The Iron Age 1936-12-10: Vol 138 Iss 24

4 10, 1936 THE STEELS THAT WERE BORN REPUBLIC LABORATORIES Indianapolis, Los Angeles, Langhorne, Syracuse, Mineola wherever trust life and limb the character steel, find Republic Metallurgists check- ing the performance Republic steels America’s speediest racing the behavior steel this part that part high speed engine alert every incident development that may indicate the need for better steel given part. The racing car the proving ground the automotive the cars drive ALLOY GENE RAL for pleasure and business are steels born Republic’s Massillon and Canton Laboratories and once known special analyses steels.” Proved thousands and thousands miles America’s speedways and dirt tracks, these Republic steels are today standard auto- motive construction. Republic today—and has been for years —the largest producer alloy steels and fine carbon steels for the automotive industry. you have problem steel, ask Re- public Metallurgist. Write Department IA. CORPORATION OHIO WHAT HAPPENED This Hoskins Electric Furnace the plant The Bower Roller Bearing Co., carburizing bearing races and heavy dies—requiring case about lurgist, says that since the furnace was installed about year ago, they have Electric they used have. The furnace has course saved money for You can with electric heat what you can other way. So, will pay you Manufacturing Co., Detroit, Mich. 2—THE IRON AGE, December 10, 1936 THE IRON AGE, published every Thursday the CHILTON CO., (INC.), Chestnut 56th Sts., Philadelphia, Pa. second class November 1932, the Post Office Philadelphia under Act March 1879. $6.00 year S., Canada $8.50, Foreign $12.00. Vol. J The Wire that Made j 4 | CHESTNUT AND S6TH STREETS, PHILADELPHIA, PA. Sales Offices WEST 39TH STREET NEW YORK, Owned and Published by CHILTON COMPANY Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. C. A. MUSSELMAN, President FRITZ FRANK, Executive FREDERIC C. STEVENS, Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS. EVERIT TERHUNE, PRNEST HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR Secretary FRITZ FRANK President J. H. VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston Hamburg, Germany Milwaukee San Francisco SANDERSON Asa JR. ALLISON Toronto, Ontario Birmingham St. Louis Buffalo Con tents December 10, 1936 Tooling for Hypoid Carrier Materials Handling Factor Economic Production.... Advanced Machine Tool Applications Packard Working Boat Propellers Automotive Industry Washington News November Pig Output Products Advertised Index Advertisers Copyright 1936 Chilton Company BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulation: ADVERTISING STAFF Member Associated Business Papers Emerson Findley, 621 Union Bldg., Cleveland Herman, Chilton Chestnut 56th Indexed the Industrial Arts Index. Sts., Philadelphia, Pa. Published every Thursday. Subscrip- H. K. Hottenstein, 802 Otis Bldg., Chicago tion Price: United tates and Pos Peirce Lewis, 7310 Woodward Ave., Detroit sexsions, Mexico, Cuba, $6.00; Can- ada, $8.50. including duty; Foreign C. H. Ober, 239 W. 39th St., New York $12.00 year. Single cents. Robinson, Park Bldg., Pittsburgh Cable Address, *‘Ironage. N. Y."" D. C. Warren, P. O. Box 81, Hartford, Conn. 7 a No. FIGURE First —We order all the steel from Ryerson and have tomorrow. Quick production—rapid turnover. depreciation—no obsolete stocks. Second—We save time and trouble. Time placing orders—time interviewing salesmen—time following orders—time wait- ing for shipment—time receiving, checking and paying for the material. —And better still, worry over meeting production schedules eliminated. Ryerson has all steels well stocked ready for immediate shipment. experienced organization, with special cutting, handling and facilities, gives added assurance against delay. When you need Ryerson—it pays. you not have the current Ryerson Stock List, will glad send it. Joseph Ryerson Son, inc., Chicago, Milwaukee, St. Louis, Cleveland, Detroit, Buffalo, Boston, Jersey City RYE 28—THE IRON AGE, December 10, 1936 Ryerson Stocks Include: Beams and Heavy Structurals Channels, Angles, Tees and Zees Rails, Splices, Spikes, Bolts, Etc. Plates—Sheets Strip Steel, Flat Wire, Etc. Stainless Steel Hot Rolled Bars—Hoops and Bands Cold Finished Shafting and Screw Stock Extra Wide Cold Finished Flats Alloy Steels—Tool Steels Heat Treated Alloy Steel Bars Boiler Tubes and Fittings Welding Tubing Rivets, Bolts, Nuts, Washers, Etc. Reinforcing Bars Babbitt Metal and Solder 4 DECEMBER 10, 1936 ESTABLISHED 1855 Vol. 138, No. Beware Bottle Necks OTTLE necks are probably old bottles themselves. know that they were part the ancient Egyptian bottles produced many years before the Christian era, which were made dipping sand core, mounted copper rod, into molten glass. The rod formed the neck the bottle, and after was pulled out came the task digging out the sand. Bottle necks serve useful purpose providing convenient place for cork keep the contents from coming out. That desirable feature. But bottle necks industry are just the reverse desirable. bottle neck industrial plant department keeps the contents that department from flowing out freely. slows down the capacity produce. Good management constantly the lookout for bottle necks, realizing that chain stronger than its weakest bottle neck operation with per cent efficiency will pull all the and per cent operations production line down its own low level. Bottle necks are subject cyclical trends. You will find that they multiply fastest the upturn after depression. And that time, which happens now, man- agement must most alert eradicate them. Bottle necks are respecters places persons. You will find them all over the plant. the production department, look for bottle necks wherever machines and tools have been use for five years more; wherever materials handling methods have not been revamped within the past three years; wherever power transmission methods have not been scientifically studied and remodeled within similar period. These physical bottle necks which have with equipment are remediable easily and quickly when once found. There are other bottle necks that have resulted from the depression which are more