The Iron Age 1936-11-19: Vol 138 Iss 21

Wean Equipment Insures High Quality —Low Cost Tonnage UNCOILING UNITS. PRESS FEEDING EQUIPMENT. SLITTERS. STRIP UNCOILING AND AUTOMATIC SHEARING UNITS. STRIP COM HOLDERS. STRIP COMING REELS. SHEET GALVANIZING EQUIPMENT AUTOMATIC TINNING EQUIPMENT. AUTOMATIC DOUBLERS. NORMALIZING FURNACES. McKAY LEVELLERS AND PROCESSING UNITS. CONTINUOUS STRIP PICKLING EQUIPMENT in- cluding: UNCOILERS. UP-CUT SHEARS. STITCH. ING MACHINES. PINCH ROLL UNITS. RECOIL. ERS. DRYING MACHINES. PICKLING TANES. and AUXILIARY EQUIPMENT. SCRUBBING. LEVELING. and OILING MACHINES for FLAT PRODUCTS. WILSON VERTICAL TUBE TYPE ANNEALING FURNACES. AUTOMATIC FEEDING AND CATCHING TABLES CONTINUOUS PACK AND PAIR HEATING FUR- NACES. WHEELABRATOR ABRASIVE CLEANING EQUIP- MENT. The MACHINE CO. WILSON ENGINEERING CO. | \ acc 4 ASSOCIATE COMPANIES you have problem iron steel, the logical man ask Republic Metallurgist. The Republic Metallurgist knows steel alloy steel, carbon steel, and pig has intimate knowledge industries that use fine steels constantly co-operating with turers the selection irons and steels that improve the product reduce production cost and has the backing the largest research organization and the largest research the industry. you would like know the best type steel for given application...if you have heat treating problem...if you are looking for longer service lower costs from steel REPUBLIC information assistance will receive prompt attention. write Department IA. Your questions requests for Repu blic Steel GENERAL OFFICES: CLEVELAND, OHIO 2—THE IRON AGE, November 19, 1936 THE IRON AGE, published every Thursday the CHILTON CO., (INC.), Chestnut 56th Sts., Philadelphia, Pa. Entered second class_matter November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. 138, 21. « costs and quality parts Union Cold Drawn Steel Bars promote They produce parts that are stronger and smooth, trouble-free operation automatic that wear longer because their higher screw machines because they are straight physical properties. and accurate size and cross section. These advantages are provided economi- They save power, increase tool life and and the expense manufacturing speed parts production because their parts reduced that the final cost improved machinability. minimized. They need machining obtain good Union Cold Drawn Steels are made finish because their surfaces are smooth shapes and grades meet all your and bright. requirements. UNION DRAWN STEEL CO. MASSILLON, OHIO Subsidiary REPUBLIC STEEL CORP. THE IRON AGE, November 19, — MONEL New Hardenable, Non-ferrous Alloy, Combining Great Strength and Hardness with High Corrosion Resistance Composition Monel new hardenable alloy made from Monel Metal introducing small quantities aluminum. Monel has all the corrosion resistance Monel Metal, and, through heat treatment, pro- portional limits excess 100,000 p.s.i. may developed and hardnesses over 325 Brinell. The following analysis typical— Copper.... 30.84% 1.50% Sulfur...... Heat Treatment and holding this temperature accordance with Figure Softening accomplished quenching from 1450° This operation should not done unless the alloy prepared for further cold working quenching preliminary operation mill production. After quenching, the metal soft BHN) and may readily cold worked. Any hardening that results from the cold working retained during the reheating and holding, which further increases the hardness. Hardnesses well above 325 BHN and proportional limits well above 100,000 p.s.i. may developed this manner, which combines the hard- ening effects cold work and heat treatment. Heat treated Monel may partially softened heating the metal and cooling air. Fig. shows the relation heating tempera- ture hardness obtained partial softening. obtain complete softening, the metal quenched water oil from 1450° higher. Close temperature control essential heat treating Monel and proper heating important outlined under forging. About one hour per inch diameter thickness required bring the metal uniform temperature. 2 4 6 8 10 12 “4 6 18 2 Hours at Temperature followed by furnace Cootng Relation hardness holding time 1080°-1100° F. Hardness G 006 3000 2 4 6 8 10 12, “ 8 20 Temperoture hundreds degrees F Fig. Relation heating temperature hardness, partial softening Monel Grades and Properties Monel supplied four hardness grades having the mechanical properties the table. Grade hot rolled and quenched obtain softness. Grade obtained cold drawing cold rolling grade material. Grades and are produced heat treating grades and respectively. Grade may produced also special heat treatment grade Figure shows the approximate rela- tions between hardness and properties. Monel supplied most mill forms. For de- tails, consult your nearest source supply shown the back this page. = = Yield Hard Tensile Strength Proportional | Elonga- Brinell ness | Serength 5% set) Limat Hardness Grade pst psi pst % m2” | 000 Kg A_ | 120000 max. 80000 max. 60000 max 40 min. | Softer than 215 B | 120000 min. 80000 min. 60000 min. min. | 215-265 140000 max. 100000 max. 80000 max. C | 140000 min 100000 min. 80000 min. 20 min. | 265-315 | 160000 max. 120000 max. 100000 max. D | 160000 min 120000 min. | 100000 min. | 15 min. | Harder than 315 —_ = 180 160 140 Rockwett "C Hardness Gongation (27) and Reducton of Aves Proportional Vieid Breaking Strength « 1000 Ps: od Impact Brinel! Hardness - 3000 Kg Fig. relation between hardness and mechanical properties Monel. Endurance Limit The endurance limit, determined special machine for testing flat strips, 36,500 p.s.i. cycles for Grade and 26,000 p.s.i. for Grade The corresponding values are 24,500 p.s.i. for B&S numbers hard phosphor bronze and 20,000 p.s.i. for soft phosphor bronze. Physical Constants 8.58; 0.31 Ib. per cu. in. Specific Heat 0.127 Coefficient Expansion 0.000015 0.000016 Thermal Conductivity (c.g.s.).......... 