The Iron Age 1937-10-21: Vol 140 Iss 17

FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Bditor Art Bdttor Metallurgteal Rditor Associate Editors JURASCHEK Consulting Bditor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, Cincinnati FRAZAR Boston Hamburg, Germany Milwoakee San Francisco SANDERSON Asa JR. Toronto, Ontario Birmingham TURNER Buffalo Owned and Published CHILTON COMPANY Publication Office Editorial and Chestnut and 56th Executive Offices Pa. West 89th New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC STEVENS, Vice-President JOSEPH HILDRETH, GRIFFITHS, EVERIT TERHUNE, HASTINGS, WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER JULIAN CHASE THOMAS KANE CHARLES BAUR BUZBY BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureaa Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Ouba, $6.00, Can- ada, $8.50 Foreign, $12.00 year. Single copy, cents. Cable Address, ADVERTISING STAFF Emerson 621 Union Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg. Chicago H. E. Leonard, 239 W. 38th St., New York Peirce Lewis, 1316 Woodward Ave., Detroit Ober, 239 39th New York W. B. Robinson, 428 Park Bidg., Pittsburgh D. C. Warren, P. 0. Box 81, Hartford, Conn. IRON AGt Contents OCTOBER 21, 1937 Equipment Policy Norfolk Western. Completes New Small Motors Hydraulic Presses with Continuous Welded Automotive Washington News Plant Expansion and Equipment Buying................ New Industrial | nn. e- a. 0. 108 ipe. free from out, tions see easy cut insi highly satisfying -removing opera make clean, tight scale, install Bethlehem makes threads that ts. find work hard spots, that. And the soft steel when you Two scale join pipe STE 20—THE IRON AGE, October 21, 1937 4 i i October 1937 ESTABLISHED 1855 Vol. 140, No. Cheerful Earful you are suffering from neurosis and its accompanying feel- ing, due the Wall Street sinking spell, recommend the study statistics antidote. Not the statistics stock prices, but the record orders and produc- tion our industry during the first nine months this year compared with the same period items regularly listed The Age major indices orders produc- tion, show decided increases for this year over last and only one, fabricated plate orders, shows decrease. The latter minor item and the decrease compara- tively small. The increases, the contrary, are very substantial ones. For example, Lake ore consumption for the current nine months gross tons, per cent over last year; pig iron output 8,657,132 gross tons for the nine months, per cent. Steel ingot production for the first three quarters this year 8,972,627 gross tons over last year and last year's performance was not all the ingot produc- tion rate should not exceed per cent capacity week week from now until the end December, would still come out with greater total production ingots 1937 over 1936. Even with the construction industry lagging, construction contracts Eastern States are $265,386,100 for the first nine months 1937, per cent. Machine tool and foundry equipment order indices are well above the corresponding period 1936. Automobile output, which geared directly demand, shows increase over 500,000 units for the nine months 1937, per cent. And speaking automo- biles, one ever saw depression this country when the automobile business was good. Who buys automobiles? People with income. Then reflect this: Farmers will average this. year $24,000,000 more income per week than they did last year. Fac- tory workers will average $50,000,000 per week more this year than last wages. Stock- holders will average $10,000,000 per week more this year dividends than last year.* This means more automobiles bought, more steel most everything. load the proper kind statistics will help keep ou- feet the ground when Wall Street gets the jitters. Authority, Babson Statistical Organization. f ‘ | } Analysis the Equipment FRANK OLIVER Editer, The Iron Age generally con- ceded that the Norfolk Western Railway one the best man- aged railroads the country. part its financial success can attributed the fact that has kept its operating costs down maintaining its shop facilities high level efficiency. great many roads, expenditures for shop equipment are looked upon necessary evil, met with only last resort. the financial minds that control the destinies most Class railroads, “equip- ment” means rolling stock and does not encompass the machine tools that keep the rolling stock repair that build it. There different type thinking the not banker controlled and free therefore from many the evils absentee management. Like many industrial institutions, but the lengthened shadow man, and the key the road’s shop IRON AGE, October 1937 equipment policy found the type thinking its president, Jenks. The story told Mr. Jenks when twenty more years ago first became general manager. The then president had program mind for new locomotive and car purchases which his staff agreed was excellent investment. When Mr. Jenks’ opinion was asked coming from what amounted rank outsider, startled his su- perior telling him that the money would better spent putting into shop equipment, raw materials and labor repair the bad-order cars that were clut- tering the yards and the dis- abled locomotives that were rust- ing the tracks. Otherwise, rea- soned Mr. Jenks, where would they put the new rolling stock when they got it? Though somewhat taken back this brash sugges- tion, the chief executive later agreed that the idea was good one and put into practice. The policy has stuck. difficulty facing any railroad justify the investment shop equipment terms maximum usage. The loading factor many machines very light, particularly those installed roundhouses. Norfolk attempting analyze the shop equipment replace- ment policy one the most successful railroads the country, the author gives fairly detailed view the entire set-up, the main objec- tives pursued, the type thinking the top the organization and the method Yet the equipment has there serve the emergency and the peak load. While the obsolescence factor may great, the reservoir useful life may even larger and will delay the replacement old equipment whose existence can not justified the basis unit