The Iron Age 1938-09-29: Vol 142 Iss 13

FRITZ J. FRANK President J. H. VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Mach CAMPBELL ALLISON inery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting 2ditu Washington Editor Resident District Editors ROBERT BINGHAM Pitisburgh Chicago Cleveland Detroit Editorial London, England Cincinnati FRAZAR FIDRMUC Boston Hamburg, Germany MEYER CHARLES Post Milwaukee San Francisco SANDERSON ASA ROUNTREE, JR. Toronto, Ontario Birmingham Roy Newark, N. J. St. Louis JR. Baffalo Owned: and Published by CHILTON COMPANY (Incorporated) Publication Offico Editorial and Chestnut and 56th Sts., Executive Offices Philadelphia, Pa. 239 West 39th St.. New York, N. ¥ OFFICERS AND DIRECTORS ©. A. MUSSELMAN, President FRITZ J. FRANK, Executive Vice-President FREDERIC C. STEVENS, Vice-President JOSEPH 8S. HILDRETH, si GEORGE H. GRIFFITHS, EVERIT B. TERHUNE, WILLIAM A. BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN H. VAN DEVENTER JULIAN CHASE THOMAS L. KANE CHARLES 8. BAUR G. CARROLL BUZBY P. M. FAHRENDORF BAUR, General Advertising Manager DIX, Manager Reader Service Member, Audit Bureau of Circulations Member, Associated Business Papers Indexed in the Industrial Arts Index. Published every Thursday. Subscrip- tion Price: United States and Pos- sessions, Mexico, Cuba, $6.00; Can- ada, $8.50; Foreign, $12.00 a year. Single copy, cents. Cable Address, ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Bidg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bidg., Chicago H. E. Leonard, 239 W. 38th St., New York Peirce Lewis. 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bldg., Pittsburgh D. C. Warren, P. O. Box 81, Hartford, Conn. RON Cont SEPTEMBER 1938 Depends Upon Your Point View Centralized Management Material Handling The How and Why V-Belt Drives Composite Construction Welded Assemblies Design Advances Presses Look Ahead the Abrasive Industry the Assembly Line Current Metal-Working Activity Washington News THE NEWS BRIEF Weekly ingot Operating Rate Rate Activity Capital Goods Plant Expansion and Equipment Buying New Industrial Literature Products Advertised Just Between Two Index Advertisers Copyright 1938 by Chilton Company (inc.) 114 iy igh est ing ks, na, ent en- ade ay, ior ost ce, es, ‘ge nt. ty- hi- pt. ot. p- til nd 54 | it 7 Production Costs Cut with Certified Alloy Steels You can depend better results less time when your heat treater guided the Ryerson alloy data charts. These charts show him the exact properties the steel with which working and tell him how get the de- sired results. does not have test. takes chances. Spoilage eliminated and sound dependable job high accuracy and uniformity assured. addition saving production costs, the Ryerson Certified Alloy plan benefits the Purchasing Depart- ment they can keep detailed record the exact Principal products stock for mediate Shipment include— Bars, Structurals, Plates, Iron and Steel Sheets, Tubing, Shafting, Strip Steel, Alloy Steels, Tool Steels, Stainless, Babbitt, Welding Rod, etc. analysis every alloy purchased. Thus possible duplicate particularly desirable close range specifica- tions repeat orders. The Metallurgical Department benefitted too for they can call for any reasonable physical requirement and sure the Heat Treater can produce the desired result. Ryerson Certified Steels also include carbon, tool and stainless steels that meet definite quality standards. They offer many advantages steel users. Let tell you the complete story. Write for booklet. Joseph Ryerson Son, Inc. Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Philadelphia, Jersey City. EST 16—THE IRON AGE, September 29, 1938 ... THE IRON AGE ... ESTABLISHED 1855 SEPTEMBER 29, 1938 Vol. 142, No. Depends Your Point View NCE upon time progressive ant colony, anxious add its collective store knowledge, determined conduct research project. appointed two members the colony leave the environment the home ant hill, travel abroad and find out what the world was like. One the two observers packed his belongings, set forth and finally came the opening rabbit hole. said himself, the door the world that have been sent the ant entered the hole, noted what saw there and returned the colony. Meanwhile, the other ant travelled another direction. came tall tree which extended upward farther than his eyes could see. must the ladder that the said he. laboriously climbed the top, observed what saw from there, climbed down and returned the colony. The day came for the observers report. Said the first ant: world deep round hole; damp and dark and smells Said the second ant: world broad and flat, bright and full color and pleasing The members the ant colony deliberated over these strangely varied findings. Having the proverbial frugality their kind they decided that would useless send out more observers. said their Chairman, two people see the world alike. Let us, therefore, strike average between these two points the ants decided that the world was neither altogether good nor altogether bad and that any rate was place where you had work you wanted eat. Then, they went back work and have kept ever since. There may thought this for industrial executives and others who are appre- hensive the future because the things that are going home and abroad. Let's remember that the observers who report these things are working places where dark and damp and where things have unpleasant smell. ought send some these fellows into the tree tops can strike average. better still, just back work and keep it. ya? 4 | ; | | 7 | | | | Management MILLS Supervisor, Transportation Department, General Electric Co., Pittsfield, Mass. ° HEN interplant movement materials, parts ranging from two ounce ca- pacitors 200 ton transformers, complicated plant layout which, under SILVER LAKE IRON AGE, September 29, 1938 ° could ever regarded designed promote efficient the result problem every sense the word. The following discussion there- fore contains two major points in- terest: (1) the story the coordi- efficient and economical solution tion the methods and equipment which have been found meet the particular needs thereof, PITTSFIELD, Mass, PLANT. GENERAL ELECTRIC Co. For materials