The Iron Age 1938-12-15: Vol 142 Iss 24

ALLISON Publication Office Chestnut and 56th Sts., 239 West 39th St., Philadelphia, Pa. New York, FRITZ FRANK President VAN DEVENTER Editor Managing Editor News Editor Editor Emeritus Machinery Editor Art Editor Metallurgical Editor Associate Editors JURASCHEK Consulting Editor Washington Editor Resident District Editors CAMPBELL ROBERT BINGHAM Pittsburgh 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 Newark, N. J. St. Louis TURNER, JR. Buffalo Owned and Published CHILTON COMPANY (Incorporated) Editorial and Executive Offices OFFICERS AND DIRECTORS MUSSELMAN, President FRITZ FRANK, Executive Vice-President FREDERIC C, STEVENS, Vice-President JOSEPH HILDRETH, Vice-President GEORGE H. GRIFFITHS, Vice-President EVERIT B. TERHUNE, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JOHN VAN DEVENTER, JULIAN CHASE, THOMAS KANE, CHARLES BAUR, 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, 25 cents. Cable Address, “Tronage, N. ADVERTISING STAFF Emerson Findley, 621 Union Bldg., Cleveland B. L. Herman, Chilton Blidg., Chestnut & 56th Sts., Philadelphia, Pa. H. K. Hottenstein, 802 Otis Bldg., Chicago H. E. Leonard, 239 W. 39th St., New York Peirce Lewis. 7310 Woodward Ave., Detroit C. H. Ober, 239 W. 39th St., New York W. B. Robinson, 428 Park Bidg., Pittsburgh D. C. Warren, P. 0. Box 81, Hartford, Conn. McINTOSH EDMONDS Contents DECEMBER 1938 Protect Jobs and Investments Opens Irvin Works Precision Machine Tools Built Factory Built Steel Houses Design Developments Press Brakes and Plant Expansion and Equipment Buying 104 Copyright 1938 Chilton Company (Inc.) yo 1455 : 2 7 | 5 must KNOW where you stand Just the navigator shoots the sun check his course, must the maker fine steels con- stantly check his product insure exact correspond- Western manufacturer was confronted with problem broaching square holes vises made from tough semi-steel alloy castings. The broach bar formerly used was made one solid section from oil hardening steel, and its service life was short. Our tive suggested unique type broach made from heat treated steel shaft into which toothed plates L-XX high speed steel were set. also made recommenda- tions for heat treating and air cooling avoid distortion. The new broaches ‘are giving exceptional results. ence with every specification. Allegheny Ludlum helps metal-working men find where they stand. you doubt the efficiency any operation involving fine steels—if you have any question requiring answer terms suit- ing the steel its job, may pay you consult Allegheny Ludlum. The A-L Research Department works with actual production problems, combining metallurgical experience with practical engineering knowledge. Result: peak efficiency A-L steels service; savings and profits for A-L customers. Address your inquiry Allegheny Ludlum Steel Corporation, Oliver Bldg., Pittsburgh, Pa. LUDLUN PITTSBURGH, PA. ALLEGHE STEEL CORPORATION 22—THE IRON AGE, December 1938 4 4 7 fee Ser | ... THE IRON AGE ... DECEMBER 1938 ESTABLISHED 1855 Vol. 142, No. “Bu Protect Jobs and Investments motor manufacturers did pretty good job last week before the Monopoly In- vestigating Committee. When you consider that they had explain the workings invention and the effect patents group practically none whom knew much about inventions, patents manufacturing operations from first hand experience industry, they did darn good job. chiefly thank for that. Charles Kettering General Motors affectionately known industry, highly charged from long personal experience with knowledge what invention and research accom- plish for human progress that radiates conviction. When talks these sub- jects, even group mummies would stand and cheer. The Committee, and particularly its chairman, Senator O'Mahoney, seemed espe- cially worried about the possibility some new invention coming suddenly which would throw the industry the scrap pile, close the plants, put their labor the dole and de- stroy the equity investors. Some bright inventor might wake some morning, per- haps, with idea for automobile with cellophane solar motor, plastic body and rubber transmission and bang! Away would the automobile industry, the oil indus- try and the steel industry. this connection, might have told the worried committee about Bugs kind that the committee members had never heard about. The path industry strewn with bugs might better say alive with them. They particularly infest new inventions. much that they have created thou- sands jobs for industrial bug exterminators. High paid ones, too. himself has served his time that profession. For the benefit any layman who might chance read this, will explain that are the unforeseen and unforeseeable mistakes, difficulties and setbacks which accompany all inventions and new developments from the dawn the idea its suc- cessful commercialization. The more important the invention, the longer takes get rid them. Getting the bugs out new idea any importance the mechanical field, and this includes getting the bugs out its marketing and distribution well exterminat- ing the technical ones, means lag anywhere from seven years for any inven- tions which are important enough have broad social consequences. the case the automatic cigarette machine, the lag was years from the con- struction the first machine the time that its consequences made impression employment the industry. the case the automobile, there was lag years from the invention the internal combustion engine the time when horses and bug- gies began their exit. Bugs are nature's safety devices for preventing economic dislocations through the coming important new ideas. They more thorough job than restrictive legisla- tion ever will. | 4 + Carnegie-lllinois pens New Irvin Works ITH the formal opening all departments the new Irvin Steel Corp. Dec. the presence several hundred guests, the corpor- ation’s facilities the Pittsburgh dis- trict have been substantially expanded. The completion the Irvin Works, for which ground was first broken May 22, 1937, puts the corporation position supply, this district, either hot cold rolled strip sheets tically any desired finish, well tin plate and tin mill black