costs. increase this loading factor, the Norfolk Western 1926 adopted the policy building all its own locomotives and part its car requirements. During the early years the depression, the solicitation the Hoover Ad- ministration, the road went right with its normal building pro- gram and helped sustain opera- tions the Roanoke shops i i ia 9 | i} i} | Hf } | = Norfolk Western has just finished building these Class type 2-6-6-4 simple ticulated roller bearing locomo- tives its Roanoke, shops. Weight with tender, 948,600 tractive effort, 104,500 Ib. Replacement Policy the Western handling depreciation charges. Policy checked with practice machine- by-machine study shop purchases since 1930, point- ing out some interesting trends tool requirements, largely brought about the adoption roller bearings locomotives. locomotive and car building pro- gram when unemployment had be- come quite marked general industry. The question arises whether sound practice for railroad build its own locomotives when such are available the outside. the Roanoke shops, the answer simple: Since the machine tool facilities are available for com- pletely rebuilding locomotive, they can used equally well for building completely new power unit; and since the machinery must necessity provided for neces- sary repairs, all its costs, includ- ing repairs, depreciation and re- placement, should charged locomotive repairs only. This means effect that calculating the shop cost_of new locomotives, overhead any kind, except shop and stores expense, charged against the job. Furthermore, when the item sales expense elim- inated, not surprising find that locomotive can built these shops cost one-third under the selling price out- side producer. presenting this slant, the author not trying make out case for either method, but rather report matter fact the philosophy the mechani- cal executives the system. Cer- tainly, the lean years this policy meant much maintaining em- ployment Roanoke, and this does not imply less employment elsewhere, since this was largely made-work program time when increase hauling ca- pacity was hardly justified the face rapidly falling carloadings for the nation whole. 1936 new program loco- motive building was begun with the development two experi- mental types articulated loco- motives. the time the writer’s visit Roanoke Aug. 11, the eighth the Class type 2-6-6-4 engines was being groomed for its first run. Two more this Class series simple articulated units are built, and then more Class Y6, type 2-8-8-2 compound freight engines are built. En- gine and tender combined weigh 948,600 and 961,500 lb. respective- ly, and are Timken roller bearing equipped all driving and tender axles. fact, was the adoption roller bearings that led the purchase many the machine tools recently installed, large percentage which are grinders because the much closer toler- ances required for this class work. Concurrently, repair pro- gram 1000 hopper cars was being completed and preparations were being made for floor, side and end repairs 1500 gondola cars. Over 1000 new cars are being con- structed outside shops, includ- ing 425 hopper cars the adjacent Virginia Bridge Co. plant. gether, since this policy was put into effect 1926, over $8,000,000 has been spent the motive power division shop orders for new rolling stock and the necessary new equipment with it. much for the background pic- ture. Now let analyze the ac- tual performance the Norfolk Western equipment re- THE IRON AGE, October ‘ ; | ii f } oF i | | ! placement through the lean years and the present. Incidentally, should noted that far the general experience the rail- roads the country concerned, there was immediate falling off machine tool purchases following the stock market debacle Sep- tember, 1929. The biggest splurge made that fateful year was the Chesapeake Ohio Railroad for its Huntington, Va., shops, which completely modernized. The last the new equipment was installed the following spring. 1930, the motive power division the Norfolk Western con- nection with its locomotive build- ing and repair programs under- taken the request the Ad- ministration prepared spending budget well over $100,000 for new machinery, but action was taken that year. was not until October, 1931, well into the slough the depression, that pur- chase authority was given. About $63,000 equipment was bought for outlying shops, includ- ing 90-in. wheel quartering ma- chine, rebuilt 80-in. journal tru- ing machine, three double floor grinders, portable miller for en- gine pedestals, gasoline-driven industrial truck and several gas- fired rivet heaters. Under the same ABOVE HIS new plain hy- draulic Landis grinder being used grind the ends the full- floating driving wheel axles for the press fit the cast steel centers. same grinder employed for grinding cast steel roller bearing sleeves all over. Toler- ances the stationary sleeve, which clamped the driving box, must match those the in- ternal bore the bearing proper press fit result. authorization, over $80,000 went for machinery for the Roanoke central shops, among which was 48-in. throat shear, 62-in. boring and turning mill, oil groove miller, centerless grinder, squaring shear, metal cutoff saw, roller pipe double floor grinder, port- able miller and electric anneal- ing furnace for the smith shop. { | 24—THE IRON AGE, October 21, 1937 j { = RIGHT HILE this re- cently acquired Heald internal grinder shown work hardened floating bushings for connecting rods, was bought prima- rily grind the bore roller bearing driving boxes. These castings, which weigh 380 and have bore, are ground internal- within 0.002 in. size. For the following three years, practically machinery was bought, although expenditures for improvements the right way, new rolling stock and equipment repairs were maintained high rate, earnings were maintained and time did declared divi- dends drop below annually. Dur- ing these years, while specific budget was set for machinery, purchases for few needed items were authorized the vice-presi- dent from time time. elec- troplating motor-generator set and 3-ton hoist were bought this way 1935, were early 1936 heavy-duty pipe threader, 