The Iron Age 1942-07-09: Vol 150 Iss 2

in Surprise attacks the Commandos spread destruction among the enemy. When men are lost these daring raids, others equal valor take their laces and keep Commando forces intact. Whiting Victory Cranes, too, that construction may changed without affecting efficiency. America’s leading crane manufac- every essential advantage Whiting con turers strain the task supplying struction has been fully retained equipment for handling the huge volume there are “frills” materials used war production, the can cooperate specifying Whiting cooperation crane buyers becomes Victory Crane when you order. more and more urgent. You will receive the same smooth Whiting has designed the Victory Crane formance and dependable low-cost oper help speed production. carefully ation which Whiting has guaranteed for engineered its required over fifty years—PLUS delivery the earliest possible moment. Whiting Cor poration, 15601 Lathrop Ave., Harvey, = = JULY 1942 VOL. 150, NO. VAN DEVENTER and Editor BAUR Vice-President and General Manager ° ° ° Managing Editor, LIPPERT News Markets Editor, ROWAN Associate Editors JAMES Art Editor, WINTERS Editorial Assistants BENEDETTO Resident District Editors Washington Pittsburgh DONALD BROWNE W.A. PHAIR Woshington Chicago Cleveland Detroit CHARLES POST San Francisco Editorial Correspondents Buffalo Cincinnati FRAZAR RAYMOND KAY Boston Los Angeles HUGH SHARP JOHN McCUNE Milwaukee Birmingham SANDERSON Toronto, Ontario BACON Seattle ROY EDMONDS St. Louis ° ° DIX, Manager Reader Service ° ° ° Advertising Staff Herman, Chilton Bldg., Philadelphia Hottenstein, 1012 Otis Bldg., Chicago Raymond Kay, 2420 Cheremoya Ave., Los Angeles, Cal. Leonard, East 42nd New York Peirce Lewis, 7310 Woodward Ave., Detroit Ober, 100 East 42nd St., New York Johnson, Market Research Hayes, Production Manager. Baur, Typography and Layout. ° Member, Audit Bureau Circulation Member, Associated Business Papers Indexed the Industrial Arts Index. lished every Thursday. Subscription Price North America, South America and Possessions, $8; Foreign, $15 year. Single copy, cents. ° ° ° Owned and Published CHILTON COMPANY (Incorporated) Executive Editorial and Offices Advertising Offices Chestnut and 5éth Sts. 100 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 VAN DEVENTER, Vice-President BAUR, Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, Secretary JULIAN CHASE, THOMAS KANE, HARRY DUFFY CHARLES HEALE This Week Editorial Technical Articles Precision Castings Buick Makes Pratt Whitney Engines Contour Sawing Naval Gun Mounts Turning Out 37-Mm. Shells Automatics Douglas Designed Aircraft Riveters From Linoleum Aircraft Stampings A.S.T.M. New Equipment: Small Tools ond Features Assembly Line Washington West Fatigue Cracks Dear Editor News and Markets This Industrial Week Personals and 127 Machine Tool Activity 130 Non-Ferrous Metals 131 Scrap 132 Iron and Steel Scrap Prices 134 Comparison Prices 135 Finished Steel Prices 136 Warehouse Prices 138 Index Advertisers 199 Copyright, 1942, by Chilton Company (Inc.) but YOU nteed ting Cor | for from burned warped resistance welds rid a ak currents resulting from random (nonsynchronous) switching short-time resist- ance welds can cause 50% variation equally timed welds. This unpredictable heat may thus produce either burned weld, good weld, cold weld for the identical timing setting. Westinghouse Synchronous Timers eliminate these varying and unpredictable power surges. Weld current synchronized—always starts and stops the correct point the wave! Thus every weld duplicate the last one because the wave form the same. rejects pitted electrodes due overheating. Just steady succession uniformly strong welds, neat appearance, and with excellent metallurgical characteristics. Westinghouse Synchronous Timers are available for either spot seam welding, and the latest model combination for spot, seam, pulsation welding, fully electronic. Ask your Westinghouse representative give you the latest information Westinghouse Elec- tronic Control for resistance weld- ing. write Westinghouse Electric Manufacturing Company, East Pittsburgh, Pa., Dept. 7-N. and Maintenan ce. Elec. estin house ing Wer has finishing. Special n- RESISTANCE WELDING CONTROL 36—THE IRON AGE, July 1942 rd YNCHRONOUS Weld Production with tinghouse Timers i thin pieces and critical metals. ing, discoloration and similar faults JULY 1942 ° ESTABLISHED 1855 Are Converted ... you necessitates having gone through the process conversion. Conversion, the sense which applies our war effort, means