The Iron Age 1941-10-23: Vol 148 Iss 17

let will lant for ery ant Is De- ak- OCTOBER 23, 1941 TWO SECTIONS—SECTION ONE THE BEARINGS Behind the Bearings the Front Building the defense equipment are thousands Machine Tools. Both get their free-moving precision and resistance wear from New Departure Ball Bearings. CONNECTICUT | | | | { > SMITH HINE Thomaston, Conn. ENGINEER- Ltd. eland, WELLMAN WENS a EQUIPMENT for opening RODUCTION BOTTLENECKS” | 4 it Wean Tin Plate Shearin — OCTOBER 23, 1941 VOL. 148, NO. VAN DEVENTER President and Editor BAUR Vice-President and General Manager Managing Editor, LIPPERT News Markets Editor, ROWAN Machine Tool Editor, OLIVER Associate Editors LLOYD RICCIARDI Art Editor, WINTERS Editorial Assistants Washington Editors MOFFETT JAMES ELLIS Resident District Editors CAMPBELL HERMAN KLEIN Pittsburgh Chicago Cleveland Detroit CHARLES POST San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON ROY EDMONDS Toronto, Ontario St. Louis Nework, Seattle DIX, Manager Reader Service Advertising Staff Emerson Findley Robert Union Bldg., Cleveland Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Leonord, 100 East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, East 42nd New York 428 Park Bldg., Pittsburgh Don Harner, Pacific Avenue, Long Beach, Cal. Johnson, Market Research Hayes, Production Manager. Baur, Typography and Layout ° ° ° Member, Audit Bureau Circulations Member, Associated Business Papers Indexed the Industrial Arts Index. Pub- lished every Thursday. Subscription Price United States and Possessions, Mexico, Cuba, Canada, $8.50; Foreign, $12.00 year. Single copy, cents. ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Office Advertising Offices Chestnut and East 42nd St. Philadelphia, Pa. New York, U.S.A. U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President JOS. HILDRETH, Vice-President GEORGE GRIFFITHS, Vice-President EVERIT TERHUNE, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, DUFFY CHARLES HEALE Editorial The Poor Little Tiger Cat Technical Articles European Munitions Cleaning Technique Carbides—From Powder Tool Bits Gear Inspection Methods American Society Tool Engineers Meet 12,000,000 Lb. More Aluminum. Welds 5-Inch Plate New Small Tools and Gages Features Line ashington The West Coast Fatigue Cracks News and Markets This Industrial Week News Industry Government Awards Personals and Obituaries Construction Steel Machine Tool Activity Non-Ferrous Metals Scrap Markets Iron and Steel Scrap Prices Comparison Prices Finished Steel Prices Warehouse Prices Sales Possibilities Products Advertised Index Advertisers Copyright, Chilton Company 119 2) Mr. Charles Brinley, President of the Baldwin Locomotive Works speaking at ceremonies when Baldwin's first M-3 tank was turned over to the Army. Baldwin needed steel immediately for model tank constructed quickly guide future production. Speed important factor, Baldwin turned Ryer- son stocks for immediate shipment necessary steel. Ryerson alloy and carbon steels were shipped from stock the same day permitting work begin once. Through this quick cooperation help many other suppliers, Baldwin was able beat the official schedule. tration typical the service Ryerson rendering daily manufacturers working the National Defense Program. Thousands emergency calls have cut down our large stocks steel, however. are still serving thousands customers will able continue this service even restricted basis, for the duration our national emergency. Joseph Ryerson Son, Milwaukee, St. Louis, Detroit, Cleveland, Philadelphia, Jersey City. Service yerson ime Helps Baldwin Save Tank Schedule 4 \ 7 The Poor Little Tiger Cat NCE upon time there was old gentleman who was kind hearted RON AGE and who had soft spot his heart for dumb animals. Particularly appealing him were forlorn alley cats and the more bedraggled they were, the more was moved compassion towards them. When saw one would open the door, call “here kitty, kitty” and then run for the milk bottle. Now that policy and practice did him harm, made him feel good and was considerable benefit the alley cats. did get few scratches once while, but the quick application iodine the scratch seemed remedy the matter and seemed him more humane than apply his boot the offending cat, many might have done under the circumstances. time went on, this interest friendless felines became almost passion with the old gentleman and became one the milk com- best customers. could not, course, provide them with lodg- ings well meals, but that did not seem matter for all them knew with uncanny accuracy when meal time arrived and called regu- larly. true that they did not exhibit much gratitude but did not mind that, knowing them dumb animals. And, after all, none them tried take advantage him making unreasonable demands trying run his business for him. OCTOBER 23, 1941 ° ° time went on, the old eyesight began fail some- what. could not distinguish the breed cats well formerly, but anything that walked four legs, had tail and meowed still received his attention and his hospitality. ESTABLISHED 1855 One day, shortly after the circus had left town, and when the cat dinner time arrived, there was newcomer the cat procession. was indeed very pretty cat, somewhat larger than the usual run, but had four legs and tail like the rest them and meowed very appealingly. was such good-looking cat, yellow with black stripes, that the old gentleman determined adopt and bring into his home. Now this pretty little tiger cat grew and grew. And grew, its appetite increased enormously. And began ask for more and more; very politely first, but after while more menacingly. And the more that demanded, the more the old gentleman gave it; for that time its claws had grown long that even could see them. And tell you the truth, they were rather terrible. Eventually, the tiger cat’s appetite grew great that the old gentle- man could longer afford satisfy Whereupon the cat turned upon him and devoured him. The moral this story? There any, unless watch your step before you adopt tiger cat. A | | | | O | | ha | | ! ' / Inland Steel for Liberty Ships Rolls Overland the Pacific Hundreds carloads Inland Steel plates and full part shipping thousands tons for this structural shapes are rolling westward great program, vital National Defense. are working days. nights and holidays building America’s Bridge Ships. three eight-hour shifts—to supply steel not only These new cargo vessels already are sliding for the Maritime but also for the down the ways. Soon they will coming faster Army. Navy, Lend-Lease Program and than ever before our history. America’s essential industries. This Inland’s The launching the “Star Oregon” from the yards the Oregon Shipbuilding Co.