Zones A,B,C and See Fig. dispatcher O-Central transfer station ---Flow materials transfer tha wa: out nec me} spa ing the plif ind ish fro Materials ° ° ° ° TYLER 4 | \ \ \ ndar FIG. EMI-TRAILER ished distribution transformers warehouse. ° ° ° well brief summary the most noteworthy results. The Pittsfield, Mass., Works the General Electric Co. grew rapidly that long-range planning layout was impossible. Almost soon new buildings were erected they were outgrown, and other buildings were necessary. Today there are depart- ments occupying acres floor space, housed 159 different build- ings spread out over acres roll- ing ground. The plant site split the main line the Boston Albany eled thoroughfares. Fig. sim- plified diagram the layout shown, indicating some these difficulties. addition, with grade vary- ing much ft., equipment constantly hauling heavy loads per cent grades, and many locations entrance buildings obtained ramps with grades high per cent. With several four and five- story buildings, materials handling often dependent the use ele- vators, and considerable remodeling has been necessary make way for larger and faster freight elevators carry equipment and heavier pay loads. Because the terrain, much equipment has been specially developed cope with problems. The company has cooperated with equipment manu- facturers the design tractors with special gear ratios and new fifth wheels for trailers knifing grades. pioneer testing solid and pneumatic tires for iadustrial equipment been done. present G.E. and the equip- ment manufacturers are cooperating the design trucks built with lighter that greater pay loads may carried low- capacity elevators and with live-load limitations. Prior 1928 each department division had its own men and equip- ment handle This system was inefficient due the sponsibility and waste equipment, together with haphazard maintenance. each division materials was just extra job for some fore- man whose primary manufacturing. THE SOLUTION 1928 was decided centralize the control all materials-handling activities. depart- ment was created study the problem and effect the consolidation. Prelimi- nary surveys showed several FIG. CHART TRANSPORTATION DEPARTMENT. RAILROAD CAPACITORS, CUTOUTS, LIGHTNING ARRESTERS, WIRE, SCREW MACHINES, TOOL ROOMS, PLATING, GALVANIZING, RECEIVING ROOM POWER TRANSFORMERS, TANKS, REACTORS, BOX SHOP, INSULATION SHIPPING ROOM, HIGH VOLTAGE BUSHINGS, PUNCH PRESSES FOR SILICON CORES SUPERVISOR DISPATCHER YARD TRUCKS DISTRIBUTION TRANSFORMERS, BUSHINGS, PUNCH PRESSES INDUSTRIAL EQUIPMENT TANK WELDING, TUBE ROLLING MAGNESITE, COMPOUND SALVAGE REMOVAL SHOP REFUSE AND HANDLING WASTE AND SPOILAGE SCRAP DEPARTMENT THE IRON AGE, September 29, | 6—AT RIGHT porcelains from stock manufac- turing floor with fork truck. ° 5—BELOW stored fork truck boxes high, saving per cent floor space for this kind ma- terial. FIG. 4—AT LEFT OADING porcelains semi-trailer with fork truck. sweeping changes One central dispatcher was appointed handle all calls for service and route all the equipment. This change eliminated most the confusion in- volved the old system, where sev- eral men had consulted the material was passing through three four divisions. Next, inspector was appointed check the productive efficiency each man and each piece equip- ment. was discovered that many departments did not need time services truck and driver, and schedules were arranged that two more departments could share the services one piece equip- ment. All equipment was inventoried and was found that per cent was inefficient because old age, obsolescence, nance. Old equipment was scrapped, IRON AGE, September 29, 1938 ange the or nted full- iver, that hare juip- age, inte- FIG. 7—ABOVE handled with fork truck. modern trucks designed ized handling, and campaign inspections, and preventive maintenance stituted keep the equipment peak efficiency. Handling methods were studied and was decided replace all highway trucks within the plant the tractor-trailer system 2). The change resulted fewer handlings and lower per ton. study the rail- system—which consisted five locomotives, miles track, and many co-owned cars—revealed that much its work could done more efficiently with semi-tractors and trailers. This most important change. And even more significant that since the widespread adoption fork trucks these trailers and semi-trailers can used even more efficiently, due | one case, finished transformers formerly had been loaded flat cars and hauled three miles order reach the warehouse which actually was but 500 feet away! This was necessary cross the Boston bany tracks. The use 10-ton semi- trailers (Fig. this job reduced the cost handling per cent and decreased the time for loading, haul- ing, unloading from hours one hour. Obvious'y, aspect this improved system has been better service customers. railway hauling, has been possible reclaim considerable floor space formerly used for tracks within the buildings and abandon much track and rolling stock, with nance. present two switching engines and railway FIG. 8—BELOW IGHTNING arresters and cutouts stored ware- house fork truck. | ae | t 4 THE IRON AGE, September 29, | Fig. finished lightning arresters semi-trailer. crane have clear tracks for the han- dling inbound cars raw material aml outbound cars ucts. small feature centralized ma- terials handling has been the oppor- tunity cooperate with the factory layout department. The perintendent, portance materials handling any manufacturing system, has and approve factory layouts that the transportation de- partment may able its part facilitating production. more, whenever the ment decides move and_ the maintenance department starts dis- mantle machinery, the transportation department able, with its centralized control, marshal enough equip- ment and men effect the move with the minimum lost production time. ANALYSIS RESULTS Summarizing gains ized contro! materials handling, the following features deserve special emphasis Consolidation for Cost Reduction: the Pittsfield Works, consolidation reduced costs and equipment investment least per cent. Such percentage significant when one considers that plant capacity G.E. deals with large pay- rolls for materials handling well large valuations for equipment. Fur- ther, materials handling theoretically non-productive and efficient management demands that handling costs rigidly controlled. 