plate. The principal divisions the Irvin Works are in. continuous hot strip mill complete with facilities for finishing hot rolled strip and sheets, complete cold reduced strip and sheet mill with the necessary pickling, an- nealing and finishing facilities, and complete cold reducing tin plate mill. The continuous hot strip mill (basic factor the production flow the entire works) nominally rated annual capacity 600,000 gross tons. The plant site covers 653 acres and situated hillside overlooking the River, between Dravosburg and Clairton. The group buildings the plant itself has overall length 4275 ft., and over- all width 1229 ft. Included the works are river pumping station, reservoir, and water treatment and sewage disposal plants where all plant wastes which might cause stream pol- lution are treated before discharge the river. The new mill will operated throughout with the exception two boilers the powerhouse. power supply comes mission lines 66,000 volts and transformed for plant use sub- Six stand finishing train in. hot strip mill. Rated capacity, 600,000 tons annually. 24—THE IRON AGE, December 15, 1938 station adjacent the mill proper. The substation includes three 3-phase 69,000/6900 volt each having self-cooled capacity 25,000 kva. and forced-air capacity 33,333 Large a.c. motors for the mill and the Monongahela River pumping station are supplied directly from the 6600-volt motors, lighting transformers and mis- cellaneous loads, are served from 6900 /460 volt auxiliary transformers. in. five stand tandem cold reduction mill. cold reduced tin plate division the new plant was the first completed. Strip pickling, cold reduc- tion equipment, and all facilities for Delivery end, in. reversing mill. the production tin plate were ready for operation March, 1938. Pending completion the remain- der the plant, coiled strip was shipped from the company’s Donald in. hot strip mill Youngs- town. Slabs for the Irvin hot strip mill are shipped over the Union Rail- road from the Edgar Thomson Works, approximately six miles away. as- sure steady supply slabs the Irvin mill, the Edgar Thomson plant THE IRON AGE, December at on) } ABOVE Continuous electrolytic cleaning lines. LEFT Placing cover over coils preparatory an- nealing tin annealing epartment. BELOW General view tin temper mill depart- ment showing single- stand mill foreground and two tandem mills upper left. AGE, December 15, 1938 ae 7 has been expanded the installation modern 45x80 in. reversing uni- versal slab mill, capable handling ingots 45,000 and rolling slabs 8x60 in. ft. long. Be- cause furnace limitations, the max- imum length slabs furnished the Irvin plant ft. These slabs are stored the 64,000- ton slab yard the north end the Irvin Works, adjacent the 80-in. continuous hot strip mill. Slab con- ditioning beds with special facilities for removing surface imperfections vided each end the slab yard. Three continuous controlled, triple-fired slab heating furnaces are installed assure ample supply hot slabs for rolling. Both ends the furnace approach table are equipped with magazine feeders. Each furnace equipped with two motor-operated slab pushers. slab return conveyor installed the end the mill ap- proach table. The accompanying table No. lists the principal equipment installed the continuous hot strip cedure. The two coilers the hot mill line discharge short conveyors which transfer the hot coils the 1270 ft. cooling conveyor. Down tilters discharging both right and left about midway down this conveyor line deliver coils the raw coil storage rooms. third down tilter pro- vided the end the conveyor line. Two 20-ton cranes, 120 ft. span, cover the main raw coil storage building, third similar crane delivering raw coils from this storage building the pickling lines. The hot strip mill finishing ment lies between the raw coil stor- age rooms the end the 80-in. hot strip mill and the cold reducing finishing department. made for handling either strip sheet comes from the 80-in. mill. Equipment the hot strip mill finish- ing department consists flying shears, resquaring shears, temper mills, recoiling and side trimming lines, with sheet pickler and scrubbing lines. Conveyors and transferring equip- ment have been installed that the products this department can diverted the various processing units with minimum handling. Coils for pass pickling lines the raw coil pickling department. This section the plant connects the South end the raw coil storage building and extends east the cold reduction department. One pickling line designed handle Tin shear line, maximum speed line 500 f.p.m. Equipment No. Scale Breaker TABLE NO. IRVIN HOT MILL Remarks Two-high, 36x66 in., 1250 h.p. a.c. motor, 1350 Ib. water Spreading Mill Squeezer No. Universal Roughing stand Nos. and Universal Roughing stands Rotary Crop Shears (2) No. Scale Breaker Six Stand Finishing Train Rotary Flying Shear Run Out Table sprays. Four-high, turntables, in. work rolls, in. back rolls, 3500 h.p. a.c. motor. Hydraulically operated. in. work rolls, 51x76 in. back rolls, 3500 h.p. motor. in. work rolls, 53x76 in. back rolls, 3500 h.p. a.c. motor. Front and tail crops may sheared off required. Two-high, in., 500 h.p. variable speed motor. Six four-high stands, in. work rolls, 53x76 in. back rolls; numbers and stands driven 4500 h.p. motor; stands and driven 5000 h.p. motor and stand 2500 h.p. motor, all being d.c. are motors run out table. square head end strip cut sheets length. Strip leaves last finishing stand speeds ranging from 1000 2000 f.p.m. Approximately 700 ft. long. Two coilers located about 380 ft. from last finishing stand. Capacity mill—600,000 gross tons annually NOTE Slabs are furnished Irvin mill Edgar Thomson Works, located six miles away. new slabbing mill was provided for this purpose. Slabbing Mill 45x80 in., driven 5000 hp. motor. Vertical rolls, also part slabber, measure in. diameter and are driven combination beveled gear and single helical spur gears. Both rolls driven 3000 h.p. reversing motor. Will handle ingots weighing 45,000 Annual capacity over tons. THE IRON AGE, December ‘ | 3 < 3 3 : ; SES _ Drive side in. three-stand tandem cold