—one the first Liberty Ships slide down the ways. Hundreds tons Inland steel were used its construction. Although the Pacific shipyards are more than No. Job—and there will stopping until miles from our Inland doing its job done. SHEETS STRIP TIN PLATE BARS PLATES FLOOR PLATE STRUCTURALS PILING RAILS TRACK ACCESSORIES REINFORCING BARS \ \ AY x » LEE An ‘ | MARCEL ZINTY Mechanical Engineer, Magnus Chemical Co., Garwood, European Munitions Cleaning week the author discussed the manufacturing flow various munitions and munition parts, well the cleaning equipment and technique for shell, bomb and grenade bodies. this second and final article, cleaning methods are described for shell and cartridge cases, bullet jackets, cups and anvils for primers, cases for anti-tank and land mines, fuses, detonators, and bullet cores. IFFERENT types wash- ing machines are cording the size, form and treatment Class parts: shell and cartridge cases, machine gun bullet jackets, cups and anvils, and anti-tank and land mine cases. These may classified into the fol- lowing categories for washing pur- poses: (1) shell cases mm. diameter, (2) rifle and machine gun cartrdige cases, 0.30 0.50 caliber, (3) shell cases more than mm. diameter, bullet jackets, cups, and anvils, and (5) anti-tank mine cases. There adapted each group. Three washing operations are re- quired making these shell cases mm. diameter and for rifle and machine gun cartridge cases: washing and pickling, wash- ing and degreasing, and final wash- ing and cleaning. For purposes was current practice use the same machine out all three operations. The only difference was the use suit- able materials construction for pickling operations. These units were built stainless steel alu- minum bronze, while ordinary units were cast iron steel. Fig. shows such machine for use shell case draws mm. Originally the pickling was done cold sulphuric acid solution, but war time demands speedily in- troduced the hot pickling operation. War demands also made necessary the addition drying and cool- ing phase, because neither time nor floor space was available allow for natural drying and cooling be- tween draws. addition, also was necessary, connection with shell cases all sizes (even mm.) connect the loading end the pickling machine directly the discharge end the annealing fur- nace that the cases would fall directly from the furnace into the pickling bath. With annealing tem- perature between 1022 and 1112 deg. F., the temperature the cases just before entering the pick- ling bath was about 662 deg. The temperature the pickling so- lution was always near boiling point, 212 deg. F., that the ac- tual temperature drop the work, corresponding tempering ef- fect, was about 482 deg. This step cannot applied the last draws, because, the cases are drawn thinner and thinner walls, and are soft after annealing, dent- ing and distortion will result from handling this manner. The machine shown Fig. the revolving drum type, consist- ing series drums line re- volving uniform speed. The lower part each drum im- mersed tank containing the hot solution required for that phase the operation. The drum may also rotate above draining pan in- Side drying chamber. Following generalized lay-out typical drum functions: TABLE Functions Drum No. Treatment Pickling, degreasing, washing Draining Rinsing Neutralization second rinsing Draining Drying THE IRON AGE, October 23, 5 w J } | | ° ° ° | | | Piss: ? Loading end Pickling degreasing drum Rinsing neutralizing Drying drum Unloading end Vapor exhauster Driving device Drying device IG. 4—This machine layout shows the pickling and degreasing process for shell case draws mm. diameter. All drums are perforated and equipped with inside worm and special interior raising device, al- lowing the shell cases pass uniform rate delivery from one drum the following, and from the first the last drum. Such ma- chines are operated two men, one the loading and the other the unloading end. Each drum designed according the length each operation and the amount parts has carry. speed changer makes possible increase reduce the duration the pickling degreasing opera- tion without altering the efficiency. The output standard units was between 1300 and 2000 draws per hr., with 30-min. pickling some instances. The pickling tank equipped with device for cooling heating the acid bath, whether the machine connected the annealing fur- nace not. such machines Loading end Draining drum Rinsing drum Pickling degreasing drum Rinsing neutralizing drum obvious that the parts are treated bulk and they roll and fall with inherent risks denting. This not harmful for the first four five draws, while the parts are thick and resistant, but after the last two draws the sides are too thin resist the shocks without denting, and was necessary abandon the use drum-type machine for these items. Therefore, the last two draws are treated the first type washing machine described, shown Fig. and the same manner shells. Such machines may cause the two last draws are not only require degreasing without pickling. The polishing finished shell cases hand buffing op- eration. The pickling and degreasing ma- chines for rifle and machine gun cartridge draws (0.30 0.50 eali- ber), shown Fig. the same Drying drum Unloading end Vapor exhauster Driving device Speed changer 32—THE IRON AGE, October 23, that used for washing cases mm. and for rifle and machine gun cartridge cases, illustrated Fig. except that the length and diameter the drums are suited the size smaller parts and there are dry- ing drums. The parts are self- drying the last solution kept boiling temperature. Owing the relative smallness the