22—THE AGE, September 29, 1938 Consolidation for Efficient Utilization Equipment: Under divided control equipment, additional trucks were often for busy divisions while other divi- sions had trucks rusting away ness—or working only small percentage the time. Under consolidation, supervisor has the time and facilities study all the latest developments mod- ern handling equipment. for cooperation with the equipment manu- facturers—and pays big dividends. Pro- gressive equipment manufacturers often have the solution dling problems. For example, one equipment manufac- turer designed large electric tractor cope with Pittsfield’s hills, and proved successful that has been used widely other plants. With divided control handling, many departments were using obsolete equip- ment. Specialized trucks were available handle the particular jobs, but one was delegated keep abreast new designs. Trucks were kept the job for years with thought improve- ment method. most cases seems that equipment development makes trucks obsolete was found that during divided con- trol handling activities many depart- ments were the amount work justify the pur- chase expensive truck. Since the consolidation handling, has been pos- sible have one truck service several departments schedule. This point especially important the utilization fork trucks—without centralized control probably one department would have initiated the fork truck method for some time, since the essential factor the fork materials. Fig. truck handling lightning arresters warehouse. ~ $ a ige 10 od- ime nu- an- to ved lely iny ble one 1ew job ve- cks urt- the fur - the OS - is rol ave hie ork low ON = Semi-trailer handling finished lightning arresters from factory warehouse. fact, the optimum use fork trucks presupposes that all handlings ries shall properly integrated. Some specialist the flow materials must coordinate the handlings through the dif- ferent departments eliminate confusion and wasteful hand labor. This coordina- tion involves the study standardized containers fit the material through its various stages manufacture, the plan- ning factory layouts eliminate bottle-necks the flow production, and the education factory foremen the parts they are play the scheme operations. Consolidation for Better inspection equipment and preventive maintenance reduce costs and prevent losses due delayed production. This best done through centralized con- trol. With the system, maintenance costs have been reduced: first, the replace- ment of worn-out equipment, and, second, careful inspections and servicing. transportation $457,000 in 1937. WORKS Probably the most potent argument for centralized control materials handling been its success under complicated conditions. 1936 the General Office Schenectady became interested the problem materials handling, and was impressed with the Pittsfield record that steered the development all other General Works similar basis— with emphasis centralized control. EQUIPMENT USED has four foremen and five group leaders control the operation the following pieces equipment: Electric tractors Gasoline tractors 297 Yard trailers trucks Tier-lift trucks trucks Fork trucks Diesel electric switch engines Railway crane Flatcars Semi-tractors Semi-trailers Highway trucks Parked central transportation yard. ORGANIZATION CENTRAL MANAGEMENT With good organization behind him (Fig. handle routine, the supervisor finds possible spend more time cost contro!, develop- ment new methods, interchange ideas with other General Electric su- pervisors, and cooperation with the factory planning department. Since his telephone connects him with ninety-two departments requir- ing diversified services and 448 eces transportation equipment ready the job, the dispatcher really the nerve center the system. Co- operating with him are the foremen charge the railroad, industrial equipment, and garage, and the group leaders who maintain five sections the Works. The staff knit together weekly meetings, which the supervisor lems. Many important methods have been inspired these forums. EXAMPLES RESULTS After thorough consideration these factors and preliminary studies through use one truck, lightning- arrester handling was put 100 per cent fork-truck basis test the system complete cycle opera- (CONTINUED PAGE Fig. works dispatcher instructing tractor drivers. a i THE IRON AGE, September 29, 1938—23 IG. seven strand Gilmer V-belt drive furnish- ing smooth, dependable power transmission from Economics Industrial Power Transmission. HERE are several important between marked that the design theories vary quite radically each case. will interest, therefore, approach the subject V-belt drives way comparison design theories. motor compressor textile mill. flat be't transmits power vir- tue the grip its contact surface with the face the pulley. This grip function the coefficient fric- tion betweea the contact surface the belt and the face the pulley, and the tension the belt which holds these surfaces together. the the term coefficient friction the belt never touches the bottom the pulley groove; the grip belt and wholly dependent upon the wedging action the sides the belt within the pulley groove. Now, this wedging action not the simple thing that would the 2—A six strand Dayton cog-belt drive operating within metal guard connects motor the base the gear-head this American tool-room lathe. and Why Belt Drives ° ° FRANCIS JURASCHEK Consulting Editor, The Age ° ° ° were solid bar metal trapezoidal shape, operating within conical groove. the belt were such solid bar metal, wedged under the tension the drive within the pu'ley groove, would require the action free from the groove after passing around the pulley. Under such cir- cumstances readily apparent that V-belt drive would waste almost continual effort unwedge the belt. Fortunately, the V-belt not solid piece metal. very limber and flexible piece rubber and can- vas and cord. And this flexibility lies the whole secret its applicabil- ity power transmitting