The Iron Age 1938-01-13: Vol 141 Iss 2

« ¥ | GENERAL OFFICES subject equipmen the ravages corrosion and con- ntenance and frequent repla costly problem BRAND BRONZE. Whereve tinual mal cements are sive fumes tough strong its forms material any depended upon with endure rovin years, imp rather tha You have for these Right af hon. Form Every ~ e phila Av B H “ FRITZ FRANK President J. H. VAN DEVENTER ect Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor -oblem Associate Editors JURASCHEK Consulting Bditor Washington Editor Resident District Editors Pittsburgh Chicago Cleveland Detroit Editorial Correspondents London, England Cineinnatt FRAZAR Boston Hamburg, Germany Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Newark, N. J. St. Louis TURNER Buffalo Owned and Published by CHILTON COMPANY (Incorporated) Publication Office Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th St., 1938 New York, OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President Production Line Yields High Output GEORGE GRIFFITHS, Progress Machine Tools EVERIT TERHUNE, WILLIAM BARBER, Treasurer Recent Developments Small Tools JOHN BLAIR MOFFETT, JOHN VAN DEVENTER Millers Predominate Current Tool Developments JULIAN CHASE THOMAS CHARLES BAUR CARROLL BUZBY FAHRENDORF Precision Forging Statistics Metal Working Activity Automotive Industry BAUR, General Advertising Manager Rate Activity Capital Goods DIX, Manager Reader Service Washington News Member, Audit Bureau Circulations Member, Associated Business Papers NEWS CONTENTS ublished every hursday. Subscrip- i iome L in tion Price: United States and Pos- Plant Expansion pment sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 year. Single copy, cents. Cable Address, ‘‘Ironage, Can't Live Promises Chain Drive Applications General Electric Enlarges Plastics Plant New Industrial Literature ADVERTISING STAFF Just Between Two - nard, t t., New Yor er, . 39th St., New Yor Robinson, 428 Park Bldg., Pittsburgh ight 1938 Chil Warren, Box 81, Hartford, Conn. Chilton Company (Inc. HOR ndure eather! stock G 64 118 119 128 154 MAY sound like heresy some, but Bethle- hem makes magnet steel the open-hearth furnace, well more expensive processes. have done for years and have perfected methods such that the lower-cost open-hearth steel fully meets the requirements for many purposes. The foremost consideration that open-hearth magnet steel offers big advantage cost. Less tangible, but still very important many users magnet steel, the uniformity. Being produced large furnaces, tons finished bar stock are obtained from single heat. 22—THE IRON AGE, January 13, 1938 xample Bethlehem service users special steels Whatever kind special steel you may use, the chances are that Bethlehem can offer you some- thing worth considering, either service quali- ties, processing properties cost. the Bethlehem organization all metallurgi- cal problems are handled central metal- lurgical division. This provides for applying all the experience obtained contacting all in- dustries the task making the best steel for any particular purpose. unique system control provides the means for consistently meet- ing highly specialized requirements. THE IRON AGE... JANUARY 13, 1938 ESTABLISHED 1855 Vol. 141, No. Can’t Live Promises XPERIENCE beginning teach that can't live have had pay rather dearly for that knowledge. But because has been expensive obtain, may perhaps prized more valuable than things less dearly bought. have taken four-year course the college depression and are now enter- ing post-graduate course the same school. Experience teaching that Uncle Sam cannot for what are unable for ourselves. matter fact, Uncle Sam myth. does not exist any more than does Santa Claus. Santa Claus really the aqgregate all the papas, mammas, uncles, brothers, sisters and aunts the world. Uncle Sam merely million Americans. have been led believe that Uncle Sam has inexhaustible pocketbook. matter fact depends upon for support. When wants money—and al- ways wanting it—he comes and asks for it. Even those relief have contribute his support from their meager relief checks through concealed taxes. Uncle Sam him- self actually hasn't cent his name and heavily debt. Santa Claus always making promises and Uncle Sam. One who has built the myth being rich uncle has live his reputation. this respect does not seem make much difference whether Uncle Sam happens Democrat Republican. Mr. Roosevelt, for example, has just made what amounts the promise hun- dred billion dollar national income, some time the future. That would mean increase, dollars, about per cent. Germany did much better than that just after the War. Germany increased its na- tional terms marks more than five billion times, through price inflation. you see that dollar promises not mean thing unless you say what dollar going buy. Mr. Hoover also made promise, although made terms commodities and not dollars. promised two chickens for every pot and two cars each garage. did not get them either. The point that cannot live promises from mythical rich uncle. have got live and fail prosper, strictly through our own performance. The sooner get this through our heads, the better. - Awe - 4 yme- . | Machine Tool Production AMAZING production records are being estab- lished the Briggs Stratton Corp., Mil- waukee, where new machinery performing 155 finishing opera- tions 800 rough cylinder cast- ings every eight hours. One the most progressive manufacturing plants the Middle West, the management this organization demonstrated its farsightedness and determination maintain modern, up-to-date establishment when the machinery that makes this achievement possible was pur- chased. The idea production line was devised for the volume output these castings from which are made the cylinders for small gasoline motors that are used with washing machines farms not wired for electricity, power lawn mowers and general farm use. The machinery which composes this production line occupies one entire side lower floor the company’s 32nd street plant Milwaukee. The machines include Davis Thompson milling ma- chine, four National Automatic Tool Co. station type drilling, bor- ing and tapping machines, Natco three-way lead