The Iron Age 1937-02-25: Vol 139 Iss 8

CHESTNUT AND 56TH STREETS, PHILADELPHIA, PA. Sales Offices 239 WEST 39TH STREET NEW YORK, Owned and Published by CHILTON COMPANY (Incorporated) Executive and Publication Offices, Chestnut and 56th Sts., Philadelphia, Pa. Cc. A. MUSSELMAN, President FRITZ Executive Vice-President FREDERIC STEVENS. Vice-President JOSEPH HILDRETH, GEORGE GRIFFITHS, EVERIT TERHUNE, ERNEST HASTINGS WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary FRITZ FRANK President VAN DEVENTER Editor WRIGHT Managing Editor FINDLEY Editor Emeritus Metallurgical Editor Machinery Editor Art Editor Associate Editors JURASCHEK Consulting Editor Resident District Editors Washington Chicago Cleveland Detroit Pittsburgh Editorial Correspondents London, England Boston IRWIN San Francisco ALLISON toy EDMONDS TURNER St. Louis Buffalo MEYER Milwaukee ASA ROUNTREE, JR. Birmingham Hamburg, Germany SANDERSON Contents February 25, 1937 Precedents Are Dangerous Heat Effect Welding Limitations Present Industrial Drive Systems.......... The Chuck Keeps Step the Modernization March...... Colloidal Graphite Die Casting Lubricant.......... Members Assemble for 147th Statistics Metal-Working Activity Plant Expansion and Equipment Buying 116 Copyright 1937 Chilton Company (Inc.) BAUR, General Advertising Manager DIX, Manager Reader Service ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bldg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg., Chicago Published every Thursday. Subscrip- H. E. Leonard, 289 W. 39th St., New York tion Price Guineas: notes and ree Peirce Lewis, 7310 Woodward Ave., Detroit sessions, Mexico, Cuba, $6.00; Can- $8.50, including duty; Foreign Ober, 239 39th New York $12.00 a year. Single copy, 25 cents. W. B. Robinson, 428 Park Bidg., Pittsburgh Cable Address, ‘‘Ironage, Warren, Box $1, Hartford, Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. ; if n | 2: | cot | | Perfection Plus FAMOUS opera star holds audience spellbound his singing role. Another sings the same notes with tech- nique equally flawless but the audience remains cold. What the difference? something subtle, intangible—the plus element that sets the super- lative apart from the everyday every field effort, whether singing, leading orchestra, directing motion picture—or making superfine alloy steels. Bethlehem Alloy Steels are made under the direction masters the art who work into them excellence that cannot fully gauged standards fixed for certain specific properties. 26—THE IRON AGE, February 25, 1937 { | 4 ESTABLISHED ... THE IRON FEBRUARY 25, 1937 Precedents Are Dangerous and complexion the Supreme Court. One the short term view; the other are two ways considering the President's proposal change the size the long pull. The speculator interested immediate effects. The investor looks the future. Both them are alike one respect. Abrupt changes management the companies whose stocks they hold are likely make them run cover. believe that most those who favor the President's plan remake the Supreme Court are taking the short term view. They are speculating upon the continuance the present national management. But that continuance means guaranteed. not beyond the bounds possibility that John Lewis may our next President. And perhaps powers that Mr. Roosevelt would use beneficently might prove malignant other hands. Assuming that the precedent set for changing the Court presidential will, let construct imaginary scene say, 1942, during the reign pugnacious John the laid the White House executive offices. Enter Executive Assistant No. EX. ASST. 117: Hey Chief, them guys the Supreme Court have just turned thumbs down, your bill make all steel executives rise and salute when- ever the played. P.J. THE FIRST: Tell the names the guys who turned fix them. (Ex. Asst. 117, thereupon hands P.J. the list the eight backward P.J. THE FIRST, rising from his chair and hurling the inkwell the cat: Grr Grr. and take their union cards away from them. EX. But your Highness, them guys haven't got cards. The char- ter the Amalgamated Union Supreme Court Justices has not been approved yet headquarters. THE FIRST: Grr.... I'll fix anyway. How old the youngest those guys? EX. ASST. The youngest, Justice Gutz, 54. P.J. THE FIRST: O.K. Tell Congress pass bill tomorrow making the age limit years for Supreme Court Justices and enlarging the Court mem- bers. And let Congress know that don't mean maybe! All fun, course, and exaggerated. But may make the long term Amer- ican wonder what might happen the power now being built the- White House should transferred hands less beneficent than Mr. Roosevelt's. Vol. 139, No. ay j t ip. 4 4 >: A : 4 = article and its continu- ation the following issue concludes the series which Dr. Theisinger outlines the method and conclusions fundamental research into the variables which influence the welding steel, with par- ticular reference ef- fect welding heat the parent metal adjacent the weld. The first THE IRON AGE Oct. 15, 1936, was devoted general ob- jectives and methods, and the THE essential differ- ence between alloy steels and plain car- bon steels that the properties the alloy tensile steels need not dependent upon alone. Alloying elements which impart strength and duc- tility are highly desirable, espe- 28—THE IRON AGE, February 25, 1937 FECT WELD partthree Certain Alloy Steels ° ° Welding and Metallurgical Engineer, second, the issue Dec. 17, the heat effect weld- ing five plain carbon steels. This article continues the dis- cussion into alloy steels. the elements studied, carbon exerts the greatest in- fluence increasing the sus- ceptibility the base plate harden after welding, states Dr. Theisinger. Speed welding, seldom taken into account, should seriously considered when the harden- able steels are welded. cially they not confer appre- ciable hardening power the steel after quenching welding. Selec- tion alloying additions the parent plate metal then assumes considerable importance for weld- structures, but still more sig- nificant becomes the necessity adopting proper welding conditions. Lukens Steel Co., Coatesville, Pa. ° ° Referring the second portion this study, THE IRON AGE Dec. 17, 1936, page 38, found the carbon