300- amp. welding machine and pre- cision centering machine. The 1936 machinery budget such was not authorized until afier the middle the year, and the equipment or- dered began come Novem- ber, 1936, and through the early part 1937. About $150,000 went into machine tools and related equipment, will detailed later. The 1937 budget did not material- ize and the data prepared for are forming the basis for the 1938 budget which should ready for approval October. expected that $200,000 will budgeted for machine tools. Blanket appropriations are made the general office and individual units will bought from pri- LEFT been grinding piston rods for the past years, but the greater flexibil- ity, higher metal re- moving capacity and increased accuracy called for the re- placement o'der machine this new Landis grinder. ority list prepared the super- intendent motive power with the aid shop committees. There committee for each shop division, such smith machine shop, with the shop superintendent general foreman represented, well two coordinating staff men, the shop inspector and the shop engineer, who serve all com- mittees. The shop engineer corre- master mechanic other roads and the machine tool authority Roanoke. The shop inspector, who gets all over the plant, repre- sents the viewpoint quality. obvious that many machines are purchased because the older units THE IRON AGE, October q are simply not meeting the newer conceptions tolerances, particu- larly since the general adoption the roller bearing. course, the purchasing department always has the final say, when comes down choice functionally identi- cal machines. Railroad purchasing agents are notorious among the machinery trade for buying price, but the example the the shop visitor that price has not been the determining factor. Al- most without exception, only lead- ing quality lines machine tools have been bought. Accounting practice obviously has bearing equipment re- placement policy. Present practice shop machinery the rate per cent year, which would indi- cate that the average life the machinery was years, obviously not this example. What hap- pens the usual event retire- ment before that time that the unreserved value the machine charged off current operating expense. This represents com- promise between the per cent years back and the practice some roads charge deprecia- tion all, which case the orig- inal cost charged operating expense the time the equipment 26—THE IRON AGE, October 21, 1937 retired scrapped. The motive would like spend about $200,000 year from now for machine replacement. This represents about per cent $6,500,000 in- vested machinery installed (with foundations) Roanoke and vari- ous line points. The $300,000 spent last eight years, the other hand, represents annual re- placement expenditure $37,500, 0.6 per cent the investment. During that period, the average age shop equipment obviously has been increasing, and at- LEFT 1936 was grinder year Roanoke. The toolroom ac- quired this Pratt Whitney vertical hydraulic grinder for finishing die surfaces and other flat parts. BELOW HIS new Blanch- ard vertical surface grinder also works roller bear- ing complimentary parts, such the spacing rings shown, work. The ammeter shown the right permits the operator gage the wheel load and hence depth cut. ‘ | | Ag P tempt now being made decel- erate not reverse the trend. The shops are far from being clut- tered with ancient machinery, however. the future, obsolescence will more determining factor, rather than wear and tear. Much RIGHT trend to- ward more milling Roanoke. This planer type Newton machine installed few years ago now has brand new companion machine Ingersoll miller used for milling the sides rods and splitting the ends. BELOW HIS modern ver- Ingersoll miller ing the sides rod ends replaced older machine that was too light handle the heavier rods the new Class locomotives reasonable time. the recent purchases were for grinding machinery meet the quired for roller bearings. Much the purchases indicated the next few years will for addi- tional grinding machinery and for millers. Two millers recent- installed replaced old ones that simply could not stand the gaff. Locomotive parts have become heavier, tensile strengths steel have been increased, requiring more power remove chips, and higher cutting speeds have become available through the use new 4 s m ‘ = 4 4 — \ cutting alloys and have been neces- sitated the basis lowered costs. Besides, the Roanoke shops, where per cent the work manufacturing rather than easier demonstrate that ma- chine can “pay for itself” the basis cost saving given number years. Present think- ing Roanoke sets this figure four years. The machine tools authorized for purchase the 1936 budget and installed during the last nine months are indicative the pres- ent trend railroad shop require- ments. There were two piston rod grinders the list. One went the air pump repair department, where replaced machine years old that could not meet the present-day standards accuracy. plain hydraulic type, carry- ing 4-in. wheel, and em- ployed for grinding air pump pis- tons and stoker engine crankshafts. Special work-holding fixtures have been devised make this prac- tically production job. much THE IRON AGE, October { | 1 ‘ i ® FTER being sandblasted and electrolytically cleaned, all side and connecting rods are zinc plated depth 0.004 in., then buffed with wire brush, largely for appearance sake. larger plain cylindrical grinder, in., went into the general machine shop for finishing locomo- tive piston rods. Piston rods have been ground this way for the past years, and this new machine re- placed old one that had worn out. Unlike most railroad machin- ery, such grinders the load fac- tor high, since there are always jobs ahead and the set-up does not vary materially. the same shop identical grinder bought machine the roller axles and sleeves adopted the newly designed locomotives. this Timken de- sign, the wheels are full floating, with live, but bearingless axle passing through the center hollow, stationary tube upon which modern Cincinnati gate shear shown the right has done much improve the effi- ciency the sheet metal division the passenger car repair de- partment. 