mental than physical and which will much harder eradicate. Skilled labor shortage, for example, increasingly frequent bottle neck. must corrected the intensification employee training. Executives high subordinate positions who have gotten the and who cannot made catch with them are also serious bottle necks. These obsolete flesh and blood detriments business can cause more slowing down, per- haps, than can obsolete equipment. And you cannot replace them overnight. this little essay, might well also speak those bottle necks that are found within each one us. For very few people not have some bad qualities that slow down the outpouring ability which good qualities should make possible. What good, for example, per cent genius who possesses only per cent will apply his talents? ARRIER plant rehabilitation pro- gram 1935, Buick Motor Co. has again stepped out and spent the last few months another $14,500,000 for new equipment, new buildings and new layout preparation for 1937 models. Part this money this year goes into plant expansion take care larger volume business. Part was spent for new machinery necessitated en- gineering changes, such the adoption hypoid gears for the rear axle. Although older existing Gleason spiral bevel gear machines and cutters could have been re- 30—THE IRON AGE, December 1936 FRANK OLIVER Detroit Editor, THe vamped for generating these hy- poids, Buick chose buy com- plete battery new units take advantage the faster cutting time available the new machines. This same move also obsoleted all tooling for producing the dif- ferential carrier since the axis the hypoid pinion offset one and three quarter inches below that the ring gear. the former spiral bevel drive these axii are co-planar. This offset necessitated such radi- ments, and fixtures well ma- chine design, that the obvious solu- tion was put entirely new line equipment designed from the ground their specific job. This has been done with but one exception and that machine has been completely retooled. The main piece this carrier malleable casting having flanged portion which bolted the banjo axle housing, half ings for the differential supports which bearing caps are bolted, and pinion support tube. The first operations the rough cast- ing are face these bearing cap seats and the flange, drill the flange and bearing cap holes and counter- sink the latter. These multiple operations are carried single set-up 16-in. Bullard Mult-Au-Matic, Fig. 6-station chucking machine with universal heads, which has been completely retooled. The first station, illustrated, for loading the piece with the dif- ferential carrier tube end down and vertical position. The facing operations are carried the next three stations, roughing, semi- finishing and finishing. Stellite metal tools are employed the first two stations, Carboloy tipped tools the third. the fifth station the drilling operations are carried on, and the sixth, countersinking. Obviously the entire drill head with its guide bushing plate must re- volve unison with the work chuck. Registration the guide plate with the chuck, and hence with the piece, effected overrunning clutch and lock pin which engages slot the chuck face. necessary, therefore, set the piece the loading sta- tion the proper angular relation this drilling operation. This done means similar locating pin which engages the chuck face the loading station and angu- lar locating T-yoke carried pneumatic ram. This yoke posi- tions the piece from the rough half holes for the differential carrier. Clamping the chuck jaws hand wrench, carried swing- ing arm. Production the Bul- lard castings hour. Two the bolt holes the flange are used locator holes all subsequent operations. Hence “ef, 4 these are reamed with 2-spindle head carried Cincinnati drill press. The four bearing cap bolt holes are tapped similar Baker drill press with tapping at- tachment. Machining Drive Pinion Bores Drive pinion bearing bores are machined battery four Baker vertical boring ma- chines two different set-ups. Both machines each battery have 3-spindle heads and 4-position in- dexing table fixtures, the front position being for loading and un- loading. These fixtures are built sturdily and have generous sized plain bearings under the table. treadle provided raise the table readily indexed hand and located with spring plunger pin. these fixtures the boring bars are piloted both top and bottom, and the bars are driven through float- ing Oldham coupling. The top pilot carried precision needle bearings, while the lower one X-alloy bushing with conical top throw the chips. Coolant pumps ABOVE with index plunger engaging the chuck. RIGHT 2—Pinion bores are roughed out this vertical Baker machine with 4-sta- table Bars are piloted both top and bottom. In- dexing hand while table mo- mentarily supported single ball. ‘ gal. per min. capacity provide the generous amount fluid re- quired for tungsten-carbide tools cutting malleable iron. the first set-up, the casting located flange downward, the tube end up. The flange clamped the front two C-clamps and hand wrench nuts, while the rear the single clamp actuated long rod extending through the top the fixture. Location and support the tube end three plungers, two them spring backed and locked place so- called whistle notches and hand screws, the third, hand screw car- ried swinging hinge clamp front. Obviously, however, posi- tioning the piece from the flange surface and the top supports are set accordingly. Dowel pins locate the flange angularly. Ejec- tion the piece off these dowels hand crank and rack and pinion movement push bar. Operations are rough bore the 32—THE IRON AGE, December 1936 tube hole and clearance hole and countersink the outer end the tube hole station two; finish bore station three, and finish ream the fourth station. McCroskey reamers are used for the last two operations. the second set-up Fig. the piece reversed, end for end, and the large bearing, ad- jacent the overhung pinion, 3—A ball thrust bearing under the air plunger permits the table indexed automa- tically this 3-station Kingsbury unit without unclamping the work. Drilling, spot-facing and tapping are performed successively. similarly