reduction mill. TABLE NO. IRVIN COLD REDUCING TIN MILL DIVISION Equipment Remarks Tandem Cold Mill Five stand four-high, in., rated capacity 100,000 gross tons annually, 600 h.p. motor first stand, 1500 h.p. motor other four stands. Strip speeds range from 600 1565 f.p.m. Will handle stock in. wide and gages 30. Four-high, in., 3500 h.p. motor, strip speed ranging from 500 1100 f.p.m. Reversing Cold Mill Three Electrolytic Cleaning Lines Gas Fired Annealing Units bases designed handle coils per base when stacked two high. Annealed stock delivered transfer car tin temper mill department. Three Temper Pass Mills Two are four-high, two stand, in. and one four-high single stand, same size. Strip speeds range from 600 1500 f.p.m., tempering strip from gage. Four have shears reciprocating type and two have drum type shears. Products are automatically gage assorted. Strip goes from shear lines batch type white picklers and from there tin house where hot dip pots are installed. Five the tinning machines are in. and the other nine are in. units. Six Flying Shear Lines 28—THE IRON AGE, December 15, 1938 strip in. width and the other will take coils in. width. Gravity type ceive the pickled coils from the re- coilers and take them point from which tractors deliver them the cold reduction department storage required. Here the flow lines split, part the material swinging the tin mill and part the cold reducing sheet di- Table No. lists important equip- ment and remarks pertaining the cold reducing tin plate division. Returning the cold reduction de- partment, find additional equip- ment for the processing pickled coiled stock listed table No. Every care has been exercised assure maximum safety throughout the entire plant and special provision has been made for the comfort and convenience the workers. Pickling, 7 4 electrolytic cleaning, and tinning lines are covered hooded eliminate steam fumes. connection with the recently installed new blooming mill facilities the Edgar Thomson Works situated six miles north Irvin and connected the corporation owned Union Rail- road, represents major moderniza- tion move integrate completely the company’s flat rolled the Pittsburgh district and incidental- rounds out similar program started some time ago larger subsidiaries the Steel Corp. Construction Details Built-Up Impellers NTERESTING details construc tion have recently been revealed about the high speed chrome-vanadium forged steel built-up impeller wheels for Allis- Chalmers blowers. These wheels are the inclosed, shrouded type, with blades curved away from the direction rotation. The hub disk and cover disk are ma- chined from single piece forgings chrome-vanadium steel, heat treated give the maximum strength consis- tent with proper ductility. After being machined, the disks are drilled and countersunk receive the rivets. The blades are forged, heat- treated chrome-vanadium The plate cut rough size with the grain the metal across the blade. The blades are milled out the sides, leaving material from which form the rivets integral part the blade. After machining, the blades are bent shape cold, then riveted the hub and cover disks. The riveting done cold, with spe- cial hand tools which insure that the rivets cannot become misalined. TABLE NO. IRVIN COLD REDUCTION DIVISION (For Sheets and Strip) Equipment Tandem Cold Mill Remarks Three stand, in., capacity 200,000 gross tons coiled strip annually. No. and stands are driven 2500 h.p. motor and number 3500 h.p. motor. Delivery speeds range from 450 900 f.p.m. Mill will handls coils from in. width. Recoiling Line Three Flying Shear Lines Side trim strip gage lighter. For strip in. wide, gage lighter. These lines equipped with two-high roller levelers, side trimmers, and drum type flying shears. Strip cut lengths in. ft. speeds from 150 450 f.p.m. Controlled atmosphere annealing type with cases and hoods. Two these furnaces handle coils in. o.d. and widths in. Muffle Type Gas Fired Annealing Furnaces Remainder furnaces designed for sheet annealing. Three Temper Mills Four-high, in. Two these mills are ar- ranged for coils sheets and one for sheets alone. Speeds range from 150 450 f.p.m. Two-high roller levelers are tandem. Temper Mill Two-high, 32x84 in. for sheets coils with two-high roller leveler. Supplemental Equipment Additional roller levelers, stretcher leveler, squaring shears, oil flying and resquaring shear lines and combination open annealing and normalizing furnace. After riveting, the outer surfaces the disks are machined remove ex- cess rivet material that the heads are not subject erosive action. Before the Chalmers blower impellers are assembled, the blades are weighed special scale, the diameter which they will located with respect the centerline the rotor. Blades equal moments are placed opposite each other wheel. After completion, each wheel balanced both statically and dy- namically, and given overspeed test. For special applications, stainless steel can substituted for chrome- vanadium steel. Systematic Control Stockroom Transactions FAIRBANKS Printomatic weigh- use the Parker Kalon Corp., 200 Varick Street, New York, provides complete printed record each wire and steel stockroom trans- addition weight, which automatically action. recorded from the dial and tare beam, the Printomatic records the source sup- ply, size material, number pieces, date and whether the material in- coming being withdrawn from stock. set the operator the desig- This additional information nating keys, and all the data are printed roll tape. This tape used maintaining perpetual inventory and the daily record goes the purchas- ing department for auditing invoices proper Fairbanks all metal, warehouse scale with cabinet dial. This accurate, legible system minimizes errors and contributes greater efficiency. THE IRON AGE, December 15, 38 Precision Machine HIS article, continued from THE IRON AGE Dec. page 36, further illustrates the use welded steel construction, this case the building Cincinnati Hydro-Broach machines. For some machine tools cast iron the most suitable; for others particu- larly special semi-special structures, welded steel construction, whole part, most