medium. Hold one your straight and look down upon from above. The lines bounding the digit either side are practically paralle!. Now flex the end the finger down- ward, the knuckle. Immediately, you observe the action from above, the flesh around the bulges outward either side. This what happens V-belt when passes around pulley. the belt runs from one pulley the the sides are like the sides your finger; but the belt enters the pulley groove and begins bend around the pulley, the sides the belt bulge outward, meet the correspond- ing sides the groove, and wedge there. Within the groove h \ 1 therefore, these side-bulges the belt form the surfaces belt contact with the sides the groove. The tighter the belt tension and the sharper the bend the belt, the greater the Herein lies the element positive grip frequently claimed one the chief advantages V-belt drives. Within the limitations the proper load V-belt designed carry, this positive grip, the result the wedging action, undoubtedly greater than the grip attained any type flat belt. the point leaving the pulley groove and the beginning the straight run the be't the other the belt leaves the groove freely and easily, the unwedging action being helped materially the reduction the bulges. due this factor that power losses this point, caused the breaking the wedge effect the belt the groove, are reduced almost inappreciable minimum. should noted, however, that there one V-belt made with sides which are concave when the belt running straight. this type belt passes pulley the bulge merely causes these sides be- come perfectly straight, that the entire side the belt makes contact with the pulley groove merely that portion the side which most bulged out. Hence have condition where the economic effect uniform wear over the whole area both sides the belt instead over portion the area both sides must balanced against the un- doubted power losses which occur due the greater difficulty freeing the belt from the wedging action the groove has passed around the pulley. There are cogent argu- ments both sides, but inter- esting note that the great majority V-belts are made sides order take advantage the bulge. Two Other Differences second vital difference between flat belts and V-belts lies the fact that, due the wedging action which takes place between the V-belt sides and the pulley grooves, much smaller are contact around the pulley required maintain grip, than needed for competent “wrap” the flat belt around the flat pulley face. direct consequence this fact, the V-belt drive ideally suited for short center distances; and 1G. 3—A strand Allis-Chalmers texrope drive transmitting power under heavy duty conditions from 150 hp. motor raw coal conveyor. may applied situation where the center distance little, any, greater than the diameter the larger pulley, even when the speed Within the limitations the proper should considerably less than with the flat drive. third vital difference between flat belts and V-belts appears the con- sideration that the flat belt homogeneous structure across its en- tire width; the tension stresses the belt being equalized over that width. the multiple V-belt the width the drive actually split into number separate belts, each more resilient than the flat belt; re- quiring careful matching vidual tensions assure uaiform pull over the entire drive width. result these differences (and the resulting consequences) the drive (which for most prac- tical purposes insofar industrial power transmission really means the “multiple V-belt is, properly designed, installed and maintained, compact and economical method transmitting power from motor the operating shafts vari- ous types machines. Within speed reduction increase ratios from medium short ceaters, today popular method connecting driven machine. rarely used ‘ong center drives, drive lines shafting, drive machines Operating condi- tions involviag excessive heat, the presence oils corrosive chem- icals, long center distances, large velocity ratios, and extremely high speeds should receive special consid- eration, and the respective advantages flat belt and V-belt drives weighed 4—A strand Gilmer V-belt drive delivers 140 hp. from diesel engine general utility gener- ator manufacturing plant. te uch the ley or ing hat as the elt. ber All- 5—An eight strand Manhattan Rubber condor V-belt drive operating Goulds triplex pump used for water flooding oil well the mid-continent field. with the utmost care before decision reached. V-Belt Advantages drives have become certain specific advantages. These advantages are many re- spects closely tied natural limita- tions, but within these limitations are wide and generous. V-belt drives are used today all the way tional horsepower drives hold equipment drives 1000 horsepower the heavy industries. Because their inherent character- istics cleanliness, they are widely strand Allis-Chalmers texrope drives connecting 250 hp., 440 r.p.m. motor 122 pulp beaters through 84-in. centers. 26—THE IRON AGE, September 29, 1938 used the food industries textile mills; because their ability withstand conditions dirt, gritty dust and moisture they are equally widely used the ceramic, cement and mining industries. Where quiet operation necessity they are popu- lar public buildings tions, ventilating and air-con- ditioning services; and the blast furnace, the steel rolling mill, the p'ant and the machine shop capabilities have found wide applications. These qualities, too, have found apprecia- tion such diverse industries agri- culture lumber What are these advantages de- tail, and their limitations First and foremost grip, pull- drives, the V-belt comes closest, under normal conditions load, standpoint positive transmission power. Because the wedging action the belt the pulley groove, the harder the pull, the tighter the grip. The natural limitation is, course, the strength the component parts the belt. Continued high tension weakens the fibres the fabric and the cords. The drive should, there- vidual belt tensions within reasonable load limits. Second, space saving. The V-belt essentially short center drive, and under extremely short center condi- tions the most successful resilient type drive. Since