The Iron Age 1937-01-28: Vol 139 Iss 4

FRITZ FRANK President J. H. VAN DEVENTER Editor Managing Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Associate Editors JURASCHEK Consulting Editor Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Cincinnati Boston CHESTNUT AND STREETS, PHILADELPHIA, PA. Hamburg, Germany Milwaukee San Francisco Sales Offices ASA ROUNTREB, JR. oronto, Ontario Birmingham ewark, St. Louis Buffalo Con January 28, 1937 Progress Forming and Forging.................... New Steel Mill Plant Plant Expansion and Equipment Buying................ Just Between Two..... 107 CHILTON COMPANY Copyright 1937 Chilton Company (Inc.) Executive and Publication Offices, Chestnut and Sts., Philadelphia, Pa. BAUR, General Advertising Manager DIX, Manager Reader Service Cc. A. MUSSELMAN, President Member, Audit Bureau Circulations STAFF FRITZ FRANK, Executive Vice-President Emerson Findley, 621 Union Cleveland Indexed the Industrial Arts Index. JOSEPH HILDRETH, Hottenstein, 802 Otis Chicaxo GEORGE GRIFFITHS, Published every Leonard, 239 39th St., New York tion Price: United States and Pos- EVERIT B. TERHUNE, oe sessions, Mexico, Cuba, $6.00; Can- Peirce Lewis, 7310 Woodward Ave., Detroit ERNEST HASTINGS ada, $8.50, including duty; Foreign Ober, 239 39th New York $12.00 year. Single copy, cents. Robinson, 428 Park Pittsburgh JOHN BLAIR MOFFETT, Secretary IGH-TEST special steels and other modern materials bear down hard tool steels. machine them successfully and economically requires unusual tool steel. Bethlehem Special High-Speed Steel has what takes bear under these condi- tions. Specially developed for gruelling service organization with more than years’ experience tool steel manufacture, Bethlehem Special brings truly unusual combination qualities bear the problems connected with machining tough, stub- born materials. Bethlehem Special has the extra stamina required for unusually difficult conditions that keeps production from bogging down when the going heavy. Experienced shop men are particularly pleased the length time between grinds. Bethlehem Special only one the complete range Bethlehem tool steels which supplies the correct grade material for every tool steel requirement. A M ‘ ... JANUARY 28, 1937 ESTABLISHED 1855 Vol. 139, No. realize that not altogether fashionable today respect one's elders, but common sense should tell that might, least, learn something from their experience. Take England for example. She has had plenty experience with labor troubles. England has been unionized country for nearly century and half. England has also had labor government, which something that have not yet experienced. England also has had something that have not yet had, but which are rapidly approaching effect, and that general strike. occurred there The British public reputedly phlegmatic temperament and slow wrath. not volatile the American public. But history shows clearly that the British public recognizes when its corns are trod upon; not only recognizes it, but takes care that the offense shall not repeated. Thus, when the general strike occurred, the phlegmatic British public suffered the inconveniences which fell upon silence. took the brunt the punishment that the antagonists attempted inflict upon each other. But started think. said itself: should the great British public, which owns the bath tub, permit mi- norities wash their dirty linen the British public, slow wrath but sure insist upon justice, got busy. secured amendment the British Trades Union Act July 29, 1927. Under this amendment, what now happening here, the detriment the American public, could not happen. For example, handful strikers and their pugnacious allies outside ‘the plant could not keep six seven times their number fellow workmen from ex- ercising the right work. For the British Trades Union Act specifies that: hereby declared that unlawful for one more persons attend near house place where person resides works ...for the purpose ... persuading any person work abstain from working, they attend such manner intimidate any person that house place ... obstruct the approach thereto other words, Mr. John Lewis and his cohorts the were practicing their present-day American tactics the good old unionized country England, they would given what known the American vernacular the can still learn something from our mother country. 4 ? | 10 Mie t THE story stainless century saga de- remittent effort improve quality and/or reduce costs. Each metal- lurgical innovation the past has placed stainless alloys new ap- plications—each drop price has boosted output startling degree. Thus, with lucrative and unplumbed future market dangling before their eyes, then small wonder that times 1Conventional means the use Heroult, Lectromelt, Swindell and Sny- der direct-arc furnaces, and Ajax- Northrup and induction furnaces. For producing cor- rosion and heat-resisting castings, the relative installed hourly capacities are estimated follows: Heroult (and Swindell and Snyder), 26,500 Ib.; Lec- tromelt, 25,500 Ajax (high fre- quency) and (low frequency), 18,300 lb. Relative production varies widely from these capacity figures. Refers the hollow-electrode fur- nace herein described, and the pro- prietary practice Rustless Iron Steel Corp. Bethlehem’s top-fired Simpson unit and Barium Steel Corp.’s Bosshardt furnace. The former shows consider- able promise—it uses chrome ore and thus direct reducing. IRON AGE, January 28, 1937 steel makers have forsaken conven- tional furnace production’ favor direct-reduction ventures’ improve quality offset the continued high cost raw materi- designed reduce costs power and charge speed production. These later practices naturally in- volve more highly supervi- sion, but are justified methods avoiding the relative high cost low-carbon ferrochrome; how- ever, the ferrochrome price were dropped, say, 5c. the author ventures that many direct- reduction experiments would lan- guish. With high percentage cur- rent stainless alloy tonnage con- fined sheet and bar stock, force been lavished the nuances ingot metallurgy. closely related industry, castings, often has been slighted, mostly because the attractive tonnage potentiali- ties frequently are