fundamental changeover. changeover not merely the physical make-up plants and products, but also the thinking that have been accustomed apply most our usual ways doing business. Perhaps the best phrase expressing this the one dic- tionary, which defines conversion diversion purpose from prior new one.” The purpose must formed before the performance begins. And since purpose matter mind and not machinery materials, the primary task converting our industries war from peace has had the tremendous one changing the thinking many thousands business and industrial executives, whose thinking determines the pur- poses which their enterprises are put. change such thinking from peace war purposes tremen- dous job, especially nation that has given littie thought war before being projected into it. manufacturing, meant that execu- tives who had been taught avoid overexpansion they would smallpox should determine multiply capacity geometrical pro- gression. meant that men who had always made the objective cost economy their keynote should lay that aside for the objective volume. With sales executives, meant the unheard and unhappy necessity saying beseeching customers who wanted buy. With advertising executives, meant writing copy that would sell in- tangibles instead tangibles. Industrial publications, such THE IRON AGE, have undergone conversion keeping with their industries. Today, you compare their editorial and advertising pages with those two more years ago, you will find the predominant purpose both help their readers help win the war. help them spreading inspiration and information. “Something give, but nothing That the purpose advertising today. well exemplified the inspirational “editorial” the Link-Belt Co. page this issue and the informative the Warner Swasey Co. page From cover cover, our editors and advertisers are united ihe purpose helping you help win the war. And that why say: “We are | | | H More Plants Help You Speed War Production Men and Machines Available Immediately for Contracts Sub-Contracts More Middle Western and Eastern companies are continuing list their available war production plant facilities with Inland Steel Co. Some these facilities are summarized below help bring the manufacturers contact with “prime” contractors Government agencies, and thus speed all-out war production. Write wire Inland for the names and addresses any the plants listed. suggest that you get touch with us, even the plants and manufacturing equipment you require are not listed this page, will gladly forward you our entire list you are interested. Wis. farm mach. mfr. has over 64,000 sq. ft. mfg. includ- ing gray iron fdry. with moulders. Excellent shipping facilities. Emp. men— could operate two shifts. War work desired machining and assem- bling. 15,000 sq. ft. warehouse fl. sp. Equipment includes: turret lathes, engine lathes, 48” boring mill, 24” planer, milling machine, shaper, drill presses, arc and spot welders, complete metal working shop and punch presses. Neb. sheet metal products job- ber and agricultural equip. mfr. desires war work. Nearly 18,000 sq. ft. fl. sp. with emp. General sheet metal shop includes all types welding equip. working ga. also other small fabrication. Equip. includes bend- ing brakes, sq. and cir. shears, punch presses, beaders, rollers, bar folders, seamers, grinders, drill presses, air pressors, Wis. sheet metal automotive stamping and specialties mfr., has over 14,000 sq. ft. fl. sp. and emp. men per shift. Equip. includes Rockford straight side and open face presses—70 ton cap. stroke, 2-30 ton cap. stroke, 2-15 ton cap. stroke; flywheel presses, 1-12 ton stroke and ton stroke, 1-15 ton stroke; electric seam and spot welders, engine and bench lathes 16” and swing, step-toe shaper 12” stroke, slitter milling mach., drill presses, grinders, air comp., shears, metal forming rolls, brakes and cir. saws. Com- plete tool room for making own tools and dies. Ohio mfr., two factory build- ings over 60,000 sq. ft.; 250 emp. Has complete facilities for war con- tract work. 2—No. punch presses stroke; 1—No. punch press stroke; Bliss Consolidated stroke; Sheri- dan embossing presses; Bliss punch press stroke; other equipment in- cludes 1—6’ hand metal brake; Ros- back hole punch press 27”, Niagara power shear, Singer sewing machines power driven; Union special power driven sewing machine, Bliss metal slitter; 1—12” power driven cut-off saw, 1—10” power driven rip saw; color work equipment; spray guns and silkscreen Ohio mfr. equip. for making light and medium weight gray iron and semi-steel