permits the motor set much closer the machine shaft than any other type belt drive, this advantage great importance the equipment manufacturer. the most popular drive for machine tools, for example. The actual limita- tion center distance equivalent the diameter the larger pulley. Third, its capacity may graded through almost infinite number steps. one V-belt manufacturer says his advertising, “It may de- handling sensitive jobs, rugged hippopotamus for jobs requiring for fractional horsepower transmission the more strand drive for heavy loads, the range exceptionally gradual. limitation occurs the many-strand drive due the leverage very wide pulley exerted the motor bearing, unless the pulley supported also bearing. Fourth, the V-belt drive ent!y quiet. When flat belts slip, there | q 1G. 7—These strand Dayton cog belt drives connect 575 r.p.m., hp. motors heavy belt elevators through spur gear reduction drives. noise; with excessive slip that noise squeal. V-belts, properly alined, not squeal when slipping. The joints splices flat belts make flapping sound when touching the pulleys. V-belts, always tured endless, not flap. clean. belt dressings should ever applied them, consequently the not become sticky nor they collect oil grease, greasy dust. Sixth, V-belt drives cushion the shock loads. They start smoothly and run smoothly because, their very nature, they are highly result both this resilient char- acteristic and the wedge-grip the pulley, properly proportioned and adequately installed V-belt drive should not require high tension for satisfactory operation; hence should impose light loads the shaft bear- ings. When V-be!t drive requires high tensions prevent excessive slip, sign either that the load too heavy for the drive, that the natural life the belts under load being exceeded. General Criticisms Among belt users the general criti- cisms most often heard V-belt drives indicate that such drives are operation speeds not greatly excess 3500 ft. per min. belt travel, that they should used heavier drives when the sheaves are large and belt speeds moderate, and that unless the newer synthetic rubber compounds are used manu- facturing the belts, they should not used under conditions where oil present, drip, mist, spray, bearing. V-belts Whatever material are between the flat belt and the chain drive with respect the must more carefully alined originally than with flat belts, and must kept excellent alinement, operate satisfactorily. Not quite much care, however, required this respect with chain drives. But any considerable departure from parallelism betweén the driving and driven shafts wi'l produce inequality load division between the belts, while any lateral pulley misalinement will produce excessive sidewear the belts and shorten belt life. Such latera! misalinement often duce squeaky V-belt operation. When used for long center distance drives, especially the belt speed strand Dayton V-flat drive connecting high-powered motor ice-plant compressor. Note the surfaced compressor pulley. THE IRON AGE, September 29, 1938—27 ip. nd li- 18 q high, the slightest pulley misaline- ment exists, the V-belts tend climb out their grooves and run top adjoining belts, occasionally roll over and run their sides. capacity the V-belt drive. Flat leather belting, unless seriously over- rated, will carry in- crease load with more difficulty than high increase slip; but V-belts when overloaded nitely weakened structure. Over- load capacity can for the proportional provision more belts. Manufacturers recognized this early stage the develop- ment the V-belt drive their practice recommending increase the number belts take care small pulley diameters, speed-up drives, unusual load fluctuations and other unfavorable factors. The basic ratings which represent be't capacity conditions remain unchanged, but the service factors applied these ratings accommo- date unfavorable operating conditions will cause the actual number belts greater catalogue recommendations. cannot operated fixed centers. Much the initial stretch comes out the first few hours days running. Thereafter there under heavy loads, throughout the life the belt. Since the belts cannot cut and otherwise rejoined the job, there must some means provided for belt take-up. This take- Injection Molding Over Die Cast Cores plastic industry continues find new uses for metal die cast cores and inserts. They are particu- larly adaptable injection molding, process which the plastic heated flow point and then injected pressure, into the mold around the metal core. coating the castings with plastic, metal finish- ing operations are eliminated and color added the product. turn, the metal gives additional rigidity the plastic and, many applications, desirable weight. 28—THE IRON AGE, September 29, 1938 usually allowed for least per cent the center distance. Since V-belts must less the manufacturer, they are not obtainable all desired lengths. Consequently the drives must de- signed use stock sizes V-belts. Sometimes this requires considerable juggling the diameters both driving and driven pulleys well the center distance. drives considerab'e capacity the inherent stiffness the larger sizes V-belts precludes the use small diameter pulleys. When small diameter pulleys must used, the alternative very large number light very wide grooved pulley. Unless such wide pulleys can supported with outboard bear- ing, the center the belt group thrown far out beyond the motor bearing, and the resultant leverage may increase the motor bearing load beyond the mended load limits. Likewise, for heavy capacity drives serious V-belt limitation high speed. The belts are gen- erally thicker than flat belt, and since given speed the centrifugal force varies weight the belt, the effect that force will felt correspondingly greater measure the V-belt drive. the higher speeds heavy capacity drives, the combined effect stiffness and centrifugal force tends lift the belts out grooves for distance recent example the process just described the Empire hand from what should the entering and leaving points. Under these condi- tions slip excessive, and tension increased cut down the slip, the belts quickly stretch beyond all