/16 118 4.38 6.98 0.0284 3/16 118 4.36 6 94 0 0284 3/16 107 3.96 6.95 0.0284 3/16 107 3.90 6.84 0.0284 107 4.02 7.05 0.0284 3/16 105 3.70 0.0284 3/16 104 3.63 6.55 0.0284 3/16 105 4.10 7.34 0.0284 3/16 103 3.89 7.10 0284 3/16 100 3.55 0284 3/16 112 4.28 0.0284 3/16 105 3.80 6.80 0284 3/16 6.65 3/16 162 3.12 7.80 0.0132 162 7.55 0.0132 3/16 162 3.15 3/16 151 2.82 0.0132 3/16 17% 3.30 7.55 0132 3/16 176 3.40 7.82 0.0132 3/16 174 3.37 7.85 0.0132 3/16 175 3.63 0.0132 3/16 151 2.71 7.36 0.0132 3/16 153 3.01 7.97 0.0132 3/16 153 2.86 7.57 THE IRON AGE, September 10, 1936—37 | 100 Cutting Speed, min. ° RIGHT 1G. 4—Effect speed tool life. Feed, 0.0132; depth cut, 3/16 and ° ° ° 200 Cutting Speed, per min. So constant. Therefore remains obtain the value and the method least squares the following relation found: 5.70 cutting speed for tool life minutes. This formula applies where the chip thickness greater than 0.015 in. For cuts with chip thickness less than 0.015 in. the formula is: 37.7 The above relations were ob- tained with the aid information from the tests forged and cast Monel Metal conducted the In- ternational Nickel Co., Inc. ap- pears, then, that there double relationship, but whether such V actually exists cannot verified the present data since the author was unable run 38—THE IRON AGE, September 1936 Cutting Speed, ft. per min. ° LEFT 1G. Effect speed tool life. Feed, 0.0284; depth cut, 3/16 in.; and ° ° Time, min. Back Length Billet Angle IG. 6—For ob- taining the re- Depth lationships for vari- ations depth cut and feed, each cut was reduced length engage- ment tool with the work and the aver- age chip thickness. ° ° ° sufficient number tests the heavier feeds. Power Measurements Power measurements were taken for nearly all tests reading the ammeter and voltmeter placed the power circuit. The average product the voltmeter and am- LEFT 5—Effect speed tool life. Feed, 0.0033, depth cut, 3/16 in. and Total Length Engagement Front Length meter readings gives the power re- quired turn the Monel Metal test piece plus that required for cut- ting. Voltmeter and ammeter read- ings were taken before and after the actual cutting each test; the average product the two sub- tracted from the product volt- meter and ammeter readings taken 200 200 ™ Time,min. | feed | while the tool was cutting, gives the net power approximately for Cutting Speeds for Wrought Metal* approximate equation for the Based Tool Life Min. power required may written follows: METAL CUT TOOL cut inches; cutting speed per cent Side Cutting Edge Angle.........20 deg. substituting the equation values Reduction Area........ per cent ine 207-22 Table gives the average Cut Speed Speed Speed Speed Speed Speed Speed The maximum, minimum and 262 209 168 139 118 104 average values are: 223 179 144 121 104 205 163 138 110 Depth Max. Min. Average 192 153 124 103 0.0033 3/16 in. 10.60 8.19 8.54 0.0132 3/16 in. 8.40 7.96 7.75 0.9284 3/16 in. 7.34 6.55 6.88 The average value for all feeds *These calculations, based part the Mr. Matsen’s article, are published courtesy The equation the A.S.M.E. Special Research Committee the Cutting Metals. This table has been enlarged the accompanying insert for the convenience readers that might de- will give the approximate sire preserve for permanent use. power only the lathe cutting Fig. power plotted against impossible plot power against that before any definite conclusions cutting speed for three different cutting speed for different depths can made the power re- quired the cutting Monel Metal more data must made available. For example, the maxi- mum momentary power demand was not considered here, although power transmission problems. How- ever, the data obtained for the three different depths cut gives least some practical information the power required. 400 The author wishes acknow- Deale, and also Dr. Eric Therkelsen and Prof. Fred Homann Montana State College. The author indebted the Inter- national Nickel Co., New York, for contributing the hot forged Monel Metal rounds for the tests and the Brown Sharpe Mfg. Co., Providence, I., for the heat treat- ment the tool bits. Cutting Speed, ft. per min. + BIBLIOGRAPHY er Science? Deale, American Machinist, Vol. 77, Dec. 1933, pp. 782-785. With Shallow Cuts High Power, kilowatts Power Required Cut Metal. Charles Robbins, Fic. 7—Power plotted against cutting speed for three different feeds. tions, Vol. 32, 1910, pp. 199-209. monel metal and for the particular shape tool used. feeds. Insufficient data makes cut. apparent course THE IRON AGE, 10, 1936—39 5 7.72. ibe ay Flexibili fast moving indus- try like the automotive, flexibility layout essential almost all operations accommodate process variations attendant upon yearly design changes. body plant, for example, not uncommon shift conveyor lines, welding machines and fixtures often once year. Stamping operations are carried also progressive lines and equally desirable able shift presses about facilitate flow from oper- ation operation. Shapes vary, number and sequence operations vary. The steady increase the size and weight body presses has made the problem simpler, with unit