not duly recog- nized. The market today for stainless booming (exactly how booming, only the Alloy Casting Association, Inc., knows—it won’t tell), and even cursory inquiry will disclose many consumer prepared switch stainless castings when LIPPERT Metallurgical Editor, The Age and prices become attractive, when physical properties, sur- face finish and corrosion-resistant properties toto meet his finicky specifications. But, like many an- other apparently attractive pic- ture, the aforesaid not the com- plete story. Many small in- experienced founder the past has embarked upon the production chrome and chrome-nickel castings, only discover that meet specifications application ingenious metal- lurgy and skilled molding tech- nique, that off-heats expensive metal can wipe out profits instan- ter high percentage floor rejections often can the same thing even the analysis the button, and that many custom- ers can and develop peculiarly regard hard spots, surface porosity, sand pits, poor ma- chineability. Every commerial alloy foundry has had discouraging encounters with each and all the foregoing difficulties. Similar experiences were first the lot the Buffalo foundry division the Ludlum Steel Co., but subsequent research over the past year cated that the proprietary and radical hollow-electrode type electric melting and refining fur- < d und | | | | | | | | | | | | | ° ° = s | nace peculiarly adapted the production chrome and chrome- nickel steels for castings. In- numerable castings different analyses and designs already have been turned out manner and subjected exhaus- tive tests, not only the labora- tory but also consumers’ plants. Conclusive proof thus has been as- sembled that this unique refining unit can and does turn out stain- less and heat-resistant steel cast- ings covering wide range closely controllable analyses, hav- ing exceptionally excellent mechan- ical and machining characteristics, unusual freedom more than adequate corrosion re- sistance all normal applications, and generally such quality fully meet the diversified demands which have grown around stain- less and heat-resisting castings whole. Such broad claims for castings must necessarily given detailed attention. And this attention in- volves some consideration the furnace itself; for only examin- ing its mode operation can the results obtained rationalized. The Furnace conceived, trode furnace was believed what the industry had long await- ed, cheap producer high-grade stainless alloys for sheet and bar stock. two-electrode two-ton unit ably turned out many batches metal having certain very desir- able characteristics. However, most observers judged its opera- tion uneconomical, view the skilled supervision necessary, the refractory destruction arising PIONEER electric fur- nace steel 1910, ioneer again stainless al- during 1919, Ludlum Steel Co. now pioneering for the third time; using the and unique hol- ow-electrode furnace, re- cently created foundry divi- sion setting new standards for stainless castings. What has done months quiet preparatory research herein set forth for the first time. from the high volved, and the complex electrode arrangement, i.e., electrodes must drilled, cores prepared and pro- vision made for slowly turning the electrodes and the same time effect continuous and fully con- trollable passage the cores through the hollow electrode. Seek- ing improve economy, 10-ton 6-electrode unit was constructed about year ago, but even though satisfactory ingot alloy was pro- duced likewise proved uneconom- ical. Attention was then redirected slightly modified 3-ton 2-elec- trode unit, and its forte pro- ducer stainless alloys for cast- ings soon was demonstrated. The furnace now used in- single-phase type, with two 10-in. graphite electrodes, which are hollow (4% in. coaxial hole) and rotate slowly insure even wear (one turn each min.). The shape the furnace shown the photo the accompanying insert; the electrodes project through the ends slight angle the horizontal, facilitate the flow reagent from the ends the hollow electrodes and direct the full arc heat the bath. The bath not part the are circuit (unlike the Heroult furnace). Cores (or briquettes) are made simple screw extruding ma- chine and subsequently baked work one man suffices pro- duce week’s supply. The core composition the ratio lb. coke, 100 chrome ore and Ib. binder such molasses. Each core in. long and slight- that they will pass with ease, end end, through the hollow electrode. Feeding, the cold end each electrode, accomplished means variable speed, continuous loop chain arrangement supplied with pusher lugs 31-in. intervals. The entire furnace tilts about the axes the electrodes that they need not disturbed during tapping. The furnace essentially dual- istic operation. The arcing electrodes melt the scrap charged the hearth and, unlike usual practice, the initial carbon content the bath little moment. Chrome-ore-carbon briquettes are slowly fed through the electrodes where, they approach the arc tip, they are smelted the ex- tremely high temperature. The resulting ferrochrome (which con- tains substantial amount chromium oxide solution) vio- lently sprayed continuously throughout the bath, the net result THE IRON AGE, January 28, 1937—i9 . : being continuous build-up chromium and simultaneous oxida- tion carbon, silicon, manganese and other oxidizable impurities from the bath. the smelting action the libera- tion carbon monoxide (and roofs have been moderately long lived, least they last long silica roofs those convention- furnaces which are habitually run very hot speed reactions secure certain metal character- istics. separator bowl made standard analysis. the left the casting just came from the sand. The two center ones have had feeder and riser portions removed and have been sand blasted. The sectioned casting the right has been polished after sand blasting only, without intermediate machining operation. some CO,) thus furnishing the furnace with continuous reducing atmosphere throughout. condition difficult duplicate standard are furnace. This refining action can, per- haps, better visualized con- sideration given conventional production Heroult furnace. Low-phos