screw tapper, Kearney Trecker milling chine, Oilgear press, Ex-Cello bor- ing machine, Barnes honing ma- chine, and Blakeslee washer, all connected Mathews conveyor tables. the head the line, the first operation rough and finish the tops and bottoms the cast- ings Davis Thompson mill- ing machine, which takes in. stock off each side with all-stellite cutters. feature this machine continuous drum holding fix- ture with capacity castings, which are clamped chain when contact with the cutters, can (Courtesy Milwaukee Sentinel) AVIS THOMP- SON machine for rough and finish milling top and bottom castings. Notice chain clamp drum type hold- ing fixture. ine seen the accompanying photo- graph. Physical labor thus held minimum. the milling operations here are finished the operator places the castings conveyor table, the work rolling the next machine, the No. Natco station type ma- chine group four, all which are built steel column and base, indexing tables, and varying number “holeunits” operating heads, mounted around the column horizontally, vertically, both. The accomplishments four machines are almost miracu- lous, they alone accounting for 128 the 155 separate operations per- formed upon these castings along the length the production line. and requiring the work only one man each ma- chine, this machinery was equipped especially for this multiple opera- tion job. One the most interesting fea- tures these machines the in- dexing machanism which causes the castings index automatically from position position around the machines the various opera-. tions are performed. The indexing table itself arranged with semi-automatic mechanical index- ing mechanism which motor driven and which electrically with all working heads the machine. safety feature included which prevents acci- dental indexing the table while the heads are advanced and tools are the work. The machine itself also elec- trically interlocked, including the clamping the work the fix- ture, the indexing the table and each the various units. The normal operation the | . | q q machines follows: The cast- ings are loaded into position the operator who then presses the in- indexes one position where locked for the particular opera- tions that stage. All heads then perform their operations and re- turn the back position. soon all the heads are back and the “pre-set start con- trol” operated, the table will index and start new cycle. “Pre- set start control” permits the ma- chine operated maximum capacity without the hazard the table indexing before the operator has completely loaded the work. While production the operator able load the work com- pletely the starting position be- fore drilling operations have been finished the various heads. The index start button pressed after the loading and clamping the OPERATIONS Position No. 1—Remove and load parts Position No. 2—Vertical Head—each part Drill for .250 diam. tappets. Horizontal Head Idle. Position No. 3—Vertical Head—each part Drill hole for diam. ream. Drill hole for pipe tap. Drill large dowel bottom oil filler hole for ream. Horizontal Head—each part Comb. rough bore large end crank bore and rough face both large and small crank bosses. Position No. 4—Vertical Head—each part Ream master dowels. Rough ream tappet holes. Drill No. (.161) diam. hole. Horizontal Head Tdle. Position No. 5—Vertical Head—each part Countersink 28. Countersink dowel. Drill drain back hole. Horizontal Head—each part Mill cam bosses width. Position No. 6—Vertical Head—each part Finish ream valve tappet holes. Finish ream master dowels. Ream hole No. (.161) diam. Horizontal Head High Output new parts completed, thus start- ing the “pre-set start control,” white lamp the top the machine indicating that this con- trol effective. soon all heads return the back position the table indexes and starts new machine cycle, which automatical- cuts out the white lamp. the parts are not properly clamped and the table begins index movement, safety device halts the cycle, and lights small red lamp the lower left front portion the machine. The oper- ator then must correct his faulty clamping before the machine able continue normal operation. for any reason any the above elements not complete their normal operations and the “pre-set start control” started, upper red lamp will indicate improper functioning the ma- chine, and the index operation No. Natco machine which performs operations ° ° ° ROBERT BINGHAM Western Editor The Age, Chicago again will checked. After the trouble corrected, the various heads must moved individual] control through the complete cycle, after which normal operations are possible once more. All the machines the line are lubricated each morning, which usually suffices for the duration the day. Two complete changes tools are kept readiness for each the four Natco station type machines, movable hand truck provided with tool trays serving this purpose. The cutters the various machines are changed specified intervals. The first the Natco machines the line performs total drilling, countersinking, rough bor- ing and facing, rough and finish reaming and milling operations 120 cylinder blocks hour, operations with each cycle the machine, two blocks being loaded each block every sec. — ° A, | rey | | | | | | | x and worked time. Thus every sec., operations are performed each two blocks. This No. machine contains seven Natco five which are mounted vertically around the column and are ar- ranged with spindle boxes contain- ing total anti-friction bear- ing mounted spindles complete with nose adjustment. The other two units are mounted horizontal position around the periphery the table steel beds which are bolted the base the machine. One these horizontal units ar- ranged with spindle box contain- ing two heavy duty anti-friction bearing mounted spindles and the other with special milling unit complete with two milling spindles. About hr. per 1000 pieces required for tool change-over this machine. The castings are held six identical stationary type fixtures, and they automatically index from station station, the various operations are performed. After this work completed the partially finished castings roll the next machine line, the No. Natco, which