content the plate metal increased, the hardening power the steel increased. Cer- tain common alloying additions made steel likewise raise the ability the metal harden after quenching, but much lesser degree than carbon. The properties these steels are due some special elements and not chiefly carbon. Many combinations ele- ments may employed order obtain the desired physical effects. Welding brings about drastic heat treatment the plate steel adjacent the weld extent depending the composition the metal and the welding proce- dure used. Since most special steels respond readily heat treatment seems reasonable expect that the welding condition should re- ceive considerable attention or- : J | 4 : ° ° ° | | 4130 (0.33 per cent carbon, lowable welding speed based 100 points in. per min. Maximum al- Vickers Brinell Hardness w Welding Speed, inches per minute PLATE 18—S.A.E. 4130 (0.33 per cent carbon, Cr-Mo) per cent Nital. Sorbite with ferrite grain boundaries. martensite in. der attain the minimum amount hardening the plate adjacent the weld. Eight Special Steels Studied Not all the special elements added steel have been included this research. The well-known elements varying combinations with each other would provide tremendous program for study. This program was confined 0.33 Carbon 375 Amperes Volts per min. the examination the following special steels: S.A.E. 4130 (0.33 per cent C-—-Cr-Mo). S.A.E. 4150 (0.52 per cent Nickel Steels (0.3 cent Ni). per cent per Nickel Steels (0.20 per cent per cent Ni). Nickel Steels (0.17 per cent per cent Ni). Cromansil Steel Mn-Si). cent Welding speeds Some troostite, and Molybdenum Steels (0.25 per cent 0.24 per cent Mo). Molybdenum Steels (0.15 per cent 0.48 per cent Mo). The samples for welding were posited the top surface the normalized plate. machining was done the plate prior welding; otherwise any dissimi- larity the “fit” tacking would doubt introduce variables THE IRON AGE, February 25, 1937—29 | 500 -AC. | | 100 | a . 0 3 700 0.52 Carbon 375 Amperes 600 500 400 Vickers-Brinell Hardness to IG. 20—S.A.E. 4150 (0. per cent carbon, Cr-Mo) per cent Nital. 4150 (0.52 per cent carbon, Cr-Mo). Maximum al- lowable welding speed based 100 points Brinell—8 in. per min. Welding speeds 12, and per min. Sorbite and troostite; completely martensitic (12 and in.). unknown proportions. alternat- ing current automatic welding ma- chine was employed depositing the beads 375 amp. and volts. The various welding speeds used ute travel the welding arc. Several steels were welded only the three intermediate speeds 30—THE AGE, February 25, was not possible that time obtain sufficient material the same analysis. required least three specimens for each welding speed since trial piece was re- quired establish the wire feed- ing mechanism and arc length for each particular run. Then dupli- cate hardness specimens were nec- essary check the results ob- tained. Primary Object the Research The primary object the search was ascertain the hard- ness values the cross section the plate. For this reason the bead itself was not important 3 ° ° a 300 - Welding Speed, inches per minute and was sacrificed somewhat that the actual response the plate might determined. practice, the proper type elec- trode wire would selected for each grade steel used; the special steels this would undoubt- edly some form covered rod. This brings into play another vari- tions namely, flux, with its many varieties composition. order carry out this pro- gram with the least number unknown factors present influ- ence the results, bare electrode wire was used (5/32 in. diam- eter). This also afforded oppor- tunity analyze the percentage dilution special elements the weld adding filler metal containing such elements only impurities minute amounts. Such work has not been completed, but the several results obtained the per cent nickel steels show that the bead approximately 1.75 per cent nickel throughout, with the exception the top the bead where the percentage this element usually lower. The hardness test specimen was from the center the crater finishing end the 9-in. bead. The cross section the sample was polished for microscopic study and etched with 1.0 per cent Nital. The Vickers hardness impressions were made 0.02 in. apart through the hardened zones and 0.05 0.10 in. apart the areas outside the affected zones. The hardness values obtained were plotted graphic form described the previous articles this series. The graphs appearing these pages show the “hard zone” which the hardest value obtained from that particular sample; the “weld” curve indicates the figure which representative the deposited bead; and the “plate” line remains the same for sample the same steel, this point taken the untreated plate. Problem One Overcoming Metallurgical Damage not the purpose this re- search recommend condemn any type steel whether carbon alloy steel. While many factors are interest the de- signer, from the standpoint welding metallurgy, the problem becomes one overcoming the metallurgical damage the plate brought about welding. Certain facts will become ob- vious the charts micrographs are studied. For ex- ample, compare the plain 0.33 per cent carbon steel with any alloy steel included herein about which similar information available. Comments have been made (THE IRON AGE Dec. 17, 1936) the effect that the plain 0.33 per cent carbon was readily weldable. Near the close this third and final article this series, the effect stress relief will shown for the 0.33 per cent carbon steel. The need for stress relief, insofar this treatment has benefited either SAE and properties the slow cooling some ternary steels. (1) the introduction special element carbon steel the latter remains first pearlitic, but the proportion the special ele- ment increases, the carbon remaining constant, comes first martensitic and then austenitic, and some- times cementitic. (2) increasing the amount carbon present spe- cial steel, the proportion special element being kept constant, generally con- verted from pearlitic into martensitic condition or, wows 4150 (0.52 per cent carbon, Cr-Mo) 4x. Welding speed in. per min. the hardness microstructure the plain carbon steel practically