bored and reamed, well the sleeve diameter and the small bearing diameter. before the casting located and clamped the flange, which now up. Two swivel fingers whose move- ments are tied together linkage are cammed upward and inward single hand lever. similar flange clamp the rear ad- vanced into approximate position through linkage connected with the lower pilot clamp mechanism and then clamped hand wrench. The bottom support plate, which engages the tube end, tilts forward for ease loading and then raises the whole piece the work posi- tion through pair rack bars actuated capstan wheel and spiral gears. Because the long pilot bars, extra long saddle movement must provided—40 in. this instance. cycle control provides coarse feed for straight boring, fine feed for counterboring, dwell clean the surfaces and auto- matic return. Output each pair Successive drilling, spotfacing and tapping three %-in. holes spaced equidistant radially the carrier accomplished the set- | 4—Coolant pumped di- rectly into connection the fixture this 2-way borer. Bars are piloted ball bearing and floating coup- lings connect the heads. Kingsbury 3-spindle automatic driller. can seen, the carrier again located the flange with tube end and clamped pneumati- cally. The air plunger carries ball thrust bearing, permitting the work table indexed from sta- tion without relieving the clamping pressure. Mechanical cam feed employed each independently driven head and automatic table in- dexing accomplished through separately driven Geneva motion. Heads are tripped simultaneously through pneumatic hookup which also provides automatic inter- 5—Finish bor- ing three direc- tions once. Clamping carrier flange ef- fected three air actuated Note the outboard pilot the right. lock that assures all heads being withdrawn before indexing takes place. Production castings hour. Finishing the Flange and Cap Sects Final operation the single casting before the caps are as- sembled finish face the flange and the bearing cap seats. This LeBlond engine lathe carrying offset locating stud the face- plate. Turning speed kept low avoid excessive unbalance this face plate. Studs and caps are then set with Thor high-frequency nut setters. The assembly now goes through series four oper- ations consisting rough boring the differential bearing holes, finish boring differential holes, large and small pinion bearing holes, tapping the differential bearing holes and burring them. The first operation performed Baker 2-way boring machine the cam-feed type, Fig. As- sembly mounted with the small and large bearing holes engaging vertical stud and the flange rest- ing three points. Its angular position fixed two dowel pins before. Hand clamping the THE IRON AGE, December 10, 1936—33 | assembly effected cone ex- panded collet which engages the small and large bearing bore. The table fixture extremely sturdy and carries the two boring bar sup- ports each which consists sleeve mounted pre-loaded ball bearings. The boring bars are keyed these sleeves and are driven through floating couplings. many other operations, tungsten-carbide tools are employed vertical plane and locked three pneumatically operated dogs which are revolved one-quarter turn and then pulled against the flange. Pilot studs again control the angular position. Single-point T-C bits are used all three bars which are fed hydraulically. The operation carried dry. Both differential bearing boring bars are piloted close the work ball bearing sleeves. The bar for the heavy stud ports the carrier as- sembly threads for ad- justing nuts are tapped. The ing tap piloted through both differ- ential carrier bores. and generous amount coolant supplied each cutter through Y-connection cored the fixture. Pump capacity gal. per min. Each bar carries roughing tools, semi-finishing bits and chamfering tools. Output units hour. These same differential bearing holes and the two pinion bearing holes are finish bored the second set-up Barnes 3-way horizontal boring machine, Fig. The as- sembly mounted with the flange 34—THE IRON AGE, December 10, 1936 pinion bearing bores, the other hand, piloted outboard sup- port, also carried ball bearings. tapping the 3-in. internal threads for the differential bearing adjusting nuts, the assembly mounted the fixture shown Fig. under 24-in. Cincinnati- Bickford box-column drill press. The assembly mounted large horizontal stud engaging the pinion bearing bore and the flange lo- cated angularly pilot stud. One side tapped time, using both the upper and lower bearings pilots for the tap, which mounted Scully-Jones floating tap holder. The holding stud has half round hole nicked out let the lower tap pilot pass without interference. clamping required, and the piece dexed the 180 deg. hand. Pro- duction about pieces hour, only remains remove burrs LeBlond lathe from which the car- riage has been omitted. Instead two guide rails are built from the bed and these the differen- tial carrier flange slid hand. The reamer bar mounted ex- tension the lathe spindle piloted fore and aft through the bearings guide while burring the threaded portion. carried wet with soluble oil coolant. ° ° FRANCIS JURASCHEK Consulting Editor, The lron Age ° ° NUMEROUS gations made within recent yearsinthe name industrial economy have shown that material the course production the average industrial plant actually worked upon only per cent per cent the time. The balance the working time the plant taken lifting and shifting the materials worked upon from machine machine, from process the plant taking the finished MATERIALS HANDLING FACTOR ECONOM PRODUCTION product into and out storage and shipping rooms. Many plants are still poorly organized that the percentage real productive labor more than per cent-20 per cent. Back 1929 when the wheels industry were speeding ever faster and faster and production was being organized everywhere such bases would enable the ut- most manufactured goods possible, estimate prepared the “Committee Recent Eco- nomic Changes” showed that per cent industry’s labor payroll was devoted solely handling ma- terials the average plant. the time this amounted more than three billions dollars. Today, spite