economical. be- ROACHING machines single ram, double ram, and large hori- zontal types—have set new pace for production and accurate ma- chining plain and curved external cylindrical surfaces. Although their ap- plication only its infancy, list their users reads like directory shops. Parts ranging from auto door safety catches broached 1200 hour, eight-cylinder motor blocks hour are being broach- today with machines having capac- ities 150 hp., respectively. How far welding enters into broach- ing machine construction worth in- vestigating. From beginning end the construction these marvels modern machinery require welding. Fig. shows what probably one the most nearly ideal welded ma- chine tool beds possible build from cost point view. consists two standard angles and stand- ard I-beam. few ribs %-in. plate are welded into the bottom and supporting feet are welded on. The amount labor per pound material abnormally low, yet the rigidity everywhere needed and the correct plane. The advantages such design are numerous. Stock material used and the cutting waste very small. The component parts fit together with- out effort. casting replace this welded structure and the same job would difficult cast and would doubtful stability over such 30—THE IRON AGE, December 15, 1938 tween there important group made machines formerly built cast iron but subject change- over welded steel knowledge weld fabrication increases and ade- quate weld shop equipment becomes available. Weld-fabrication ma- chines this group depends first its suitability, and then its ability equal get below the cost cast iron designs. length, unless the depth section increased considerably. Cylinder-Block Broaching Machines Let consider the giant cylinder block broach. pointed out earlier, rigidity vital, yet these machines are ft., in. long. Figs. 13-19 show this machine various stages construction. The rough bed after welding weighs 26,000 worth mentioning that cleaned 3/32 in. over the entire flat surfaces. cast-iron bed for this machine satisfactory rigid- would weigh 39,900 45,000 Ib. These welded machines contain cast iron, sheet steel, steel plate, steel cast- ings, forgings and heat-treated alloy parts; each form metal applied where best suited the work required it. The material chosen dictated its mechanical properties and the relative merits each for the work and service that called upon perform. other words, our en- gineers are able select the best mate- rial for each application. Then there the broach work fix- ture for handling and holding the block. Strength well vital here, yet must have some pretty big openings, embarrassing places, for the cylinder blocks, piping, dust removal and operating details. \ ° ° addition, the casting the fixture would complicated the fact that each machine this type usually special. working out the operations, minor changes rearrangements may necessary. With steel, the most carefully controlled procedure, may make enlarge openings can close holes move lugs and bosses. other words, with welded steel fabrication have freedom design and manufacture that the engineer limited cast iron can only dream and hope for. Then there the hydraulic oil pip- ing. make screwed fittings for LEFT main structure single ram Hydro- Broach front the machine used form it. RIGHT IG. 12—Completed single Broach the main mem- ber which pictured Fig. work this nature would not only quite expensive, but difficult me- chanically, not impossible. This piping gas welded and the quality such joints well known. The chip troughs, oil catchers and numer- ous other accessories necessary machine tools are bent and welded. There much question but that welded steel plays really vital and necessary part the construction machine tools. What Determines Use Cast Steel There are many reasons why should use welding machine tools, ° ° MADDOX Chief Engineer and Supervisor Weld- ing, respectively, The Cincinnati Milling Machine Co. and Cincinnati Grinders, Incorporated but they all boil down just one; namely, that good, very good economics weld certain types and classes machine tools and details. There are machines whose inherent design features are such that cast iron the proper material for their con- struction. This group includes ma- chines built large quantities and in- tricate nature. Here cast iron completely suitable that other mate- rials are not competitive present state development. the other extreme are special semi-special structures which can- not afford cast for any the numerous reasons stated this paper. the most important group all, consists the border line cases which were cast iron and which have been changing over steel our knowledge and equipment expands. Strange say, this last group far more important the welding shop than those machines that are definitely steel structures. The reason for this apparent abnormality that without obtaining much the load for the weld shop that this competitive group carries, the weld shop and its person- nel seriously handicapped two conditions. First and most vital the lack equipment. With minimum equipment fabricating shop can build machine tool base, column rail for 14c. the other hand, similar design, but one quite differently detailed and built using reasonable amount standard ma- chinery such plate shears, press brakes, punch presses, hydraulic presses, nibblers, circle shears, power cold saws and other machinery this type, will built for much less. foundry casting costs have gone recent years from 5c. per structure has become more and more competitive. While some factors have tended increase welding costs, the actual finished cost welded struc- tures has been definitely the down grade. This has been brought about design trends and increased knowl- THE IRON AGE, December 15, edge the part the engineer and the shop. The use has been very definite factor not only reducing our costs but im- proving the appearance our ma- chines. Considering the fact that structure properly designed and work- out the shop will 20-40 per cent lighter weight than casting for the same purpose, the spread cost that has existed between certain types castings and the welded struc- ture has decreased