negligible. This not true the steels higher hardening power. However, bear mind that the subject residual stresses does not come within our scope this work. Carbon Combination With Special Elements Returning the alloy steels find that carbon combination with special elements increases the tendency toward air hardening the section the plate adjacent the weld. Carbon content should kept low hold the struc- tural constituents low order. Prof. Albert Sauveur “The Heat Treatment Iron and Steel” formulates few propositions from Guillet’s theory the structure Hard zone 642 Vickers-Brinell. already martensitic, into austenitic condition. (3) The greater the amount carbon the smaller the proportion the special ele- ment needed cause structural transformation, for instance pearlitic into martensitic martensitic into austenitic. (4) The greater the amount the special element the smaller the proportion carbon needed cause structural transformation. Although the above deals with higher percentages chemical elements than contained the low alloy steels with which are concerned, have drastic quenching the heated metal the welding process (CONTINUED PAGE 115) THE IRON AGE, February 25, a } = ‘ Limitations Present that, from the economic point view, there are distinct limitations the effective use all present methods transmitting power from driving shaft driven shaft, and that these limitations are increasingly apparent any present system industrial trans- mission which seeks make the 32—THE IRON AGE, February 25, 1937 power input the system usable the highest possible degree. has been said this series discussions that individual motor drive, while yielding many advan- tages, costly best; and that modern group drive, while retriev- ing many the expensive wastes inherent individual drive sys- tem, not panacea, and does not suit all conditions operation. is, matter fact, serious mistake decide offhand, before all the facts given situation are thoroughly investigated, that one system the other best for the plant question. Studies should made not only depart- ments the plant, but groups machines each department, with due consideration being given production factors, material han- LEFT the tendency get away the limitations cone step-pulley belt drives this compact lathe drive powered with hp. Wagner Electric two-speed constant horsepower induction motor, totally inclosed. For roughing out operations the motor run 1750 r.p.m.; for the lighter finishing cuts operated 3500 r.p.m. ° ° ° BELOW UILDING construction has im- posed the principal limitations the drive problem here. upper floor, narrow bay and low ceiling make combination that almost impossible lick except with indi- vidual motor drive. Phpto courtesy Westinghouse Electric Mfg. Co. 3 i 5 al| Drive Systems dling factors, motion economy fac- tors and the general questions lighting and safety, well the obvious factors investment cost, operating cost and mainte- nance cost. Some the most common limita- tions met determining the right type system which may most profitably employed may listed follows: The Power Requirements Individual Machines. general, machines which require hp. more for operation, and which im- pose fairly steady load the motor more than half the rated motor horsepower, are usually best driven individual motors. Under most industrial conditions, group drive motors are best mounted over- head. Since very large motors are unwieldy replace quickly case failure, overhead mounting tends limit the motor size 100 hp. less—more frequently about hp.—and thus the effective group- ing machines which take large loads made difficult unless means are devised locate the transmis- sion system under the floor, just steel pulley department, Dodge Mfg. Corp., Mishawaka. single motor operating three main shafts and one countershaft drives fifteen machines considerable saving over individual motor drive. the fifth chapter the series The Economics Industrial Power Transmis- sion, Mr. Juraschek draws attention many obvious limitations present drive equipment. The first article appeared Dec. 19, 1936. above the floor back the ma- chines. Where several machines are located closely together, each developing large loads highly in- termittent character, often pos- sible combine them group for the purpose averaging high peak loads, cutting power costs and improving power factor. Such problem requires very careful de- signing the transmission system secure low operating and mainte- nance costs. the other hand, machines requiring smaller horse- powers, particularly when their loads vary widely, may usually grouped advantageously order ideal. FRANCIS JURASCHEK Consulting Editor, THE IRON AGE Lighting and general working conditions are practically ° ° ° improve both the power factor and the electrical efficiency operation. Character Plant Operation. The general character operation the plant may well have in- fluence the question individual vs. group drive. shop which runs maximum capacity through- out the year, producing the same product all the time, the grouping drives production units pre- sents many economical advantages. somewhat lesser degree, the shop which runs maximum pacity two three shifts per day, one time, then practically shuts down for period, can operated economically with group drive sys- tems provided those systems are carefully adapted logical produc- tion units machines. Where, how- ever, the character the work varies widely, either from day day from month month, most job shops, and the set-up work each machine not uni- form over successive periods, has been found that individual motor drive presents flexibility opera- tion which more balances the usual operating ad- THE IRON AGE, February 25, 1937—33 ° | are x e€ for materials handling systems. The rigidity such under-the-floor on-the-floor transmission systems must weighed against the ad- vantages individual motor drive such cases. best group drive system not flexible indi- vidual motor drive, but the attain- ment that flexibility must had increased cost for electrical power distribution. ABOVE large hat factory batteries machines are placed back back, with the belt drives between, out the way, arranged small groups for production control. This