the urgent necessities the past few years cutting all costs production the very bone, these figures have not changed materially. The labor payroll devoted materials han- dling work alone still the neighborhood three billion dol- tremendous and exacting tribute levied production econo- my. “Manpower, once the most easily harnessed force the uni- verse, and the cheapest, has become the most expensive factor with which industry must reckon.” any job lifting, shifting, tot- means human muscle when can done more economically means mechanism, waste, sheer and simple, matter how cheap the rate wage for muscle may be. This was demonstrated most forcibly few years ago when contractor building three-mile long embankment Shanghai, China, found more profitable use dozen electric industrial THE IRON AGE, December 10, 1936—35 +. MACHINING GROUP Multiple Radial drill Old Layout New Layout trucks with dump bodies instead three-cents-per-day Chinese coolie labor transport the fill. Not every materials handling job can done more economically mechanically than hand. Many occasional jobs not warrant the investment required for mechanical handling devices. But this state- ment almost automatically sets the criterion for consideration what jobs may profitably han- mechanically: All movements material which are regular, re- peated and/or continuous their nature. shining example the automobile production line, which 36—THE IRON AGE, December 1936 Spind Multiple drill conveyor Millin machine Operator the continuous flow principle production has enlisted the aid mechanical handling equipment astonishing degree. Improper handling methods, out- moded handling methods, and fre- quently system handling all, are responsible for surprising amount wasted human effort industrial production today. Gen- erally these wastes may traced directly failure the part management analyze intelligent- the two inter-related factors production flow and motion econo- my. Conversely, where two factors have been carefully con- IG. I—A relocation machines accord- ing production flow principles made pos- sible this department take advantage modern materials han- dling methods cut down the travel ma- terials and save many labor costs. sidered plant, not only will di- rect savings found the han- dling materials, but other, indi- rect, savings almost inevitably re- sult, the speeding produc- tion, the lowering the cost ap- plying power machines, the re- ducing working inventories, and often the improvement the quantity and quality the prod- uct. Watch the Small Loads not surprising that the han- dling loads great tonnage has had far more attention from man- agement than the handling small loads. Large loads are more obvi- IG. 2—Five lines work gradually con- verge one delivery point. this layout the continuous ciple production utlized the fullest possible degree, with materials handling equipment design facilitate the progressive movement work. Tapper Boring ously potential sources wasted human effort. But frequently the sum-total the efforts required handle many light loads often and repeatedly the plant muscle instead intelligence will out- weigh thousands dollars the costs moving the occasional even consistent large loads. the careful planning and sys- tematic routing all materials that much can still done re- duce the three billion dollar tribute levied production hand labor. Systems Material Handling Briefly stated, all materials han- dling equipment does one both two things: lifts load, shifts load, both lifts and shifts load. the various com- binations these efforts are con- tained all the problems that are handling materials. This per- haps-an over-simplified statement, but little thought will show that 3—One the newest de- velopments the handling coils strip metal the trough- section roller conveyor. The coils roll gravity from one part the mill another. Designed and installed Mathews Conveyer Co. 4—Reloading coal (or any similar loose material) made proposition means such equipment here illustrated. Haiss loader picks from storage pile, and delivers the material portable belt conveyors bins railroad cars. such simplification worth while, for other reason than center the attention the fun- damentals the situation. The types equipment fitting into these categories may listed roughly follows: LIFTING EQUIPMENT Cranes: Hand, Power, Overhead, Jib, Gantry Wharf, Magnet. Hoists: Hand, Power, Pneumatic. Derricks: Stationary, Traveling, Portable, Cargo. Winches. Elevators. — Loaders: Log, Car, Grab-buckets, Skips, Power Shovels, Dredges. SHIFTING EQUIPMENT Cableways: Suspension, Cable- tramways. Overhead Trackage: Tramways, Trolleys. Conveyers: Package, Loose Ma- terial, Assembly, Gravity. Industrial Railways. Industrial Trucks and Tractors. Hand Trucks. Commercial Trucks and Tractors. Ships: Scows, Barges, Ore-handling Vessels, Tankers. Railroad Cars: Dump-cars, Special THE IRON AGE, December 10, 1936—37 bs Gondolas LCL Compartment Cars. LIFTING AND SHIFTING EQUIPMENT Overhead Cranes and Trackage. Special Industrial Trucks, Tiering Trucks. Elevating Conveyers. Loose Material Blower and Suction Systems. Coal and Ash-handling Systems. Lime and Stone-handling Systems. Derricks: Stationary, Traveling, Portable, Cargo. Various combinations lifting and shifting equipment, etc., etc. the application all these types equipment industrial production the economic problems involved include not only consider- ation the most efficient and low- est cost means getting materials and away from jobs, but are concerned likewise with the factor the utmost motion economy the machines production. Hence the study any particular mate- rials handling problem inevitably linked with study the eco- nomics production flow. For instance: mid-Western plant manufacturing automotive equipment, continuous but haphaz- ard growth over number years had witnessed the addition sev- eral one and two-story buildings and sheds the original three- story plant, and the placing ma- chines these buildings loca- tions better adapted the exigen- cies building construction than the orderly flow economic pro- duction. Then change man- agement made possible the moving the business plant an- other city, where