use- fulness. Analysis these criticisms shows that V-belts are unsatisfactory ap- plications where they should not used. But that true any type drive. single type industrial power transmission equipment panacea. brief description V-belt shapes and materials was given Chapter 29, The Characteristics Industrial Transmission Belting. similar de- scription V-belt pulleys, will given later chapters deal- ing with the characteristics trans- mission pulleys. Here important note that development the V-belt drive which increasing interest the so-called drive.” When small motor pulley drive large driven pulley short center distance, the large pulley may the V-belts riding over the flat sur- face the face just flat belt would. The small motor pulley is, course, the usual grooved V-belt type. This drive cross between the true V-belt drive and the flat belt drive, which the V-belt advantages positive grip and small contact angle are combined with the economy using existing flat-face driven pulley, under conditions which might make short-center flat belt drive unsatisfactory. plastic, injection molded over die cast metal core like the one shown the left the illustration. The coat- ing less than in. thick and pro- vides lustrous plastic finish. Here the die cast core weight and rigidity. The round knob finished stamp matching Tenite, molded two parts which are then cemented together. provide with some means attachment the body the stamp, the lower half the knob molded around threaded metal insert. This then screwed onto the post the metal die casting which threaded before assembly. considering vidual parts which must incorporated complete structure, the designer faced with the task selecting from structural shapes, plates, forgings, stampings and castings. the construction heavy and complicated machinery, this selection especially important. Often when has been decided weld fabricate instead cast, the possibil- ity combining structural shapes and castings overlooked. While there set rule where this combination advisable, may said that com- posite construction advantageous where expensive forming equipment and pressing forming operations would required rolled steel were used, where there are surface irregularities contours which would, fabricated, unnecessarily expensive. One the more frequent uses castings composite con- struction bearing housings massive shape heavy section. Properties Are Similar The designer and manufacturer need have hesitancy using com- posite construction, considering that available steel castings have physical and chemical properties which closely Abstract paper read before the Phila- Chapter, American Welding Society. omposite Construction Heavy Welded HOLLINGSHEAD Engineering Department, Morgan Smith Co., York, Pa. approximate the properties plate. is, however, true that cast- ing with chemical composition sim- ilar rolled plate will have lower physical properties than the plate. the examples composite con- struction which are follow, the castings are specification A-27-36, grade modified with 0.25 per cent carbon maximum. The plates used are low carbon welding quality steel similar A.S.T.M. spec- ifications, with tensile strengths from casting quarter section Plate rings with : ribs complete € Cylindrical plate steel section, 7 4 quarter section Conical plate steel frustrum quarter 45,000 65,000 Ib. per sq. in., and yield points from 24,000 33,000 Ib. per sq. in. established fact that the grain structure both cast and plate stee! near the welding zone changed the welding process. also well known that proper heat treatment will correct the metallurgical structure and also relieve the stresses caused welding degree which accept- able the industry. This final heat treatment, most cases, amounts PLAN VIEW Quarter section throat ring sketch unit adjustable blade turbine illustrates the economies that may realized judiciously combining cast steel and rolled steel. The employment castings the construction this unit reduced the number pieces required 60. THE IRON AGE, September 29, the ‘ial ter le- es, 3 ‘4 al- nat ive ce, ed, elt ‘ue ve, rht stress relieving from 1150 1200 deg. Preparation Joints preparation the joints for welding very much the hoth castings sections machine chamfers the facilitate assembling and reduce weld areas. With castings, the cham- fers may also gas cut, chipped, the chamfers are cast, fillet weld sufficient, con- sidered good practice grind the casting bright metal where the weld made. larger types are usually advisable cast. Composite Construction Reduces Cost good example the use heavy steel castings welded assembly shown Fig. This unit the Smith-Kaplan adjustable now under construction the Morgan Smith plant for the overall dimensions this unit the rough are ft. outside diam- eter, ft., in. inside 30—THE IRON AGE, September 29, 1938 The outermost part section, where the lower bearings for the wicket gates are located, cast steel welded place. The entire ring built four sections which are together. The weight the castings required for the complete ring 60,000 compared with total rough weight 144,000 Ib. for the complete throat ring. The func- tion this unit turbine not essentially strength member, but rigidity and absence vibration are very important factors. From hydraulic point view, the inside contours are utmost importance. apparent that had casting not used the assembly shown, would have been necessary have substituted four five plate thickness per quarter section, which would formed the double curvature shown. The cost the pressing dies and the forming, together with the gas-cut trimming and fitting, and subsequent welding the segmental joints, would exces- sive. addition, there would the problem providing for LEFT 2—In this example tion, applied tur- bine runner, the utilization plates building the buckets permitted the use thinner material than would have been the case had castings been used. RIGHT 3—The use com- posite construction the wicket gate illustrated this drawing gave much lighter finished product than have been ob- tained had the entire gate been cast. The cost both types was about equal. vidual bearings for the lower gate stems. The possibility excessive warpage and