0.06 62.8 microhms per cm. cube 62.0 microhms per cm. cube 61.9 microhms per cm. cube Grade A....... 378 ohms per circular mil-foot 373 ohms per circular mil-foot Grade D....... 367 ohms per circular mil-foot Temperature Coefficient 26,000,000 Torsional 9,500 000 Fabrication Monel fabricated the methods outlined be. low. Further information given bulletin available request. Forging: Practically any shape forgeable steel can forged Monel. The forging range 1799- 2175° Proper heating important. Avoid ing the hot metal heating atmospheres other sources sulfur. Use furnace designed that the flame does not impinge directly the metal and maintain slightly reducing (2-5% excess CO) furnace atmosphere. Charge the metal toa hot the work rising temperature never excess 2200° Material that later heat treated must quenched water oil from above 1450° Pickling after hot working facilitated quenching water which added 1-2% ume methyl alcohol. Bulletin T-9 gives pickling formulae. machinable. Better finish obtained with Grade than with the softer grades. Cutting speeds for Grade are about half those used for machinery steels: higher speeds can used lathe work. The tools used are tough high speed steel, such Rex the high tungsten low vanadium type. Sulfurized mineral oil used abundantly cut- ting lubricant. The springy chip from Monel requires attention prevent gouging the work, sheet metal shield can used keep the chip out the way. Tool design important. Blunt tools are used and they are ground provide good support for the cut- ting edge. The back clearance ground plane angle with the perpendicular and has been found highly advantageous especially milling cut- ters and hobs, grind small land wide the cutting edge, the plane the land being exactly perpendicular. circular tools this land ground circumferentially. The top and side clearances may varied suit the work. Side clearances range from and top clearances from 12° Cutting lubricants must removed thoroughly from parts that are heat treated after ma- chining. Silver Soldering and Welding: Monel silver sol- dered using Easy-Flo Solder and Handy Flux, both which are obtained from Handy and Harman, Fulton Street, New York, Monel can metallic arc welded using flux coated rod supplied INCO. Monel isa new alloy, wide practical experience has not yet been accumula welding it, but there appears reason anticipate unusual difficulties. Gas welding not applicable Monel. Grinding, Polishing and Buffing: Monel takes high polish. Grinding done under water fluid coolant wherever possible excessive heating affects hardness. Magnetic Properties Monel all grades non-magnetic both the soft and fully hardened condition temperatures above —40° and the permeability the air for magnetizing forces Gilberts per cm. The magnetic transformation point usually below —110° F.; though hardened Monel occasionally shows magnetic transformation point Literature Technical bulletin T-9 giving more detailed infor- mation the properties, heat treatment, fabrice- tion and uses Monel available request. Send for List showing all bulletins and other literature Monel Metal and rolled nickel. interested also nickel steels, nickel cast nickel bronzes, etc., ask for List well. Copies this page are available form. Send for yours. THE INTERNATIONAL NICKEL COMPANY, INC., WALL STREET, NEW YORK, 16—THE IRON AGE, November 19, 1936 2 wore 180 200 20 200 | { on CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, Owned and Published CHILTON COMPANY rcm. (Incorporated) and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. MUSSELMAN, President FRITZ FRANK, Executive Vice-President other e WILLIAM BARBER, Treasurer JOUN BLAIR MOFFETT, Secretary FRITZ FRANK President J. H. VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors F. JURASCHEK Consulting Editor Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNDTREE, JR. ALLISON Toronto, Ontario Birmingham St. Louis Buffalo Contents—November 19, 1936 The Economics Industrial Power Transmission......... industrial Apprenticeship 1936 Model......... How Arc Weiding Cuts Costs Jigs and Fixtures...... Use Photoelectric Pyrometer Shape Mills.......... Cement Bonded Sand Mold Making................. Stamping Buick Fenders New Equipment Automotive Industry Statistics Metal-Working Activity Washington News .......... NEWS CONTENTS Copyright 1936 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau Circulations ADVERTISING STAFF Member Associated Business Papers Emerson Findley, 621 Cleveland Published every Thursday. Subscrip- Hottenstein, 802 Otis Chicago tion Price: United States and Pos- Peirce Lewis, 7310 Woodward Ave., Detroit sessions, Mexico, Cuba, $6.00; Can- ada, $8.50, including duty; Foreign C. H. Ober, 239 W. 39th St., New York $12.00 year. Single copy, cents. Robinson, 428 Park Pittsburgh Cable Address, ‘‘Ironage. Warren, Box 81, Hartford, Conn. hot kling ‘ or, for inery The Rex type. Cut- lonel out cut- been actly ound range ighly ma- sol- both in, 82 flux been kes fluid ating | = ROLLED steel, now the most widely used form steel, rapidly becoming even greater utility steelmakers turn out sheets that en- able die presses remarkable things. great new continuous strip- sheet mill places Bethlehem posi- tion supply sheets the quality needed still further explore the BETHLEHEM STEEL COMPANY, General Offices: possibilities this method manu- facture—sheets stand the in- creasingly drastic forming operations these days. Backed source raw steel that has made ingots for high-grade sheet manufacture for many years, this new mill turns out sheets and strip that are unsurpassed re- spect finish and physicals. Bethlehem, Pa. District Offices: Albany, Atlanta, Baltimore, Boston, Bridgeport, Buffalo, Chicago, Cincinnati, Cleveland, Dallas, Detroit, Hartford, Honolulu, Houston, Indianapolis, Kansas City, Los Angeles, Milwaukee, New York, Philadelphia, Pittsburgh, Portland, Ore., Salt Lake City, San Antonio, San Francisco, St. Louis, 34—THE IRON AGE, November 1936 St. Paul, Seattle, Syracuse, Washington, Wilkes-Barre, York. Export Distributor: Bethlehem Steel Export Corporation, New York. b ie + 4 3 ... THE IRON NOVEMBER 19, 1936 ESTABLISHED 1855 Vol. 138, No. Have Faith American our friends wants opinion. writes follows: overwhelming victory Mr. Roosevelt the recent elec- tion naturally presents new problems industrial management throws added emphasis existing ones. What phase managerial responsibilities, your judgment, will most This