28—THE IRON AGE, October 21, 1937 the inner races the bearings are pressed and which anchored the driving boxes. The outer races have light press fit the wheels. The axle hollow forging with plugged ends and ground for the press fit the cast steel wheel hubs. The bearing tube steel casting made the Roanoke foun- dry, and ground all over the outside. The tube mounted expanding mandrel and ground the same machine used for the axle. Incidentally, the wheel fit the axle rolled lathe before grinding compress the metal prevent loose- ness occurring service. The tubes are carried driving boxes that fit standard locomotive pedes- tals and the driving boxes are ground internally fit them. For grinder with automatic diamond sizing attachment was acquired. has able swing driving box weighing 380 its face- plate. The same machine also available for other internal grind- ing work hardened sleeves and the like. Another grinder also performs some work roller bearing parts. vertical surface grinder with revolving table for facing spacing rings for roller bearings, lateral liners rods and air com- pressor valve cages. The machine has 18-in. segmental wheel, and provided with ammeter for indicating the motor load and guiding the operator the amount feed. Another vertical surface grinder, but with reciprocating table and separately attached mag- netic chuck, has been installed the tool room for grinding forging 4 + 4 } \ | | | dies. has 14-in. wheel and 34- in. long chuck. The cutter grinding department also has new machine. double wheel floor type grinder especially designed for carbide tools. Since the first the year, about carbide tipped tools been either bought built for ap- plication for lathe boring mill operations cast iron brass. Without speeding the machines, hr. week has been saved the machining rod brasses, for ABOVE crucible shown the right has replaced three pit-type coke ovens used for heating crucibles for the bat- tery Schwartz brass melting fur- naces. RIGHT large size press brake stalled the freight car shops capable bending plates ft. long in. thick and has already paid for itself cost saving over work performed obsolete machine. example, simply the down time between grinds. carbide tool will last month be- tween grinds compared with few hours for the high-speed tools formerly used. More recently, the Norfolk Western has begun buying carbide blanks and silver soldering them their own milled shanks. Silver solder strip form, in. wice 0.005 in. thick, used connec- tion with “Handy” flux. Adjacent the tool department the small tool heat- treating division, which equipped handle almost any problem this line. round out the bat- tery gas-fired and fur- naces has been added new elec- tric furnace with 36-in. hearth. rated kw. ca- pacity, capable maintaining temperature 1850 deg. F., and provided with recording poten- with the rolicy providing more (CONTINUED PAGE 80) THE IRON AGE, October t 5 | | it a | J i! Completes New Small Motors Plant Operations Transferred from East Midwest EIGHTEEN months ago the Westinghouse Electric Mfg. Co. was faced with the problem expanding its Spring- field, Mass., plant the result increased sales. More space had found for the manufacture its domestic refrigerator and air conditioning compressor units. The problem was whether the needed space was obtained erecting new buildings up- rooting the small motors division and moving elsewhere. Decision was favor the latter. After reconnoitering, the com- pany selected the Relay Motors property (motor trucks and buses) Lima, Ohio, which afforded some 400,000 sq. ft. floor space site about acres. Foremost this decision was the nearness Lima the geographical center the company’s fractional-hp. motor market. And this means IRON AGE, October 1937 MILLER Machinery Editor, The Iron Age significant savings transporta- tion charges not only finished motors but raw materials and supplies. Also, and not least, improved customer service, includ- ing shortened delivery time and quicker parts replacement. Fur- thermore, the move providés per cent increase peak production. Acquisition the property June, 1936, was followed immedi- ately the planning vast stream activities designed evacuate soon possible the small motors division the Springfield works and equip and man the new plant without inter- ruption scheduled shipments. This involved extensive rehabili- With Delay Deliveries tation several old buildings; the specification and purchase con- siderable new manufacturing equipment, together with the re- conditioning and retooling much the Springfield machinery; the transfer and the housing Lima executive, engineering and su- pervisory personnel; and the re- cruiting and training more new workers. All this has been carried out successfully that within little more than months after the selection the Lima site all but one the five major manufacturing lines have been transferred and are full production. addition, entirely new motor line—a 1/200- hp. flea-power motor for electric razor—has been operating for some time. this writing, the Lima plant, with more than 1500 employees, producing some 40,000 washing machine, ironer and domestic | } | | ‘ i | ef | u ij i| § 4 4 ( | \ | is | stoker motors per month and more than 10,000 razor motors. next Christmas, year after the first motor came off the first production line, monthly production ex- small motors. Springfield, the set-up for large-lot, continuous manufac- ture, with five separate production lines backed tool, die and heat treating, stores and other contributory departments. Each line entirely self-contained, each virtually factory within itself. Renovation and rearrangement suit the needs large-scale production small motors imme- diately followed acquisition the old Relay Motors tion the tool and die department was next receive attention, then the feeder and stores departments, and finally the first the actual production lines. Some the fea- tures these various departments the new plant are outlined what follows. Large Working Force Hired And Trained Completion these departments was preceded, however, the hir- ing and training the