with five vertical and four horizontal heads, performs drilling, core drilling, countersink- ing, rough and finish boring, rough 26—THE IRON AGE, January and finish reaming, counterboring and spotfacing, and milling opera- tions each two blocks with each cycle the machine. this machine the five vertical units contain nose-adjusting spindles the spindle boxes. Three the horizontal “holeunits” are arranged with spindle boxes con- taining spindles with nose ad- justments, while the fourth ar- ranged with special milling unit which feeds vertical plane and complete with two milling spin- dles. Time required per 1000 blocks for complete tool change two hours. From here the blocks travel Kearney Trecker milling machine, which mills the valve chamber face, the Carboloy-tipped cutter being changed every 2500 castings. The valve guide inserts are then pressed into the valve stem guide holes Oilgear hydraulic press. Brinell reading 200 220 shown the casting. After these operations are fin- ished, the No. takes over OPERATIONS No, 1—Remove and load pieces. Position No. 2—Vertical Head—each part Rough bore cylinder. Comb. core drill and end mill starting clearance for valve guide bushing Horizontal Head—each part Drill for .6130” diam. ream. Core drill crank hole. Drill Position No. 3—Vertical Head—each part Drill valve guide bushing holes. Drill for .435/.4355 ream. Horizontal Head—each part Comb. rough ream and spotface .6130 diam. hole and 1%” diam. boss, Position No. 4—Vertical Head—each part Drill for 5/16 tap. Rough ream valve guide bushing holes Countersink 1—.435/.4355 diam. hole. Horizontal Head—each part Finish ream 1—.6130 hole. End cut bore cam hole. Finish ream diam. crank hole. Position No. Head—each part Countersink for 5/16 tap. Finish ream valve guide bushing holes. Ream 1—.435/.4355 diam. hole. Horizontal Head—each part Mill oil well crank hole. Position No. 6—Vertical Head—each part Semi-finish bore cylinder. Horizontal Head—each part Idle. TRECKER milling machine left, and Oilgear press right. Valve chamber being milled, and the valve guides pressed into place. 3 ot Natco, which performs operations each two blocks every minute. (Milwaukee Sentinel photo) OPERATIONS Position No. 1—Remove load (presenting manifold face) Position No. 2—Drill intake. Drill pipe tap. Drill 1—% x 20. tap drills. Position No. 4—Countersink holes. Countersink pipe tap hole. Countersink 20. Position No. 5—Tap pipe tap. Tap 2—10 32. Tap 1—% 20. Position No. 6—Idle. ” BELOW drilling, countersinking and tapping operations are accomplished this Natco machine every minute. the cylinder blocks and perform drilling, rough and finish ream- ing, countersinking, chamfering, rough and finish form facing and end milling operations each the two blocks every minute. The five horizontal and five vertical heads this machine contain total nose adjusting, anti- bearing mounted spindles. crank bore cut) Position No. Drill 28. faces. Drill pipe tap End mill 7/16 deep. ABOVE operations are performed this Natco, each two cylinder blocks each sec. OPERATIONS Position No. 1—Remove and load parts (top and large end Vertical Head—each part Drill valve guide holes. Horisontal Head—each part Position No. 3—Vertical Head—each part Rough ream valve guide holes. Horizontal Head—each Semi-finish bore and finish face upper and lower crank holes and part Position No. 4—Vertical Head—each part Finish ream valve guide holes. Horizontal Head—each part Aline ream crank holes. Position No. Head—each part Chamfer top cylinder bore. Semi-finish port and seats. Rough form face oil filler. Head—each part Countersink 28. End cut bore cam hole (piloting plate finishing crank hole). Position No. 6—Vertical part Finish ports and seats. The tool change this particular requires only one hour 1000 pieces. The last Natco station type ma- chine the production line con- tinues the finishing work the cast iron blocks performing drilling, countersinking ping operations each two blocks every sec. Three “hole- units” and one Natco tapping unit Finish form face oil filler. Horizontal part Finish ream cam hole (piloting plate finished crank shaft are built the vertical position around the column, the holeunits containing spindles, and the tapping unit, lead screw spindles complete with tap holders. Only min. per 1000 pieces required change these tools. Self-lubrica- tion the taps feature this machine. the completion these op- erations, hardened valve seat THE IRON AGE, January 13, 1938—27 r inserted, and the cylinder ished-bored Ex-Cello boring machine, 0.015 in. stock being re- moved. Tool life here some 2000 pieces, only five minutes being nec- essary for tool change. Now the bore honed, strokes Barnes honing machine re- moving 0.001 in. stock, the allow- ance size being 0.0005 in. and out round and taper, 0.0002 in. Only min. per 1000 pieces allowed for tool changeover this machine. Another Natco machine, three- way lead screw tapper, the next view the lead screw tappe 28—THE IRON AGE, January 13, 1938 992 the line, individual lead screw spindles being contained the three horizontally mounted units. All tapping operations, holes the bottom the casting, seven the top, and five the crankside, are taneously. The taps average 9000 holes each. All the drilling, boring and tap- ping now being completed, the cyl- inder blocks are moved Blakeslee washer where boiling hot cleaning solution forced un- Under less pressure and using r—notice the self lubrication tubes, tanks and brushes. three way lead screw tapper work—23 holes are tapped simultaneously. OPERATIONS Head—Bottom hole with pipe tap. Head—Top Tap holes with 5/16” taps. Rear Tap holes with taps. ‘ap hole with pipe tap. = weaker solution, the blocks are rinsed. checking equipment every ma- chine where tolerances and ac- curacies are checked before rolling the blocks the next stage, inspection processes must suc- cessfully passed before the cylinder blocks are sent the motor assem- bly department. The allowances give accurate indication the work which these machines are capable. The diameter reamed holes in. and less are held total tolerance 0.0005 in. The large bored and reamed holes are held total tolerance 0.001 in. Every min. floor inspection