not hard question answer. Beyond all doubt, the most impor- tant subject for the next year two least will that employer- employee relations. may not palatable for some face the facts, but like not, what have the United States today labor you doubt that, look the shifts Pennsylvania, Ohio, Illinois, Michigan and Connecticut. Labor, employed well unemployed, reelected Mr. reelected him the expectation that would things benefit labor. The great mass American workers evidently believe that Mr. Roose- velt can and will more for them than their employers could would do. this belief, not the facts which may eventually prove right wrong, that important and significant the employer. not now question whether the President did better selling labor than did the employers labor. Nor whether promised labor more than its employers felt safe promise. These questions are beside the point. The big, important thing for you think about this: great majority those who earn, depend upon wish for wages expect the Administra- tion better their lot. Just suppose that this did not come pass. Could the employer expect hope escape unscathed could shown that his kind had been responsible for throwing monkey wrench the wheels? That why say that employer-employee relations the dominant topic for our consideration for some time come. There must oppor- tunity given any one say that American employers have done less than all that was humanly possible better the lot both our employed and our unemployed. big job for big men. means serious and intelligent self- examination, followed resolution and action. for one, not think too big job for American employers, for have faith them. 7 P | af : | q q = 4 FRANCIS JURASCHEK Consulting Editor, The Iron Age this discussion, and others follow, at- tempt will made clarify the basic principles power transmission from the eco- nomic viewpoint such lan- guage the non-technical executive may readily grasp. Later, simple descriptions the functions all types power transmission equip- ment will given with par- emphasis upon the they play when proper- used; and finally specific ° has been variously estimated that the cost the power required drive the machines American industry amounts one and half billion dollars year. This cost, like the cost materials, equipment and labor, *“A Practical Analysis Some Fundamentals Industrial Power published Mechani- Power Engineering Associates. 36—THE IRON AGE, November 1936 problems power transmis- sion will analyzed vari- ous types manufacturing plants. means this ap- proach through economic principles and functions equipment actual appli- cation problems, viewed al- ways from the angle what may done eliminate wastes the use management may consider its specific problems intelli- gently and beassisted ing out reasonable solutions. basic element the price manu- facturer must pay make goods; cannot escape it. The cost not uniform all industries, but may vary from less than per cent more than per cent the total cost manufacturing. The implications, therefore, statement the opening pages booklet* which has had wide cir- culation among industrial execu- tives during the past four years are startling: “Not over three-quarters the rotary power produced any given source used pro- duction any plant. Ina large number plants, another quar- ter unnecessarily wasted.” This statement, which means that faulty power transmission wastes one-quarter one-half the pow- produced for the purpose driving machinery, has stood un- challenged and undenied. Further, hundreds capable engineers have admitted its essential truth. Back this waste power, which engineering problem, lies even more serious problem economics. Actually the proper understanding the engineering problem largely dependent upon the clarity with which the under- lying economic problem stated, grasped and applied the facts particular situation. Too frequently only the obvious en- gineering facts specific drive problem are considered any plant, and the solutions worked out, | N DUSTRIAL = generally rule thumb methods from the experience some old and trusted employee, not strike the real roots the difficulties. practical analysis the eco- facts involved the trans- mission power from source driven machine begins with this fact: All manufacturing power originates the form rotating shaft. The source may water- wheel, steam internal combus- tion engine the industrial plant, public utility central station oper- ating motor the factory. What- ever the source, the power becomes usable when turns rotating shaft. Practically all manufactur- ing loads are carried some form power application rotary shafts driven machines. between the rotary shaft that fur- nishes power and the rotary shaft which utilizes power the driven machine, that the losses mentioned above occur. There are certain losses under ideal conditions, course, for friction takes its toll everywhere and slip evitably, but large savings may effected the proper combination engineering and economic plan- ning. necessity, all types power generators deliver relatively large blocks power, and manufactur- ing loads are for the most part relatively small for each driven machine. The manufacturing prob- lem then concerned with the eco- nomic distribution large blocks loads. The Question Cost Into this problem, when viewed from the angle economics, enters the cost the invested capital re- quired provide the transmission system, the cost operation that system, the cost maintain- ing it, the relations between that system and the costs production flow, materials handling, labor, safety and plant light- ing; and with all these factors must considered also the general type operations for which the plant responsible, the need lack need providing machine mobility accommodate change production from time time, and the question whether the plant operates steadily full production every day, rushed death one time and sharply curtailed another. obvious that all these fac- tors should considered equally with the engineering problems in- volved the actual transfer power from one rotating shaft another, the most effective and economical use made the power required for manufacturing operations. That