necessary personnel. For the general produc- tion layout, the highly developed scheme the Springfield plant could followed, but the other major factor the production equation, the human factor, pre- sented somewhat new prob- lem. Men and women from farm communities, and inexperienced in- dustrially, had recruited and trained, mechanics, many whom had migrated other localities during the depres- sion, had secured. Also, and very important, seasoned execu- tives, engineers and production supervisors had enlisted from other Westinghouse plants. dentally, competent executives and supervisors were this case un- usually important because the necessity picking with inex- perienced personnel the production load plant with many years experience behind it, and doing with little interruption shipments large volume orders. Like the more other divi- sions the Westinghouse com- pany, the Lima small motors plant entirely self-contained unit, even design, sales, purchasing and accounting. Like the others, vice-president located East Pittsburgh, this case Ralph Kelly. Next Mr. Kelly, and lo- general manager, formerly head the company’s Micarta plant. Other executives include Boothby, manager engineering and sales; Davis, assistant manager engineering and sales; Smith, general superinten- dent; Wilson, division audi- tor; and Kelly, purchasing agent. charge industrial relations and working directly under Mr. Frenger Stump, formerly treasurer the Relay Motors Corp., and Virgil Knisely, also identified with Relay Motors and other local interests. these men fell the responsibility recruiting factory help needed, the housing executives and supervisors and their families—150 more them—from other Westinghouse plants, and the arranging number employee services. Employees present number about 1500. these 1350 are local, drawn from radius about miles. Skilled labor for the mainte- nance and tool and die depart- ments, and operators for the feeder sections were the first employed. The feeder section, should explained, consists screw machine, punch press and other departments that supply semi-finished and finished parts for the main production lines. Then, well ahead the installa- tion the first production line, training school for winders was started. This was under the super- vision assistant foreman from Springfield and was supple- mented group instruction means slow motion pictures. Later, skilled mechanics were se- cured for the first production line and along with them were put op- erators who when trained formed nucleus for the second produc- tion line. explained below. Large Cafeteria and Rest Rooms Installed the same time various em- ployee services were being ar- ranged. These included cafeteria and lunch room, automobile park- ing facilities, hospital and dispen- sary, recreation and rest rooms, and athletic field. The health, accident and life insurance plans common other Westinghouse plants were put into effect and, looking the future, apprentice training courses have been estab- lished. planning all details the new factory special attention was given safety because the in- dustrially inexperienced type operating personnel. This extends every direction, from the thor- ough safeguarding hazardous machinery the elaborate system general and local lighting, and FRENGER, general manager the new Westinghouse, Lima, Ohio, fractional- horsepower motors plant. THE IRON AGE, October | | | even the clothing women op- erators farmerette suits. The cafeteria, which for all departments, shop and office, ac- commodates 320 one sitting. large, well-appointed general rec- reation room adjoins it, and each side are separate men’s and women’s lounges. The latter, not- ably light and airy, are equipped with comfortable modern furniture, ping-pong and chess tables and the like. baseball diamond was laid out early the spring and three soft- ball teams, two men’s and one wo- men’s, organized active units 32—THE IRON AGE, October 1937 Lima’s “city band and glee club are also being formed. The apprentice training school has more students, all 1937 graduates the Lima Area High School, with which the company has been cooperating since last June. These apprentices will re- ceive actual shop experience machine tool operation, tool and die making, etc., supplemented classroom instruction the plant. Renovation and rearrangement the old Relay Motors plant re- quired the expenditure more than quarter million dollars. Though not the order named, this renovation included painting walls and ceilings, the walls alone requiring more than 12,000 gal. material, which, incidental- ly, was supplied the company’s Mansfield, Ohio, plant from paint salvaged the processing re- frigerator cabinets. Roofs had cafe- teria that ac- commodates 320 one sitting was among first employee service units installed. Adjoining are well appointed lounges and large general recreation room. ° ° ° ° ENEROUS park- ing space, with plant police direct traffic, has been pro- vided for employees, many whom live from Lima. repaired entirely replaced and some the concrete flooring had renewed. Plumbing and heating and sprinkler systems had done over rearranged, and the power house thoroughly re- habilitated. Factory power lines were changed throughout from under-the-floor conduit system Be, | | | | i} ae. H overhead square duct system— the Square 100 128-ft. office had sound-proofed and provided with suitable floor cover- ing, along with partitioning, light- ing, furnishing and other details. Lighting System Major Feature outstanding feature the lighting system, believed the largest mercury-incandescent stallation this country. More than 600 combination lighting lu- minaries have been used. these, three 150 watt incandescent lamps are spaced symmetrically about Mogul socket for the 400-watt high-intensity mercury vapor lamp, and are attached directly the top the reflector. The mercury lamp produces 16,000 lumens and the three 150 watt incandescent lamps produce 7740 lumens. tures are spaced 18-ft. centers, ft. from the floor. Average in- tensity illumination about 35- ft. candles. Supplementary lighting pro- vided machines and benches that require it. The adequate light- ing—both