castings 200 each. Plant covers over two acres, active over yrs. Has capable staff, desires war work subcontracts. Ind. struct. steel shop and gray iron fdry., 60,000 sq. 140 men, 18—3 ton elec. hoists, Ryerson friction saw cuts 24” beams, flame cut- ting equip., 2—angle shears cap. angles, 2—wide flange beam punches, 4—punches for angles and flats, 1—sheet shear cap. 10’, plate shears 48x 2—electric rivet heaters, 2—Hanna riveters, rivet hammers, drill presses, reamers, Rand air comp., 1—Cincinnati press brake cap. 12’, misc. equip. incl. pipe cutting and thread machine, metal bandsaw, bar shear, ete. Foundry making gray iron castings 1000 714 tons per day. Mich. machy. and fdry. plant has available approx. 400 man hours per month for broaching medium and heavy broach jobs. Machine has ton cap. 12” wide, 60” long—latest hyd. type capable producing most ac- curate kind surface broaching pos- sible. Wis. refrigerator mfr. needs war work subcontracts. Over 158,000 sq. ft. fl. sp., incl. warehouse; employing 350. Sheet metal shop han- dling anything ga., good shear and folding equip. including all kinds welding units, conveyorized high-bake ovens, and complete wood working dept. Facilities include punch drill presses; squaring and cir. shears; press, bending and box brakes; wood planers; cut-off, band rip and variety saws; moulders; boring mach.; shapers; jointers; riveters; arc, gun and spot welders; milling mach.; surface grind- ers; lathes and hack saws. Nationally known (Ill. and metal sheets and coils. Complete facil- ities for plating and polishing, with over 89,000 sq. ft. fl. sp. and nearly 300 emp. Handling steel, brass, tin plate, aluminum—sheets, coils, strip, flat wire all sizes, gages and tempers. Equip. includes electro-plating generators, sheet buffing machines, coil buffing machines, ga. sq. shears, ga. sq. shear, No. Waterbury Farrell rotary shear, ga. 24” rotary shears, Hallden 26” leveler and auto. shear, grinders for en- gravers plates, combination sheet and coil lacquering unit, crimp 50” crimping mach., crimp 38” crimping mach., scoring mach., nickel solutions, copper, chromium and brass solutions. Wis. structural steel plate and ornamental fabricator, em- ploying 150. Has 37,000 sq. ft. fl. sp. for war work subcontracts. Structural shop equip. incl. 15” and 40” cap. punches, 12’ bending rolls, sq. shear cap., brake No. cap., high speed shear No. 20” and 36” plain drill presses, No. and No. Spindle Barr drill presses, welders, hack saw, angle roll, grinders and misc. hand tools. Mach. shop has: No. spindle drill press, Flather shaper 12”, and radial drill presses, No. and No. universal mills, 20” single spindle drill press, Monarch lathes, 26” planer, cap. pipe machine, Millholland turret lathe, New Haven lathe bed, Davis Key seater, and Racine power hack saw. Nationally known Mo. stove mfr. desiring direct sub- contract war work, with complete equip. for metal forming incl. punch presses, brakes, and shears, also prepared heat treating. Large cap. for gray iron work 500 per unit. Approx. 300,000 sq. ft. sp. siding. Ind. structural steel fabricat- ing plant desires war con- tracts sub-contracts. Able begin work once. Complete fabricating shop, blacksmith shop, templet shop and two warehouses. Thirty-eight years’ ex- perience light, heavy riveted and welded structures. Facilities for punch- ing, shearing, forming, bending, riveting and welding. Small mach. shop equip. Ample room for receiving and shipping outside fabrication and assembly. Southern Mich. agricultural hdwe. spec. mfr. with 30,000 sq. ft. fl. sp., wants sheet metal assem- bly punch presses, and power ga. cap. all widths; high speed spot welders. Sheet metal shop incl. rollers, brakes, folders; tin shop; soldering fres.; modern paint lac- quer spray booths. Ample storage, own siding. Capable staff and ample labor. 38—THE IRON AGE, July 1942 c PHAIR Western Editor, THe AGE ° ° ° and ferrous castings, including stainless and other alloys, unusually close tolerances being accomplished currently method combining the so-called lost wax process, new type highly re- fractory investment place sand, and centrifugal casting. This process, developed the New Method Casting Co. New York, has aroused the interest many design engineers plants produc- ing war equipment. Castings are being produced this company aluminum, bronze, beryllium copper, cast iron, carbon steel, stainless steels other alloy analyses tolerances 0.001 in. all surfaces. few small pieces are being produced which are being held tolerances 0.0005 in. all directions. Among