steel scrap iron ore added, and car- bon and other elements are removed oxidizing slag. Pig nickel added and melted, the oxidizing slag removed and finishing slag added. Chrome built additions chrome, final deoxidization addi- tions are made, and the heat tapped quickly possible avoid expensive chrome losses. Being direct-reduction process, the hollow-electrode furnace neces- sarily operates quite high tem- perature, usually the neighbor- hood 3400 deg. Thus, refrac- tory wear severe, but Kromag steel scrap could used for the entire charge. However, des- pite constantly rising price level, and scrap still the most economical source nickel and chromium. The primary function the hollow-elec- trode furnace melt and refine the charge, not act the only source chrome and build the analysis from, say, zero. 5Somewhat higher than the power input conventional furnaces. Rea- son: The furnace smelting ore well melting and refining the bath. 20—THE IRON AGE, January 28, 1937 Concerning the time and power requirements the hollow-electrode furnace, consider and heat. About 2000 ordinary and stainless charged cold. With the are and cores feeding, the charge melted about min., which time the metal snap test may analyze 0.44 17.4 Cr, and 10.08 Ni. Two hours later, the metal tapped, with final analysis 0.075 18.54 and 9.67 Ni. Note the drastic carbon reduction with con- comitant elevation chrome. Power consumption about 1000 kw-hr. slightly The Metal judging the value the hol- ducer stainless alloys, consider first its ability turn out metal definite and easily controllable analysis. Carbon content con- stantly reduced, often below 0.03 per cent, and recarburization meet specification routine pro- cedure (compare with most foun- dries’ unwillingness much below 0.25 per cent, arising from refining difficulties and reluctance loose fluidity), and the same time chromium being maintained definite level being built without any difficulty. Since both silicon and managanese are re. duced with the carbon, tomary recharge definite amounts the former two ments obtain higher fluidity for pouring thin-sectioned castings. Practically all alloy specifications containing per cent more chrome are produced the hollow- electrode furnace, types being follows: Chrome Nickel Per Cent Per Cent 0.5 All these analyses are made below the average carbon con- tent, that is, contrast general casting procedures the trade. typical heat might give analysis 0.29 0.22 Si, 16.6 and 35.2 Ni; the particular melt observed the author, the carbon was dropped from 0.29 0.10 per cent min., and was neces- sary recarburize the bath for final pouring. Another trial heat had final analysis 0.09 0.20 Si, 19.8 and 11.3 Ni; the carbon content declined from 0.37 per cent the final 0.05 figure min. Fluidity-Porosity steel not much concerned with ingot comparatively simple operation. the same token, sur- face porosity, scabbing, etc., al- though abhorred, not mean the scrapping heat. the foun- dryman, however, each and every one these tendencies momen- tous. Metal must chasing around the mold, fill large spaces and solidify perfectly thin sections, consequently fluidity essential avoid cold-shuts and mis-runs. And metal must gas free, otherwise internal porosity and piping will result. And sur- faces must relatively free from porosity scabbing; for casting essentially finished product and can stand little chipping, ma- chining, meet these problems, usual carbon effect better fluidity. Likewise, the metal often pretty well dosed with deoxidizers pro- st : | | | | | | | | | . 4 = 4 YLINDRIC chrome-o coke briquettes are {upper center), and fed two furnace electrodes, shown the furnace side vie The entire furnace tilts and completely killed metal difficulty (lower shown the left: sur 18-8, ring for milk the pipe coupling for 200 and the frame for film devel 300 Photos for AGE Rol Yarnall Richi INDRICAL hrome-ore- are extruded and fed through the rodes, one which side view (lower pour (upper right), metal cast without Typical castings are ower) surface grinding milk evaporator; (upper) for nitric acid weighs 18-8 rectangular side developer weighs for THE IRON Robert Richie. duce metal gas free possible. Metal from the hollow-electrode furnace need not treated. Carbon can low desired, and final deoxidization neces- sary for the metal constantly refined reducing atmosphere’, also, the FeO concentration dis- solved the melt extremely low. fact, the metal lies the killed dead, deader (sic) than any alloy the writer has seen, and comparable molten lead. And, oddly, the metal seems pick life even during pour- ing. High pouring temperatures are easily maintained and, inas- much the fluidity high and metal gas free, the usual ranges chrome and chrome-nickel alloys pour quietly and give castings which are exceptionally clean and free from porosity. High pouring temperatures— and the hollow-electrode pours very high temperature —are usually considered undesir- able view the peculiar scour- ing cutting characteristics these molten alloys, which severe- seemingly belies the ac- cepted fact that dissolves large quantities molten steel and sub- sequently liberated lower tempera- ture give rise blow holes and other defects. Alloy steel the hol- low-electrode furnace has maximum opportunity pick CO, inasmuch the atmosphere 100 per cent and the metal far above the melting point. But moisture enters the fur- nace (say some damp fluorspar), has been found that hydrogen becomes available and gassiness ensues. Thus, hydrogen (hydrides some sort) may the guilty party. 2.