weights running 500 tons. Heretofore, the practice has been make individual foundation pits for these monsters. Some have been dug ft. bedrock. Often one-third the press below the floor level, but unlike forging hammer, movable machinery, such pneumatic cushion beds, the base which access must had. The weight must carried from the press shoes the ground through concrete columns outside the pit cap usually resting piles. Once such pits are located the shop floor, there incentive great enough warrant changing them. Yet shift few feet between machines facilitate handling stampings be- tween operations. provide just such flexibility, the construction engineering de- partment the Fisher Body Corp. resorted original type IRON AGE, September 10, 1936 overall press pit for the new Gen- eral Motors stamping plant now getting into operation Grand Rapids. Before describing the de- tails the solution the prob- lem, the general layout will re- viewed. The press shop designed produce 2000 sets body stamp- ings daily. has five bays ft. wide 260 ft. long for the longer sections roughly C-shaped structure. each bay are two production lines presses, making ten all. the large equipment, there are five 500-ton seven 300-ton and twenty 200-ton units. There are six presses full line. The largest presses used make Fisher Body steel “turret tops” weigh approximately 970,000 lb. apiece and carry dies weighing 140,000 Impact load figured 500,000 additional. The ar- rangement such that any one these big fellows can spotted anywhere the 154,000 sq. ft. floor space, within certain broad limits. brief, network steel gir- ders cribs has been constructed within monolithic waterproof concrete pit boat. Over 2000 tons steel went into the press foundations alone, exclusive any the superstructure. The con- crete pit has some unusual points LEFT ORM'S eye view one the press pits show- ing longitudinal rails supported con- crete pillars and 36- in. Press weight 490 tons. RIGHT ODELS wood and paper help engineering decis- ions when unconven- volving large expenditures are being considered. This model shows the presses General Motors new stamp- ing plant Grand Rapids. ° FRANK OLIVER Detroit Editor, The Age from the floor level, has bottom ft. thick resting piles driven ft. in. centers both direc- tions. fact the entire building, including die shop, metal shop and power plant, rests over 6000 piles. The walls the pit taper from in. the base in. the top. make the whole struc- ture single monolithic unit, the pit was poured continuously, day a 4 and night, the rate cubic yard minute until some 7000 yards had been poured. For water- proofing, membrane asphalt tar and pitch was first laid down. flexible enough stretch should any cracks develop from press vibrations. has been indicated, each the five bays there are two longi- tudinal pits running the full length (CONTINUED PAGE 121) THE IRON AGE, September 10, | ig a ° ° ° i i at ay ARF, Evaluating Shop Jobs AGE rates industry present two distinct problems. The first concerns management and consists the adoption general wage scale based costs and wage rates within its dis- trict. The second concerns the industrial engineer and consists determining the relative value among jobs, the relative position vari- ous jobs within the wage scale adopted the manage- ment. Itis the second, job evaluation, that the subject this accompanying article. The necessity rating jobs lies maintaining balanced labor market and being able more confidently jus- tify individual the various differentials wage rates, the latter now more necessary, perhaps, than ever. analytical method rating, the point sys- tem, here outlined Mr. Bass. Actual application this system will discussed coming issue. your shop men ever question the equity your rate differentials? so, you have refer district rates general comparisons for your justification? For years that what we, along with most other industries, have had do. Let take case illustrate: Mike Puloski dissatisfied with his hourly rate. Now Mike intellectual giant, but fair- rational human being. not primarily interested the com- pany’s general wage scale, and knows little about price indexes and district rates. What does know that his job requires cer- 42—THE IRON AGE, September 1936 tain skill and involves certain defi- nite responsibility, and comparison with other jobs his own department. His complaint not generally with any absolute rate, but rather based upon what his job paid relation others. down talk with him, and are invariably greeted with the question “Where the did you get this rate?” This in- volves long explanation how different jobs have been fitted into the wage scale what judgment would indicate was their proper relative importance. Mike, how- ever, feels that result his closer perspective the work, his judgment just good ours and his judgment indicates that are wrong. ask Mike pick out the job with which feels his should compared, and sit down dis- cuss with him. “To start with Mike, let’s con- sider the mental requirements your job. You have study your drawings and figure out your set- ups, and layout your work and cal- culate