artificial and natural— this plant immediately notice- able visitor. Die Shop First Installed This plant renovation was car- ried out according schedules de- signed permit the earliest pos- sible installation, whole part, essential service and feeder departments—the vanguard the actual production lines. Close upon its heels came the setting machinery, oper- ators for which were the mean- time being secured and trained, explained above. About per cent all the new plant’s machinery either new reconditioned. This alone involved expenditure more than $1,- 000,000. First installed was the tool and die shop, which occupies more than 16,000 sq. ft. located the second floor wing the main building, and unusual- light and airy. Virtually all machine tools are new and latest design. Intricate lamination and other dies, cutting tools, special gages and all jigs and fixtures are made and reconditioned here. The de- partment houses the tool crib, well the heat-treating facilities for the entire factory. other Westinghouse plants, the tool and die room in- cludes tool design section which operates under the general super- visor the department. With the tool and die room in- the setting the vari- ous feeder departments was started. These are located for the most part single, separate girls are preparing rotor assemblies for moving the next machine operation the rotor assembly line. inspection capacitor motors with Thermoguard. These are for stoker service. present there are tool and die workers, drawn for the most part from Lima and vicinity. Some- thing the organization and work this department will included another article. building and floor space about 63,600 sq. ft. one end this building there railroad siding and receiv- ing dock for incoming raw materi- als, which include sheet steel, bar THE IRON AGE, October | | i stock and bearing bracket castings. Immediately adjoining are large raw material stockrooms. From these the bar stock passes the adjacent screw machine depart- ment, while the sheet steel takes one two more routes. far, the automatic screw ma- chine unit consists —both automatic and hand screw —used for the most part for the production 3/16 in. %-in. rotor shafts. Most the machines are latest design, with speeds and feeds that permit effective use cemented-carbide tools, and some are equipped with unique automatic chip conveyors. Acces- sory equipment wringers for the reclaiming cut- ting oil. ENERAL view stator wind- ing group soon after the first motor production line was installed, that for washing machine motors. Subsequent changes include the wearing safety clothing almost all the op- erators. Sheet steel processed the feeder sections ranges from 0.005 0.250 in. thickness, the latter for motor frames. stacked tool and die room, the first department in- stalled. Here, unusually light and airy quarters, intricate rotor and stator and other dies, and tool- ing for the entire plant made and maintained. the stockroom grades and sizes lots about 3000 and delivered the various produc- tion groups overhead monorail conveyors, which also handle the bar stock. stated, the sheet steel takes one two more routes. Elec- trical sheets for laminations first long lamination varnishing and baking oven, then one number slitting shears and high-speed dieing machines, which produce one operation both ro- tor and stator laminations for some types small motors. present, the primary and second- ary laminations for the 1/200-hp. razor motor are also made here, i} 3 } ERE — special high-speed presses equipped with automatic coil feed. Material for motor frames and feet taken directly the shear- ing section, where cut width and length and then formed into equipped with air ejecting de- vice. Sheets for the motor feet ° ° RIGHT several automatically- controlled Westing- house electric fur- naces the modern- equipped heat treating department, which serves not only the tool and die de- partments, but vari- ous factory units the heat treating shafts, switch parts, etc. are cut size and then formed shape 800-ton power press. All presses here, well else- where the plant, are thorough- equipped with safety devices, and automatic feeds all types are employed. Hydraulic presses and power shears are found further along the line, well number small feeder units that include inspec- tor’s station, battery resis- tance ring forming machines, group starter spring winders, motor starting switch assembly benches, and razor motor lami- nation assembly group. Next line, and the extreme end the building, there fin- ished parts storeroom, equipped i ‘ with weighing-counting scales and other modern conveniences. Next room, and large degreasing ma- chine for removing oil from the products both the power presses and the screw machines. the cast-iron bearing brack- ets are taken from box cars, they are placed storage one wing the main building close prox- imity immense enameling furnace, the first operation these end brackets that enam- eling and baking prior machin- ing. From this, they the various machines faced and drilled, and then each their as- sembly, they are, course, rights and lefts. BELOW one the motor pro- duction lines, with aisles and working stations cleared show the tion mercury-incan- descent lighting sys- tem, one the standing features the new With the tool and die shop and the feeder departments completed well under way, attention was turned the installation the first the five small motor manu- facturing lines. This major step the move from Springfield, Mass., Lima, Ohio, includes number interesting details, which will cevered another article. THE IRON AGE, October § t L mii @ hie | 3 ‘ i? gi Hydraulic Presses unique design hy- draulic press, having welded continuous type frame, has been devel- oped Lukenweld, Inc., Coates- ville, Pa., and several manufactur- ers automotive clutch and brake linings, plastic makers, well linoleum and rubber product manu- facturers have adopted for pre- cision press work. Choice the type frame construction was in- fluenced largely the desire minimize the weight the presses and obtain the maximum rigid- ity possible, particularly from the standpoint eliminating bending deflection the