the cumulative errors haps much that additional allow- ance for finish would There would a'so more shop han- dling for positioning welds. using casting the assembly, the number individual pieces was per ring, the shop time was cut considerably and there was culty securing the The cost comparison favored the use casting. Additional Machining Allowance Required interesting note that previ- ous experience with this type heavy structure indicated that the stock al- lowance for machining wou!d less had used the pressed plates instead the casting. Another example where composite construction used turbine parts shown Fig. This runner com- posed cast steel crown weighing 6500 and machined cast steel band weighing 5800 together with hot formed runner buckets steel plates weighing 7000 making total weight for the entire unit 19,300 using plates for the construc- tion the buckets was obtain sufficient strength with thinner material than would have tained had the buckets been cast. The use the thinner material increased the vent cross-sectional area the water passages, thus increasing the turbine output. The pre-machining the crown and band exact size and shape and smooth surface not only allows for more perfect assembly Cast stee/ upper stem, Plate gate, stee/ lower /b. — ‘ q ° A ¥ 7 al 3 3 : 4 < * Section A-A an- ing ber cut pe. use ice the runner buckets, but duces better balanced runner. Casting Previously Used Before welding was this runner was most frequently made one solid casting, using cores for all the mold excepting the crown and hub structure. The cast- ings required when struction was utilized building the runner were much simpler make, the cost was considerably less and the possibility having build up, chip and grind for the ba'ancing the runner buckets was avoided. Fig. shows fabricated wicket gate adjustable guide vane which employs the use formed plates for the gate proper and castings for the gate stems. entire gate cast steel would acceptable here, al- though the gate shown somewhat lighter than would have been the case had been cast. The cost would have been about equal both cases. using composite construction, however, was possible utilize our present shop equipment and keep most this work our own plant. Pressing dies were required for the side wa'ls, but this case the die cost was spread over gates, the same the pattern cost would The surfaces the castings which were welded the plate were in. high and ground bright metal the foundry. Here case where the use composite construction enabled perform the work with existing equip- Bridgeport Brass Co. Completes New its new rolling production brass, copper cop- per-base alloys for industrial and com- mercial use has been announced the Bridgeport Brass Co. Built cost more than 000, the new plant, which all roll- ing mill operations the compan will located, the first major step expansion and modernization program inaugurated 1937, accord- g 3 ow Be: ing Ralph Day, president and general manager. The plant, utilizing the straight-line production principle similar employed other major has total floor area more than 220,000 sq. ft. and the largest single unit the major buildings main- tained the company Bridgeport. estimated that the new mill will have production capacity over 6,000,000 Ib. metal per month. mill office and laboratory oh is ment and thus keep the work our own organization with additional cost. While many cases where would possible completely fabricate with structural shapes and plates, the result might the eye and the cost would probably out proportion what should have been, had some castings been used. Unless all the available materials for construction, including castings. are considered, manufacturers and fabricators are overlooking important factors sound and economical de- trated here show some the uses composite construction turbine work, they are not conclusive the design each individual structure presents its own problem. signs. building houses all research develop- ment and testing facilities the com- pany. Approximately nine acres ground were acquired for construction the rolling mill and the office and laboratory building. Stone Webster Engineering Corp., Boston, developed the design, constructed both buildings and installed equipment. The Morgan Construction Co., Worcester, were the consulting engineers, working conjunction with company engi- neers, the development the ing mill equipment. More than 1375 tons structural steel was used the construction the rolling mill and the unbroken win- dow area the four sides the building amounts approximately sq. ft. New Scrap Trading Company Organized Pittsburgh ITTSBURGH.—The Steel Trad ing Corp., with offices the Clark Building here, has been organized deal new and used iron, steel and nonferrous products both domes- tic export trade. Berkman president; Max Meltzer, vice-presi- dent, and Louis Berkman, secretary and treasurer. Mr. Meltzer has his own company, the Max Meltzer Co. for many years. Berkman and Louis Berkman are the Louis Berkman Co., which has been long engaged the scrap trade Steuben- ville, Ohio. THE IRON AGE, September 29, ivy al- no tes ite rts er, ni- eel re- tal jer | 7 — : | 4; Recent Desi largest bending press world, both size and ca- pacity, has recently been installed the Baldwin-Southwark Corp., Phila- delphia. 6000-ton capacity, capable cold bending Hedges-Walsh-Weidner Division Combustion Engineering Co., Inc., Chattanooga, Tenn. The bending press consists two 3000-ton, four-post hydraulic presses beams ft. long., ft. deep and in. thick. These bending beams are both above and below the foundation BELOW huge Baldwin-Southwark bending press, weighing 1000 tons, was recently installed Combustion Engineering Co. plant. capable bending plates ft. length and in. thick into shapes for high pressure drums. 