the steels being cast are the stainless groups, 18-8, 302, 304, 303, 308, well SAE 1020, 1035, 2315, 2320, 2515, 3120, 3312, 3415, 4150 and 4620. Aside from the higher degree dimensional accuracy possible with this new process, complex sections and surface designs are being re- produced with excellent accuracy. See Fig. and Behind the never ending search foundrymen for greater dimen- sional accuracy, search particu- larly fruitful during the past two years, has always been the desire reduce, not completely elim- inate, machining operations. This factor has been the motivating force the adoption this new method various war industries. non-ferrous Precision Castings modern modification the lost-wax process de- scribed herein. This method utilizes refractory invest- ment which makes possible the casting stainless and other alloy steels, non-ferrous materials. this process, the master pattern usually developed directly from stock sample the part, whenever possible, save pattern costs. This sample reproduced bismuth alloy master pattern (Fig. rubber plastic mold, depend- ing upon the design and number pieces made. will noted that the master pattern combines both the pattern and the mold. two parts permit removal the sample. Where castings carry undercuts have cored sec- tions, the pattern made with re- movable sections. sam- ple brass castings illustrate the sharp threads which can cast the process described this ar- ticle. The pieces are shown the as-cast condition. Note the coring the valve bodies the right. When the master mold com- pleted, used form the wax core pattern. Usual foundry terminology somewhat confusing describing this process mold has its own pattern—a wax pattern which destroyed the process making the casting. effect, this pattern might con- sidered the same light hard sand core, differing only that produces the entire cavity. The master pattern shown Fig. the simplest form pat- tern used with this process. THE IRON AGE, July 1942—39 ° ° ° j . n t- n X- ° ° ° 7 production runs, the pattern will carry several castings, the exact number depending upon the size the piece. the average produc- tion casting, such those shown Fig. and there would also removable sections representing the cored areas. Fig. ring cast one piece experimen- tal basis during study the pos- sibilities this casting process. After the wax has been poured into the master pattern, per- mitted solidify and then re- moved. This wax form placed flat metal base. indrical flask placed over this 2—Typical stainless steel cast- ings produced experimentally this new method. All pieces are the as-cast condition, except hydraulic cleaning treatment. ° ° form and the liquid investment poured into the flask. The flask vibrated electrically remove the air. some cast- ings vacuum employed assure thorough removal the air. This treatment followed cold set- ting period about min., during which time the investment becomes quite hard. The mold then placed oven for about hr., and under- goes slow baking constantly 3—One pattern was used produce these castings three metals, stainless, brass and aluminum (from left The composition the investment was altered each case suit the characteristics the metal being cast. 40—THE IRON AGE, July 1942 rising temperatures. reached, the wax becomes liquid and removed turning the mold upside down and letting the wax run out. The flask this point ready for pouring. This done cen- trifugal casting machine while the flask still extremely hot. After the casting temperature has dropped past the critical zone, the flask removed and the mold material knocked off the casting. This cooling requires min. Some castings are quenched and some tempered, necessary. Sand- blasting employed for final re- moval any material which may remain corners cored sections. obvious that the two key points the process are the wax and the refractory. And always been the case where the lost-wax process involved, there considerable reticence divulg- ing the composition the wax and the investment. The base ma- terial used for the wax form is, however, comparatively plentiful domestic grade, treated elim- inate residue and hold shrinkage minimum. For much closer dimensions, experimental work being done replace wax with low melting point metals. The refractory material very fine (it will pass through 340 % q 4—Sample master bismuth alloy (left) and rubber. These molds are used produce the wax form. Production molds would carry number impressions. mesh when dry). The composition this investment adjustable suit the type metal being poured and