parts, there denting ef- fect either draw during the pickling washing process. Standard units are capable hourly output 50,000 draws any kind. The machine, shown Fig. for pickling and final washing, cleaning, and burnishing for the last draw rifle and machine gun cartridges, combination the one for pickling and degreasing, with special burnishing device line with the washing drums. particular feature this ma- chine that entirely auto- matic and continuous, including the burnishing operation. The rough cartridges are introduced the loading end and they come out the unloading end completely pick- led, degreased, washed nished. The machine operated two men, and standard units were built for hourly output 50,000 cartridges. After the final washing, the tain level means elevator and then mixed with measured quantity hard sawdust before entering the burnishing barrel. the exit the burnishing barrel, cartridges and sawdust are auto- matically separated and the saw- dust regenerated and automati- cally reincorporated with new load cartridges burnished. Large Shell Treatment Owing the dimensions case draws above mm. and espe- 5—This machine design for pickling and washing rifle and machine gun car- tridges between 0.30 and 0.50 caliber. ; the tor red ore rel, aw- ati- new hell spe- shine kling and car- 0.30 cially the anti-tank mm. and the mm. shells, the machine shown Fig. would not advisable. The pre-war practice was use the old still tank process for the pick- ling and washing these parts, but increased demands, due war needs, compelled speedy develop- ment automatic and continuous units capable large production, with minimum man power. drum |Mixer driving device D [Rinsing drum M |Cartridges separator E INeutralization drum i N |Sawdust exhauster closed baskets which the parts are loaded bulk such way that they cannot roll one another even though the baskets are con- stantly rotating. Another feature the fact that each basket contains only one kind unit. This machine well adapted mine cases since provides for complete rotation units and hence thorough contact with cleaning solutions. 6—Pickling, washing, machine layout for rifle and machine gun cartridges, between 0.30 and 0.50 caliber. Fig. The draws, they come out the annealing furnace, fall into cold water tank where they are cooled. They are then raised and taken loading table where man places them upright suit- able racks. The loaded racks are hung overhead conveyor and successively immersed the differ- ent pickling, rinsing, neutralizing tanks. The racks are then emptied the unloading end and returned. special device provides for the complete handling the racks and out each tank and for their return the loading end the machine. Standard units were de- signed for output mm. shell case draws per hr. should noted that (1) bullet jackets are fragile and precautions must therefore taken avoid denting and damage rolling each other being dropped bulk, (2) cups and anvils are very small units, and cannot mixed with other items, (3) anti-tank mine cases are rectangular boxes form other munitions items. With these facts view, clear that special type machine needed for such items. Fig. shows such machine, the major feature which the use The baskets, shown Fig. are suspended conveyor which immerses the parts automatically and continuously the different washing and rinsing solutions. The return travel the baskets ac- complished the upper part the machine drying, cooling-off section. special device makes the baskets rotate and out the washing and rinsing solutions. Standard dimensions baskets abroad were 9x9x20 in., but they ‘an made suit any conditions. One man can handle the loading and unloading about baskets parts per hr. Cleaning Class Parts has been stressed previously that fuse parts and detonators must extremely clean. Another re- quirement that the cleaning op- eration carried out such manner avoid damage the precisely machined parts the dif- ferent items which constitute fuse. Another difficulty due the fact that complete fuse composed sometimes different units made different metals and different shapes (often differ- ent plants), varying from spring hollow cap. All these items must treated apart, without any risk mixing together. Therefore, the adequate type washing machine for fuse parts was the type shown Fig. which all kinds parts may treated the same time without risk mixing together, provided each basket contains only one kind part. Some baskets are specially designed with shelves and cells hold most delicate parts such the brass threaded bodies fuses. Detonator parts are handled the same manner. for bullet cores, they are washed either machines the type shown Figs. depend- ing the material which they are made and the kind finish re- quired. After fuse parts are sepa- rately washed they are assembled make the complete fuse. The body partially tinned, after which there water test, followed final washing and drying opera- tion the machine shown Fig. Finished and assembled fuses are placed special shelves stacked fours fives, each shelf containing about 100 fuses. The piles shelves are placed jointly the conveyor combined washing and drying machine the type shown Fig. Fuses are passed successively through the following sections: degreasing; rinsing No. rinsing No. drying. Stand- ard units have hourly output 5000 fuses and are operated two men. Installation Washing Machines shell plants washing machines are installed line with the manu- facturing process after the last machining operation and before the automatic paint-spray machine, the plant delivers painted shells. large European manufac- turing plant equipped for 60,000 mm. shells per day, the final washing operation was carried THE IRON AGE, October 23, 1e 7 the ck- ur- ted Washing section Ist. Rinsing section 2nd.Rinsing section Heating coils Conveyor Drying cooling section Cooling device Vapor Conveyor device Loading-Unloading end Sprayers Baskets 34—THE IRON AGE, October 23, 1941 ABOVE 7—This machine for pickling, degreasing and washing shell cases greater than mm. diameter. LEFT 8—Fuse and detona- tor parts and bullet jack- ets are washed machine this layout. BELOW IG. 9—This machine de- sign was developed