—These cast- ings, made from hollow electrode metal, have received treatment other than The cast chain 18-8 stainless, the decora- tive plaque 18-8, the sectioned diesel piston head the six small clamps are 18-8 and the two boiler feed valves are and tax the bond and cohesion the molding sand, thereby result- ing surface and internal poros- ity. However, the author wit- nessed many castings poured Buffalo, both simple and very com- plicated shapes, and subsequent examination showed little porosity surace imperfection. Probably the lack gas evolution was decided compensating factor. The Buffalo foundry employs conventional sand mold practice; molds are baked skin dried necessary. Because the metal completely gas free, has been found essential for good results the size feeders and risers castings. example feeder and riser practice shown Fig. this particular casting known cream sep- arator bowl, made standard and analysis. Note the clean surface as-sand-blasted, and how the metal takes high polish with- out intermediate machining. group castings, shown the insert, demonstrate the good surface obtainable large cast- ings, having both thin and heavy sections. group small cast- ings, including 18-8 chain, shown Fig. Machineability The machining martensitic, ferritic and austenitic stainless and heat-resisting steels must carried out more slowly than for ordinary steels, and complicated high frictional qualities, brittle- ness under impact, great toughness hardening under cold work. improve the qualities (of, say, and 8), the usual pro- cedures are dose the metal liber- ally with selenium and phosphorus phur, which lessens the frictional effect. After many tests, the metal from the hollow-electrode furnace has shown consistent excellent machin- ing characteristics, usually par with bar stock containing sulphur selenium. Ludlum at- tributes this free machining char- acteristic the presence cer- tain inclusions the alloy, which arise from the dispersion chromium oxide the hollow elec- trodes throughout the base metal. This view checked the imme- diate drop machining ability soon the inclusions are reduced and removed the usual slag and deoxidizing methods. For this rea- son the inclusions are usually re- tained, particularly view the fact that they have been found materially affect corrosion resis- tance and, also, possess some duc- tility under the forging hammer. The inclusions most prominent are (a) the brittle, refractory non- malleable chrome oxide (b) silicates sometimes entrapping iron sulphide, which type segregate THE IRON AGE, January 28, . TABLE Machining Tests Stainless Steel Melted and Refined the Hollow-Electrode Furnace Steel Analysis Machining Surface State Operation Type Tool Feed Depth Cut Remarks 0.17 18.04 turning 18-4-1 HS. 0.06 in. smooth. porosity sand spots. Tool OK. 0.11 18.88 7.64 as-cast turning Co. HS. 127 0.015 in. Surface good. porosity. sand holes. Tool OK. 18.88 7.64 as-cast drilling H.S. Rd. Drill OK. Surface holes smooth. Clean. porosity, sand holes. 8.07 as-cast turning Co. 104 0.010 in. 0.013 Surface good. porosity. sand holes Tool OK. 0.17 18.66 8.07 as-cast drilling H.S. Rd. Drill OK. Surface hole smooth, clean. porosity. 0.19 19.01 29.29 as-cast turning 18-4-1 HS. 0.030 in. 1/16in. Tool OK. Finish good. porosity. 0.19 19.01 29.29 as-forged turning 18-4-1 HS. 0.020 in. Tool OK. Finish good. porosity. 9.99 as-cast turning 18-4-1 HS. 0.005 in. 1/32 in. Tool OK. Finish good. porosity. sand holes. turning 18-4-1 HS. 107 0.030 in. 1/16 in. Tool OK. Finish smooth. porosity. possesses good The results number ma- Various samples, including 18-8, forging temperatures, and often tend form envelopes around dendritic areas, especially near the feeder points the castings; and (c) another type chrome oxide not precisely identified exact composition, which somewhat ductile forging temperatures and reacts quickly ordinary stainless alloy melted conventional manner, the inclu- sions found are usually combina- tion FeO, and some- times associated with the various oxides. The source the inclusions the slight oxidation metal during tapping and pour- ing. Therefore, inclusions (a) and (b) are generic character, but (c) typical the hollow- electrode and this in- clusion credited much the free machining ability. These three types inclusions are shown the photomicrographs Fig. Note the one view, showing forged and speci- men, how the one type chrome oxide (c) and the silicates are elongated, thereby showing their malleability, and how malleable unaffected. Tests for iron oxide (as unas- sociated FeO), manganese oxide and manganese sulphide have gen- erally produced negative results for hollow-electrode metal. complex chrome oxide has been detected German ferrochrome furnaces and, the author believes, has also been found metal produced Rustless Iron Steel Corp. Thus, apparently arises from the reduction the chrome ore. 22—THE IRON AGE, January 28, 1937 chining tests are tabulated Table Note that the speeds ob- tained are quite high. Physical characteristics these same analy- ses are quite favorable, both for as-cast and forged metal. Table Corrosion Resistance previously mentioned, quan- tities chrome oxides are often left the metal facilitate ma- chining, and tests have shown that these oxides most cases exert deleterious effect at- resistance. 3.—(Left) As- cast condition diameters; etchant aqua regia glyc- erine; this view shows the average structure and type which are present, chrome oxide the malleable type chrome oxide, and silicates. As-cast condition diameters, etched with KMnO, and washed with oxalic acid, show chrome Malleable type .of chrome oxide has been at- tacked etchant and eaten out. (Right) Forged and 500 diam- eters, unetched show dispersion inclusions. 20-10, 16-18 Cr, and 20-30 Cr-Ni, as-cast, heat-treated and forged, all have been subjected per cent sea salt spray tests room temperature for periods hr. and have shown excellent re- sistance. Similar samples exposed atmospheric attack the vi- cinity the Ludlum plant Watervliet, Y., have shown rusting, pitting anodic type corrosive attack after months’ time. Cr-39 Ni-0.19 alloy, re- fined the hollow-electrode fur- gr | pe 4 % - ome TABLE Tensile Tests for Castings Stainless Steel Made the Hollow-Electrode Furnace Steel Analysis State Temp. Proportional Yield Test, Limit, Point, Metal Deg. Lb. PerSq.In. Lb. PerSq. In. 0.17 18.04 7.64 as-cast 22,500 31,500 0.18 19.01 29.29 as-cast 20,000 29,000 0.18 19.01 29.29 as-cast 1700 16,150 0.11 19.68 9.99 as-cast 12,500 26,500 0.18 19.01 29.29 forged 53,500 0.18 19.01 29.29 forged 1700 0.11 19.68 9.99 forged 52,500 71,000 0.11 19.68 9.99 forged and treated 1850 deg. F. Tensile Elongation, Strength, Per Cent Red. 36,590 3.5 15.2 159 67,250 20.5 22.3 131 16,850 19.0 26.4 ee 69,500 41.0 37.2 140 93,500 22.0 17.7 207 22,750 16.0 45.4 nee 97,000 38.5 49.1 196 84,750 53.0 57.0 