they are not applied the situation) suit the building, rather than the build- ing designed suit the machinery. Mill construction became nothing more nor less than box-like struc- tures from one half dozen floors, with side walls and roofs erected for the primary purpose RANCIS JURASCHEK, who has re- cently joined the staff The Age consulting editor the sub- jects industrial power transmission and materials handling, well known both these fields. After eight years engineering work transferred his affections the advertising and sales promotion industrial equipment, serving the marketing counselor's staff McGraw-Hill Publishing Co., organizing the industrial advertising the Hanff-Metzger ad- vertising agency, heading the adver- tising and sales promotion division The Yale Towne Manufacturing and becoming President the Frey- stadt-Juraschek industrial advertising agency. During the past two years was manager the Power Transmis- sion Council and that capacity has established the most friendly relations with the principal executives among the manufacturers power transmis- sion equipment and assisted organ- izing world-wide educational effort promote the economical use power industrial plants. considered thousands plants today must obvious also, the truth the statements made re- garding power wastes admitted. First Principles Industrial power transmission first became factor the general manufacturing problem when the invention the spinning frame Arkwright provided the basis for the Industrial Revolution En- gland. Thereafter, manufacturing, hand-working moved from the home the factory. The work hands became multiplied enormous- machines, and introduced the basic problem the use power. Waterwheels and steam engines were the first sources that power; from these sources ropes and then belts drove huge, slow-speed jack- shafts. turn, belts drove driving shafts countershafts which the machines were finally belted. Machinery layouts were designed (if indeed that word can properly protecting the machinery and goods process from the ravages the weather. Shaft hangers were in- stalled where the exigencies ceil- ing roof beams permitted, with- out regard the points load. Consequently (and also because light alloy steel shafting had not yet been developed) shafting was made heavy, withstand the con- siderable bending stresses drives located many feet away from the nearest hanger. Poor design, heavy equipment, bearings badly propor- tioned and even more badly lubri- cated, all united make frictional losses terrifically large. But power was cheap, one knew anything better, and output was far ahead hand work that these losses could and were neglected. Obsolescence, Per Cent Strange say, however, almost per cent the machinery in- dustrial plants America still being driven system power THE IRON AGE, November 19, 1936—37 4 2 transmission basically the same this. Old-fashioned lineshaft meth- ods these plants differ from the methods used our great, great grandfathers only the techno- logical improvements which have been effected equipment. The system (or lack system) oper- ation the same. The development the electric motor was the first break give rise real improvements power transmission. The motor made pos- sible for the first time direct ap- plication power each machine. the beginning was substituted for the source energy for en- tire shop, floor, department thereof. faint glimmering the idea grouping machines somewhat logical units brought breaking down the shop floor department into operating groups. Finally, with the develop- ment the small motor, individual machines were motorized, either belt chain, through direct coupling gears. many advantages were im- mediately apparent individual motor drives compared with the old-fashioned lineshaft system, that pronounced swing this method took place without due considera- tion the economic principles in- volved. Thousands plants today use the individual motor drive sys- tem cost out all proportion true economy. Finally men began studying the possibilities grouping machines such way secure efficient operation lowest overall cost, and modern group drive was evolved. This system power transmission, wherever can applied, both efficient and econom- ical beyond any other method yet developed; for based upon study the economic well the engineering principles involved transferring power large blocks from one rotating shaft number rotating shafts rela- tively small blocks. Compromise Modern group drive essentially compromise between individual electric motor drive and lineshaft drive. should called modern electrical group drive, because essentially based upon the electric motor source power, with that power delivered through line- shafting logical group ma- chines. This brief historical sketch 38—THE IRON AGE, November 1936 Problem: heavy duty buffers one department metal working shop now individually motor driven hp. motors connected short Motors mounted machine frames, bearings per drive. Unit Drive Total installed 840 Operating hours per 4,368 Average motor load ........ 25% installed, motors hp. each) (As obtained from management (Obtained from motor efficiency (Allowing mechanical losses) (Obtained from power factor curves) Installation Costs Motors and controls .... $9,198.00 7,721.00 Mechanical Drives 1,932.00 $18,851.00 Fixed Charges (From motor price book) (From Table Average Wiring Cost) (Compiled from equipment catalogs) $2,827.00 per year Power Computation 840 hp. 25% average motor load 210 hp. output system. 210 hp. output 78% average motor efficiency 269 hp. input system. 