for washing and drying assem- bled fuses. Washing section Ist. Rinsing section |2nd.Rinsing pump device |Conveyor section Drying section Washing pump Ist. Rinsing pump | exhauster end |Conveyor driving dev f | five machines, the type shown Fig. arranged bat- tery special washing room. drawing plants where shell cases and cartridges are made, pick- ling and washing machines are usu- ally line with the annealing fur- naces. Fig. shows the layout the annealing, pickling, washing, and burnishing department one the most up-to-date European plants. This plant was equipped produce 200,000 rifle and ma- =) Q Elevator driving shaft Loading table Pickling tank Rotating bas Vapor exhauster Draining after pickling Rinsing tank Drying oven ets chine-gun cartridges per hr., 5,000,000 per day. fuse plants, washing machines are located general washing room where all parts are collected. loading. plants, washing ma- chines are located according re- quirements, either for fresh stored projectiles. They also have deal with used shell cases order recover them for re-load- ing. Therefore, loading plants are generally equipped with suitable Burnished cartridges finishing Cartridges burnishing Draining after rinsing Baskets rotating device Neutralization tank Draining after neutralization Drying device Unloading table Conveyor stretching device Overhead conveyor ELEVATION- VIEW ONE UNIT types washing machines case cleaning operation should necessary some stored fired items. Ed. note: will noted that the data covered this article not include any discussion the specific types cleaning materials best suited the machines and op- erations involved. has been done ad- visedly order confine the story the subject washing methods and washing ma- chines particular. complete handbook available covering the various cleaning com- pounds suitable for munitions cleaning. worthy note that most these cleaners were extensive use abroad prior 1940. They are, course, wide use today American munition cleaning operations. Revolving annealing ovens Washing pickling machines Burnishing machines Pickling machines Main vapor collector Loading case the oven Loading case hoisting device IG. the layout the annealing and washing department European plant duces 5,000,000 0.30 caliber cartridges per day. THE IRON AGE, Octboer 23, 1941—35 oven |Cooling tank F Annealed draws press = F From Powder Tool Bits ABOVE, LEFT producing cemented carbides. These new metal powder sifters are capable screening and sifting enough powder hr. produce 25,000 Carboloy standard tools. LEFT for carbide tools through the development this auto- matic tabletting press, with production capacity well the hundreds pieces per hr. Powder fed grav- ity from the hopper. LEFT hydrogen atmosphere electric furnaces Carboloy, this sintering unit can handle million grams carbide blanks for standard tools every hr., pass- ing them through the complete heat treat cycle—from presse blank hardened tip. . intense interest powder metallurgy, fabrication and working methods, story the carbide tool old story, and yet entirely new again since the in- standard tools has permitted the adoption large-scale production methods industry. The illustrations these two pages show some the highlights how one company, Carboloy Co., Inc., has adapted mass production methods powder metallurgy. trolled furnaces. This one alone can produce 2000 square tools every hr. RAZING tips shanks, once hand operation, now handled precisely con- cilitated reds LEFT sand-blasting enclosed booths finishes the tools, Steel-cut- tools are copper colored, tools for machining cast non-ferrous materials. million ressed automatic grinder especially developed speed grinding tools. Continuous operation, this grinder finishes side and top angles and clearances. will grind 1200 standard tools every hr. devices and machines re- ferred the first part the article are ‘intended pri- marily for checking individual ele- gear teeth independent other elements. Such devices are especially useful for checking orig- inal designs during various stages manufacture, when check individual tooth elements de- sired. close study the action gear teeth will reveal that there always more than one tooth af- fecting the operation mating pair gears that careful check the individual elements does not present complete picture. in- dividual tooth element check does not indicate what effect certain error one tooth will have an- other tooth. inspection all errors combination more nearly meets the demands manufactur- ing because more closely ap- proaches the actual conditions ob- tained when the gears are operation. inspection machine known the Red Liner, deriving its name from the red-line chart gear inaccura- cies which produces. Its operation based the principle that errors gears affect their center distance relation when the gears are brought into intimate contact and rotated. One gear (generally master gear known accuracy) held the driving spindle, the latter being re- tained fulcrum bracket. The fixed stud, depending upon its design. Errors the gear being tested impart movement the ful- crumed bracket. This, turn, through multiplying lever ar- rangement, operates pen which contact with constantly mov- ing paper chart. device charts all errors combination and makes permanent record. possible analyze the chart produced and determine the magnitude 38—THE IRON AGE, October 23, and location various inaccura- cies. The multiplication 200:1, that error 0.001 in. the gear represented 0.200 in. the chart. Charting Gear Tooth Inaccuracies This inspection machine positive- reproduces the inaccuracies the work, and when the gear inspected checked against mas- ter known accuracy, the result composite all the errors the inspected gear. The errors, how- ever, the accompanying charts, 12, 13, 14, and 16, show, can analyzed and their location and magnitude determined. These charts present the following errors: (1) shortened tooth resulting lack continuous action, Fig. (2) Variations tooth spacing circular pitch, Fig. (3) Variation pressure angles between two gears, Fig. 14. (4) One gear cut eccentric, Fig. 15. (5) One the gears with high fillet causing interference, Fig. 16. Red Liner checking