nace, has been tested the as-cast state per cent H.SO, 160 deg. F., and after 152 hr. the weight loss amounted 0.00370 gram per sq. in. Another type steel (KA2-S, Ludlum analysis), made standard electric arc type furnace and hot rolled the conventional manner was com- pletely dissolved 130 hr. similar test, showing weight loss 0.06889 gram per sq. in. similar analysis made the hol- low-electrode furnace, the as-cast condition and containing consider- able amounts oxides chromium, was completely dissolved hr. with weight loss 0.51966 gram per sq. in. This indicates that this = a particular analysis suffers some- what from the retention oxides. Intergranular corrosion using CuSO, plus solution, have demonstrated that the 18-8 types steel made the hollow- electrode furnace are about equal commercial 18-8 hot-rolled forged, provided that the castings are given heat treatments, usually air water quenching from 1850 1950 deg. Mixed acid corro- sion tests, using the H.SO, plus mixtures ployed, tend show that the 18-8 types made the hollow-electrode furnace are best after being heat treated, although has been found that initial attack, that is, during the first hour test, samples the as-cast condition, was gen- erally much less pronounced than the case 18-8 other stain- less steels made the usual type electric arc furnace and hot forged and rolled shape. far, there has been little op- portunity garner many results actual service applications hollow-electrode metal. However, one customer has reported that after days per cent nitric acid, during which time approxi- mately 2,500,000 acid has flowed over it, the castings (18 and show loss weight, nor has there been any indication change structure. THE IRON AGE, January 28, 1937—23 > POWER Better belting technique and advances electrification mark power transmission progress. This the third and concluding part the article the issues Jan. and Jan. 21. FRANCIS JURASCHEK Consulting Editor, The Age Manhattan Rubber Mfg. Division Raybestos-Man- hattan, have cord section the neutral axis composed heavy strands cotton impreg- nated with strong, tenacious, slow-aging rubber friction com- pound, producing homogeneous, inseparable unit strength, durability and flexibility. The useful life V-belt under normal conditions being limited excessive stretch, the fact that the new Condor V-belts have shown repeated and exhaustive tests stretch only 1.6 per cent 1.9 per cent their length insures long and useful life. typical in- 24—THE IRON AGE, January 28, 1937 stallation these belts large lathe drive shown Fig. 35. The combination V-belt drives and pivoted motor bases has been further improved the Rockwood Mfg. Co., the theory that V-belts and pivoted motor bases naturally belong together and should designed and installed take the utmost advantage the natural benefits which each are capable producing. maintaining con- stant tension the belts during operating periods, and removing tension from them when the drive idle, the life the belts con- served. Likewise properly pro- portioning the belts the drive the greatest possible advantage may taken the constant tension fea- ture the pivoted motor base, that smooth operation results. typical example unit-designed Rockwood V-belt drive and Rock- wood pivoted motor base shown Fig. 36, where the motor mounted ceiling beam and the shaft supported nearby hanger. Gears and Couplings Link-Belt Co. announces new line worm gear reducers sim- ple, compact, accessible construc- tion, offering great flexibility driving arrangement. These new reducers are made wide range ratios and capacities, with single double reduction and horizon- tal and vertical types, all provided with precision tapered roller bear- ings and automatic lubrication within dust-proof gray iron hous- ing. The output shaft with its chilled phosphor bronze worm wheel can located above be- low the worm shaft, which made low-carbon alloy-steel forging, carburized and heat-treated after the worm threads have been cut thereon. feature the double reduction reducer the unitized attachment the primary reduc- tion unit the side the final reduction housing. remarkable set gears re- cently produced The Falk Corp. illustrated Fig. 37. This huge double reduction finishing scalebreaker drive with roller bear- ings and self-contained lubricating system. Falk Bulletin No. 10,000 describes brief detail line precision products including gears, speed reducers, motoreducers, heavy drives and couplings serve practically every industrial need. unique universal self-alining coupling especially adapted where difficulties arise the alinement the driving and driven shafts, where alinement not positively assured where the driving and driven member foundations sup- ports are not rigid, announced the Harris Coupling Co. shown Fig. 38, the coupling designed allow parallel misaline- ment displacement 3/16 in. between both shafts, and deg. angular them, both together. The in- terior members the coupling are designed and arranged that the gravitational centrifugal forces 4 double reduction finishing scalebreaker for steel mill. between the driving and driven members relation one the other are eliminated. This design removes the lateral thrust both shafts and their bearings, and al- lows free compensating both shafts anywhere within the speci- fied limits. Thus there are losses ABOVE 36—A typical Rockwood V-belt and Rockwood pivoted motor base combination. LEFT 35—Manhattan Rubber's Condor V-belts driving large lathe. caused through misalinement even where such misalinement large, either parallel angular; alinement high low speeds; functional parts are protected from abrasive substances which may en- (CONTINUED PAGE 100) THE IRON AGE, January 28, 1937—25 FORMING FORGING Marked improvement equipment, in- creased production rate and increased precision product characterize the developments forging. This the concluding part the article which appeared The Age Jan. PRENTISS Cleveland Editor, The Age parts above* mentioned forged very close dimensions, normalized, cleaned, and coined the desired shape and size, leaving the outer surface smooth and clean for the case hardening operation any hardening treatment that de- sired. All this accomplished