some angles, but this other?” “Well, no, not quite,” may an- swer. “Very well,” reply. “You also need considerable amount manual skill, that is, you need accurate sense touch and you can’t all thumbs, but does your job require much this kind skill the other?” “It requires awful lot more.” “That reasonable,” may re- ply, “but does involve much responsibility?” “No, but look the working conditions, would rather have that other job any time.” spirit open mindedness, will all probability assume the same attitude toward us, and that case, his answers will pretty gen- erally agree with our own ap- praisal. So, here are agreement certain those fundamental qual- ities which themselves justify | | ‘ | ° ° Industrial Engineer, South Philadelphia Works, Westinghouse Electric Mfg. Co. ° ° ° differentials job values, and yet, the total relative values the two jobs. cannot categor- ically say that are right, for have only our judgment guide us, and while may little more accurate than Mike’s, far from infallible. Point System Yardstick The sole reason for our continued failure agree rests upon the sim- ple fact our having means measuring the proportion the job’s value that was represented this lower degree mental require- ments, this lot more skill, and this variance and working conditions. had had yardstick set-up beside these qualities, that was possible every case measure the number inches difference, the algebraic total all those pluses and minuses would represent the differ- ence value between the jobs. When this, have what commonly known point system for the evaluation jobs. This not strikingly new. For number years has been used different forms and with vary- ing degrees success limited number businesses. Probably, the reason for its not more general adoption due partly the lack publicity given it, and partly the lack uniformity its success. Failure Lies Approach However, where its application has not been satisfactory, rea- sonable assume that the failure rests the approach made set- ting the system, rather than the fundamental theory the sys- tem itself. For job evaluation nothing more than subjecting the wage element cost the same analysis that for years have subjected the time element. The micro-motion camera has been used measure seconds, and yet, wage rates have been predicated upon little more than general compari- sons. With respect wage rates, in- dustry has two distinct problems. The first belongs management, Blading turbine rotor and consists the adoption general wage scale, which must compatible with costs and with labor rates within its own district. The second belongs definitely the industrial engineer. consists determination relative value among jobs, what the same thing, their relative position within the wage scale. this second problem, the in- dustrial engineer’s most valuable instrument can well thought out and carefully applied method job evaluation. This method should not construed, however, means miraculously deter- mining the absolute economic value any given job. opinion, should not bear any relation all hourly rates, until the rela- tive position values are applied the adopted wage scale, and this can anything. Moreover, wrong consider this approach the determination relative job values scientific, for that implies something which THE IRON AGE, September 1936—43 possesses the accuracy mathe- matics. whatever means the positions jobs rate structure are determined, comparative judg- ment must used the last anal- ysis determine the differentials. Now, wherever problem must referred judgment, the accuracy this mental appraisal will contingent upon the number factors which must mentally weighed and considered. So, can segregate these factors, this method job evaluation, and consider them separately, our problem applying judgment will much more sharply focused, and possible errors will consider- ably minimized. Real Need for Accurate Job Rating The need industry whole for more accurate rating jobs very real—not, however, from the standpoint cost reduction, for this does not necessarily follow. The needs that are important, are for: 1.—Maintaining balanced la- bor market, and 2.—Being able more confi- dently justify differentials wage rates. For industry whole pay more for given occupation than worth relation other jobs attract disproportionate vol- ume labor that trade with the eventual and inevitable result generally unbalanced labor supply. The ability rationally justify rate differentials going become more necessary from now on. The day when foreman could categor- ically state that rate was right and let that past. La- bor going demand more and more reasonable accounting for rate differences, and industry must position give them some- thing other than mere opinion. This apt brought even more the forefront the rapidly emerg- ing vertical union. With union ac- tivity confined largely the crafts, this problem does not exist, but with the industrial union, which embraces the sweeper well the toolmaker, the prob- lem not only will exist but will un- questionably made point discussion. Selection Factors Measure The ultimate success failure any attempt