ma- chine charts all gear errors tion and makes permanent record. functions the principle that errors gears affect their center distance rela- tion when the fixed stud, brought tact and rotated with master gear mounted spin- fulcrumed Charts Cut, Hardened, and Lapped Gears addition recording tooth errors, the Red Liner also indicates the condition the contacting tooth surfaces. Fig. shows chart gear cut gear shaper without any particular pains being taken obtain extreme accuracy. fact this would represent average gear for this particular diameter and pitch. The accumu- lative errors not exceed 0.001 in., but the tooth surfaces are not extremely smooth and there are slight errors circular pitch. This, however, would satisfactory gear could used without be- ing heat treated after cutting. While great strides made producing steels for mak- ing gears, still impossible put gear the fire and have come out the same condition which went in. Distortion, al- though some cases slight, still takes place, and shown Fig. 18, this particular gear did not im- prove any when placed the fire. Almost invariably gears swell dur- j * & ing hardening. The two points the teeth which the greatest dis- tortion takes place the fillet and the top the tooth. The fillet usually rises, and the top the tooth thickens the end, which the Red Liner indicated combined interference and pressure angle variations. Before this par- ticular gear was put the fire, the accumulative error was 0.001 in. When came out the fire, this error had grown 0.003 in., that the tooth action was not smooth when the gear was the “green” condition. lapping this gear the Fel- lows gear lapping machine, using internal-gear type lap, was possible bring the gear back practically its original condition, shown Fig. 19. Not only has the accuracy the gear been im- proved, but the tooth surfaces are considerably smoother, assuring that this lapped gear would quieter operation than both the and the hardened gears. Comparison Spur and Helical Gears Attention should drawn the fact that all the previous discus- sion has dealt principally with spur gears. Helical gears properly cut and mounted show decided im- provement tooth action over spur gears. This largely due the fact that helical gears contact progressed across the face the tooth. This condition can spur gears, which, infinites- imal thickness, would create pitch point action that would develop into helix. this helix had advance equal the cir- cular pitch the face width the gear, would have what known “continuous helical should understood, however, that far the length the ° ° DOUGLAS HAMILTON Fellows Gear Shaper Co., Springfield, Vt. the second and concluding part the article, the author illustrates how gear errors may checked combination, and analyzes the factors causing gear noise. Use helical gears solution the noise problem and calls for special checking apparatus. The importance tooth bearing emphasized. line action concerned, this the same for two spur gears the same pitch, tooth length, The essential difference that helical gear when properly de- signed and cut always contact the pitch line some one plane. The helical, warped shape helical gear tooth, introduces several problems that are not com- mon spur gear. Some these are diagrammatically presented Fig. 20. the first place, ical gear can viewed two planes—plane rotation, and nor- mal plane. the plane rotation, the tooth shape the same that whereas, the normal plane, the tooth thinner, the pressure angle less, fact all the tooth proportions the normal plane are different from what they are the plane rotation. These two planes, course, greatly increase the inspector’s problems, because addition checking the tooth elements that are common spur gears, the helix angle introduces other elements that are prime importance accurate helical gears are produced. Another point connection with helical gears not generally appre- ciated the distinction which must drawn between lead and helix angle. Lead helical gear tooth the distance that the helix travels one revolution the cylinder. The lead measured the pitch circle. the other hand, there are several helix angles, such the outside helix angle, the helix angle the pitch circle, and the angle, which the helix angle the base cylinder. therefore essential that the specific helix angle indicated. Unless other- wise specified, this considered being the pitch circle. Mating helical gears, course, have what are known right and left-hand teeth. order that proper tooth action may result, both gears must have the same twist, so-called helix angle. checking gears, however, the operation generally referred checking the lead, the amount the helix definite distance. Running Tests Desirable Many devices are employed for this purpose, some which give fairly accurate results. however, become generally appre- ciated that actual running tests two mating gears, properly handled, are much more reliable final check than any so-called lead-checking device. This par- ticularly true when gears must checked production basis. requires very short time run two gears together; takes considerably longer check the lead any the lead-check- ing devices, especially there any apparent variation the teeth around the gear. point this connection should mentioned, THE IRON AGE, October 23, 1941—39 } | | ° j ° ' oth tes ing cy. nu- not ry | | en ik- al- ig. | THE RED LINER FOR AUTOMATIC GEAR INSPECTION — THE FELLOWS GEAR SHAPER COMPANY » SPRINGFIELD, VERMONT, U.S.A. HE RED LINER For automatic Gear @ @ 12—Lack continuous action. This chart gear, the teeth which have been shortened such extent that continuous action not obtained. Action interrupted each tooth passes through mesh, causing jagged peak and then constant building action again ceases. FOR AUTOMATIC GEAR INSPECTION — JHE FELLOWS GEAR SHAPER COMPANY, SPRINGFIELD, VERMONT, USA TWE RED LINER Fom automatic GEAR IG. 13—Uneven tooth spacing, generally called errors circular pitch, produces characteristic chart. This particular gear was cut with cutter, each alternate tooth which was purposely ground off from its true spacing position. There are jagged peaks the line equal one-half the number teeth the gear. THE RED LINER FOR AUTOMATIC GEAR INSPECTION FELLOWS GEAR SHAPER COMPANY, VERMONT, THE RED LINER FOR AUTOMATIC VARIATIONS PRESSURE ANGLE 1G. 14—Variations pressure angle. This chart gear that varies pressure angle from the master against which was compared. There are jagged peaks equal the number teeth the gear. This error was purposely exaggerated. Slight errors pressure angle produce chart somewhat similar sine curve. THE RED LINER AUTOMATIC GEAR INSPECTION THE FELLOWS GEAR SHAPER RED IG. concentricity the pitch circle common error which the Red Liner clearly records. This chart gear purposely cut about 0.004 in. eccentric. causes the recorded line depart from the datum line, reaching the maximum deviation one-half way around the gear. IRON AGE, October 23, q i E RED LINER | LINER Gy THE RED LINER FOR AUTOMATIC GEAR INSPECTION Jue FELLOWS GEAR SWAPER COMPANY, SPRINGFIELD, VERMONT, 6.6. 