the use intricate dies and punches placed within coining press the proper size. This press shapes, slots and sizes such parts the rate 100 per hr. many cases, one hundred more are finished the time one part could machined the regular method; thereby making saving which outstanding any automatic machine production. “Furthermore, the use the coining press many designs are permissible which otherwise would impossible use, due the prohibitive cost production. Johnson, president, Rockford Forge Co., from Jan. issue, page 26—THE IRON AGE, January 28, 1937 finish these parts the drilling and broaching the central section are the only operations required. All dimensions are pressed within the limits plus minus 0.005 in. limits which are not exact. These facts should not over- looked the industry, for such applications fit very nicely into the mass production scheme.” Summarizing the advances the forging industry, Jones, National Machinery Co., Tiffin, Ohio, says: “During 1936 the trend the forging industry and forging ma- chine design has been towards the same ultimate goal—low weight, close limit forgings that are more nearly the desired final size and shape. Much progress toward this end has already been made, and the resulting savings have been marked that continued effort along this line expected.” The modern high-duty forging machine built this company has short compact under-slung steel frame which reinforced with large diameter tie bars. This type frame has extremely low fac- tor spring underload and con- sequently, stated, the dies stay fully closed during the action the heading tools the hot stock, resulting well filled forgings without excessive flash. Die aline- ment has also been given close at- tention, the long narrow pilot over- arm heading and gripping slides insuring, pointed out, accurate registration the heading tools with the gripping dies. “Displacement piercing deep holes and punching and trimming operations this machine are longer considered stunts but are now accepted practice,” says Mr. Jones. “Forgings are duced complete with holes ready for broaching. There are part lined fins trim off and, fact, many forgings produced this modern machine are made without flash any point, thus eliminat- ing all subsequent trimming oper- ations. Considering pound material trimmed off forging flash, and drilled out hole machined off else- where excess finish represents expensive material that must carried the inventory, must handled and from the forge shop, must heated and forged and consequently must carry the same overhead the forging it- self and its ultimate value only the cheapest kind scrap, obvious that low weight, minimum finish forgings and the equipment that makes them possible are eco- nomic necessities.” The comparatively recent addition modern forging equipment the vertical Maxipress made the National Machinery Co. This was developed coin forgings pro- duced the high-duty forging machines and brings the forgings still closer the finished size. The forgings are made ready for high production chucking machines and grinders this press. and “hogging off” operations get the forgings fit finishing jigs are eliminated, Mr. Jones points out. This type work requires extreme rigidity and accuracy alinement. The machine has steel bed reinforced with large diameter shrunk-in tie bars. The ram the long piloted over-arm type. The pitman direct connected, the \ shut height adjustment being taken care large wedge the lower die seat. The shaft un- usually large diameter and the full eccentric type. This con- struction, stated, results freedom from spring and insures extreme accuracy die registra- tion. present demand for machines that will increase production, Mr. Jones states that additional progress this direction been made the development the high-duty forging machine and Maxipress. The friction clutch, which incorporated both machines, states, results almost instantaneous starting. Longer life claimed for the wearing parts because the elim- ination shock and jar through the use this type clutch. Con- sequently there less time down for repairs and adjustment. The friction air clutch both machines made oversize that the plates will not slip the machine over- loaded. The Maxipress has quick and positive ejection and both ma- chines are arranged for convenient feeding. Grain Flow Buyers forgings are paying more attention structure and grain flow and some, particularly the automotive field, are now furnishing samples sketches in- dicating the grain flow they desire, states Anderson, sales man- ager, Acme Machinery Co., Cleve- land. Railroads are using more forgings for locomotive and car parts and there trend the same direction makers agri- cultural implements, reports. More forgings are being coined the automotive industry, added Mr. Anderson. This reduces finishing and some forgings require only grinding finishing operation. also reports development forging high-nickel alloy bolts. The bolts are heated between every op- eration the header get uni- form structure, three five oper- ations being required, depending the size the bolt. The trend the manufacture forging machines during the past year has been increase weight and provide deeper die space, permitting greater multiplicity operations, states Mr. Anderson. There also trend toward using the eccentric type shaft, thus eliminating the crank and provid- ing more rigid machine and also trend toward sliding head movement that takes the place Pitman. This type construction, claimed, reduces maintenance and gives more area with lower pressures per square inch the high pressure point. “Accuracy products, coupled with high rates production, has provided the highlight the way trend the forging industry during 1936,” states Har- rison, vice-president, the Cham- LEFT Fic. 12—Erie crankshaft hammer 12,000 capacity. ° ° BELOW Fic. 13—Erie double frame forging hammer. THE IRON AGE, January 28, 1937—27 atic ths ie Fic. 14—Forge shop Chevrolet Division General Motors Muncie, Ind. bersburg Engineering Co., Cham- bersburg, Pa. “Dies made greater exactitude than ever before, machining allowances are being cut, draft has been suc- cessively reduced during the last three years from deg. deg. and