rationalize job 44—THE IRON AGE, September 10, 1936 values lies large degree the proper segregation for measure- ment those factors which create wage differentials. Obviously, any factors are omitted from measurement, jobs which derive their principal value from this source would heavily undervalued. the attempt made measure specific qualities certain job trade, the num- ber these qualities that will necessity have measured when the evaluation scheme embraces wide range different jobs, be- comes legion. order make the plan simple possible and eliminate the danger overlook- ing any contributing qualities, the belief that the only proper approach along the lines those qualities which are fundamental and general nature. While this does not relate the mea- surement factors specific and concrete might otherwise, does eliminate the dangers com- plexity and disproportionate evalu- ation that have already pointed out. this plan, the approach selection factors along the line fundamental principles. Very broadly speaking, felt that there are only three elements contributing job values. These are: 2.—Personal Characteristics. 3.—Working Conditions. make further subdivision these factors would give much less analytical approach the problem than that which originally set out make. necessary, therefore, review these three elements with view any further possible breakdown which will still embrace fundamen- tal qualities. 1.—SKILL Skill its broad interpretation knowledge subject combined with mastery its technique. Such skill, however, must presuppose certain inherent intelligence. job becomes more complex, and its administration becomes more dependent upon reasoning, and less upon acquired motor skills, the in- telligence needed perform be- comes increasingly greater. therefore, fundamental and general fac- tor which should measured separately. Two other general and funda- mental elements skill immediate- become apparent, namely: B.—Knowledge facts, and C.—Whatever acquired motor skills are necessary. These, therefore, together with intelligence constitute the major part all skill. Under the factor knowledge must considered all knowledge required whether academic specific nature, and under motor manual skill, the degree this type skill needed. There one other element wise measure under skill, and this is: D.—Learning time. While this obviously redundant knowledge and manual skill, desirable for two reason: First, permits remeasuring from more objective viewpoint these two important factors acquired skill. Second, permits measuring ex- perience, which not covered any other factor. There are jobs requiring many years experi- ence master, yet, which these additional years not add appre- ciably either knowledge man- ual skill. measuring learning time, possible compensate for this extended experience. The detailed factors selected measure SKILL are then: Mental Re- quirements. B.—Knowledge Required. C.—Motor Manual Skill, and D.—Learning Time. TICS Considering personal characteris- tics, there are again several differ- ent types, but only one which necessary consider. This is, that characteristic caution, careful- ness, accuracy, the possession which enables individual safely assume responsibility. Since the value this factor contingent upon responsibility, will called responsibility and measured such. 3.—WORKING CONDITIONS Consideration working condi- tions brings light one fundamen- tal division that can made. This between the A.—Personal application which required some degree every job, and the B.—Hazards undesirable condi- tions occupational na- ture that are only present in, occasional jobs. | ) Vice-President, Brown Sharpe Mfg. Co. Drawn John Frew for The > P f | } | Again, personal application subject logical division. This is, the one hand: a.—That physical fatigue which re- sults from heavy laborious work, and the other b.—Nervous fatigue, which results from close continuous con- centration the senses. Occupational working conditions sired, according their character. Therefore, under the ele- ment WORKING CONDI- TIONS, measure: A.—Application (a) physical and (b) nervous; Working Conditions, (a) Hazards, (b) Heat, (c) Dust, etc. Measurement factors such those enumerated are such general nature applicable any industry, textile, metal manufacturing, cabinet making, processing. might appear though were mistake make the scheme general, and though would better make specific the plant industry involved. that were possible, probably would be; but where the one plan must evaluate several totally different types job with- the one plant, must such general nature that automati- cally becomes applicable any type job any industry. Construction Rating Scales Having decided what factors can logically apply measure, the next step becomes that de- ciding how this measure applied. The final object any plan job rating, job classifica- tion, job evaluation should determination relative job value comparison each job all other jobs. Therefore, the final form that job evaluation takes, one rating scales. other words, sufficient number representative jobs are ranked, listed the order their degree