quite capable withstand- ing the high temperatures involved pouring stainless steel castings. Despite its density, the investment self venting that its structure sufficiently porous permit gas escape through the investment. While there are refractory mix- tures available which will stand 4100 deg. F., the bulk the work being done the range 2800 3200 deg. The flask ma- terial does not create gas when re- ceiving the molten metal. Gating these castings ex- tremely simple and established the master mold. The diameter the gates averages about one- twelfth the greatest thickness Air Hammer ESPITE the widespread use air hammers, particularly the aircraft industry, means have heretofore been available for quickly checking their performance against predetermined standards learn their operating efficiency. new test stand developed the Burklyn Corp., Los Angeles, gives this data indicating the three basic factors affecting air hammer performance. Operated from shop air line, the test stand uses pressure reg- ulator for uniformity and flow meter .to indicate air the casting. button used serve reservoir. Molding standardized 3x3- in. flask, the number castings flask being determined the size the casting. The daily out- put from mold ranges from 200 300 pieces, depending upon size. The chief limitation the process the size, with the capacity the present being limited mum size in. Experi- mental work under way covering the casting larger pieces. The production line arranged that one group workers pro- duces the wax impression, while another pours the flask material. The economics this process are somewhat complicated the. size limitations present, but, within its workable range, finding use Test Stand consumption. Two other gages in- dicate force exerted the hammer and blows per min. The force gage calibrated 200 and the blows per min. indicator reads 5000. The stand designed primarily for aircraft type rivet hammers capable driving aluminum rivets 7/16 in. diameter and soft iron dual rivets in. diameter, requiring max- imum cu. ft. air per min. Larger flow meters and gages can provided test larger ham- mers. 5—This ring was cast experi- mentally show the possibilities the process. The entire ring made from single casting. for many small parts, many cases becoming part assembly with- out any further machining. outstanding advantage the field stainless that opens. Other precision methods casting, such plaster molds, are usually defeated the high temperatures involved stainless. However, the refractory used this new method apparently capable handling stainless satisfactorily. Four pat- ents covering the process have been applied for. THE IRON AGE, July - | | q Buick Makes the specially tooled machines installed Buick its new Aviation Engine Plant the Middle West are pictured these pages. The engine being produced now large quantities Pratt Whitney, 14-cylinder, 1200-hp. engine HIS Sommer Adams special seven-spindle machine for end milling bolt head clearances the front main crankcase. The aluminum part located from the center hole and angularly from previously reamed hole. The head then brought down, thus end milling the seven surfaces one puss. BELOW LEFT X-CELL-O two-way machine for drilling, reaming, coun- terboring and chamfering the cylinder mounting stud holes aluminum semblies. Work located the hole the rear crankcase and radially two dowel holes. The first head comes and drills holes, then the fixture indexes automatically and another series holes drilled. The sec- ond head reams, coun- terbores and chamfers with combination tools. This cycle re- peated until all seven series stud holes are takes drill and ream deck series holes. multiple-spindle, six-sta- tion indexing machine for fin- ishing two spark plug holes either front rear cylinder heads. Station No. Load one either head, locating centrally flange and radially from fins. No. Drill hole. No. Core drill and rough counterbore in. diameter hole. No. Combination rough ream and finish counterbore in. diameter hole. No. Finish ream for tap and finish in. diameter hole. No. Finish tap left- hand thread. The above operations finish one hole, then the head indexed manually 180 deg. and the cycle repeated, thus completing one head. BELOW RIGHT Matic for machining the lower portion the aluminum cylinder head outside and inside. Station No. Load, using eccentric ring over fins for locating and driving from rocker box. No. Rough bore thread diameter, rough counterbore pilot, rough turn flange diameter and rough spot dome. No. Rough form dome, using generating