and some cases passed the equal point. There are many different problems confronting the iron foundry today. For example, steadily rising costs due many factors such dust control, smoke prevention, labor problems and over-all costs. According the May, 1938, issue Factory Management labor cost runs from per cent the total cost fabricating shops while the foundry runs from per cent the total costs. With the present labor trends, this becomes really important factor. True, the modern mechanized foundry every effort being made reduce these costs and above-mentioned troubles. However, almost all efforts along this line increase the overhead seriously. Thus, have the situation wherein modern trends are working together 32—THE IRON AGE, December 1938 stalled large large cylinder-block broaching machine. IG. Making the last bend the main plate for large horizontal broaching machine. the main plates the large horizontal Hydro-Broach. IG. Upper set ribs in- broach. 16—Machin- ing the bed make steel structures more and more competitive with cast iron. The Problem Special Structures all kinds machinery construc- tion, there always exists the problem special structures. The cost making patterns for many large special structures, where only one two will required, prohibitive. The delivery steel bed machine will two four weeks better than the cast-iron machine. The pattern alone will take long long- build than the welded steel struc- ture and cost much more. The cooling the pit adds about another week the time required. put another way, have found that the large welded bed can completed the time the shop can build the im- portant sub-assemblies. The bed would one piece and would some per cent lighter than the equivalent casting. The casting would fit into flasks else would pit job with all the trouble that entails. When steel bed welded know going all right the first time. There will core shifts, hard spots spongy iron. With large special casting, the problems start when the pattern foreman begins ~ » re ‘ Marie ° use block broach. — THE IRON AGE, December Fic. Cincinnati horizontal Hydro-Broach broaching machine operation cylinder blocks. study the drawing. Quite bit engineering shop contact necessary even before the pattern made. The foundry superintendent and foreman have work out the risers, the gat- ing, special vents and the rigging hold the top down the pit jobs. After the pattern and cores are made, excessive amount supervision necessary order put the mold to- gether. Generally contact man from the pattern shop required help set the cores. After pouring the cast- ing, necessary wait three days week for cool before dig- ging out the pit. With the cores inside, may too heavy for the cranes lift out the pit. the casting bad, nearly two weeks lost the delivery. Naturally the percentage scrap and rejects large special castings will higher than standard ones. When the cost the scrap dis- tributed over the special castings re- quired, the advantage welding such structures becomes more apparent. other words, given the proper machinery and tools which are recog- nized the correct equipment for processing the steel, the welding shop will produce machine ‘tool structures which will competitive with cast iron. Then, with the cost line that the economics the weld shop justifies larger percentage the borderline load, large enough organ- ization will established that when special machines that must made steel come along, their construction can completed quickly for the short delivery which desirable spe- cial machinery. The cost will then little more than standard machines and well below the cost structures, built with the minimum equipment. There another aspect this prob- lem which often overlooked. With 34—THE IRON AGE, December 1938 steel structure have the flexibil- ity being able make preliminary tests and minor changes meet new unanticipated changes the part being machined for, the machine tool structure itself. Plates, braces, ribs, passages, details all kinds may added where they are needed. This flexibility, this freedom construc- tion, especially valuable jobs where there time for models extensive pattern developments. makes special machinery more eco- nomic standard equipment would do, but not wanted for any one many reasons. some special cases the problem anticipating all the conflicts and in- G.19—This weld- fabricated bed for giant cylinder block broaching ma- chine consists two standard angles and standard Simplicity and low cost are among the advantages. terferences the component parts difficult that even standard ma- chines good economics build the first few parts machines steel. After all the bugs are ironed out, first class pattern equipment can built with confidence, knowing that and there. While such condition not prevalent, does happen and this approach the problem certainly ex- pedites the getting into production with the minimum expenditure time and money. Design Advantages Knowing steel and cast iron do, knowing the advantages and limita- tions each, realizing that each must properly applied are give the customer the best possible ma- chine for his work reasonable price and the same time make profit, know that the direct result changing from cast iron proper design and construction steel re- sults either reducing weight in- creasing rigidity, whichever the de- signer chooses usually desires both. should not overlooked that with steel, the engineer does not have corner there compromise an- other location, all for casting reasons. does not have worry the whole good casting the first even the second third trial some difficult structures. knows that some structural problem does develop, the cutting torch are welding rod will solve for him. knows that the strength and ductility weld-metal today such that can depend this structure not failing the welds. course, the welding practice, the same the foundry practice, must right every sense the word. The supervision must trained, and with the proper background good me- chanical knowledge. The welder can- not just the first individual who comes looking for job. Many times even good welders checked and guided their work, keep the quality their