269 hp. 746 (hp. per kw.) 200 kw. 200 kw. 4,368 hrs. operation per year 873,600 kw. hrs. per year. 873,600 per kw. hr. (cost management shop) $8,736.00 pr. yr. Power factor penalty (or fixed charges power factor corrective equipment due operation below 85% Total annual power 450.00 pr. yr. $9,186.00 Operating Cost Computation Fixed Charges Power Charges ....... Maintenance Charges: motors controls drives bearings $2,827.00 9,186.00 (On basis $10 per 420.00 Annual $12,433.00 not, course, complete. suf- ficiently so, however, indicate the major trends development, not necessary this point into the details various types equipment understand the fact that development has been (until the past few years) wholly along technological lines rather than economic. Only the most isolated circumstances has the plan- ning and installation drive been made with due consideration the effect will have upon the costs manufacturing, and par- ticularly upon related processes manufacturing. drive met the obvious production requirements, that was all that seemed necessary. And, day when production-at- any-price was the order the day, perhaps there was need con- sider economics per se. Production Costs Important Today For the past few years many things have occurred change that Often- times now possible saving pro- duction costs makes the only profit realizable business, what with restricted markets, keener competi- tion and still costly methods dis- tribution. Power costs are being examined critically, not only the source, but likewise the use. With this starting point, the transmission power driven machines has become real study. had long been assumed that what now known “modern group was (wherever | | | Modern Group Drive Problem: Same heavy duty buffers, assumed divided into groups, utilizing normal load factors and consequent high efficiency motors. Each group will require one hp. motor connected belt overhead shafting and thence belts the machines. Shafts, ft. long, 23/16 in. diam. anti- friction bearings per drive. Total installed hp. ......... 240 Operating hours per 4,368 Average motor load Average motor efficiency Average drive 86% Average power factor motor Drive hp. aver. motor (As before) (From effic. curves and normal Id. factor) From motor efficiency curves) Allowing for mechanical losses) (From power factor curves) Installation Costs Motors and controls. Wiring Drives Fixed Charges $2,394.00 3,800.00 $7,901.00 $1,185.00 per year Power Computation 873,600 kw. hrs. 73% unit drive efficiency) 637,728 kw. hrs. actually consumed machines operating for one year. 637,728 kw. hrs. 86% (average modern group drive efficiency) 741,500 kw. hrs. required modern group drive system. Power factor charges—none $7,415.00 pr. yr. Total annual power cost...... $7,415.00 Operating Cost Computation Fixed Charges Power Charges Maintenance Charges: motors controls drives bearings (On basis $5.00 pr. Annual Cost ....... $1,185.00 7,415.00 250.00 Comparison: Annual Cost Unit Drive system $12,433.00 8,850.00 Saving due system $3,583.00 could effectively applied) less costly than old-fashioned lineshaft drive, than individual motor drive. Actually, however, few could substantiate that assumption with definite figures. Within the past four years this has begun rem- edied certain research work carried out typical American in- dustrial plants the case study method. Since this research work has embraced both economic and engineering principles, the results have been extremely interesting, and provide the bases for definite conclusions. For practically the first time, comparable figures were deduced various industries the actual costs delivering power ma- chines. Also, this research work established the fact that costs installation, operation and main- tenance were not the only figures considered; that side side with them must considered other factual data such flow, materials handling, produc- tion capacity used any particular time, personnel the machine at- tendants, and many other related things. These considerations really begin with the character the shop. What may highly desirable transmission system flour mill may vitally wrong for machine shop; what good cotton weave shed may bad paper making plant; and never safe think that because Ford Gen- eral Motors finds one way doing things highly profitable the same thing will yield similar profits soap varnish plant. Where standardized product made con- tinuously the drive conditions are apt entirely different than where different products are work- each day each month. Robert Drake prefers classify in- dustrial plants from the transmis- sion viewpoint three categories: The typical American manufac- turing plant, which averages over ten-year period little less than single shift operation maxi- mum capacity, with large night shift the busy season boom years and short-time operation the depths the depressions. bo The “feast famine” industry— the plant which some depart- ments work night and day while other departments have nothing do, and which shuts down al- most entirely depression year the dull season. The plant that averages two shifts, except for single shift op- eration dull season three four months’ duration. Shop equipment laid out today facilitate continuous flow processing operations and elimi- materials. This first economic that buildings are planned ac- commodate these factors rather than these factors being forced into the layout building. But coincidentally with such lay- out equipment should study volved driving the equipment. Often more economical system transmission drive will dictate some rearrangement equipment. For instance, even when individual mo- tors are used every machine the question wiring distribution and location controls will affect the placement Wiring distribution must therefore considered essential ele- ment the transmission system, equally with moving electrical mechanical equipment, since en- ters into the economic study operation. The Least Possible Ultimate Cost any investigation the eco- nomics power transmission the one prime object must dis- cover how deliver the necessary power the point use the lowest possible ultimate cost. There are, course, many cases which certain types machines must driven directly. rolling mill, for instance, definitely falls into this THE IRON AGE, November é 4 | ~ | by: List Cage Induction Motors 1200 VOLTS H.P MOTORS category and special machines such are used the automotive industry for the simultaneous progressive machining identical parts. And small machine may differ much its load and oper- ating characteristics (such the need for widely varying speeds) from number other machines that cannot logically fitted into system drives. However, the great mass industrial ma- chinery can still classed equipment requiring