brand new building was erected house the production the equipment for- merly made the old plant. real opportunity was presented lay out the operations logically the new building and take ad- vantage modern mechanical han- dling systems tie together the various steps the production processes. The net result the changes effected were these: the manufacture carburetor the old plant the total length travel all the parts going into the fin- ished product was 3750 feet, handling cost estimated cents per carburetor. the new plant the length travel was cut down 960 feet and the handling cost less than cents per car- buretor. This not unusual ex- ample the savings which may effected orderly and mechanical 38—THE IRON AGE, December 1936 routing materials compared with haphazard production ods. Considerations Design The first consideration the de- sign materials handling sys- tem that the material handled. Loose material may sucked through pipes, trans- ferred grab-buckets storage bins, deposited conveyer belts. terial may effectively handled and overhead trackage; materials tote boxes bales, bundles, rolls sheets may handled ef- fectively belt gravity roller conveyors; heavy parts may spotted accurately machines cranes traveling hoists; coils wire strip metal, rolls pa- per may effectively handled 5—A recent mono-rail electric hoist with attached cab developed Euclid Crane Hoist Co. conserves weight and thus requires less power for operation because the extensive use welded construction. Small articles may placed tote boxes and carried roller con- hoists overhead tracks. Larger pieces may picked magnet slings cranes hoists, (in the case boxed materials ma- terial rolls sheets) picked hand trucks special types industrial trucks, for transfer. The type material handled will thus exercise influence the choice equipment handle effectively. The second consideration the layout and character machines which the material de- livered, the character the process which the material treated. molten ma- conveyors industrial trucks tramway systems; bars, rods, tubes and sheets may handled con- veyors, special slings tram- way systems, etc., etc., accord- ance with the needs the machines processes which the material being brought, from which being taken away. The possible arrangements and combinations equipment and methods are almost infinite, and the choice leaves the user with ample scope for the use his imagination the matter securing effective handling low cost. The third consideration de- signing materials handling sys- tem that the flow produc- tion through the plant. This turn linked with the question | 4 | | | motion economy leading to, actually at, and going from the ma- chine process under considera- tion, and also the allied question the effective application power that machine process. Almost inevitably careful analysis these interrelated problems results the salvaging avoidable wastes any plant. study production flow, diagrammatic form shows how machines and cut down the time and distance travel from one another the material worked upon. study motion economy the machines shows whether not dif- ferent groupings placements the machines will cut down the charges labor attendance. And shows what advantages, any, may had from the grouping machines into the most logical pro- duction units. Taking these three questions together enables the in- vestigator plan most intelligent- the system materials handling which will permit the most efficient and most economical movement the goods worked upon from the raw state the finished product. application materials handling equipment isolated problem. reap the greatest advantages from the substitution mechanical devices for human muscle, all the factors outlined above must studied together—for the handling materials only one factor complete production problem. better example the truth this statement can cited than (once more) the automobile assembly line. keep that assembly line moving always forward definite rate speed, that finished auto- mobile may roll off the delivery end according schedule, every op- eration the plant must keyed into that forward movement. given instant this part and that must delivered the required point the line—or else the whole line halts. any simpler prob- lem production, unless all the operations are keyed together, time machine work, and de- livery materials and parts, hitch occurs the flow produc- tion—and production costs rise. what value speed the de- livery work certain set machines the means taking that work away the next opera- = 6—A special design Mercury electric industrial truck developed for the handling coils metal rolls material. smooth, cylindrical ram inserted the hollow center the roll picks the roll from the floor for transfer another location. cause piling parts that point? Time Costs Money Time costs money the indus- trial plant well effort. Time therefore should keyed into pro- duction just accurately effort. Machines only earn their keep when they are working; not when they are idle. Therefore es- sential that the work fed the machines just rapidly the machines can absorb it, keep them busy earning profits. Time and effort may conserved this connection planning material handling systems which are keyed into production flow and motion economy. interesting example this principle given the charts Fig. prepared Allan Mogensen. Both charts represent the flow production machining electric motor frames. handled prior investiga- tion the economics the prob- lem the ten operations required criss-crossed backward and for- ward less than six times. After the work had been laid out the straight line, continuous flow prin- ciple, moved progressively from (CONTINUED PAGE 90) IG. 7—Service Caster Truck Co. responsible for this combination hand truck arrangement. The lighter truck loaded with material, then rolled onto the truck, the skid side the latter raised form the fourth side the out-door truck, and the whole load moved with ease over distances. THE IRON AGE, December 10, 1936—39 he ADVAN MACHINE PRACTICALLY all the equipment the con- necting rod and piston machine lines for the new Packard Six new and rep- resents the latest practice. Some the