output the best. When take the long range view the question welding applied machine tools, realize that there will opportunities build machines which will reasonable cost and the same time that will match the performance equipment built with cast iron. Therefore, the use weld- ing future constructions depends largely upon mechanical suitability the material for particular applica- tion and its ability equal get below the cost cast iron designs. BELOW EAMLESS tubs are now being made Geuder, Paeschke Frey Corp., Milwaukee, for the Speed Queen elec- tric washers made the Barlow Seelig Mfg. Co. Steel Corp. assisted the develop- ment this tub, said the first made stainless steel. | <3 at i | ‘Saal . Factory-Built Steel Houses steel houses shown herewith are the result months experimentation Peoria, which has been engaged for years the manufacture mobile earth scrapers and graders. the experimental period more than houses were designed and built suc- cessively progressively improved methods and were rented and oc- cupied employees the company whose experience living them provided useful ideas for improve- ments design and construction. Now the company satisfied that the houses built its present designs and its Production HARRY WILKIN PERRY latest methods are right for sale home buyers. They are offered three, four and five-room standard sizes plans, but the manufacturing system flexible and permits building other sizes and designs and also pri- vate garages, summer cabins, barns, tourist cabins, storehouses and the like. The three-room house ft. square. The four-room ft. in. square, and the five-room in. ft. in. the widest part. They are strong but light weight con- struction and are thoroughly insulated against heat end cold. When properly grounded earth they are effectively protected against lightning. the manufacturing process, in. 94-in. sheets 12-gage steel having tensile strength 55,000 65,000 Ib. per sq. in. are under 600 tons pressure into sunken panel design and the same operation the four edges each sheet are pressed down right angles form flanges. The sheets are then coated both sides with non-corrosion paint. pair these sheets, with the flanges to- THE IRON AGE, December ward each other, electrically welded interior steel spacers set intervals not more than ft. and pressed-steel trusses placed just inside the edges and against the flanges. The result the production standard hollow panels in. in. Half-size panels are made the same way. The panels are made three thicknesses: in. for floors; in. for walls, parti- tions and ceilings, and in. for use where plumbing and electrical connec- tions are installed. Under test, the panels support weight 100 per sq. ft. without measurable deflec- tion. These panels are then built into one-piece house structure arc-weld- ing them together the flanged edges. floor, wall, partition and ceiling sections are built they are filled with rock wool density Ib. per cu. ft. This insulates the house whole and each against heat transfer and noise and against fire, water absorption, decay and insects. The flanged joints give rigidity the floors, walls and ceilings and are water-tight. There are cracks catch and hold dirt leak air, and there can warping and shrinking wood structures. The water-tightness was well demon- strated when six-room house was floated its own bottom across the River, towed tug, from the factory one side the farm the company head the opposite side. are covered with three coats plastic material which both fire and water proof and available seven colors and shades. Walls and ceilings are sponged over corrosion paint with stipple paint, and kitchen and bathroom are given coat enamel. The walls therefore can washed without dam- age. Exterior walls are spread with standard outside paint and, while wet, are sprayed uniformly with even- textured sand, followed coat selected color. Two coats waterproofing asphalt are applied the roof. the houses includes oil gas-fired air-conditioning heat- ing and cooling unit, modern enameled- heater and 30-gal. enameled-iron bathtub and wall lava- tory with vitreous-china toilet and electric wiring with outlets all rooms for lighting and household appliances water-heater, air-conditioner, range, radio, shaver. Prices the houses, f.o.b. factory delivered and erected within miles Peoria, are $4,500 for the three-room, $4,700 for the four-room, and $5,000 for the five-room. Wire Drawing Controlled Water Cooling PRING wire with combination high tensile strength, excep- tional resistance fatigue and uniformity gage now being pro- duced new type wire drawing machine, first its kind, installed the Jones Laughlin Steel Corp. The chief innovation these machines, which are the general Connor type gineering Co., water cooling sys- tem used control the heat generated 36—THE IRON AGE, December 1938 the drawing Another me- chanical change that the take-off wire overhead rather than through the block center, making easier thread- ing and simplifying transmission. This control heat generated metal cold working becoming in- creasingly important the attainment exceptional physical properties and uniformity size wire. Since these low temperature ranges the time element more important than actual temperature, the artificial cooling the wire during working not only serves suppress the heat, but designed primarily curtail the duration the critical heat. The effectiveness this cooling feature demonstrated the fact that the finishing block, No. wire 400 ft. per min. cooled fast that more than three four Wraps the block fillet have any sens.ble EAT generated the drawing process controlled water cooling system these new Aetna-Standard ma- Jones said give su- perior spring wire. | Methods and Equipment In- dustrial Materials Handling. vibratory principle em- successfully different handling operations bulk materials: separate and clean various sizes material; 2—to feed material other equipment, and, 3—to move hot, corrosive readily clogging materials evenly and pre- determined rates flow, continuously forward. The vibrating motion may caused either mechanically, elec- trically, and the frequency and ampli- tude the vibrations may