tool, (pic- tured center). No. Rough and finish face flange, counterbore and form radius outside flange. No. Finish form dome. No. Finish ream thread diameter hold- ing +0.002 in. from radius and angle; finish pilot diameter +0.002 in.; finish turn flange di- ameter in.; finish form radius outside flange ond chamfer edge bore. YPICAL automotive set-up this Kingsbury multiple head, way type machine for drilling, spotfacing and tapping miscel- laneous holes the cylinder head. There are three different set-ups each the front and rear heads. The first machine this type drills three side holes, six rocker box cover holes, two scav- enger pipe and three miscel- laneous holes. The second ma- chine this battery spotfaces three side holes, drills four angu- lar holes, counterbores six rocker box cover holes, counterbores two scavenger holes, drills and spot- faces one tap hole. The thied ma- chine taps six rocker box cover holes, taps two scavenger pipe holes, one taper thread two top holes, three side holes and one back hole. BELOW LEFT LUMINUM sprayed the head and assemblies this automatic metallizing machine. The part loaded station No. then indexes station No. where the part rotates pre- determined speed. The matic gun travels the bar- rel angle then travels back down another angle order get between the fins. The third station sprays the cylinder head. has two automatic guns which oscil- late various angles get between the fins the head. The fourth station has two mounted for additional spraying the cylinder head, while the fifth tion has manually operated gun for touching up. The sixth station used for touching and un- loading the sion demands. RILLING, core drilling and semi-finish boring wrist pin hole aluminum alloy piston Ex-Cell-O two way, six-spindle precision boring machine. Each head carries three spindles and traversed and from the fixture hydraulically. Fixture traversed from rear front three cycles. Only one pair spindles are working time. the rear position the piston drilled 11/16 in. diameter from both sides; the intermediate position, the work core drilled in. and the front position fix- ture, the semi-boring operation performed. During the traverse the boring heads the fixture locked position. BELOW RIGHT turn face angle, back angle and front angle reduction fixed gear blank Gis- holt Simplimatic lathe. The gear forging received from the heat- treating department the stabil- ized stage and pleced three jaw chuck locating from the in- side bearing diameter. The rear tool block set the correct angle and travels to- wards the the ma- chine turns the face angle while the front slide containing two tool blocks travels toward the head- stock and back and front angles the gear, forms the radius the o.d. the gear and chamfers the front angle corner. | | | } Contour Sawing < tour sawing 8-ft. radius the two sides naval gun mounts. The work pivoted about trunnion the lower part the fixture and pulled through the saw means the handwheel shown the left. the right rear, contour machining being performed the gun cross bracket. 2—Rear view the radius control fixture shown Fig. The pivot point may clearly seen the base the tilting fixture. IRON AGE, July 1942 CHAMBERLAND MACHINE tool not neces- sarily producing its maxi- mum capacity just because being operated hr. per day. times, milling machine, lathe, planer shaper has remove much stock that feeds must sub- stantially reduced avoid tool and machine breakdowns. Conversely, feeds could doubled tripled only minimum amount stock removal was involved. course, the amount stock removed governed the tolerances that are formation the piece—be forg- ing, casting rolled plate. great concern the machine shop the most effective removal this material allowed for finish. Contour sawing, either itself conjunction with other ma- chining operations, offers means for quickly bringing work size and for removing large quantities stock without producing much the way chips. The application this method fabrication rough forgings and heavy plate work well exemplified recent installa- tions such precision bandsaw ma- chines the Naval Ordnance Contracting plant the Northern Pump Co. where the 105-mm. com- bination anti-aircraft and anti-sub- marine naval gun for merchant ships being made. this plant, batteries contour sawing ma- chines not only reduce previous minutes, but relieve many basic ma- chine tools like milling machines that they can produce their top efficiency, now that they are longer burdened with initial heavy stock removal overloads. the Northern Pump plant, two manufacturing