32—THE IRON AGE, September 29, 1938 FRANK OLIVER Associate Editor, The lron Age ° ° line, the bottom beam resting the cast steel platen each press. The have 50-in. diameter rams, operating under sure. each side there push-back rams arranged for high speed work, and under the bottom die there are four manipulating rams for handling the work. Unique features the design the presses are the rangement the pressure Advances Presses main cylinders take eccentric load- ing, and also the and thrust block device the moving beam, permitting eccentric loading without throwing any side strains either press. Only the working parts are placed above ground, the overflow and pneumatic filling tanks, intensifier, being below floor level. The press served plate heating fur- nace capable taking plate ft. wide and ft. long. Large Inclinable Press large piece equip- ment for its type new size Master Series inclinable press with ABOVE vidual motor drive for this large size Niagara inclinable press with crankshaft. ° and Other Sheet Metal Machinery Niagara Machine Tool Works, Buffalo. The complete line series now extends from in. this size. Included the engineering features the machine are two air counterbalances connected the slide; heavy duty 14-point engage- ment sleeve clutch with gle-stroke mechanism; rigid cast steel frame; device equipped with anti-friction bearings adjustable and removable gibs, with multiple V-ways; breech block die clamp; and self-contained back gear assembly with anti-friction bearings, mounted within the frame. Main shaft are split 45-deg. angle. Punch Presses MODERN line punch presses has been developed Ferracute Machine Co., Bridgeton, ap- pearance they are moderately stream- lined and utilize much less floor space than the former conventional design. are high quality steel castings, finish the redesigned frames new line Ferracute punch- the Verson Press Co., 93rd Street and Kenwood welded steel construction, and all moving parts except the fly- wheel and clutch are contained within the crown. Clutch air actuated, with disk type friction brake combined. Though the ram adjusting motor contained within the ram plates, read- ily accessible. Press shown measures in. between hous- ings and available with the solid frame capacities ranging from 100 500 tons both single and double-suspension types. Tie-rod machines one, two and four-point suspension world's largest bending press described this digest an- nouncements the manufacturers received recent weeks, also large punching presses and two types column type presses large size. Several punch press accessories are also mentioned. Advances design hydraulic equipment include compact, streamlined assembly press, high speed general purpose press, bench type and special dual cyl- inder construction for automotive application. Two machines for form- ing Pittsburgh locks sheet metal joints are illustrated, well nibbling type machine for cutting intricate shapes sheets. designed give maximum strength stems, and couplings are heat treated, LEFT SPECIAL process used give smooth ing presses. RIGHT RAME this 300-ton all-steel, full eccentric press, made may also had. and the shaft supported over- hanging bearing that forms part the main frame casting. Frame jour- nals are bushed with high grade bronze, are other important bearing members. Rams are extra long, and the ram bearings are bronze lined give long wear. The presses are equipped with either direct drive, and gears and flywheel are in- closed suitable sheet metal guards. Four-Point Press PPOSED motion rocker shafts running from front back and actuated eccentrics are featured the No. lever type four- point press developed Bliss Co., Toledo, for blanking and shallow forming work. Thrusts are distrib- uted equally over the gibs under all loading conditions, stated. The main outer links straddle the outer web the crown and transmit the load direct thrust through the web. Due the linkage, slight THE IRON AGE, September 29, on rts ir- ft. in., with in. adjustment performing drawing operations dwell bottom stroke obtained, de- sirable for drawing work. The slide counterbalance cylinders are mounted the uprights, thereby keeping the clean-cut lines the frame. The clutch the multiple disk. pneumatic type and drive Control push buttons and speed normally strokes per min. Stroke ABOVE MARQUETTE pneu- matic cushion the bed makes this Bliss 84- in. single-action press suitable for shallow form- ing work, well blanking. specifically for the auto- motive trade. RIGHT structural shapes both forward and return travel the automatic spacing carriage pos- sible with the Pollasky automatic spacer. 34—THE IRON AGE, September 29, pressure than required jaw clutch. unites the shockless, in- stant engagement and durability the friction clutch with the positive, simple action the jaw pin clutch, according the maker. The clutch said engage instantly any point the cone when the treadle pressed. The clutch built suit specific applications. for spacing the work, and automatic carriage which grips the work and carries through the punch. When angle iron being punched, one template used for the holes one leg, the other for the second leg. Templates are set placing pin wherever hole desired. The carriage stopped the pin and simultaneously locked the table. Upon completion the punching the carriage moves the next stop. When holes one leg are com- pleted, the gripping jaw swivels and simultaneously the structural member moved sidewise the proper gage line through the action opposed air The carriage driven small air motor and the template stops the carriage are operated compressed air through valve co- ordinated with the punch ram. Car- riage travel about ft. per min. The machine handles angles in., channels in. and plates permit the use high fundamentally single-action press. low dies. The bed contains Marquette pneumatic cushion for Punching Spacer automatic spacer for punching 3918 North 23rd Street, Milwaukee. clutch, made the Industrial device consists spacing table Clutch Co., Waukesha, Wis., said carrying two fixed templates which hold over 250,000 torque have number holes graduated with greater spring treadle taf 4 q ; ' aat q Hydraulic Press Developments ETALWOOD MFG. De- troit, has recently redesigned along modern lines line stroke, high-speed hydraulic presses for assembly work for broaching. The unit clean cut appearance and completely self-contained, with the pressure cylinder below the table. Motor pump and oil tank are attached the rear the base plate and counterbalance the weight the main parts the press. using two- colum