made where castings are selected random and checked. After every tool change additional check- ing done. The Briggs Stratton Corp., which also makes automobile ac- cessories, sells the small motors which these castings have been following are essential part, nearly all the major washing ma- chine companies. products upon which these gasoline engines are used are standard washing ma- chines with the motor mounted pedal. Although may seem strange power washing ma- remembered that extensive rural areas have yet electrified, and that this type machine big labor-saver for the usually (CONCLUDED PAGE 92) 4 Formula developed for calculating the (actual machine running) times required spooling wires vari- ous diameters, spools various dimensions and various rates rotation. following formula has been The symbols used text are follows: D—Diameter drum (inches). B—Breadth between flanges (inches). d—Diameter wire in- inches. wire per foot. R—Revolutions per hour. T—Time hours, W—Total weight wire spooled time (T). F—Total feet wire spooled time (T). K—Empirical constant for that par- ticular diameter wire. Derivation Formula The revolutions required wind one layer wire the drum is: (1) layers B/Ka The ft. wire wound the drum per revolution is: (2) Ft. per rev. D/12 The ft. wire wound the drum the first layer will be: (3) layer Circumference The diameter the drum will regularly additional layers wire are added. Let the diameter any time. Then: Substituting for (one layer), from formula (3). FKd 12Kd (Machine Time Only) PENTLAND Industrial Engineer, Pacific Works, Columbia Steel Co. ° ° ° The time required spool the first layer will be—the revolutions (first layer), divided the revo- lutions per hour. Equating formula (3) and for- mula (7) 12F Kd wDR Kd The general equation for the number feet spooled time 12F Where the effective diameter drum at any time (T). Substituting from formula (6): 12/ 12DBF (12) Since number feet time equal the weight wire (W), divided the weight per foot (12DB) The figures parenthesis de- pend upon the dimensions the spool and the r.p.hr. the spool- ing device. Therefore: (14) Wire Spooling Time Where The constants must calculated for extreme limits diametérs and plotted. error per cent the de- termination the proper constant will reflect per cent error the calculation the time. The constant includes normal per- centage packing the wire and in- cludes belt slippage. Two New Murex Electrodes LECTRODES named Vertex and Genex, respectively, have been added the extensive line offered the Metal Thermit Corp., 120 Broadway, New York, sales agents for American Murex Corp. The new Murex Vertex electrode reverse polarity rod designed for welding mild steel flat, verti- cal and overhead positions. used for general shop work where positioning parts during welding not practical, and also em- ployed structural welding, such as, shipbuilding, bridge ing construction. The Genex elec- trode all-around type that may used all positions and readily bridges gaps between plates where assembly fit-up poor. straight polarity electrode. THE IRON AGE, January 13, 1938—29 | ° ° ° 3 : — W ; 3 ~ 1937 Progress Machine HIS the conclusion Mr. Oliver's review machine tool develop- ments the past year. The previous installment appeared the Annual Review Number The Iron Age, Jan. page 221. Shapers 200 per min., the rocker arm and link high-speed shaper brought out the Cincinnati Shaper Co. are made aluminum. Ram Meehanite operating cast iron bearings. The clapper retainer can made inoperative and tool lifter available for use with cemented car- bide tools. Atlas Press Co., Kalamazoo, Mich., added bench shaper its line. In- V-belt, the machine has stroke range in. and four speeds from 200 strokes per min. Table has horizontal travel in. and travel in. Five auto- matic cross feeds are available. Threading and Tapping Machines Design improvements the 2-in. threading machine made the Landis Machine Co., Waynesboro, Pa., in- clude the mounting the headstock directly top the bed, heavier and thicker bed, and speed changes from 118 r.p.m. effected through pick-off gears. model motor-driven model are available. The motor drives through silent chain. 30—THE IRON AGE, January 13, 1938 Landis Machine Co. also redesigned its 2-in. pipe threading and machine. The bed has been made heavier and the ways are covered steel guards attached the tool car- riage, which has travel in. Chuck speeds range from 163 r.p.m., provided eight-speed gear box driven from single pulley motor headstock. Gear shafts are roller bearings. The same firm has also designed portable mounting for its “Little Landis” pipe threading and cutting machine, with two rear wheels and single guide wheel and lifting handle the front. Oster Mfg. Co., Cleveland, rounded out its line “Tom Thumb” motor- driven portable pipe threading ma- chines, which now take care pipe from in. Model 512-A equipped with die-head integral with the carriage for rigid support. The holder for the cut-off, reaming and chamfering tools operated heavy block ball crank. The Geometric Tool Co., New Haven, Conn., brought out precision threading machine designated No. 14. Either two-jaw vise stand- ard collet chuck are available with pivoted mounting giving zontal and vertical adjustment the work. large capstan wheel actuates the vise well automatic work gage which swung out the way the vise tightened. Drive V-belt from motor base. Pick-off gears provide wide range spindle speeds for cutting standard pitches 9/16 in. and finer pitches larger diameters. Haskins Co., Chicago, de- signed air-operated jig for its high- speed tapping machines. machines thus equipped, pneumatic piston moves the work blank the tap. uniform pressure maintained throughout the stroke. pressure regulator and pressure gage in- cluded with the foot treadle that sup- plies the pressure. The jig also ap- plicable for other operations, such Pre-set tapping and reversing pres- sure, means long helical springs, feature tapping machine in- troduced the Procunier Safety Chuck Co., Chicago. speeds ranging from 385 2240 r.p.m. are available take care taps ranging size from in. down No. Other features include precision height adjustment the table and depth