under each factor. These jobs should cover the range the portion the wage scale subject evaluation, and con- tain many intermediate exam- ples are necessary give *This should not misconstrued attempt fake figures. The actual rate that would result from evalu- ation the lowest class labor would not living wage. The points added the curves this manner, represent the difference between this actual evaluated rate, and the rate industry has established minimum view contemporary living stand- complete picture the relationship jobs the case each factor. When this has been done, the evaluation any additional job becomes purely matter fitting into these key rating scales what would appear its proper location relative jobs already ranked. Weighting Factors Necessary There are three definite advan- tages applying point weightings the factors, and using points making the evaluation. the first place, the mere rank- ing jobs under each factor con- tains significance until these rankings are some way mea- sured and some abstract measure obtained which will express the value jobs their mutual rela- tionship. The obvious advantage there method measuring the results obtained. Second, all the factors selected are not equal importance con- tributing job value. However, careful weighting, possible represent these varying values, and reflect them the final point value the job. Third, using points, there al- Ways remains concrete measur- able record the analysis made, and should the rating subsequently questioned, the actual evaluation always remains and can readily rechecked. Just how much intelligence worth relation learning time and all the other factors will al- ways question. There little objective measure for any these weightings which must estab- lished. However, good judgment can approximate their relative im- portance, and the subsequent evalu- ation jobs whose value fairly general agreement will tend uncover any serious errors. Embodying Geometric Progres- sion the Point Values Theoretically, any ture should embody the mathe- This true regardless the method which position ratings are made. For there series jobs which the theoretical value each succeeding job worth increment more than that preceding it, the wages paid should also more the same increment. using point method evaluating jobs, the embodiment such curve the wage structure becomes relatively simple. With relative point weightings assigned the various factors, curves can drawn semi-log paper from certain minimum value the selected maximum maximum value, course, must established for some known condi- tion, and does not necessarily rep- resent the limit which the evalu- ation carried. These maxi- mums simply reflect the highest levels responsibility, intelligence, the jobs under consideration when the relative weighting the factors was made. takes only two points determine straight line, that all care about here. Any these curves can ex- tended for any other jobs which would require ratings above the maximums previously established. Selection the starting point for each these curves, introduces another consideration. The value the lowest condition under each factor not zero, for every job re- quires some learning time, only day so, and every job requires some intelligence. Moreover, the geometric progression the actual wage structure started from zero, and not from the level the minimum wage. Therefore, the selected point value for the mini- mum condition under each factor not sufficient bring zero points out equal zero cents per hour, when the points are eventually re- lated the wage scale, sary add sufficient points this minimum each case that this condition will met.* After curves are drawn from this new minimum, perfectly permis- sible subtract this added num- ber points from all values taken from the curve. doing this, are only making the absolute start- ing point our geometric progres- sion point values coincide with the absolute starting point the natural geometric our wage structure. order get this geometric progression into our job rankings, divide the curve into suitable number equal increments along the arithmetic ordinate. The point values taken from the curve these various steps serve classes ratings which all jobs are assigned. When the job rankings under each factor have been as- (CONCLUDED PAGE 123) THE IRON AGE, September 10, | 7 | : ° JONES ° ° THE name “Tool En- difficult even for those devoting all their time it, specify exactly what should does include indi- cate its exact boundary lines. Yet many the elements tool engi- neering originated antiquity, for certainly even Pharaohs Egypt tooled the stones build their world-famous sepulchers, tool engineering was old. The designing and building tools, and the planning manu- facturing processes had been incidental function general en- gineering for many years. The function received little attention, and required little attention, until interchangeable manufacturing be- came general. interchangeability, that is, the mak- ing thousands identical de- tails, without the assumption near perfection form and dura- bility tools. Nor possible visualize the parts