vary ac- cordance with the purpose at- tained and the physical characteristics the material handled. The feature which distinguishes vibratory equipment from other types handling apparatus the fact that there definite forward motion the equipment accompany the load. Except for roller conveyors, all other handling equipment moves with the load, and even roller conveyors there continuous forward motion the top surfaces the rollers, even though the rollers themselves remain fixed positions. vibratory equip- ment the back and forth movement rapid and such low amplitude any case that differs completely from the movement any other type Vibrating Screens and Conveyors ° ° FRANCIS JURASCHEK Consulting Editor, The Age ° handling equipment. But this particular motion which enables vibra- tory apparatus things virtually impossible for any other mechanism. sharp distinction should made between “shaking” and “vibrating,” although essentially they may re- garded alike. applied mechanical equipment, motion slow frequency and large ampli- tude; “vibration” motion high frequency and small amplitude. There little choose between shaking screen and revolving screen; both work equally well separating large sizes from small particles non- caking bulk materials fairly ponder- ° able mass and weight. Vibratory equipment, however, will anything that shaking equipment will do, and many things besides. this discus- sion only true vibrating equipment will considered. Vibration may imparted body that fixed position two means. Mechanically generally accomplished either the centrifugal effect unbalanced weight at- tached rotating shaft, or, more usually, transmitting the reciprocat- ing motion collar surrounding eccentric rapidly turning shaft. Electrically generally accomplish- attaching the shaking deck deck Robins vibrex screen, mechanically operated and adapted fine sizing and intermediate screening lighter materials. THE IRON AGE, December 1938—37 1G. 2—Four single deck Robins gyrex screens installed domestic coke plant and each receiving feed tons per hour. the armature vibrating electric motor. either case the motion im- parted constrained within close limits; the free vibrations are damped the rigidity the supports the structure, and are thus caused high frequency and low amplitude. All mechanical is, generally speaking, lower frequency than electrical vibration. Regardless the amplitude the motion given the equipment, the factor frequency that differ- entiates vibration from mere shaking. great deal less power need ex- pended light driving hammer operating very rapidly send home piling, than heavy, slow-acting hammer. quick series light taps will more thoroughly “pack” barrel flour than number slow, heavy blows. Likewise vibration will more readily separate convey fine, sticky powders than mere shaking; and with lower expenditure power. ac- 38—THE IRON AGE, December 1938 ceptance these facts has caused the rapid development within recent years many lines vibrating equipment, outgrowth former shaking equipment. Vibrating Screens Vibrating screens are used separ- ate small sizes bulk materials from large sizes, and for cleaning the mate- The screens are always set angle that unseparated material flows onto them gravity the high end, and the material which too large drop through the meshes the screen passes off the lower end continuous stream. The angle which the screen set, and the rate flow the high end, are adjusted sible accomplished the stream passes along. Too steep angle too rapid feed will result some the small sizes the material passing off the lower discharge end, in- stead dropping through the mesh the screen. The screen equipment may single, double, triple deck, according the number operations fineness the result desired; the coarser screens being above, that the final, lower operations grade the small- particles. The preparation sized bulk mate- rials daily becomes more exacting. longer can poorly sized materials find ready markets. Under the pressure more precise specifications the stand- ards sizing are becoming more strict. consequence, one screening device panacea for all screening problems. The solution any screening prob- lem must based some certain objective view, know the proper relation the physical characteristics the material the screen required, ° ° ° limitations each type equipment, approach the economic problem involved with open eyes. The five principal objectives pur- poses screening are scalping, siz- ing, by-passing, rescreening dedust- ing, and washing. Not all these operations apply every screening Scalping removes merely the large oversize particles, and does not call for close sizing. From per cent the material handled passes through the mesh the screen. usually regarded rough, prelimi- nary operation. Often can satis- factorily accomplished with stationary grizzlies, perforated chutes, revolv- ing screens. the heavy industries consists removing fines ahead primary and secondary crushing, removing waste unsuitable mate- rial. the chemical process indus- tries, normally used remove foreign improperly processed mate- rial, well oversize material ahead fine reduction and processing. Sizing produces one more prod- ucts graded classified size. this operation considered well pass about per cent the mate- rial handled through the mesh the Sizing screening the true sense the word. Screens were originally designed and developed for this duty. Generally sizing screens are applied one the following operations; the preparation grad- ing finished material, the elimina- tion oversize undersize particles from finished material, the separa- tion valuable from waste mate- rial, the sizing material for the next step processing treatment, sizing closed circuit for crush- ers, grinders ball tube mills, air- separators, classifiers. By-passing prevents further reduc- tion fine material, eliminates RIGHT 3—Two Link- Belt double deck heavy duty vibrat- ing screens screen- ing the dust and fines out small sizes bituminous coal preparation plant. BELOW vibrating screens installed the shakeout end foundry production line, for separating the sand from the castings. part the load which would other- wise