machines are unique and illustrate unusual approaches the problem finishing these au- tomobile components. the case the cylinder block some the unusual opera- tions concern broaching. After the piston pin boss chamfered one side drill press, both sides the bolt bosses and nut seats are broached Oilgear unit. This operation conventional, but the second broaching set-up has some unusual features. between the two operations the caps are first sawed from the rod forging Cincinnati Hydromatic milling ma- chine. There double-ended fix- 40—THE IRON AGE, December 1936 this second article the series two, machining operations are described two completely new lines equipment for connecting rods and pistons for the new first article, THE IRON AGE Nov. 12, page 28, covered unusual opera- tions the manufacture the cylinder block and crank- shaft. ture the table and the work position, four rods are sawed time through the use only two cutters. This result possible arranging two pairs rods deg. each other and deg. the horizontal. Each cutter en- gages two forgings time different sectors its periphery. Enough stock left the sawed faces for later finishing opera- tion. Pneumatic clamping the work employed. The other fixture being loaded during this work cycle. Broaching the half holes the rough both cap and rod fol- lows Oilgear 15-ton double- slide vertical broaching machine. There are two independent fixtures, that one can loaded while the other the work position. Rod and cap are locked the fixture hand crank and cam with equalizer for high spots, and loca- tion from the bolt bosses back the cut the face and eliminate grinding operation the face. shuttle slide carries each fixture forward the work position and withdraws the tools clear the work the stroke. Shuttles are operated hydraulically through separate control levers and are in- terlocked that the broach can- not move down until the shuttle slide the work position move until the shuttle slide withdrawn. the work position the shuttles are locked double toggle arrangement. Eliminating rough boring operation, 3/16 in. bearing section, leaving 0.0075 in. internal grinding the cap and rod assembly. variable-delivery pump permits PACKARD speed selected experience dictates regards cutter life be- tween grinds. This particular unit also features hardened and ground ways both the broach and shut- tle slides. Rods and caps are then placed pairs special Greenlee drill- ing unit with 8-station trunnion fixture rotating vertical plane. Here the bolt holes are drilled two steps and reamed, and two bleeder oil holes are drilled the rod. Drill units for the latter are mounted angle the turret housing. addition there milling attachment for cutting the lock grooves rod and cap. Clamp- ing the work and indexing the turret fixture are hand. Bolt holes are countersunk hand conjunction with motor driven tool. Final operation before the caps and rods are assembled drill the long oil holes through the web 6-spindle Leland-Gifford drill press using fluted high-speed steel drills and step feed clear the holes chips. After assembly the faces the rods are ground parallel Blanchard machine for the following set-up. this the piston pin hole drilled and reamed successively horizon- tal Davis Thompson Roto-Matic. This machine has trunnion fixture rotating ver- tical plane between two 8-spindle heads which rotate with the fix- ture. Stationary end cams actuate the spindle feed and advance the reamers the left-hand head after the drills the right-hand head have been withdrawn. Rods are located studs the large end connecting rods are sawed apart time this unique fixture mounted the table miller. Each cutter engages two rods time. and are clamped hand. These holes are then chamfered hand against reamer drive motor, but the big ends must chamfered drill press. The rods are now ready weighed and equalized hollow milling the large end hori- zontal drill press. The bushing the small end pressed hydraulic press and chamfered hand. Weighing and chamfer- ing the small end then take place. Before the large bore finish ground battery Heald Gagematics, finish reamed and burnished 4-spindle drill press. Final machine operation the rod diamond bore the piston pin hole Ex-Cell-O six-spindle double-end precision borer. Three rods are the work position, while three are being loaded. Rods are loaded vertical position with the large bore located flatted alinjng plug and clamped against the ground seats three swiveling fingers. This arrange- ment insures the hole being bored parallel with the large end bore. The small end located angularly with flattened plug which withdrawn after two spring plugs clamp the sides. This plug with- drawal with the machine cycle. Movement the table accomplished hydraulically. Spindles run 3600 r.p.m., remov- ing 0.008 0.010 in. stock with feed 0.0015 in. per rev. The long. Output for the entire line set 300 complete rods hour per cent efficiency. The piston line set for 250 units hour. has some un- usual features also. First opera- THE IRON AGE, December 10, | tion chuck the rough perma- nent mold casting 4-spindle automatic turning operations. These include rough turning the and ring lands, rough forming three ring grooves and chamfering them, rough fac- Pi. 4 * spindles the machine, only three are working, the fourth being loading position. Obviously the pistons are chucked from the in- side and this machine double hydraulic clamping employed through dual cylinders with con- centric piston rods. The object the half holes the rough both rod and cap and facing the joint accomplished this double-slide Oilgear broaching machine. The work- holding fixtures are mounted shuttle slides which are interlocked with the movement the broach. ing and centering the closed end, and facing and chamfering the open end. All tools are carbide tipped. Compared with the way this job being handled pistons for the 120 model, one operation and one handling has been elimi- nated and production has been in- hour. Although there are four 42—THE IRON AGE, December 10, 1936 apply heavy clamping pressure the closed end the piston and light pressure the open end not distort the skirt. The next step drill twelve 