compli- cated assembly passing through factory from machine machine, and from process process, their various stages manufac- ture from the ingot the final as- sembly line, without also assuming the pre-existence very careful planning. the fewest words, tool engi- neering the devising manu- facturing processes, the orderly arranging their sequence and the designing all production equipment. vision the breadth and scope tool engineering, one need but recall that each machine, and each device used conjunction with machine, any device used the hand workman manufactur- ing process tool. The development and spontane- ous growth mass manufactur- ing has had profound effect upon nearly every phase human ex- 48—THE IRON AGE, September 10, 1936 istence today. The continued ad- vancement civilization will de- pend largely upon the advance- ments made mass manufactur- ing. But continued development mass manufacturing can only follow the development tools. Because the growth mass manufacturing and the consequent importance and immensity the Tool ngineering problems tooling, they were in- evitably divorced from general en- gineering and the new profession tool engineering born. Master mechanics, tool, die and machine designers, plant superin- tendents, and other engineers and executives with varied titles had been doing tool engineering nearly long was possible without the benefits association which could coordinate their activities, as- semble the information they needed and aid the solution their pe- culiar problems the older so- cieties have met the needs their members. Historians can usually throw halo romance around the events natural actions individual individuals instrumental pio- neering movement founding empire. But seems those who founded the American Society Tool Engineers that heroics had part its humble beginning. The time was hand and the con- ditions were ideal, heroic efforts sacrifices were necessary. Indeed the simple circumstance, prosaic situation, that really started the American Society Tool Engineers was the “Hunger- ing and thirsting after knowledge” group students the little Detroit College Applied Science. They had been conducting Tool Engineering Society for several years. Aside from considerations good fellowship, its principal purpose was having experienced tool engineers bring practical in- formation for presentation their meetings. This did not provide close con- tact with tool engineers the stu- dents needed, Jones, presi- dent the college, conceived the idea reorganizing the student society into national society for tool engineers. first discussed the idea with Ford Lamb, the Consolidated Machine Tool Corp., who consented attend meeting provided one could arranged with other tool engineers. week after this, around the middle February, 1932, small group was invited meet the college discuss the idea. Those present were Frank Shailor, who was then die design instructor the college; Frank Hartlep, then chief tool designer for the Timken-Detroit Axle Co.; Guy Swartz, the Swartz Tool Products Co.; Otto Poelke, then the Cadillac Motor Car Co.; Ford Lamb and Jones. Organization plans were worked out subsequent meetings which were attended additional tool engineers. March thirty- three tool enginers representing cross-section manufacturing Detroit elected five their number officers serve for period one year. Siegel the Packard Motor Car Co. was elected presi- | = dent. Smila the Chrysler Corp. was elected first vice-presi- dent, and Earl Ruggles the Gemmer Mfg. Co. was elected sec- ond vice-president. The first sec- retary was Sargent the Pioneer Engineering and Mfg. Co. Fors the Stenger Die Tool Co. was elected treasurer. About three weeks after the elec- tion officers, first general meet- ing was held Webster Hall Detroit the evening March 23, for their installation. this time the membership consisted approximately 200 senior and junior members. The society was chartered under the laws the State Michigan non-profit corporation March 31, 1932. One the most impelling rea- sons for organizing the society was keep tool engineers advised what was taking place throughout the entire tool engineering field. That the young Society set about with real speed evidenced the fact that 500 copies 24-page journal the society were mailed the membership and potential members the latter part April— within days the date its incorporation. bore the May, 1932, date. was compiled, edited, and managed completely commit- tee known the “Publicity Com- “A.S.T.E. Journal” was published under Lamb’s leadership until the May, 1933, is- sue when the chairmanship the publicity committee over Jones, who was re- sponsible for the publication the Journal until the Feb., 1935, issue. From that date this, the offi- cial organ the society has been published under the business man- agement the Bramson Publish- ing Co. and editorially supervised the committees appointed the Society president. the time the publication was turned over the Bramson Publishing Co., its name was changed from Jour- nal” “The Tool Engineer.” The January, 1936, issue The Tool Engineer had circulation more than 5000 c