now one the largest users drop forging equipment producing eight throw crankshafts with deg. draft the dies. “There has been more general acceptance the best quality grades alloy steel preference carbon steel for rams and anvil caps, and the thought strength that poor economy equip hammer with alloy steel heat-treated ram and anvil cap with dies different material. “There has been marked ten- dency during the past year use still heavier hammers such well known classes work automo- bile connecting rods parts similar weight and con- tour. Definite physical improve- ment has been noted connecting rod forgings produced heavier tool which requires fewer blows wherewith fill the die with hot metal.” Hammer Types The recently designed double frame forging hammer which has been applied the principle design developed recent years for steam drop hammers appears have gained popularity. During the past six months his company has sold more double frame forg- ing hammers than did the pre- 28—THE IRON AGE, January 28, 1937 ceding years, states McDonald Reed, Erie Foundry Co. Practi- cally all these have been from 5000 10,000 lb. rated sizes. Pre- viously smaller sizes had the call. Operators, according Mr. Reed, report increased output due im- proved cylinder design, easier con- trol and greater percentage pro- ductive time. the board drop hammer field motor-driven hammers continue outsell the belt-driven type, accord- ing Mr. Reed. number motor-driven board drop hammers which are self-contained but have heads the belt-driven type and are operated through V-belts from motors mounted the backs the frames were built his com- pany during the past year. This said less expensive construc- tion than the usual geared head used motor-driven hammer and the development being watched with interest number drop forgers. some cases the V-belt drive been used, but the motors have been mounted structure supported from the roof trusses over the hammers rather than being mounted the ham- mers themselves. the competition between steam drop hammers and board drop ham- mers Mr. Reed states that during the past year the former have out- sold the latter ratio about Small, high clutch forging ma- chines and are .recent .addi- tions the line the Ajax Mfg. Co. is 4 .coms 4 two one. attributes the lead the steam drop hammers the demand for hammers the larger sizes which the board drop ham- mers cannot compete. Considering only hammers the smaller rated sizes for work within the range the larger 4-roll board drop ham- mers built his company, the board drop hammers their own, Mr. Reed states, and they have run ahead the steam drop hammers sizes around 2000 lb. However, adds that there still some work done compara- tively small hammers for which rapid blows and flexibility con- trol are highly important, creating demand for 1000-lb., and 2000-lb. steam drop hammers. Indicating the trend the use larger hammers, commer- cial drop forging shop Illinois recently placed order for 25,000-lb. Erie hammer which will shipped early this year. present believed that there only one hammer this capacity this country and this used for its own company that not cater outside jobbing work. The company purchasing the hammer has demand from its customers for larger drop forgings which will require hammer the increased size. Many forge shops have steam drop hammers rated 12,000 the country with rat- ings from that size 18,000 lb. The shop installing the hammer therefore will take place very limited group capable handling unusually large drop forgings. Another unusually large ham- mer, one 20,000-lb. capacity, was sold the Erie Foundry Co., and will shipped shortly England, where will used for drop forg- ing automobile propeller frames. 16,000-lb. Chambersburg steam drop hammer for making crank- shafts was installed last year the Buick Motor Co., supplement- ing hammers installed the Buick plant for the same pur- pose during the previous year. Automotive Forgings Crankshaft forging speeds have been increased improved ham- mer design. The crankshaft ham- mers installed Chevrolet and Chrysler last year were 12,000- capacity and, while they are not identical, they are all fitted with the new flat valve cylinder. though the 1937 Chevrolet crank- shaft weighs about lb. more than the used, the new hammers are able forge the shaft with fewer blows. The rams and piston rods the new hammers are identical with those the old, that there was built from the ground they were able apply their knowledge and long experience without the necessity compromises make the layout fit with plant al- ready existing. The plant con- sidered model both respect building construction, ventilation, Fic. and dies for making sockets for carpenters’ chisels the Ajax. 4 4 4 ry > q 4 ous clutch mechanisms the same weight handled. But the new hammers are faster and strike harder blow, even though the cylinder bore has been reduced in. compared with cyl- inder bore in. the old ham- mer for handling ram the same weight. The Chevrolet automobile forge shop built last year Muncie, Ind., and known the Chevrolet- Muncie Division General Motors Corp., regarded the outstand- ing addition the drop forge in- dustry during the year. This plant was laid out and being operated men who have had years drop forging experience and are provided the larger sizes Ajax forging machines. materials handling and equipment. The forging equipment consists seven Erie steam hammers, five Erie motor-driven board drop ham- mers, nine Erie presses, five Erie cold trimming presses, six Ajax forging ma- chines, Ajax forging press and Ajax gap roll. Complete clean- ing and heat treating equipment also provided. Cast Versus Forged Cranks Drop forgers and manufacturers forging equipment have watched very closely developments the automobile crankshaft field see any the other automobile THE IRON AGE, January 28, 1937—29 = sal) Ax = AG Cone manufacturers would follow the lead the Ford Motor Co. and change from forged cast iron crankshafts. any other automo- bile builders followed Ford’s footsteps, was expected that would the two others competing with Ford the volume produc- tion field. However, batteries hammers for forging crankshafts were sold during the year both