processes are ma- jor significance the production these 105-mm. gun mounts, name- ly, welding and contour sawing. Be- ° ° ° cause most the components welded require varying amounts cutting and shaping, the contour machining procedure impor- tant ally welding prepar- ing the parts that accuracy will obtained squareness and alinement the integral unit. (See “How Avoid Poor Fit-up Are Welding,” THE IRON AGE, Nov. 1941, 55.) While numerous parts the gun mount are completely finished contour sawing, much attention also given roughing many other components requiring conventional other special forms finish machining. Many the contour sawed surfaces are finished band filing the same equip- ment. Aside from the fact that the change from sawing filing vice versa requires but few min- utes, continuous filing least three times faster than jig filing, which usually confined much smaller work. For one thing, there non-cutting return stroke in- volved and usually the continuous filers are more heavily powered. any event, there set-up time involved, and tool and power costs are among the lowest for any ma- chine tool. The accompanying photographs and job descriptions are indicative the rapid progress made the contour machining process since its introduction eight years ago. For some the most interesting con- large and heavy components, refer Fig. showing two the largest units set for band sawing opera- tions gun slides and gun cross brackets respectively. Both ma- chines have reinforced tables due the weight these parts. Special work holding fixtures have been pro- vided, but because the fast rate production keeps these machines open for considerable amount work less complicated nature, provision made readily remove reposition these fixtures. The shown being Naval Gun Mounts Some ingenious fixtures have been devised for contour machining production basis many welded assemblies and forgings the 105-mm. combination anti-aircraft and anti-submarine gun for merchant ships, now being made one the Naval Ordnance Contracting plants. result, standard machine tools, like millers, have been relieved much heavy removal work and their overall usefulness thereby work for which they are ° machined the central foreground, part the carriage for the 105-mm cannon. The barrel mounted through the large hole which can seen the end the slide, nearest the floor the posi- tion shown. There are two trunnion ° ° bearings the sides the slide. The lower one can best seen Fig. which view taken from the rear the machine. This bot- tom trunnion nests the sockets the fixture, thus permitting the entire slide pivoted from this 3—Special rolling fixture used support the gun cross bracket while being cross-cut. THE IRON AGE, July 1942—47 . > | | 4 a | | 4 4—The same fixture shown Fig. but turned right-angles for cut parallel the axis the tube. Note that fixture base divided into two plates, provided with four sets rollers each, for travel right- angles. Additional outrigger table supports have been provided this machine. 48—THE IRON AGE, July 1942 point that the saw will cut the required 8-ft. radius both sides the slide. The assembly re- versed take the cut the other side. may seen, the fixture positioned the proper angle provide 25-deg. bevel radius. This was formerly milling oper- ation and each slide tied ex- tremely expensive machine for hr. The contour machining time and the large automatic mill- ing machine returning higher dividends than ever before work for which best adapted. Incidentally, the milling machine costs about times much the contour machine, and for this par- ticular radius forming job took three times long sawing. The cut in. long one side and in. the other. The material SAE 4620 steel and the entire slide welded construction. Fig. shows close-up view production job the gun cross bracket, seen the right back- ground Fig. Fig. the work holding fixture set for the horizontal cutting position and reset for the parallel cut shown Fig. Fig. shows special rotating 5—Cir- cular fixture used facili- tate cutting off clamp- ing lugs bronze gun sight cover. the inset shown con- tour sawing the automatic valve block for control the gun ram- mer action. 