6.6. 0 6.8.6.6. 8.0 -6.6.6. 6.6 66 62 4 6 6 @ 6 48.6 6 6 IG. There difficulty locating fillet interference causes series abrupt departures from straight line shown here. this case the cut gear was purposely made too shallow that contact took place the fillet before the profiles the teeth could come into intimate contact, causing the gears alternately come together and then spread apart with little involute action. and that that sometimes tooth apparently correct lead but running test, appears off. this gear were checked lead-checking device, and the test made approximately the pitch line, the lead might show all right. The error caused variations profile from one end the tooth the other. other words, the bearing may the bottom the tooth one end, and the top the other, giving what might called “cross bearing,” and yet the lead the pitch line would exact. Some these conditions, espe- design, are diagram- matically Fig. which shows 10-pitch pinion standard blank diameter having teeth, deg. full length, and mesh with gear teeth. Contact takes place advance the interfer- ence point the line action the left, and are for trouble. The question, therefore, quiet gear tooth action some extent tied with design because there are certain definite factors that must all cases carefully con- sidered. There are this particular case five solutions this problem: The outside diameter the 40-tooth gear can reduced the point where does not interfere with the flank the pinion tooth, retaining the same ratio and center distance. The ratio can changed use pinion having greater num- ber teeth. This will also affect the center distance. The pinion can cut oversize and the gear undersize tional amount, retaining the same ratio and center distance. The pressure angle can in- creased, retaining the same ratio and center distance. (Use smaller base circles). Finally, the pinion can en- blank suited for teeth. This will retain the same ratio, but will increase the center distance. will noted that the gear tooth “hooks” into the flank the pinion tooth for considerable dis- tance inside the point ference, and prevent proper tooth action. The position the pinion and gear teeth where interference commences cated the dotted outline. have this point dealt principally with what might becalled measurements the physical di- mensions gear teeth. This present day practice only the preliminary stage accurate gear production and might considered simply means end. Much has been learned during the past few years about gear tooth action, and more particularly, tion the tooth action quiet gear operation. There always has been, still is, considerable mystery surrounding the subject quiet gear tooth action. Those who have been engaged this work have doubt had cases where two sets gears all their physical dimensions appeared exactly alike, and yet, one pair gears operated quietly, whereas the other pair was noisy. Vibration Causes Noise approach this problem are, however, assured one basic fact—noisy gears are the re- sult vibration. some vibration the result unbal- anced forces outside the gears themselves, and the vibration transmitted the gears. other cases, the gears set vibrations due inaccuracies tooth shape and other dimensions, ing. Our so-called physical dimension inspection will inform tenths thousand inch the varia- tions tooth elements. will not, answer the question tooth bearing, its location and area. To- day gear experts are paying much more attention the tooth bear- ing than they are any other one factor. Tooth bearing, however, closely allied with several other factors, such pressure angle, tooth shape, axial alinement, etc., that order get anywhere, must necessity have control over these various factors involved. were dealing with one two plane surfaces, our problem would much simpler. Instead, are dealing with multiplicity curved surfaces, and these sur- faces are motion and are con- tacting each other generally high speed. consider gear teeth simply levers unequal length with the fulcrum point the pitch line, the number levers being equal the number teeth the gears mesh, have fairly accurate picture the prob- lem involved. generally con- ceded that the are approach should less than the are re- cession obtain the best tooth action, and what been said regarding interference, evidently necessitates that the con- tact the teeth case should THE IRON AGE, October 23, —---— — 17—Chart average gear cut gear shaper. circular pitch. The tooth surfaces are not extremely smooth and there are slight errors THE RED LINER FOR AUTOMATIC GEAR INSPECTION — ‘THE FELLOWS GEAR SHAPER COMPANY, SPRINGFIELD THE RED LINER For automatic i8—Red Line chart heat-treated gear. error had increased 0.003. Before was put the fire, the accumulative error was in.; when came out, the THE RED LINER ror automatic GEAR INSPECTION — THE FELLOWS GEAR SHAPER COMPANY, SPRINGFIELD, VERMONT 19—Chart heat-treated gear that has been brought back practically its original condition lapping with internal gear type The tooth surfaces are considerably smoother than the gear. take place outside the theoretical initial point contact. During the past five years, the automotive industry, which probably the largest producer accurate gears the country, has changed over almost entirely from the use spur gears helical gears