stop, and offset foot pedal. Thread Grinders combination thread grinder for both tool room and production work was brought out the Jones Lam- son Machine Co., Springfield, Vt. will grind any the commercial types thread, right left hand, and using simple type former, will grind taper combination straight and taper. With attachments, its range practically unlimited. The helix angle range has been in- creased include deg. right hand deg. left hand. Change gears provide for pitches from in. Work in. long may held between centers and in. thread d.c. motor drives the wheel spindle. Turning Machinery special station-type turning ma- chine was built the Partool chine Co., Detroit. essence, eight-spindle chucking machine with the work spindles arranged radially and the entire unit rotatably mounted ‘ % - ° ° the loading station one point. Pro- duction 900 universal-joint flange hour. The tool blocks, two station, are mounted large shafts and are actuated and from the work cams. Coolant distributed from central tank top the machine, One thing often leads another, seldom that basic machine mentally different function. The ex- ception the double-spindle turning machine for rear axle shafts which the Landis Machine Co. developed from its double-spindle lead-screw type threading machine. place chasers, four milling cutters are used, operating the same plane. in- teresting feature traveling center, backed long helical spring, which maintains constant pressure against the work. The center travels back through the spindle while the carriage advances. feed gives variable feed and variable time. Turret Lathes Following the introduction its original motor-on-spindle turret lathe, Bardons Oliver, Inc., Cleveland, brought out geared electric turret lathe designed around high-torque, quick-reversing motor the flange mounted type. drives through gears that slide splined shafts without clutches. Reversal effected through magnetic reversing switch, and six spindle speeds are ob- the headstock. Double this number speeds can obtained with two- speed motor. The unit will handle bar swings work 1314 in. diameter over the ways. The turret slide has movement in. and six power feeds. Cross carriage units may furnished with hand screw feed, lever feed automatic operation, there elec- automatic chuck and bar feed. The first electric model, designed for brass work, has back and spindle drive four- reversing motor mounted di- the arbor. Electric braking, and feed the bar stock been provided for. motor driven cam drum actuates the and bar feed action, which only sec. feature the turret slide and roller bearing large size, which eliminates the customary turret binder lever. Both the turret slide and the saddle are provided with wear strips hardened steel. new 12-speed transmission the sliding gear type, roller bearing equipped spindle, automatic spindle brake and independent power rapid traverse and feeds both the cross slide carriage and the turret carriage are features the improved line entire table unit swivels about the col- umn and the table tilts about horizontal axis miller, which has slid- ing gear transmission ball bearings and roller bearing spindle, pre- loaded. 3AL, and heavy-duty turret lathes introduced the Ma- chine Co., Madison, Wis. The three machines differ only capacity, which varies from in. bar size and from in. chucking diameter. Either fixed center cross feeding turrets are supplied. Drive from motor mounted the headstock. Headstock cast integral with the bed and made nickel semi-steel. Bed ways are steel, hard- ened and ground place. Gisholt also produced huge turret lathe with 34-in. chuck and 16%- in. unobstructed bore through the spin- dle. described more fully under hydraulic applications. Another improved turret lathe the past year the No. 4-H combina- tion bar and chucking machine made Millholland Sales Machine Co., Indianapolis. Speed changes are from mounted “zero” Timken bearings and precision ball bearings. All other headstock multiple splined shafts are mounted ball bearings. Once the speed has been selected, con- trol the machine single lever. feeds are provided. The ma- chine available either with with- out power cross feed. Bar capacity 15¢ in. and for chucking work the swing in. over the bed. Application Unit Heads Last year saw the further applica- tion the unit head principle mul- equipment, particularly the automo- tive field. For 1937 model production, the National Automatic Tool Co. pro- duced number huge center-column machines weighing tons apiece. One such has four vertical work heads the central column and four horizontal heads disposed radi- ally. Another unit has five vertical THE IRON AGE, January 13, ing ind ith ted heads, three horizontal heads and one coming from the floor angle. these units, drilling, core drilling, counterboring, countersinking and spot facing operations are performed cylinder blocks held fixtures indexing table 110 in. diam. Automatic loading and clamping more common connec- tion with these unit head machines. Greenlee Bros. Co., Rockford, ap- plied the idea entirely new method finish boring cam and crank verted position, the block hand cranked endless chain into position from which elevated power and automatically clamped. cam bar attached one the unit heads actu- ates this mechanism and gives the two- step action necessary allow the bor- ing bar inserted eccentric position relative the holes before the work brought into boring po- sition. Slots the guide bushings allow the single point tools clear. Two angular heads perform spot fac- ing operations the same set-up. Longitudinal staticn tunnel type machines are also growing use automotive production, and there have principle. Natco built four-work sta- tion machine for core drilling, rough and finish boring cam and crank holes cylinder Two blocks are loaded time movable rack bars which convey them from station station down the tunnel formed the bridge construction between the facing machine ways. Unit heads carry core drilling spindles from oppo- site sides and single large head car- ries eight boring bars sets two roughing pairs and two finishing pairs. Hydraulic elevators clamp the work position and provide the step drop the blocks clear