platen. The first press this kind, Fig. was placed service Sep- tember, 1933, the plant the Wellman Co., Cleveland, manufacturer molded and woven brake materials. This press used the cold forming powdered metals into bi-metallic friction ma- 36—THE IRON AGE, October 21, 1937 terials which are the form clutch facings disk type brakes for airplane landing wheels. has capacity 1350 tons total working pressure under hydrau- lic pressure 6000 per sq. in. The frame this press, shown Fig. weighed only 5380 shipped from the weldery. ft. 11% in. high, with 32% in. between the uprights. Its main strength members are two plates special welding quality steel, measuring 112 1/16 in. length, in. width, and in. thick- ness, weighing 2194 each. They were formed into U-shape and joined make the band butt- welding the ends the formed plates, using full strength welds since the welds must absorb the full tension load. The base and support for the frame proper con- sisted seven other formed steel plates, welded the band. Although load 1350 tons working the steel side members this frame, flat butt joint, properly made, the ideal type joint. Parent metal was carefully selected. The full strength the weld was attained welding the joint from one side the plate, chipping out the back the first bead until only clean metal re- mained, and completing welding installed the plant Co., Cleveland, and equipped with con- tinuous welded frame designed and fabri- cated Lukenweld, Inc. ° the other side the plate. Thus, the joint contains only clean metal and positively slag. Using selected specified steel known and homogeneous character- istics, and using welding technique with governing specifications guar- anteeing the solidity and homo- geneous elastic nature the joint, together with the selection type welded joint that does not incorporate internal discontinui- ties, and with proper supervision insure compliance with the ap- proved technique, such structure may designed for working ontinuous | { + 1 } | i \ | | | i | . J £ | | it i ii stress value that per cent the yield stress the steel. This the yield point. The uncertainty involved not working the steel the yield point due mechanical considerations possible loads. Knowing that there are incipient rips the structure the usual order magnitude, and having selected design with type deflection that not detri- mental the operation the press, there reason why the material should not worked stress that just under the yield strength the steel. Any attempts work over the yield strength the steel will, course, result plastic deformation each time the load applied. When completed, the entire frame the press was thoroughly fur- nace-stress-relieved order eliminate all residual stresses which may have been developed weld- ing. Stress-relieving eliminate residual loads, structures subjected dynamic loading, highly recommended. Its extremely low cost—about per lb. this example—added only $13.45 the cost the welded frame and very cheap form insurance against hazard that may very expensive. The design this press frame such that the steel ideally used pure tension. Mechanical requirements load distribution from the bottom the hydraulic cylinder the steel hoop were met the use semi-circular slugs cast iron compression. Utility and economy dictated the employ- ment cast iron because its desirable properties compres- sion. This advantage, combina- tion with its low price per pound, made cast iron ideal material for this application. Fig. shows the press with the cast iron mem- bers position. Such construction used this press frame minimizes the curvilinear type deflection in- herent the conventional type press platens. The curvilinear type deflection detrimental dies other equipment that depends for support the rigidity the platens. The only type deflection exhibited this press straight tension elongation the side mem- bers, which elastic motion parallel the motion the hy- draulic cylinders. Therefore, does not affect die alinement. the manufacture clutch disks from powdered material, the disks must uniform thickness. Some the airplane brake linings manufactured the Wellman com- pany have finished thickness 0.015 in., with tolerance thick- ness only 0.001 in. without ma- chining. For such work, only precision press may used. Ex- ° ° EVERETT CHAPMAN President, Lukenweld, Inc. ° LEFT Welded steel continuous type frame for the 1350-ton hydraulic press. BELOW 3—Press frame shown with cast iron compression members position. THE IRON AGE, October | § ii > 4 i 3 ff a 4 4 4 4—A 3000-ton hydraulic press with welded contin- 500-ton hydraulic press built Stewart uous frame. has diameter hydraulic cylinder operating under pressure 6000 per sq. in. perience has demonstrated that required precision provided the continuous welded frame type press. this type press, since the side plates extend continuous band around the semi-circular cast iron members, support given the cast iron members over the en- tire area their curved surfaces, and they are loaded only com- pression. Thus, beam action and resultant deflection are practically eliminated, Whether not there any variation the physical properties the upper and lower sections the continuous welded frame, both sides each half must uniformly. The elastic ex- tensions the two side members must necessarily exactly alike. further advantage the con- tinuous welded frame that the total amount machining re- duced. The frame itself requires machining, apart from founda- IRON AGE, October 1937 tion bolt holes. The flat surfaces the cast iron members are pre- machined before assembly into the frame, whereas the curved sur- faces are left the rough state. Molten zine cast between the platen and the frame develop uniform bearing between the mem- bers. The flat surfaces the blocks are lined accurately and tapped bolts hold them with permanent rigidity the frame. Where the press intended for precision work, however, advisable machine both the contacting sur- faces the frame and the cast iron compression members. should noted that once the con- tinuous welded type frame has been placed service, further adjustments need carried out, other than those usually necessary every hydraulic