set-up was intelligently planned reduce unit power costs the absolute min- imum. Photo courtesy American Pulley Co. vantages the group drive system. This particularly true when the variations work make necessary frequent change location machines, the automotive industry, frequent change models cause the scrapping whole de- partmental machine make way for new production ma- chines. Materials Handling Considera- tions. Oftentimes the necessity for overhead crane service, con- veyor systems, well certain types obstructions peculiar the construction the building, will dictate the adoption indi- vidual motor drives, even though possible nowadays devise group drive systems with the trans- mission equipment mounted under the floor, the floor alongside the machines, leaving space clear 34—THE IRON AGE, February 25, 1937 The Concentration Ma- chines Given Area. Where ma- chines are widely separated the limitations group drive are ob- vious, and individual motor drive usually indicated. Where machines are concentrated closely group drive becomes important eco- nomic factor. Here again study that machines now separated may BELOW the hanger set-up this modern group drive extremely flexible. The hangers may shifted with ease along the line the shaft- ing; the channels supporting the hangers may moved easily right angles the line the shafting. Machines may located re-loca- cated anywhere the Photo courtesy Industries, Inc. ABOVE plate open- coln Electric motor built the body frame modern milling machine. Note also the chain drive which likewise concealed when the cover plate shut. RIGHT HILE these group drive line- shafts are modern type, supported anti-friction bearinged hangers, the hangers can only moved new locations ac- commodate possible changes locations, culty and consider- able expense. Photo courtesy American Pulley Co, logically located close enough each other make group drive production units possible. Unless the character the work demands wide separation the machines study the effects grouping should made anyway from the standpoint effecting greater mo- tion economy. Speed Variation Requirements the Machines. Sometimes the requirements for machine speed variation may determine the choice drive system. With individual motor drive step-by-step speed vari- ation may obtained multi- speed motors, and stepless speed variation slip-ring brush-shifting motors, shunt- wound motors, mechanical variable speed transmissions, squirrel cage motors with inbuilt variable speed transmissions. With group drive methods step-by-step speed variation can obtained pulleys and/or countershafts, and stepless speed variation me- chanical variable speed transmis- sions. Choice the most suitable means for any situation will depend the conditions the service met, and will influenced the comparative cost either system. Machine Mobility Require- ments. Although this touched upon above, should THE IRON AGE, February 25, 1937—35 listed separately limiting fac- tor group drives, for despite the comparative ease which the modern rectangular steel stringer system affords the problem shifting both machine and transmission lo- cations, machines equipped for individual motor drive are still capable being moved new loca- tions more easily. This ticularly true when, the group drive system, countershafts are employed. Production Schedule Delays Due Breakdowns. spite the fact that great improvements have been made recent years design and construction electric motors, with consequent longer life and more freedom from the breakdowns former days, cer- tain amount trouble with elec- trical equipment almost inevit- able. judge between the merits one transmission system and another this point matter which depends largely the plant manufacturing set-up. Motors the sizes generally used for group drive are apt more rugged and long-lived than those used for direct motor drive. This not al- ways true, course, since even small motors are being built now very rigid standards and speci- fications. Yet, because the fact that, when properly selected for the duty, group drive motors are never subjected serious over- loads, while the direct drive motor, particularly such are used drive metal cutting tools, may and frequently meet this condition, experience shows that breakdowns service are found much more frequently the individual motor drive system. The effect such breakdowns the production schedule must judged the time required get the machine back into service, and the result the interruption the work its relation the output the ma- chine which has temporarily stop- ped functioning. With group drive the breakdown the group motor much more serious than with individual driven machine, since the work many machines instead but one brought stand- still until repairs are effected. This condition infrequent occur- ence, however, because the very nature group drive the factors which cause most breakdowns tend disappear the general level- ling peak loads which the sys- tem promotes. group ma- chines, momentary increased de- 36—THE IRON AGE, February 25, 1937 mands for power one machine, due say dull tools, oversized tough stock, stiffness the machine because recent over- hauling and replacement parts, will almost invariably balanced lessened power demands the other machines the group. With identical machines working identical product, abnormalities power may general effect, and will more apt cause strain and possible interruptions pro- duction than when the machines the group are merely related function and not the same work. With number machines com- cyclic variations the power de- mands each machine tend cancel out. The larger the group the more complete this evening the resultant load, and conse- quently the more trouble-free be- comes the the system. has been estimated that well- organized plants where adequate supervision and maintenance serv- ice had, delays due breakdown motors need not run more than one-half one month per hundred group drive motors installed. The failures per hundred individual drive motors similarly run industrial plants sel- dom run less than three times these time delay periods, for re- placement repairs. Number Machines Which Can Logically Grouped. When only