the boring tools. The Foote Burt Co. two-way oil gallery driller another four-station machine which the block moves sideways through tunnel which car- ries the clamping mechanism. Both indexing and clamping are effected hydraulic power. The holes are drilled steps from both sides three sta- tions and the fourth single drill breaks through and crosses over into the hole drilled from the other end. Each opposing head has its own hy- draulic unit. The Hammond Mfg. Co., Cleveland, supplied another automobile manufac- turer with similar two-way machine for drilling oil line hole block. The work clamped and indexed horizontally between five 32—THE IRON AGE, January 13, 1938 tions. Step drilling takes place the first three, reaming the fourth, and the fifth station oil tube pushed place from the bottom magazine rack. Still another longitudinal type station machine has been built the Niles Tool Works Co. which both two-way horizontal heads and vertical heads are combined. Hydraulic feed applied each the six unit heads and hydraulic power indexes the block between stations and effects the eleva- tion and clamping the work. Space considerations are the only limit the number unit heads that Greenlee Brothers Co., for example, built machine with five heads one vertical plane coming angles deg. from the horizontal both sides V-8 block, the fifth head be- ing vertical. Because the paths the two top angular core drills the head movements are synchronized that one withdraws, the other approaches the work. Other developments way ma- chines contributed greater accuracy, particularly cylinder boring oper- ations. One such machine, built the Foote Burt Co., provided with water cooling for both the heads and the machine ways prevent distortion, the boring bars are supported ex- tended sleeves with the lower bearing next the T-C cutters, the head slide made extremely long (54 in.) and the square lock ways in. apart. These machines are fully hydraulic, including clamping action. Welded steel construction used for all but the unit heads. The Fox Machine Co. has also made use the idea for unit head machines for drilling cylinder blocks, except that the heads are cam fed rather than hydraulic. Fox has even extended welded steel construc- tion its standard, vertical head mul- tiple driller very modern design. Column and base are arc-welded rolled plate, and the ard I-beams. Cast iron used, how- ever, for the column ways, but the circular (indexing) table and special work-holding fixtures are all welded. The unit hydraulic power head mounted central column has also found application eight-spindle vertical station-type lathe made the Sundstrand Machine Tool Co. The particular design for rough turning and crowning cast iron pistons and every station tooled alike. Each hydraulic unit has hydraulical chuck for the work, which revolved and fed down the fixed turning Crowning the head performed T-C tool carried yoke which swung are the work head ad- vances. The entire set-up rotates about the column and one revolution finishes hour. Still another application the unit head principle the unit head millers, announced the Newton division the Consolidated Machine Tool designed permit converting single- purpose machines into general-purpose units. The machine planer type, with individua! motor- driven milling heads mounted on. either side vertically the arch space. One such machine for machin- ing tractor transmission cases has two horizontal heads and units, plus auxiliary spindle be- tween the two large vertical cutters. Either adjustable-speed d.c. motors pick-off gears are supplied effect various cutting speeds. The heads can repositioned along the holding flanges which are drilled with closely spaced bolt holes for Table feed hydraulic, with optional screw feed. Unit Head Boring Machines Ex-Cell-O Corp., Detroit, has ap- plied the unit head idea different way line two- and three-way precision boring machines, designed primarily for automotive production applications. The boring spindles are carried three-point precision ball bearings and each driven indi- vidual motors through V-belts. Hy- draulic traverse mechanism located the base and there separate pump and control panel for each head. Cutting cycles are automatic. Holes from in. diam. can bored and cutting speeds 400 ft. per min. are possible. The Defiance Machine Co., ance, Ohio, built large heavy-duty machine with 25-ft. bed length for boring, facing pump and other large castings from opposite ends. There are two adjust- able work platens which fixtures can attached, and each spindle head has independent mechanical feed ft., with maximum distance spindle noses. Sliding gears provide spindle speeds. Another application the unit head principle found the line zontal boring, drilling and milling ma- chines table type, floor type and planer type, made Wm. Sellers Co., The unit head con- tains the driving motor and clutches, a 4 1 7 7 7 q | unit ally motor- arch two ertical effect can ding losely tional ines ap- are ball indi- Hy- cated arate Toles min. duty for ring ures ft. ead ori- ma- and on- all speed and feed changes, and hand and power traverse spindle, head, saddle and table. All shafts revolve anti-friction bearings. The spindle itself nitralloy and carried precision preloaded. The main spindle has and the auxiliary spindle speeds. There are speed changes the feed mechanism for the head, saddle and table. The directional con- trols the head and saddle are the the column and the directional control the table the saddle. These machines are made spindle sizes from in. up. the table type, table sizes range 120 in. Universal Types Machines The Brown Sharpe miller has the knee angular adjustment vertical plane right angles the spindle, together with horizontal feed the entire knee as- sembly the same plane, and also contains auxiliary universal mill- ing head with adjustment any angle Work can milled any plane, drilled, bored reamed different angles without the use special fix- tures. Cutters can used simultane- ously both the auxiliary milling head spindle and the main spindle. Another unit applying the same gen- eral principal the improved Colby Cochrane-Bly Co. Rochester, Through the addition