5/32-in. holes the third ring groove. This done mounting the piston indexing fixture front Kingsbury drilling head. each withdrawal the drill, the fixture plate automat- ically indexed. The drill bushing with tended lug which engages the ring groove. Two such machine units are employed. They compare with one 12-spindle drill unit arranged radially the 120 model piston. Multiplicity Operations One Machine Then follows multiplicity operations, carried dry special Greenlee machine, face- tiously dubbed the “Goldberg” ma- chine because the many opera- tions performs. core drills the wristpin holes, cuts two inter- nal lock wire grooves with expand- ing tools, drills four %-in. holes the wristpin bosses angle and one hole the skirt; saws two 3/64-in. slots beneath the third ring land and similar slot the skirt. This machine horizontal, vertical and angular drilling and sawing machine. The two angle drill units are quill flange-type motors the ends. There three-station hand in- dexing drum-type fixture mounted the central position. Each station carries two pistons with the piston pin holes right angles each other. One piston com- pleted each index the drum. The wristpin holes are reamed hand against motor-driven tool, and then follows series turning operations lathes. the first, the piston chucked Sundstrand automatic lathe, the closed end recentered and the open end faced and chamfered deg. angle. Rapid advance the feed position this machine almost instantaneous and the cutting operations are carried very high peripheral speed. Finish turning the and ring lands, finish forming the ring grooves and chamfering and finish facing the ends are done Sundstrand 10-in. automatic Stub lathes equipped with three cam-bar operated slides, front and rear and auxiliary vertical slide. both these lathe operations carbide tools are employed. Rough grinding the and finish grinding follow battery Cincinnati 18-in. hydraulic piston grinding machines employ- ing 3-in. wheels. This piston the new Nelson Bohnalite “Auto- thermic” type which incorporates RILLING, ream- ing and milling operations are com- bined this special Greenlee machine with 8-station trun- nion fixture. The angular heads drill two bleed holes the rod. thermostatic elements steel and aluminum alloy. manufacture, the skirt ground oval, but operating temperature takes cylindrical shape when the ele- ments assume curved form owing this double end Davis Thompson Roto-Matic, the pis- drilled and reamed successively. Trun- which are hand. the difference expansion be- tween steel and aluminum. The center boss later faced spindle drill. The piston then ready core drilled for weight balancing machine. this unit the weight the piston the pan scale determines how far the piston descends over the cut- ter which has fixed upward THE IRON AGE, December 10, 1936—43 q travel. Obviously the piston clamped rigidly place, once the balance ceases oscillate, and upon relieving the clamping pres- sure the balance scale should revert zero indicate that the piston matches with the standard. Packard tin-plates its pistons means acid dip, which current used. This operation follows after all burrs have been removed and the piston washed BELOW diverse operations are combined this machine than any other the Packard plant. This Greenlee unit has core drills, grooving tools, three saws and two angular drill units carried quills with flange mounted motors the top. has been tripled and one operation and one handling has been eliminated performing all operations the piston one this New Britain-Gridley automatic chucking machine. and inspected. Prior plating, the piston given alkali wash and cold water rinse. There then remains one machin- ing operation—diamond boring the wristpin hole, which done Ex-Cell-O machine very similar the one used for diamond boring the small end the con- necting rod, except that tungsten carbide tip used. this ma- chine the pistons are loaded, dome downward, hardened and ground bushings and against two locating buttons the bottom the fix- ture. Two pistons are loaded time and line the holes, locating fingers are mounted swivel bracket which swung into position. When the correct posi- 44—THE IRON AGE, December 10, 1936 | t | tion found, equalizer clamp operated jig lock swings down and clamps the open end the piston. The swivel bracket sup- porting the locating high-speed Sundstrand auto- matic lathes used for finish pistons. the background may seen new battery Cincinnati rough and finish ° ° ° RIGHT ARTICULAR tention has been paid clamping the connecting rod Ex-Cell-O precision boring machine, while the piston pin bushings mond-bored. One head performs rough boring, the other finish boring. counterbalanced and automatically pulls out its plugs and swings out the way. this two-way ma- chine one head rough-bores and the other finish-bores. Both em- ploy jump feed rapid traverse between bosses. the finish the cut, there dwell and brake applied, bringing the spindles stop before the tools are withdrawn. straight score mark immeasurable depth left. the completion the stroke, the pistons are ejected hand lever working through the two locator buttons the bottom the fixture. Rough feed 0.004 in. per rev. and finish feed 0.0015 in. Finish stock removal varies between 0.008 and 0.010 inch. There remains only wash the piston oleum spirits and blow off. This particular line made entirely new equipment and represents the best practice that can found today for the manu- facture automobile pistons. THE IRON AGE, December 1936—45 = ‘ 4 : = | THE potentialities baby cupola and the op- erating technique are de- scribed this article, which was extracted from manu- script appearing Fonte the Foundry Trade Journal, The author, Guy Hénon, reviews how quality irons can produced miniature units, and, also, presents the dimensions and USERS’ specifications for cast irons, when always involve consider- able tonnages. result, foun- dry today has prepare, sin- gle melt, several widely differing qualities iron, each having con- form within narrow limits the tolerances stipulated. Obviously, and the fact has been remarked upon several occasions, prac- tice very difficult, with ordi- nary cupola, obtain one