Chevrolet and Chrysler. Builders these cars are said have made very careful study the substitution the cast iron for the forged crank- shaft and their investment forging equipment during the year ran into hundreds thousands dollars, this indicates that there not trend cast crankshafts. Incidentally, the Ford design has short crank because the V-8 con- struction, and stated that this crankshaft because this design probably better adapted for manufacturing from forging than either the Chevrolet Chrysler crankshafts. Comparing board and steam drop hammers, Mr. Harrison states that each type has its own particular field application and choice must based types and quantities pieces made and operating and installation expenses. While board drop hammer installation requires immediate adjacent power plant air compressor, the size forgings that can produced this type limited, well the flexibility technique which characterizes the steam ham- mer installation. Forgings which 30—THE IRON AGE, January 28, 1937 require considerable drawing, states, are not adapted for produc- tion board drop hammers, but almost any forging that can made board drop hammer can also made steam drop hammer. Steam Versus Board Drops There are few exceptions this, these being mostly confined work the large area, thin sec- tion type where rapid cooling the metal when placed between the dies makes highly desirable that the constant blow feature the board drop hammer employed. Mr. Harrison the ad- vantages and disadvantages the two types hammers follows: The steam drop hammer en- tirely under the control the op- erator, whereas the board drop hammer the operator simply con- trols starting and stopping. comparable classes work the steam drop hammer more pro- ductive than the hammer. The steam drop hammer oper- ator generally more highly skilled operator than the board drop hammer operator. The over-all investment board hammers usually less than that steam hammers for the same amount production. Forgers showed considerable in- terest during the year regarding the advantages and operating hammers com- pressed air place steam. number hammers were in- stalled for air operation, states Mr. Reed, and some steam operated shops have been changed over air. Incidentally the steam drop hammer previously mentioned, which will shipped England, will isolated in- stallation and will operated compressed air, since was de- cided that this would more ad- vantageous than install steam boiler and operate steam. Two compressor units, each half the required capacity, will used be- cause compressor unit would have been large that its delivery could not made reasonable time. The average steam hammers will other tures, the Acme Model cushion drive forging ma- chine now has system. perform equally well with either steam air, Mr. Harrison states. However, warns that every forge shop cannot changed over air operate economically. Steam Versus Air Forge shops mass production making parts for the automotive industry can rule more air, according Mr. Harrison, be- cause the high load factor they can maintain their boiler plant, which can made very efficient plant and which can produce steam low cost. Forge shops this class work with large orders, have infrequent die changes, and usu- ally several operations are com- pleted the metal with one heat. these shops are usually oper- ated 24-hr. basis, their standby time small. semi- production plants usually operated single shift and making rather small lots forgings and having rather high standby losses steam, the load factor the boiler plant decreased and this type plant will usually show economy when operated with air instead steam. Forge shops doing repair job- bing work where flat die forging hammers are used, have unusu- ally low load factor and the stand- losses are even higher than the production shop. This type installation, Mr. Harrison’s opin- ion, can very profitably changed over air operation. One shop using drop and four flat die hammers has changed from steam air, Mr. Harrison stated, estimated saving more than $15,000 year. Briefly summarizing his com- ments, Mr. Harrison states that air operation for forge shops most economical when the load factor low and steam not needed also for other work. High Speed Small Work For rapid production wide variety intricate upset forgings well for making nuts, bolts and rivets, two bolt-heading and upsetting forging machines em- bodying completely new design, shown Fig. 15, were brought out recently the Ajax Mfg. Co., Cleveland. These models, rated l-in. and 1%-in. capacity, are equipped with the Ajax air clutch ABOVE 1G. 20—Forging 4-in. anchor Boston Navy yard RIGHT Four- in. anchor chain links the die- lock type ma- chine forged in. Ajax air clutch. which used the company’s larger forging machines. These small forging machines because their high speed are particularly suitable for light small work that cools rapidly, well for work that calls for hole which pierced the machine instead being drilled after the piece forged. One the illustrations, Fig. 16, shows the dies and tools for mak- ing sockets for carpenter’s chisel, thin wall forging high carbon steel, with one the ma- chines. These new machines are compact, occupying less floor space than earlier models. They produce work close tolerances. many cases machine allowances are said little more than are required for removing the decarbonizing skin and, where precision finish not required, machining can entirely eliminated accurate forging. The air clutch, with its instanta- neous treadle response, stated, has increased production, decreased fatigue the operator and makes possible the completion single heat forgings which formerly required reheat after preliminary upsetting. The smooth, cushioned action the air clutch has re- placed the rack and jar which always accompanied gagement, and said have substantially reduced idle machine time for maintenance and repair. The band brake, which released mechanically, set cam oper- ated lever which stops the machine accurately open stroke. The toggle grip the same the larger machine, with the large diameter pins, which are sub- jected the grip load, middle sup- ple shear. The crank movement with eccentric pin used i