mechanism. larger press frame 3000- tons capacity was designed Lukenweld, Inc., and installed Bolling Co., Inc., Cleveland, for manufacturer automobile brake linings and friction clutches. This press also equipped with welded con- tinuous type frame. October, 1935, the plant the Wellman Co. This frame, shown Fig. like the initial frame, utilized carefully selected parent metal and full strength re- inforced welds. The band was made from two steel plates, 169% in. length, in. wide and in. thick, each weighing 7394 lb. The center center distance the radii the end bends ft. in. and the frame ft. height, in. width and in. between up- rights. shipped from the weld- ery, the frame weighed 18,000 concentrating heavy pressures over small areas, desirable very heavy hydraulic pres- sures order that given size ram will exert maximum tonnage. the 3000-ton press illustrated Fig. was decided work the hydraulic mechanism 6000 Ib. per sq. in. This pressure far ex- ceeds usual commercial practice, and the difficulties using such pressures all hinge around the u | t f i | | | ut i: ° | . i ‘ | | tightness the hydraulic cylinder itself. Using high strength alloy steels, and newly developed weld- ing technique, has been possible produce 35-in. cylinder which will withstand this pressure with- out any sign leakage. This welded cylinder shown the press. October, 1935, Stewart Bol- ling Co., Inc., Cleveland, built 2100-ton hydraulic press similar design, utilizing welded frame fabricated Lukenweld, Inc. This frame consists two steel plates, measuring 156 1/16 in. long, in. wide and in, thick, forming the band. The overall dimensions the frame are ft. in. height, in. width and in. between Drawings for Testing Machine drawings have been prepared the standards committee the Society Automotive Engineers from which machine may constructed test V-belts the methods specified the new S.A.E. stand- ard for V-belts and pulleys. De- signated S.A.E. Nos. 7-7-10 and 7-7-11, these drawings are obtain- able from the Standards Depart- ment the society, West Thirty-ninth Street, New York, 50c. and $1.00 per set, members and non-members respec- tively. International Nickel Buys Cold Mill Steckel cold mill has just been shipped the International Nickel plant Huntington, Va., Cold Metal Process Co. This mill will suitable for rolling monel metal, nickel, Inconel, well and stainless steel, widths 12% in. This unit probably the heaviest reversing cold mill which has ever been built for rolling strip in. width. The housings measure approximately in., the back- ing rolls are in. diameter and the work rolls in. diameter, both having in. faces. The back- ing rolls are mounted roller bearings having capacity 850,- uprights. Like the earlier frames, was thoroughly furnace-stress- relieved, and weighed 10,850 Ib. shipped from the weldery. This press installed the plant prominent automobile manufacturer the Detroit terri- tory. was placed production two hours after erection, not sin- gle adjustment being necessary. used cold molding special compositions shapes and forms. Late 1935, two 500-ton presses with continuous welded frames de- signed and fabricated Luken- weld, Inc., were built the Bol- ling company. These presses were furnished automobile brake lining and friction clutch manu- facturer and were put into service 000 Ib. 100 The total weight the mill 125 tons. This mill equipped with 600 h.p. elec- trical equipment supplied the General Electric Co. The mill equipped with Steckel-Lamb gag- ing device, which will have im- portant function perform, par- ticularly when rolling Inconel. This material will used strip form for electrical resistance purposes, and many cases accuracy within in. gages will desired. without single adjustment. One illustrated Fig. The design continuous welded frame type press applicable all pressing problems. embodies not only the basic im- provement equalizing the strain the tension members but also eliminates the problem deflec- tion since places the platens pre- dominantly compression. The factor safety has been increased, and generally, first cost lowered. These basic improvements are ap- plicable both moving cylinder and moving ram types presses, and hence all forms hydraulic any size tonnage. The new mill has capacity for making reductions plain-carbon material per cent per pass, but ordinarily when rolling previously mentioned, the reduc- tions will not exceed per cent per pass. International Nickel requires such heavy mill because the hot- rolled strip used quite heavy, some instances being thick 3/16 in., consequently unusual rugged cold mill required deal with such heavy and refractory material. very heavy cold mill will roll metal, nickel, and Huntington, THE IRON AGE, October q | i} q ij | 3 { cae ae 7 i week the author reviewed the various types protective coatings which may applied metallic surfaces, and discussed con- siderable detail the various organic and inorganic materials which may contaminate surfaces and thus result poor amplification protective coating. How these foreign materials may removed efficiently and economically also was described part, and the conclusion this dis- cussion contained the following four pages. solutions can used for clean- ing zine base die castings. The concentration this material from oz. the salt per gal. The bath can used immer- sion electrochemical solution. Cleaning can merely immersing the objects the solution, which heated 200 deg. for period approxi- mately min. Electrolytic cleaning superior the above, and can obtained making the objects cleaned the cathode the above bath, which maintained 200 deg. Generally the treat- ment will complete less than min., provided the current dens- ity sufficient cause excessive gassing. either case the clean- ing not sufficient thin film, consisting of, among other mate- rials, zinc phosphate, formed the product. This film prevents the proper adhesion coatings ap- plied later, and for this reason must removed. cold per cent solution hydrochloric acid will accomplish this approxi- mately min. The tanks for electrolytic clean- ing generally are unlined welded steel containers. The solutions al- ways contain sodium hydroxide