for automobile transmission application. This change was not made because helical gears can made cheaper. was made with the object obtaining quieter ac- tion. 42—THE IRON AGE, October 23, investigate the action pair spur gears, would easy see that quietness action almost impossible obtain for the reason that just soon wear takes place, the tooth shape changes. This due the fact that the teeth wear those points where they slip upon one another, and spur gear instead wearing in, wears out shape. This not true the same extent with helical gears, especially when the latter are made that the advance the helix the face width equal slightly greater than the cir- cular pitch. With helical gears de- -signed along these lines, the gears are continuously contact along the pitch line some one plane. The result that the teeth not have opportunity wear out shape the same manner spur gears, and hence, will remain quieter much longer. Other problems the application helical gear- ing, that instead dealing with : THE RED LINER Form AUTOMATIC GEAR INSPECTION — THE FELLOWS GEAR SHAPER COMPANY, SPRINGFIELD, VERMONT, UV S.A. THE RED LINER FOR AUTOMATIC GEAR INSPECTION | ‘ 5 AFTER LAPPING plain involute surface, are dealing with combined involute and warped surface, involute have the proper bearing hel- the reason that can consider helical gear simply multiplicity lamination being set off advance the other correspond the helix helical gear. order obtain full advantage the vir- tues the helical gear, neces- sary that get tooth contact across the entire face width the gear else not obtain what helical overlap. Speeder Test The final test gears for high- speed operation known speeder test. Mating gears which are operate together are held rigid shafts, located the exact center distance which the gears will held when the assembled unit. One these shafts driven motor, some other means, which applied that vibration from the motor the drive are not transmitted the them- selves. Usually red lead placed one these gears, and the other either left plain coated with Prussian blue. They are then ro- tated together, both with and with- out braking pressure. ing one these speed tests that pair gears when running light, without load, may not have tooth bearing that extends from the base circle the tip the tooth, and yet, when brake ap- plied the driven gear, the bear- ing area spreads out, running closer the top the tooth. At- tempts have been made measure the difference the shape tooth when shows full bearing under load, and low bearing run- ning light, but far means has been determined definitely state just what this difference is. known, however, that the care- ful application light film red lead the tooth will indicate variations about in. slight change the pressure imposed spreads the bearing. Whether this due the compres- sion the material, tooth deflection, debatable question because even slight load changes the height the bearing the tooth. DEVELOPED PITCH CIRCLE DEVELOPED BASE CIRCLE DEVELOPED OUTSIDE CIRCLE OUTSIDE HELIX ANGLE ANGLE (VH) AXIS GEAR OUTSIDE HELIX BASE HELIX LEAD ANGLE(VU= LEAD HELIX ANGLE (VH GEAR TEETH NORMAL CHORDAL (NCA NORMAL SECTION TANGENTIAL BASE CIRCLE AND PARALELL GEAR AXIS LINE A-B NORMAL PLANE SECTION NORMAL PLANE ROTATION ——— ‘BASE CIRCLE (BC) CIRCULAR PITCH CIRCLE (PC) HEIGHT PLANE NORMAL CHORDAL THICKNESS (NCT) FACE (FW) CHORDAL ADDENDUM (CA) THICKNESS CHORDAL HEIGHT SECTION PLANE ROTATION PITCH PITCH LINE ELEMENT. (PLE) SECTION NORMAL PLANE FWe COTAN VH FACE WIDTH CIRCULAR PITCH GROOVE WIDTH COMNON TANGENT LINE ACTION MATCHED PINION, TEETH 20° HELIX ANGLE GROOVE DEPTH HERRINGBONE GEAR FACE co ier WIOTH GROOVE WIDTH (GW) STAGGERED HERRINGBONE GEAR 20—Because the shape the tooth the plane rotation and the normal plane different helical gear, the problem inspection more complex than for spur gears. Fig. shows sections four helical gear teeth indicating what meant various kinds tooth bearing. contended some that confining the bearing full length bearing the center the face width, and then letting taper out toward the ends the teeth, shown, so- called “hooking” avoided. Hook- ing, claimed, results noisy operation. This may so, al- though would appear that mis- alinement more responsible for hooking than the location the tooth bearing. has been demon- strated very conclusively auto- motive practice that helical gear produced that gives full tooth bearing under load the drive side and lowered tooth bear- ing the coast side the quietest possible gear. Gear men have different reasons for wanting the tooth bearing lo- drive and the coast sides the gear teeth, respectively. gen- THE IRON AGE, October 23, 1941—43 EQUIVALENT PITCH RADIUS (EPR) GEAR CONTACT \ DISTANCE ALONG FLANK PINION THAT GEAR TOOTH INTERFERES INTERFERENCE POINT \ \ \ ACTION. POINT PINION TEETH are five possible solutions correct this faulty gear design which contact takes place advance the interference point the line action. solutions are outlined the text. erally believed that the teeth pass through mesh under load, they deflect and interference takes place These between the tip the rear face the contacting tooth and the for- ward face the advancing mat- TOOTH BEARING LOWERED BEARING TAPERED BEARING CROWN BEARING 44—THE IRON AGE, October 23, IG. Various types tooth bearing helical gears. Ais full bearing extending from the base circle the top the tooth, and across the entire face width. lowered modi- fication the tip tapered bearing shown which would indicate shaft mis- alinement, variations lead, differ- ences pressure an- gles both ends crown bearing, which has recently come connection with the production cal gears. the same amount ing tooth. backlash, however, helical gears customary with spur gears, this might not happen, but improvements are made manufacturing methods, amount backlash permissible has been gradually reduced that to- day about 0.002 0.003 in. back- lash maximum for 8-pitch, full- length tooth gears. some cases the permissible backlash even less. This neces- sitates, course, gears that are accurate spacing and with minimum eccentricity the pitch circle. were possible make gears absolutely accurate far spacing and concentricity were