very small number ma- chines can grouped logically, driving them group means sacrificing one the most impor- tant reasons for using group drive —the saving total installed mo- tor horsepower based the con- sideration that the maximum power demands all machines not occur one and the same time. For instance, with only three four machines the group, can- not assumed that most them will not “get step” simultane- ously peak loads fairly fre- quently, and thus cause stalling the motor. This would particu- larly true the individual machine loads fluctuated great deal. the group under such circumstances cannot increased say double the number machines wiser consider either individual motor drive, much larger group drive motor capable handling the “in- step” peak loads. the other hand, where the nature the ma- chine loads intermittent and sharp peaks occur frequently enough make the use indi- vidual drive motors reasonable ratings troublesome, every effort should made form large groups machines, even though the size the group drive motor has several hundred horse- power. Universal Rule The large amount industrial transmission modernization work which has been undertaken the past few years simply confirms the statement Robert Drake 1932 that “It unusual find plant where careful study the eco- nomics the situation well manufacturing and production con- siderations point installation either completely group driven completely individually driven. After eliminating those depart- ments where one the other type drive offers definite and con- siderable advantages from manu- facturing standpoint, there remains considerable portion the plant where one method will give just about good results another, both are planned with equal in- drives for these portions the plant that economic considerations should most carefully weighed.” brief, there universal rule that ¢an applied the problem. All factors must care- fully weighed each situation, and power transmission must tailor- fit each case the utmost results are obtained the effective and economical use tions each system drive must limitations which present the ma- jor problem application. addition the limitations which have been outlined above with respect the systems pow- transmission, there are numer- ous other limitations which apply more particularly the various pieces equipment used pow- transmission system. Although space prohibits detailed discus- sion everything this nature, the following outline may con- sidered useful indication the line along which improvements sought bring any method system power transmission its fullest effectiveness: Motors. The squirrel cage alter- nating current motor is, without x doubt, the most widely used type motor American industry. has wide range usefulness, and relatively cheap. But not highly efficient electrical in- strument. develops its best effi- ciency full load. When not fully loaded the efficiency falls off rapid- ly, and the power factor declines even more rapidly. must over-motored, since start- ing peak loads are always greater than normal running loads, and since all machines are not op- erating all the time. plant where many small individual mo- tors are used, the combined elec- trical efficiency low, and the power factor abnormal. plant using group drive systems, both these factors are largely compen- sated for, but never completely. Group drive systems may often raise the power factor operation corrective equipment needed secure economical operation. With individual drives corrective equip- ment almost always necessary. While true that unity power factor motors may used, they are expensive compared with squirrel cage motors, and either synchronous motors power fac- tor condensers cost even more. There need for type motor relatively low cost the squirrel cage type for ordinary machine driving use, which will op- erate higher efficiencies three- quarters half load, and which will enable the power factor held around 80-85% the average industrial plant. Belting. More than three quart- ers the leather belting now the market distinctly inferior quality. Less than per cent hide can used for good quality leather belting, and even this must tanned carefully, the tannage varying with the service which the belt put, and the strips assembled into the finished belt with care. There crying need REVERSING mill can only driven effec- tively adjustable speed direct cur- rent motors. shown, the 10” 26” 24” 4-high mill driven 500/800 r.p.m. 500 hp. motor; the two reels each have 150 hp. 300/1100 r.p.m. motor. ° ° ° for leather belting, since mere in- spection rarely tells the purchaser anything about what buying. The present lack system grad- ing and marking belting all the different belting manufacturers means nothing, and the only safe recourse for the purchaser buy from house with reputation for fair dealing, and keep care- ful records the life and service each belt buys. The old adage “caveat emptor” still holds with majority leather belting manu- facturers, unfortunately. Rubber and composition belting has made enormous strides re- THE IRON AGE, 25, 1937—37 cent years. The markets for rub- ber belting have been widening continually until today they may used with great satisfaction al- most everywhere leather belt may manufacturers are constantly spending huge sums research The with the aim improving their belting; very little similar research being done the leather belt- ing manufacturers. Both leather and rubber belting should de- veloped secure greater coeffi- cients friction between the belts and pulleys, give longer useful life, stretch less and “creep” less. Shafting. far cry from the three and four inch shafting used our grandfathers the light, high-speed steel shafting today. But there still great deal room for improvement. The use many the special, light alloy steels now available the result recent metallurgical research would cut down still fur- ther the weight shafting, and thus reduce frictional loads. Hangers. seems strange that one has yet brought out aluminum alloy shaft hanger. least two man job today mount hanger, change its location new position the shop. There reason why aluminum alloy hanger least (CONTINUED PAGE 124) ath The Chuck Keeps