and the same time reasonable costs, high-duty cast iron buyer’s speci- fication, and short delivery time with small tonnage, many cli- 46—THE IRON AGE, December 10, 1936 BABY CUPOLA construction data for several types cupolas. stated that, provided the raw ma- terials are homogeneous and exact composition and properties, the irons ob- tained will both economi- cally produced and im- proved quality, compared with the same irons melted full-sized cupola. ents demand iron-founders. Many producers, therefore, have their disposal, addition the ordinary cupola, melting equipments which enable them produce small quantities metal known good quality price which, not low, least acceptable. These melt- ing plants are the crucible, the small oil-fired rotating furnace, the elec- tric radiation furnace, and finally the baby cupola. the last-named with which this article concerned, and will shown that fits very well with the requirements noted above. Lighting-up and running baby cupola are very simple, and are quickly effected. The thermal efficiency equal that the large cupola, but the expense bed coke less. Where several different quality irons are melted, the amount “change-over” iron will small, and will, therefore, easily taken the actual tonnage paid for. The very low starting-up costs al- low the production limited quan- tities iron the baby cupola un- der favorable economic conditions. Some these baby cupolas are worked the basis 220-lb. melts. The iron produced with these con- ditions normal quality, which would not the case small quantity were melted full-sized cupola. The possibility making small melts eliminates the necessity waiting for accumulation sev- eral small orders for any particular grade iron. These orders, urgent, can fulfilled and when they are received. Further, the ease starting and running enable the baby cupola put into com- mission the most favorable time for prompt delivery—for instance, with very urgent order, the mo- ment when the molds have just been ° ° q —— FRONT ELEVATION — closed. The baby cupola, fact, worked the interval be- tween the tapping the ordinary cupola even the same time. Exact Composition The technical advantages the baby cupola are, general, less known than its economic advan- tages; yet possible produce cast irons precise chemical com- position and very high quality. fact, addition the ease sepa- rating the charges, baby cupola results less chemical and physical alteration irons charged therein than would the case cupola larger capacity. this connec- tion the following figures relate baby cupola 15.7 in. internal di- Carbon charge made wholly low-carbon pig iron containing 2.5 2.7 per cent was tapped from the cupola with car- bon content varying from 2.9 3.2 per cent. mixture mild steel turnings and medium-phosphorus iron result- iron carrying 2.6 2.8 per cent carbon. mixture made two-thirds mild steel and one-third high phos- phorus iron yielded iron with 2.3 2.6 per cent carbon. The same charges melted large-sized cupola without receiv- and with normal blowing undergo carburization about 0.3 per cent above those just cited. Silicon and manganese losses.— The successive analyses phos- phoric iron remelted large number times baby cupola have previ- ously been noted the author paper read before the French Foun- drymen’s Association. inter- esting point out that, while the TRANSVERSE SECTION A-B LEFT cu- pola used Réaumur for melting malleable cast iron. BELOW 2—Girardet cupola. This unit has output about 440 per hr. FRONT ELEVATION SECTION THE BOTTOM PLATE RIGHT 3—Cupola in- stalled the Foundry Technical Institute Chapelle, France. The hourly output about 880 iron retains normal composition and structure, that say, during the first melts, the losses silicon and manganese remain relatively small. The losses over the first five melts 3.8 per cent for silicon and 9.5 per cent for manganese are con- siderably lower than the losses gen- erally encountered under identical conditions with cupola larger dimensions. Sulphur pick-up.—In the course the same experiments required nine successive meltings order for the sulphur content, which initially was 0.029 per cent, exceed 0.10 per cent. previous state that the mechanical qualities high-strength pig iron remelted baby cupola undergo alteration less important order than that which results from melting large cupola. Practical experience confirms this theory. can, there- fore, said that with the baby cupola irons can produced the quality which distinctly su- perior those irons produced ordinary cupola. Practical Limitations The use baby cupolas re- stricted because the following considerations: One can only pour small castings with weight the order 220 The small hourly production does not provide facilities for the execu- tion sizable orders. This plant, therefore, can only envisaged “doubling” larger cupola, its THE IRON AGE, December 10, 1936—47 Ki PLAN | S! being limited the meeting urgent orders and producing small castings high-quality cast irons. The iron tappet not always perfect homogeneity when the charges themselves geneous. With charges steel- mix iron, differences 0.3 per cent the silicon contents castings poured from the same melt may found. will shown later how this variation, which too great for certain applications, can re- duced. Finally, the running the baby cupola and its maintenance present certain difficulties which are not al- ways insurmountable. The ironfounder wishing install baby cupola can turn special- ist who will deliver efficient unit very modest price. If, the other hand, the founder governed strict economic considerations, can construct himself. the following paragraphs and the ac- companying illustrations are given hints capable guiding the iron- founder his choice the essen- tial construction details. This ac- count, will understood, has been limited the peculiarities the baby cupola. should therefore taken only supplemental data published full-sized cupolas, particular the papers Ronceray. Construction Baby Cupolas The essential characteristic these plants small output, hence small internal section and conse- quently reduced blast. not possible for workman get into the interior the cupola carry