relatively small blocks power, and located plants containing many similar allied types machine loads. For all these cases, system in- dustrial power transmission should considered which will utilize the best advantage the sum total power required drive the machines. Outside this system, and treated separately, are just two general classifications MOTORS $1760 machines; those such peculiar characteristics load and opera- tion cannot included with others, and machines requiring high power demand, out propor- tion the demand other ma- chines around them. But, “systems” power transmission the industrial plant, have only three propositions consider: old-fashioned lineshaft drive, individual motor drive, and modern group drive. Since old- fashioned lineshaft drive has been proved inefficient and costly, and since competent engineer will today recommend its further use view the unquestioned economies which may effected the use either the two modern systems, lineshaft transmission will ruled out the discussion once. Individual motor drive applied equipment not the special pur- PRICES SQUIRREL CAGE INDUCTION MOTORS 1200 * Spring 1934 550 VOLTS Tue larger the motor, the less the per horsepower cost. IRON AGE, November 19, 1936 ONE MOTOR Spring 1934 motor horsepower large and small packages. pose type the high power de- mand type above mentioned, widely favored today for many rea- sons other than economic. com- bines improved appearance and high degree safety with unsur- passed machine mobility and absence overhead construction the plant. Most these are had this system only the ex- pense increased operating cost. Modern electrical group drive combines the best economic advan- tages the electrical and mechani- cal transmission systems, producing lower net production costs wherever can logically used. This sys- tem not panacea. contains many faults and not applicable all industrial situations. Where has been properly designed and installed, however, economies amply justify the most important forward step power transmission since the de- velopment the commercial size motors. The Distribution Power considering these two systems power transmission, essen- tial remember the fundamental difference encountered the dis- tribution the relatively blocks power required for each machine, from the source energy available the plant. the in- dividual motor drive system, num- ber machines, with varying loads and varying periods operation are fed electric energy distrib- uted each machine-motor. The motor horsepower provided must the sum the starting loads, the maximum operating loads re | / \ \ (whichever the greater) all the motors collectively. Since this sum, the “electrical demand” al- ways greater than the sum the normal running loads the ma- chines, the load factor operation low. The system must neces- sity “over-motored”—and motor horsepower costs money. When these same machines are provided with interconnected me- thus seen that the real ques- tion involved designing system power transmission for in- dustrial plant today comes down this: How many machines shall driven from one motor? That ques- tion dependent the relation between the economics power transmission and the problems production flow and material han- dling the plant under considera- about one-ninth the cost hp. hp. motors. Or, put ina different way, the single hp. motor costs $7.82 per hp., while the half-hp. motors run the cost per hp. $68. This accounts for motor costs alone. When considered that, because low load factor operation greater installed motor horsepower required drive the same number machines with in- per cent the machines American industry are still driven this fashion. Between and per cent the total manufacturing cost can saved here complete revamp- chanical drives operated from one motor, the horsepower that mo- tor need only the sum the normal running loads all the machines collectively, since the ma- chines may started sequence instead all together, and peak loads will stagger themselves auto- matically throughout the cycles operation the machines. Load factor operation consequently high, and less installed motor horsepower required the mod- ern electrical group system. ing power transmission methods. tion. Let first analyze the eco- nomic factors the two systems, leaving for later discussion the problems production flow and material handling. Since, however, the electric tor the heart both systems, will interest look briefly motor costs small and large packages. The diagrams op- posite page indicate cost one hp. motor the squirrel cage, induction type dividual motor drive, and the addi- tional wiring and control cost either balances outweighs the added cost mechanical drive equipment the group drive system, large part the greater cost the in- dividual motor drive system ex- plained. What Are the Costs Driving Machines? the study transmission costs necessary first evaluate (CONTINUED PAGE 114) THE IRON AGE, November : “ , ° ° ° PROGRAM train- ing fit young men for key positions its plant and which differs some particulars from the usual apprentice training course was placed operation few weeks ago Thompson Products, Inc., Cleveland. intensive and broad year period provided, important features which include the lim- iting the course small, carefully selected list students and the entering into contract between the company and the ap- plicant for enrollment and his par- ent guardian, under which the apprentice agrees continue his course training through the four-year period. Apprentice training programs were, largely abandoned during de- pression years and recently manu- facturers with the shortage skilled labor that already evidence have come realize that the demands industry call for revival methods training boys become skilled mechanics. The training 42—THE IRON AGE, November 1936 PRENTISS Cleveland Editor, The lron Age might called new model meet 1936 conditions. The Thompson training course designated the Thompson industrial training stead being given appellation apprentice train- ing course. The manufacture automobile and air valves, the Thompson products, highly specialized industry that car- ried the Thompson company high production