Step the Modernization Marc WAITE ° ODERN machine tool practice provides severe test stamina. Par- ticularly this true work- holding devices. The chuck, for example, stands between two fires; the power the machine spindle and the re- sistance the cutting tool. use popular expression, ments material cut- ting practice have put new responsibilities upon the chuck. Today, must thoroughly engineered unit into which built the accuracy re- quired multiple parts production and ability keep pace with in- creasingly severe requirements presented modernized machine tools. This article, while based upon the methods the Skinner Chuck Co., New Britain, Conn., not endorsement type chuck. Its purpose record significant progress within subsidiary machine tool industry meeting problems work- holding under the new capabilities cutting tools and the resultant condition stresses, speeds and precision specifications. Facilities the Skinner plant 38—THE IRON AGE, February 25, 1937 must able both take and dish out." this article, Mr. Waite gives insight into the matter chuck moderniza- tion, exemplified the known maker these ma- chine appliances. now cover operations machining solid forgings, steel castings, standard grade gray iron castings, and iron castings alloyed with nickel, chrome molybdenum basic materials for chuck bodies. The company, however, dates from the days when all chuck bodies were ordinary gray iron castings. new arrangement shop facilities, heat treatment garded the most important operation manufacturing, par- ticularly the chucks heavy- duty type. much other machine tool procedure, technical cooperation with the steel maker has been the basis developing materials having specific charac- teristics suitable for the gaining several advantages. Details this preliminary steel research may passed with the comment that any steel, held its makers suitable, eligible prove its worth elimination tests. such cases, the possibilities cost re- ductions manufacture are care- fully weighed against material prices. Parts the company’s new heat-treating department are shown Fig. and Special spaces are provided for laying out work for heat treatment. The equipment includes large elec- trically controlled furnace, regu- lated instruments, and controlled electric furnace for first and second re-heats. Drawing done hot air with range 350 1200 deg. quenching bath oil used, with the oil tank sufficient size and capacity take care the largest load handled the carburizing furnace. the oil bath, the oil surrounded water jacket which motor- ized agitator, operated through thermometer control. light case work, where only few pieces may wanted, but quickly, standard cyanide salt bath used. Since carbide tools throughout the shop, treating room provides for brazing bits low-carbon shanks. For this work, pre-heating furnace, electrically controlled, used conjunction with high-speed fur- nace. Development heat treatments has included certain clay and sand methods, featuring the use alloy caps, for case control spe- retard carburization. connection with the retarded case thus ob- tained working surfaces, said that final heat treatment, not only the desired wear re- sistance obtained, but that there also increase material strength amounting some in- Heavy-duty forged chucks, hogged from the solid, and having fine-grained structure, are recent new standard line. The assembly includes special steel bodies, jaws. scroll plates and pinions, all heat- treated and free from material 100 per cent inspections. Typical chuck types are shown Fig. and standard sizes, chucks now run in. diameter and well onto 1000 weight. forged chucks afforded recent manufacture 28-in. indepen- dent chuck weighing 850 lb. for | | ° ° | | 4 IGS. Views the new heat- treating department the plant the Skin- ner Chuck Co., New Britain, Conn., where heat treating held the most impor- tant operation the manufacture mod- ern work-holding chucks, ; use Warner Swasey turret lathes, Fig. Inspection breakdown tests simi- lar those found automotive practice have been evolved. For example, for the purpose constantly investigating competi- tive steels and for checking con- tinued reliability selected steels, torque-testing machine spe- cial design provides for recording resistance breakage 100,- 000 lb. this machine, actual tests have shown 97,000 in. lb. Parts such shanks, jaw screws, pinions foi chucks, may tested separately finished chuck may mounted the machine table for unit testing all component parts under operating conditions, but with extreme stresses. im- pact screw-thread testing machine, Fig. connection with Rock- well hardness-testing equipment, employed assure that thread- impact resistance and freedom- from-brittleness specifications are met while work process. These specifications call for prac- against previous screws, in. in. drop 5-lb. weight. gaining the hardness, wear and THE IRON AGE, February 25, 1937—39 \ ABOVE Forged steel body, heavy-duty independent chuck, weight 850 diameter in., for use Warner Swasey turret lathes. ° ° ° BELOW IG. device for brittleness and strength sing 5-lb. weight and high-speed steel drive pin, impact measured. RIGHT IG. Serrated, 3-jaw type, power chuck, equipped with top-jaw keys, two of which are shown position, and one the right the chuck. These attach top chuck jaws through top-jaw nut, shown the left. grades. high torque objectives, now production practice employ the higher alloy materials screws, rather than carburize the lower t hydraulic pump unit, which with gage mounted ma- chine base and having heavy spindle assembly for work holding, utilized for testing the jaw and scroll threads for brittleness and impact resistance. provides material comparisons well check manufactured parts. the former case, interesting note that strength, controlled depth, often varies much per cent the shearing off carburization scroll threads. Prominent metal- lurgists interested research work this plant have reported test results indicating that the cross section tooth which threaded right angles the grain selected steels, stronger for chuck use than thread which cut with the grain. Capitaliza- tion these indications, they pertain further chuck better- stage. The