concerned, they operated together without backlash except for the question lubrica- tion. Backlash introduced large- take care manufacturing and assembling errors. Measuring Backlash Several different methods used for checking backlash. The common method place the mating gears pins located the correct center distance measure the backlash use feeler gage inserted between the teeth. Another method place the gears pins and bring the teeth into intimate contact and then determine the difference between the standard and the measured center distance. This last check does not indicate backlash directly but can determined the following formula: are Pressure angle Difference between standard and mea- sured tance. The third method use dial indicator connection with fixture for holding the gears pins. The gears are set stand- ard center distance and two read- ings are taken—one with the teeth contact away from the indicator, and the other rotating the gear that the opposite side the are contact. This, course, measures the movement the gear and hence the backlash between the teeth. checking helical gears, the backlash measured the normal plane and not the plane ro- tation. with the to- full- sible are tha the icity rica- ring are The the the then the the then veen ured heck the nea- dis- ind- tor, rear the rse, rear the mal To- ° ° Tool Engineer Turns War Production” was the theme the semi-an- nual meeting the American So- ciety Tool Engineers held Toronto, Oct. 16-18, under the aus- pices the Toronto and Hamil- ton, Ont., chapters this fast growing society. was the first national meeting the A.S.T.E. held Canadian soil. feature the meeting was that Thurs- day and Friday dozen firms the two areas, all making war ma- terials, threw open their doors the visitors, who came from all parts the United States, from New Hampshire California. These tool engineers viewed what said the largest machine gun factory the world, saw ar- tillery shell cases drawn presses, shell fuses turned automatics, and optical goods made for range finders. They vis- ited plants making high explosive shell, airframes propellers, the Enfield rifle, anti-aircraft guns and machine tools. Everywhere the visitors went, they were impressed with the new structures filled with the best American machine tools, num- bering into the thousands. Except for the shell case plant, which was using hydraulic presses built Canada, few Canadian machine tools could seen among the vast array equipment made the and even fewer British ma- chines. The machine gun plant had close 900 milling machines, for example, practically all one Another rifle plant had about 500 millers competitive make. was obvious all that Canada has been tre- mendous market for American built machine tools the last two Tool Engineers Turn War Production years. some appeared, how- ever, that more attention might paid special tooling, especially the milling machines, which many instances were simply fitted with vise instead quick lo- cating fixture. General purpose machinery almost universally used and even special set-ups standard machines are rare present. Yet addressing the banquet Friday night, the Hon. Clarence Howe, Minister Munitions and Supply Canada, indicated that the productivity these American machine tools were far ahead the productive schedules given British manuals, which were used for original Canadian estimates. Estimated Output Doubled “After the machinery has been set up,” Mr. Howe said, “we in- variably find that the machine tool requirements are excessive and the estimate much greater than necessary. The re- sult has been that have been greatly over preliminary estimates output. some cases, after have been able double the esti- mated output given factory.” Explaining that the Canadian machine tool industry itself has been expanded about 600 per cent since the war began, Mr. Howe continued: still have machine tool shortages our factories and still have buildings ready and waiting for machine tools, but general told that deliveries (U. S.) tools Canadian plants the position your industry and its delivery program would war- rant. Your record entirely cred- Meanwhile “bits and pieces” program spreading work wher- ever machine tools could found being carried out. Machine shops the mining and newsprint industries, for example, are all do- ing war work Mr. Howe said, and continued search being made for all existing capacity. The Min- ister also said was happy re- port that any resistance from large subcontractors subletting work being broken down and the gov- ernment now receiving excellent cooperation. After reviewing the productive capacity specific Canadian Mr. Howe said that Canada now pable fully equipping division troops about five six weeks. The great bulk present production for export the theatres war. Speaking the labor supply, the Minister said that the present program only about per cent manned, but that there are still great reserves labor draw on. then told how the early part the war the government estab- lished standard wages, plus cost living bonus, and added: “In general, labor has accepted this basic policy good grace and has cooperated working out the THE IRON AGE, October 23, 1941—45 iG 3 ia } | | | | | | | j | | | i | j / | | | | Hon. Clarence Howe tions and Supply was speaker. details without loss production time. There little excuse for strike any Canadian plant under present conditions. Many our industries can boast that not one hour has been lost result strike lockout any its plants.” Mr. Howe was introduced Alex. Grey, president the Grey Forgings Stampings, Ltd., Toronto. Frank Curtis, chief engineer, Van Norman Machine Tool Co., and president the A.S.T.E., presided the banquet, which was attended 650 mem- bers and guests. Arnold Thomp- son, president, Tool Engineering Service, Toronto, was introduced general chairman the con- vention committee, well all his fellow workers the two Can- adian host chapters. Used vs. New Machines Defending the adoption used machines war time production, Arnold Thompson, speaking the first technical session, pointed out that although most manufacturers would like tool war work with new equipment (and this deemed advisable for the prime contract