plant. The training program adopted de- signed give the students train- ing the company’s method carrying its activities and meet its particular manufacturing problems. Starting boy the bottom and giving him the proper training grow the organi- zation the opinion the man- agement preferable taking men who have had training else- where and must retrained fit into the company’s methods. Four-Year Course Each student under edge the machinist’s trade and also executive training. dents, expected, will qualify least for tool room work the completion the course and some will capable being de- veloped into supervisors. While the company has not yet experi- enced shortage skilled help, felt that would suffer short- age the future unless adopted plan apprentice training. The training course set comprises | ° ° ° hours instruc- tion the four-year period. this 9200 hours will de- voted shop work and 800 hours class work. The pay rate cents per hr. for the first year, cents per hr. the second year, cents per hr. the third year, and cents per hr. the fourth year. students distributed throughout the plant, being placed alongside regular employ- ees the charge the foremen the respective departments, who give them instructions the opera- tion machines and they engage production work rapidly they gain sufficient training the par- ticular machine, although, course, they are not expected develop much speed the start. Under this plan responsibility for seeing that the apprentice receives proper kind training rests large extent upon the fore- man. The entire supervisory or- ganization expected its utmost training the students. The regular- work schedule the plant hours per day, five days week. Part the class- room instruction given from o’clock Friday afternoon during time for which the students are paid, and part Saturday morn- ing, during their own time. While working the various depart- Form 788 ments the appren- tices are required observe the same regulations that apply regular employees. The curriculum, which subject revision, fol- lows: FIRST YEAR Excellent Good << CONSOLIDATED INSTRUCTION RECORD INDUSTRIAL TRAINING PROGRAM THOMPSON INC. Name Shop Work - Ha Mo. Screw Machine—Elementary Mo. Screw Machine— Advanced Class Work 100 Hrs. Mechanical Drawing 100 Hrs. Machine Shop Practices SECOND YEAR Technical Trades a rw (a) Plunge cut (b) Pass through Mo. Miscellaneous Class Work 100 Hrs. Tool and Machine Design Hrs. Metallurgy Hrs. Chemistry THIRD YEAR Technical Trades Mo. Automatic Screw Machines Mo. Forging Practice Mo. Heat Treatment Mo. Inspection Mo. Screw Machine—Advanced Mo. Cylinder Grinding Mo. Centerless Grinding Instruction Started Class Work Class Work Hrs. Factory Accounting Hrs. Factory Management 50 Hrs. Metallurgy Laboratory Hrs. Chemical Laboratory FOURTH YEAR Technical Trades Mo. Toolmaking Mo. Machine Repair—machine work general Class Work Hrs. Business Administration Hrs. Time Study 100 Hrs. Lectures jects, including Products, Marketing, Finance and visiting other ing plants. The recently started training class was limited twelve mem- bers. Only graduates nical high school are admitted the course and they must have (CONTINUED PAGE 74) QUARTERLY APPRENTICE REPORT Industrial Training Program Products, Inc. Quarter Ending Average Poor Deficient Mo. Service Ship- ping Mo. Drill Press Mo. Milling Ma- emarks chines PARENTS SIGNATURE Mo. Engine Lathe THE IRON AGE, November 19, 1936—43 PERSONNEL DIRECTOR We q ° ° ° ° stability, endurance, artistic accomplish- ments and decided economy cast iron, the great dome the United States Capitol building Washington presents all-time and outstanding monu- ment. Frequently referred one the finest, not the finest specimen architecture its character the world, rather surprising how few persons realize have taken occasion learn the exact structural nature this notable dome and the historical sig- nificance some its features. That formed iron castings 44—THE IRON AGE, November 1936 engineering information today, not- withstanding the fact that the structure was built over years ago. interesting note that despite the emphasis given nu- merous other standard and special structural materials for Govern- ment buildings varied kinds recent years and the natural cen- tering attention these later and more modern structures, noth- ing has been developed this di- rection eclipse the pre-eminent position and prominence the Capitol dome the Federal city. Situated Capitol Hill, prac- tically the center Washington, this masterpiece cast iron construction physically dominates many people know that the dome our National Capitol made cast iron? of every approach the nation’s Capitol most imposing manner. Through superior workmanship mold production, the use iron castings highest basic quality, and finally, skilled performance erection, the distinctive and stately architecture this struc- ture brought out remarkable detail—rigid, permanent and there stay. The Capitol dome presents striking example the value and utility this material for struc- tural purposes three-quarters century ago, towering today the same state preservation and stability when constructed. Two domes have figured the history the Capitol building, the ° ° “La j “low dome” the rebuilt Capitol, following the fire 1814, which reference will made later, and the present structure. Erection the latter began 1856, near the conclusion the term Presi- dent Franklin Pierce, and was com- pleted finally 1865, nine years later, about the time the Civil War came close during the adminis- tration President Abraham Lin- According official records, the columns, ribs, plates and other cast iron members used the con- struction, including cast iron orna- ments, totaled 8,878,743 ap- proximately 4500 tons. The mate- rial was cast and furnished Jones, Beebe Co., New York, prominent the iron industry that day. Made With Two Shells The dome proper consists two massive iron shells, outer and inner shell, respectively, formed the cast iron plates. the upper section the unit, these are sup- ported heavy cast iron rib sections semi-ellipsoidal shape, comprising the skeleton framework the structure. These ribs above the outer colonnade, rest