working out special wear-testing machine gives its first model, Fig. the promise increasingly accurate determina- tions alloy prevailing under different conditions ten- sile strength. This testing said have yielded valuable informa- tion. this connection, method for the lubrication all moving chuck parts has been devised and said hold possibilities for major development the use chucks. Manufacturing machines, equip- ment, practices, methods employed may in- terest indicating problems which builder. Some these are briefly referred and illustrate the type study under way the chuck industry, for meeting holding requirements. Heavy-duty forged chuck bodies are turned heavy Warner Swasey, Jones Lamson, and Gisholt turret lathes. Particular attention regularly given maintenance extreme cross-slide accuracies for assuring precision the chuck seat, which becomes (CONCLUDED PAGE 122) ‘ ¥ 40—THE IRON AGE, February 25, 1937 lubrication die-casting that are subjected high temperatures often- times difficult problem, inasmuch most lubricants either lose their viscosity chemically decompose under high heat. Experience has shown, however, that all lubri- cants compounded for the purpose those containing colloidal graphite and similar problems the high temperature field. Not only the graphoid surfaces formed such material possess low coefficient friction and act protective coating mov- ing parts, but they are also re- sistant oxidation and are incom- bustible 600 deg. consideration this material from the standpoint actual die-casting procedures fol- lows. The word limited properly those parts produced from metal molds dies, the ex- erting forces being either gravity the pressure from hand-oper- ated plungers, and hy- draulic devices. This pressure maintained until solidification complete. The dies are usually Colloidal Graphite Die-Casting Lubricant ° ° WILLIAM JENNINGS ° made from heat- treated alloy like chrome-vanadium steel, and are applicable for cast- ing the yellow metals well those alloys having zine, tin, lead, aluminum base. One the reasons for the use such metal dies obtain within narrow limits and solid casting that requires little machining. Although accurate lathe methods produce quired smooth finish, the purpose the die, however, somewhat defeated its surfaces are not treated with non-gumming lub- ricant parting solution like dispersion graphite, as, for example, practice, the dies cores are first dipped into droxide solution order cleanse them any absorbed grease-like substances. Where the parts re- quiring treatment are too large for immersive purposes, gasoline brushed over the surfaces cleaned. The concentrated colloidal graphite product commercially sold then diluted with water the proper consistency and worked over thoroughly eliminate any agglomerates. The three main methods coating mold with this material are spraying with such devices the Vilbiss gun, dipping into prepared baths, and swabbing with brush, listed ° THE IRON AGE, February 25, the order their most efficient and economical use. Several coats are initially applied order obtain the proper metal impreg- nation form the so-called “graphoid that enables the free and rapid flow metal essential well-formed castings. The surface thus formed then polished whenever possible. some instances the graphite de- posit may function better the mold heated temperature above the boiling point water, say 125 deg. This temperature, however, should not high make the water flash and dis- lodge the graphite particles. Fol- lowing the initial treatment with the graphite material quency subsequent applications depends upon the speed produc- tion and the difficulty removing the cast objects, both factors which are determined the op- erator. mold and core wash applicable general conditions consists, said, one part (by volume) concentrated graphite ten parts distilled water. For tempera- tures around 400 deg. one- fourth part volume sugar glucose added the above solu- tion. For work 700 deg. C., per cent heaviest density com- mercially pure sodium silica recommended, while approxi- (CONTINUED PAGE 82) 2 a > ~ ( ° ° : 2 tg be Officers Inducted— Medals and Honors An- nounced Special Lectures and Meeting for Students—227 Technical Papers Presented Metal- lurgical, Mining Subjects, and Production and Use Oii and Industrial Minerals. WITH almost every conceivable metallurgi- cal and mining subject covered over 200 technical papers, with multitude special features gaged attract both the practical and the theoreti- cal engineer, with the serious as- pects the meeting set off attractive entertainment features and plant visitations, there little doubt but what the 147th meeting the American Institute Min- ing and Metallurgical Engineers, held New York, Feb. 15-19, was one the most successful the association’s history. Registration members and guests the Engi- neering Auditorium for the five-day period totaled 2000, the best turn- out record, which reflection part the attractive program offered and, also, probable im- provement the financial status many members. The annual dinner and reception the A.I.M.E. was held Wednes- day evening, Feb. 17, the Grand Ball Room the Waldorf-Astoria Hotel. John Lovejoy, retired 42—THE IRON AGE, February 25, 1937 2000 president the institute, and Rolland Allen was introduced president for 1937. Awards and honors announced the dinner were follows: the William Law- rence Saunders Medal Erskine Ramsay; the Anthony Lucas Medal Edgar Pew; the Cer- tificate Honorary Membership George Samuel Rice; the Robert Hunt Prize for 1937 William Floyd Holbrook and Thomas Joseph for their paper, “Relative Desulfurizing Powers Blast Fur- nace Slags,” presented the Feb- ruary, 1936, meeting; and the Johnson, Jr., Award John Hassler, “for meritorious work advancing the quality and prepara- tion raw materials for the blast furnace.” Nine men the Class 1887 Legion Honor were wel- comed the assembled dinner guests. The Institute Metals Division annual dinner was held the East Ball Room the Commodore Hotel, Thursday evening, Feb. 18. The after-dinner talk Samuel Wyer concerned itself with “Con- tributions Way Out Today’s Economic The annual lecture the Institute Metals Division was