the reduction equipment. usually passes average but per cent the load through the mesh the screen. For best results the screen should one that will agitate heavy burden material and cause quick release the fines through the screen openings. Rescreening dedusting removes from finished, sized product the fines THE IRON AGE, December 1938—39 | = he dust which have been produced the final processing, handling and stor- ing operations. not considered good practice combine rescreening with sizing operation, the combi- nation usually both expensive and largely impracticable. Washing final screening opera- tion, resorted when rescreening does not clean the material sufficiently. may done with either water air, and the basic purpose essentially finer rescreening, remove fines dust which adhere, spite agita- tion, the larger particles finish- product. Water sprays pressure are played the material passes over the screen, air under pressure forced down through, through the screen and the burden be- ing agitated. Physical Characteristics After the screening operation has been classified objective pur- pose, the next step analyzing the the physical characteristics the material screened the type screening equipment best qualified for the operation. There are six these characteristics which are impor- tance. Materials per cu. ft. densi- and over have fairly easy “through- Materials weighing less are normally very fine size and are affected other factors, far their ability screen easily are concerned. 40—THE IRON AGE, December 15, 1938 ~ 5—Battery tioning ing feeders putting material conveyor large cement plant. ciple the Jeffrey-Traylor feeder small, light duty feeder. ° The shape the particles vitally affects the screening problem. Round spherical shapes, such glacial sand, screens most readily. Cubical crystalline shapes such crushed ore stone, coal, salt and sugar, screen less readily. Flaky slab-sided parti- cles tend clog the openings, and usually require square opening wire cloth. materials, such wood- chips, are light density and have tendency cling together and mat, making them difficult size. Texture physical characteristic has little effect upon sizing except for sticky oily conditions. Materials having talcy sticky texture, such clay sulphur, not generally screen easily, either coating the wire cloth actually filling the mesh. Materials having oily greasy texture, such graphite, screen readily high capacity and high ef- ficiency. The temperature material near normal not important, but the material extremely hot, such roasted ore, special wire cloth re- quired. Hygroscopic materials such salt screen more readily when warm hot. The moisture content any mate- rial determining factor any screening problem. Its presence material affects texture and therefore screenability. There are three forms moisture: surface, inherent, and water crystallization. Absence moisture generally implies free screen- ing. Moist materials tend cling to- gether and therefore require more Inherent moisture only important when tions cause the material sweat and acquire surface moisture. Similarly atmospheric conditions materials having water crystalliza- tion sweat and become sticky. Size the final material character- istic considered. careful study this factor discloses the correct opening wire cloth produce the desired product, and affects capacity and efficiency. Thus may seen that the prob- Stator lem selecting screening equipment not simple, but actually varies marked degree accordance with what may desired the screening operation. Equipment double deck Robins Vibrex screen shown Fig. This mechanical- operated. drive shaft, running 1800 r.p.m., carries heavy counter- weights within the circular boxes at- tached either side the frame and held yokes suspended from either end the frame. The entire frame moves with uniform “circle-throw” motion, especially suitable for the fine sizing and intermediate screening such products carbon, cement, coal, coke, foundry sand, graphite, gypsum, lime, salt, sand and gravel small sizes, soda ash and store sand. Robins Gyrex screens employ the more usual shaft eccentric and collar impart vibratory motion the screen frame. The Gyrex screen more powerful big brother Vibrex screen, and will handle not only fine and intermediate sizing, but ° ° ° | a D q also great many coarse, heavy mate- rials not adapted the lighter equip- ment. Fig. shows four single deck Robins Gyrex screens large domestic coke plant where total such screens are installed. Each screen receives feed tons per hour. Fig. single deck Palmer-Bee vibrating screen simple construc- tion employing eccentric- collared shaft drive. This drive gives the entire screen frame vibrating motion with each revolution the shaft and keeps the material al- ways turning. Fig. two Link-Belt double deck shown action bituminous coal preparation plant, screening the dust and fines out small sizes. Fig. shows installation Link Belt vibrating screens the shakeout end foundry production line, for separating the sand from the castings. Vibrating Feeders Vibratory feeding equipment used for the purpose insuring continu- ous, even flow material pre- determined rate, sugar bleach- cement-clinker grinder. Or, coal predetermined steaming rate. When- ever, these similar operations the rate feed importance, the vibrating feeder factor. Vibrating feeders generally pulsations alternating current cause heavily wound stator become in- termittently magnetized and attract armature rigidly attached vibrat- ing bars which are part the mov- Particles are projected from the deck Jef- frey brating feeder continuous series rapid forward hops; 3,000 7,200 strokes per minute. moments when the stator not magnetized, these bar sections, rea- son their tension, cause the feeder frame move away from the stator. Thus high frequency vibration double strokes per second duced the feeder, amplitudes con- trolled the adjustable tension the vibrator bars. typical heavy vibrating feeder installation shown Fig. This battery Jeffrey propor- tioning pan feeders putting material predetermined rate flow. The oper- ating principle the Jeffrey equip- ment clearly shown the small ca