directly over and bear the circular cast iron footing provided the base this level the dome. The extreme height the dome above the base line the east front the Capitol building the end the cast iron construction, omitting the statue top, 267 ft. in., while the height from the top the balus- trade the building the same point noted 198 ft. in. its widest level, the base the dome has diameter 135 ft. in. There are cast iron columns spaced equal intervals around the lower portion the exterior the dome, these representing the States the Union the time erection. The cast iron ribs, noted above, may stated, con- vey the same significance. Three rows windows are arranged the structure three different levels, uniformly spaced, each di- rectly above the window below, starting the first level. These windows are graduated size, both width and height, the smallest be- ing the upper section the dome. Each row consists exactly windows, similarly for the States then forming the Union. Thus the dome receives light through 108 windows, but only one row these, the lower, shows through both the cast iron shells into the rotunda. Symbolizing the Thirteen Colonies The design the extreme top portion the dome, generally re- ferred the lantern, and known Greek architecture the Tholus, emblematic the colonies which became the original States; there are cast iron col- umns the unit encircling the lantern, while the latter, turn, has windows, conveying this significance. According estab- lished custom, the lantern illumi- probably the first photo- graph ever made the Capitol, back the early 60's when photography was its infancy. The Tiber River, shown the fore- ground was later filled and become part Pennsylvania Avenue. Photo Courtesy U. 8S. Army Signal Corps. nated whenever Congress night session. The top the dome surmount- with the famous bronze Statue Freedom, the work Thomas Crawford, well-known sculptor that day, residing Rome, Italy, where the figure was modeled. The plaster mold was sent the United States and the bronze cast the foundry Clark Mills, then lo- cated the Bladensburg Road, near Washington. The statue ft. in. high, thus giving total height the tip the dome 287 ft. in., above the base line the east front the building, pre- viously referred to. The bronze statue weighs 14,985 lb. The exterior iron shell the top the dome provided with series openings admit addi- tional daylight; the aperatures the rays are deflected reflectors arranged that the light falls effective way the inside the canopy forming the interior the dome, illuminating the top the canopy with its noted fresco panel depicting Force and Progress, painted Burmidi. night, artificial light used from 425 out- lets encircling the base the canopy, giving hightly artistic il- lumination this part the dome. stairway between the outer and inner cast iron shells leads from the base the dome the lantern top. This stairway, starting the office the Arch- itect the Capitol, located the building, formed exactly 365 steps, one for each day the year. Just beneath the base the cano- py, railed gallery traverses the (CONTINUED PAGE 122) THE IRON AGE, November 19, 1936—45 | | ASIF | q a ° ° ° { | MANY production plants have per cent adopting are welding. Savings are made materials, reduced labor and lowered production time. The labor and time savings with welding come from the simplicity the electric application. Given the design for certain jig fixture, the toolroom merely cuts standard mill shapes and welds them together. Typical Tooling Cost Savings Cost Saved Welding Welding fixture .... 40 per cent Milling fixture ..... 50 per cent per cent Machining fixture per cent Boring fixture ..... per cent Assembling fixture. . 40 per cent Welding fixture .... per cent Fixture built scrap The accompanying illustrations show number typical welded steel jigs and fixtures. Each unit shown has resulted definite sav- ings the maker. The welded steel drill 46—THE IRON AGE, November 1936 ° ° tured Fig. used for drilling seven holes from three directions the work shown the right the illustration. Note particu- lar the overhang the legs. This possible without danger frac- ture because steel has ample impact strength. The lugs the jig are strong, yet very light construc- ° Part Typical Tooling Savings ° DAVIS Vice-President, Lincoln Electric Co., Cleveland ° tion, welded their proper loca- tions. welded construction, cross-sectional design con- cern beyond the usage the jig. Since welding permits reduc- tion sections and elimination much the reinforcing over- hanging parts, the jig becomes lighter 2—Welded steel drill jig for drilling seven holes from three directions. ABOVE 3—Boring and back-facing fixture open construction. serves valuable productive energy and contributes largely the low- costs provided welding. Fol- lowing statement the cost the are welded drill jig. Burning and welding $1.75 $7.00 Machining .......... hr. $1.75 $34.02 Savings are per cent. The boring and back-facing fix- ture Fig. used with bar feed head. The work performed the fixture consists drilling the holes shown the part the right and facing the 7-in. diameter boss. The fixture shown was built which per cent less than would have cost otherwise. The open construction this weld- fixture allows the operator conveniently insert the back facing cutter and also observe and mea- sure the cut. Time and money were saved weld fabrication the jig pictured Fig. This jig built entirely steel and used for machining the arbors woodworking ma- chines. consists heavy plate which guides are accurately welded. Fig. shows milling fixture for face gear box. Here fixture design which, spite its simplic- ity, actual record costs per cent less are welding. Its cost LEFT IG. welded jig for fast ma- chining woodwork- ing machine arbors. Photo courtesy Jones Superior Machine Co. BELOW fix- ture for face gear box. THE IRON AGE, November { | ‘ was only $98.88. this, $17.50 was for burning and welding, $71.75 for machining and $9.63 for metal. addition, welding provided strong, rigid fixture, and open construction that eliminates chip pockets and makes cleaning easy. The two long fixtures illustrated Fig. represent saving $28