high-speed (up 2100 r.p.m.), drilling, operations can performed sin- gle machine, and with dividing head, spiral gears, milling cutters and wide variety other work centers for- merly limited horizontal spindle machines can handled. Both the milling and the shaping heads ad- any angle from vertical hori- zontal and deg. from front back. radius tool attachment that replaces the clapper block the shaper ram will shape punches from the rough without undercutting. The tendency continues combine operations, particularly special-purpose machines. The New- fon division the Consolidated Ma- chine Tool Corp., for example, has center drilling and milling what essentially drum-type three-station fixture used the drum, and end milling shafts takes place while the drum indexing from the loading station. The two milling spindles are mounted directly are the two drilling spin- which come into action the third station and during this part the cycle, the hydraulically fed drum dwells against index pins. Greenlee Brothers Co. carried the idea even further equipment stalled for 1937 model automobile pro- eight-station trunion fixture combined drilling, reaming and slotting lock grooves automotive connecting rods and caps. trunion type, unit head piston machine made the same firm, core drills wrist pin holes, cuts two internal lock wire grooves with ex- panding tools, drills four holes the wrist pin bosses angle and one hole the skirt, besides sawing two slots the skirt. Hydraulic Applications One the best examples almost complete hydraulic control double-housing hydraulically operated planer for heavy-duty applications, which was added the line open- side planers built the Rockford Ma- chine Tool Co. Not only the table itself hydraulically actuated, but the cross feed the head, rail clamping and tool lifting the return stroke are similarly controlled. Control traverse the rail head, elevating lowering the rail and operation the master motor switch well the instant stopping the machine effected from pendant push-button station. Short strokes can made about shaper speeds. This in. the table in. The Barnes Drill Co. has applied hydraulic transmission its vertical honing machine, giving infinite varia- tions spindle speed between 100 and 250 r.p.m. unit control lever simul- taneously starts rotation and recipro- cation the hone, permits recipro- cation alone rotation alone. The machine may equipped with hy- draulic dwell for blind end cylinder honing. The spindle carriage air counterbalanced. The Gisholt Machine Co., Madison, Wis., has applied hydraulic power 34-in. three-jaw chuck used turret lathe with unobstructed bore 16% in., designed for machining large steel forgings. standard lead screw used feed both the cross slide carriage and the hexagon turret carriage, the advantage being mak- ing the machine available for use with large collapsible taps. Hydraulic chucking also em- ployed the New Britain-Gridiey Machine Co., New Britain, Conn., a.six-spindle, high-speed automatic chucking machine, which mounts two- three-jaw chucks. Instantly adjust- able chucking pressures, read gage, are provided within range 300 per sq. in. and the feed automatically thrown out should the hydraulic pressure fall below any set amount. There also electric interlock that prevents operation the machine until the necessary pres- sure built and further prevents indexing until the chuck closed and the spindle clutches are engaged. Last year, the Sundstrand Machine Tool Co. began market its hydraulic units. Its model pumps consist low- and high-pressure units built into the same body with the control valves. Quick action for rapid ap- proach, for example, may taken care the large capacity pump low pressure and the clamping working pressure produced small volume, high-pressure unit. Both are the “Rota-Roll” type mounted the same shaft and driven motor speed. multiple-piston type fluid motor also being marketed Sundstrand. The smallest size rated hp. 900 r.p.m., but can run low line multiple piston pumps has also been brought out for use with the fluid motors. The Oilgear Milwaukee, brought out design multiple-piston pumps The pistons are small size and large number and are disposed radially circular block. Conical surfaces the ends the pistons bear against the concave surface reaction ring, eccentric the piston block, and the amount this eccentricity governs the stroke. Pumps and motors operating this principle are available sizes from 150 hp. and with working pres- sures 1100, 1700 and 2500 Ib. per sq. in. Various types controls are available, including remote control. The Oilgear Co. also brought out line combination pumps, each unit heing equipped with low-pressure, constant volume gear pump and high-pressure, constant variable- delivery radial piston pump. For rapid traverse pressures 300 Ib. per sq. in., the combined output both pumps used, and for the feed, only the high-pressure pump used, the gear pump output being by-passed. Pumps are available from hp. capacity. Both pumps are enclosed unit case, and large variety controls can furnished. THE IRON AGE, January 13, 1938—33 tools, about Corp. single- 7 | ty a> RS | Recent Progress Small this, the concluding portion his review small tool developments during 1937, the author deals with progress made the application the various carbides machining operations. The first installment this review appeared The lron Age Jan. page 265. Fig. shown set-up for turning stainless steel valve noz- zles with Stellite-2400 tools, speed 125 ft. per min., removing 3/16 in. material feed 0.010 in. per The high chro- mium content this casting makes extremely tough, that under or- dinary conditions tool life would limited. With the new tool material, pieces between grinds obtained. Small tools, tipped with tungsten, tantalum and titanium carbides, still find very prominent place metal- working shops. Developments this field include more diversified line tools, and the addition improved and new grades carbides for specific purposes. Since shop executives have recognized the producing qualities tipped tools, there has been rather widespread replacement obsolete machine-tool equipment during the past year, order that peak perform- ances can