presented Prof. Hutton the University Cambridge. His subject was “Re- fractories.” (See abstract herein.) Dr. Paul Merica, vice-presi- dent the International Nickel Co., Inc., the author the 1937 Howe Memorial Lecture, spoke Thursday afternoon “Progress the Improvement Cast Iron and the Use Alloys.” Probably the most unusual the special features during the five-day session was the “experience” meet- ing for students, held Monday af- ternoon under the sponsorship the Committee Student Rela- tions. Six past presidents the in- stitute—Henry Buehler, Everett DeGolyer, Howard Eavenson, Reynders, George Otis Smith and Scott Turner—were seated the head the table and answered numerous questions ad- vanced assembled young men regarding their professions, their careers, related matters. Many the inquiries were asked from the floor, although number had previously been submitted writ- ing. Student members benefited con- siderably attending special lecture the subject physical metallography Prof. Bar- rett the Carnegie Institute Technology. This talk, especially designed for students, dealt with the fundamentals and usefulness stereographic projection methods studying metal crystals. Friday numerous members and their families took advantage the low-cost excursion arrange- ments visit Bridgeport, Conn. Groups visited the Bassick Co., Bridgeport Brass Co., Bullard Co., General Electric Co., Raybestos- New York | Sek f a | | < t Mem ber Assemble For 147th Meeting Manhattan, Inc., Remington Arms Co., Sikorsky Aircraft Corp., Un- derwood Elliott Fisher Co., and Warner Brothers Co. number members also took advantage the institute’s regular annual Ber- muda cruise, which sailed Feb. 19. Refractories The Institute Metals annual lecture, delivered this year Prof. Hutton (Goldsmiths’ Profes- sor Metallurgy, University Cambridge, England) and dealing with the subject refractories, at- tracted considerable amount interest, both because the scope the data presented and, also, be- cause the subject one which has generally not received the atten- tion worthy of. Professor Hutton pointed out the scientific study the constitution diagrams binary and ternary refractory oxides has been foremost the United States, led the work the Geophysical Laboratory Washington, all which has laid firm foundation for the whole sub- ject. One has remember, how- ever, that much greater degree than with the constitution metal alloys, the equilibrium conditions are sluggishly arrived that, many practical applications, possible with appreciation ac- cept the definition this field covering the “chemistry frus- trated reactions.” The applications petrological and X-ray methods examination are also proving most fruitful advancing the in- dustry’s knowledge. the manu- facturing side, high-pressure form- ing, de-airing and electro-casting represent major advances recent years, according Mr. Hutton, also does the utilization new ma- terials both from diligently sought out natural resources, from arti- ficially produced materials such silicon carbide and fused alumina. Above all the industry has been advanced the recent cooperative effort for Standardization Test- ing Methods, which again Amer- ica has taken foremost position. The insistent call for progress refractories, said Mr. Hutton, seems due firstly the urgent de- mand for more rapid metallurgical production, which entails higher temperatures and the concomitant more severe conditions service; and secondly the greater con- sideration which being given the thermal efficiencies metal- lurgical processes. both these directions, the industry still only the bottom rungs the ladder ascent. example the severe con- ditions which exist, consider the open-hearth production steel, which present-day temperature con- ditions have recently been investi- gated with the help new form optical pyrometer. Temperature the steel after melting down, 3000 3180 deg. F.; temperature flame after melting down, 3240 3720 deg. F.; and temperature BSTRACTS Herein: Solidification Rimming In- gots"; Rimmed Steel "Factors Influ- encing Segregation and Sol- idification Steel "Oxides Basic and Steel"; and Cast the refractory roof after melt- ing down, 3040 3130 deg. The foregoing temperature mea- surements were made with fur- nace built with silica roof and the limitation temperature entire- due the fact that any higher temperature would entail the very rapid melting the roof and de- struction the whole furnace. Whereas readily possible suitable regeneration, the selec- tion combustible gases, and utilizing recent knowledge the importance radiation from lumi- nous and non-luminous gases at- tain flame temperatures 4890- 5070 deg. F., e., about 1800 deg. higher than the maximum steel temperatures present prac- tice, operators are probably limited even the silica brick roofs are re- placed with chrome-magnesia any other the better refractories present available commercially. Although now known that radiation far more important than convection for the transmis- sion heat units from the burning THE IRON AGE, February 25, 1937—43 3 4 Les Wy ‘ 5 | ran > Lop } | gases the metal, obvious that there needed high “tem- perature head” possible, and the fact that the refractories can only withstand such low temperature shows how radically they fail at- tain any reasonable standard for designing much the present-day furnace equipment. The ordinary open-hearth, said Professor Hutton, only has ther- mal efficiency about per cent —40 per cent the heat going the stack and radiation and other losses accounting for the other per cent. This crude economic wastefulness should surely offer powerful incentive striving for drastic improvements. The bugaboo initial cost construction has for far too long hindered rapid advance. Does really pay construct furnaces with life only few hundred heats, with high upkeep costs, and with overall. efficiency of, say, per cent? Does silicon brick 5c. really show overall economy over super brick 50c. even dollar? Fuel economy and above all long life and long runs between repairs furnace struc- tures may far offset such high costs and render the use and development super refractories real value the progress the metallurgical industries, according Profess