obtained. all, carbides have made remarkable pro- 34—THE IRON AGE, January 13, 1938 Tools gress and are being used more ex- tensively than ever means de- creasing manufacturing costs and increasing the quality finish and ac- curacy, such may seen the representative applications that follow. Fig. shown Carboloy set- for machining cast iron pulleys, in. diameter. The operation in- cludes grooving, boring and facing, and completed min. rather novel arrangement both the front and rear tool blocks may seen, which two sets tools, one above the other, are used for rough and finish grooving. Another interesting set-up for ma- chining valve bodies and plugs il- lustrated Fig. The operation handled Heald Bore-matic with Carboloy tools. The fixture the left holds valve body, which the taper FIG. for turning valve Stellite. FRANK CURTIS hole finish bored means the tool shown the boring bar directly front. the spindle shown the rear, valve plug finish turned the tool shown the tool block. From this, will seen that complete set —one body and one plug—is finished each cycle. Both parts are made bronze and are cut speed 3800 Carbide-tipped reamers have proved successful because the exceptional finish they offer, well their long life, that the long run their use actually reduces hole and tool costs. The standardization line ream- ers, therefore, excellent example that well illustrates the progress being made tool manufacturers the field carbides. The Morse Tool Co., Detroit, has developed such line that includes both machine and ex- { t ° ° ; the irectly the ned From ete set nished ade 3800 long use costs. ream- ample being the Tool line with straight and taper The machine reamers are made sizes from in. diameter, and the expansion from The use carbide-tipped expansion new undertaking which represents notable advance the carbides. The design difers from the usual tool steel ex- reamer, because expanding strain placed the tips, fea- ture that required new principles. 11. They can expanded quickly any size within their range, which direct proportion the diameter, expansion. Fig. shown set-up for the milling cast iron manifolds Cincinnati Hydromatic. The machine has five spindles, four which are horizontal and one vertical. The horizontal spindles are fitted with 2-in. diameter carbide cutters and operate 318 The vertical spindle car- ries cutter which runs 212 Approximately in. mate- rial removed and the production pieces per hr. manifold may seen standing the front the ma- chine. Milling with inserted-blade cutters has always been outstanding ap- plication for tungsten carbide because the many gains made possible, such higher speeds, faster feeds, better fnish, greater accuracy and longer life between grinds. the past, how- ever, milling has some extent been trated exceptionally large cutter used for the face milling aluminum ingots. The cutter in. diameter, was made the Ingersoll Milling Machine Co., and equipped with motor and removes 3/16 in. material. The cutting speed 3000 min. The cutter has rough- ing blades and four finishing blades. Because the inability grind such alarge cutter unit, made with quickly detachable blades that are separately and then reset the cutter with indicator. Tantalum carbide performances the ma- steel. Carbide manufac- have greatly improved this type cutting material, that economica! are assured quite variety ofwork. There still some distance go, however, but quite likely that the present strides will continue time goes on. tantalum carbide job for machin FIG. ARBOLOY tool set-up for turn- ing pulleys. FIG. ET-UP for ma- chining valve bodies and Heald Bore-Matic. ing steel ring gear shown Fig. 14. Eleven rings are mounted fixture and are finished the speed 305 ft. per min. The feed 0.027 in. per revolution, and the depth cut in. The tools are tipped with Vascoloy-Ramet and the average life 225 pieces per grind. The outside diameter gear 155¢ in. Titanium carbide also adopted successfully the cutting steel. This form material com- prises tungsten carbide base, with the addition anywhere from per cent titanium, much the same order that used for making tantalum carbide. Titanium has the ability resist cratering better than straight tungsten mixture, and has less affinity for steel that “pick minimized. The use carbides for machining steel requires exceptional tool rigid- ity, that deflection and “spring” FIG. tipped expansion reamers are new development. THE IRON AGE, January $ FIG. LEFT milling set-up for mani- folds. ° FIG. CENTER IRTHITE TIPPED cutter in. di- ameter. ° ° ° FIG. LEFT wheel for tered carbide tools. ° ° ° 36—THE IRON AGE, January 13, 1938 the tool eliminated. Tool overhang should not exceed more than one-half that tool height. Less better, tool, therefore, should not project without support more than in., and on. This point too often overlooked, with the result that per- formance falters. get the most results, far best provide the correct type holder and use pro- portionately larger tools. line with the progress sintered carbides has been the development grinding equipment. ing done with diamond wheels, which have been improved constantly during the past year so, enabling the very rapid resharpening prac- tically any type tipped tool. Fig, FIG. carbide tool set-up for finishing steel ring gears. impregnated wheel used for sharpen- ing single-point tools. With equip- ment this kind possible sharpen carbide tools corresponding high-speed steel tools. improved type cutter grinder for sharpening inserted blade milling cutters illustrated Fig. 16. grinder, and has heavy duty type spindle, mounted three anti-friction bearings, and provided with fly- wheel, that constant wheel speed assured. The machine equipped with dial indicator for convenience inspecting sharpened cutters before being removed. The time required for sharpening tipped cutter this ma- — > — ter, not lan often the pro- intered lent larpen- wheels, nabling prac- Fig, imond- pars. rpen- quip- ols. face 16. ukee type fly- peed pped ence fore ma- chine about the same that re- for sharpening the average high-speed Stellite cutter equal proportions. Machines this type have done much broaden the use small tools with carbide inserts. Beryllium