4 a 3 | fixture used cutting off the lugs bronze gun sight cover for the same gun mount. These lugs are re- quired for clamping during previ- ous machining operations the piece. The base disk the fixture fastened squarely the table and the ring disk mounted ball bearings, permitting the gun sight cover revolved freely for cut- ting off successive lugs. opening provided for the saw clearance the base disk. the inset Fig. some the sawing operations are shown the automatic valve blocks for control the rammer action the gun. The rammer the assembly which loads and unloads the 105 mm. shell into the chamber. The material being contour sawed 10-in. thick SAE 1020 Ledloy (0.15 0.30 per cent lead) steel. The former mill- ing time for three cuts each valve block has been reduced from Fig. trunnion bearing race shown being shaped from 4-in. thick drop hammer forging. The entire exterior outline completed this 36-in. throat contour ma- chine, which one battery this size. big profile production was two pieces per day. Four parts per day are now being produced the new way. tion that contour sawing machine not piece equipment for every machinist toolmaker tinker with. While the operating details the machine are not exceedingly hard master, maximum precision the minimum space time can trained operator one given all opportunities master the tech- nique. Some manufacturers this equipment are very cooperative giving special training along these lines. RIGHT 7—Batteries contour sawing machines are not only saving tons material for this Naval Ordnance Contracting shop, but are also speed- ing operations. Parts are ma- chined two six times faster than previously, and equipment thereby released has increased its production tremendously. outside contour this bearing race completely shaped the contour saw from 4-in. thick drop forging. THE IRON AGE, July 1942—49 i a Subland Aole Roll support form too! Recess ° ° ° Cut-off layout for primary bar stock operations 37-mm. shell in. Acme- Gridley verted into bar ma- chine. 50—THE IRON AGE, July 1942 MIDWESTERN manufactur- has attained high produc- tion the 37-mm. shell the sole use equipment hand” set compact area occupying only about 1600 sq. ft. floor space. Because this company engaged the production number other war contracts well the manufacture im- portant farm equipment, the area devoted 37-mm. shell necessarily had compact. The fact that new machine tools chased forced the production en- gineering staff design complete tooling its own. The six steps the primary operation, shown Fig. are Acme-Gridley chucking machine which had been used for years machine wrist pins. was changed into bar stock machine fab- ricate the shell. The six operations are performed one complete cycle. shown Fig. the circular forming tool rough forms the entire piece except for center rib which purposely left un- touched. This rib comes into play the second position when acts direct roll support, providing rigid and constant setting for size control, while the oil hole drill forms more the support extremely important screw machine work this char- acter and the use the rib tribute the practicality the company’s set-up. the third position, the rib dis- appears becomes part the band seat being rough formed this step dovetail tool. But the roll has moved the right and now rides the bourrelet the support, while the drill completes its required depth. the same time, facing tool mounted the side the form tool holder finish faces the nose. the fourth step, the entire shell shaved. Roll supports are set finish dimensions, plus about 0.005 in. develop the necessary roll pressure. this position, the necking recess tool forms the recess and chamfers and sizes the urning Out 37-Mm. Shells support Semi finish form | | ° ° ° Automatics minor dimension for tapping the nose. the fifth position, knurl- ing, tapping and burnishing oper- ations are performed. Knurling handled very satisfactorily here be- cause sharp rise the cam provided for that the knurl ap- proaches the work rapidly and rides slightly past the center the and returns immediately. the knurl should drive more than two three revolutions, there would danger getting double knurl but the sharp rise avoids this pit- fall. Minor Control Tap tapping the minor dimension, Warner Swasey releasing tap holder used with The screw machine tooling illustrated this article was all designed for use with existing equipment, some which had been converted from chucking bar type. LEFT 2—Second opera- tion tool layout for 37- mm. shell New Britain- Gridley chucking machine. RIGHT 3—Ball bearing jector used Brown Sharpe automatic which band forming and stamp- ing performed. tipped circular form too/ THE IRON AGE, July q ed in- lay ar- the the and the etes ame nish are the the minor control tap. Minor diameter control most important here for the following reasons: Before tap- ping, the minor diameter held between 1.0705 1.076 in. re- lieve the tap cutting pressure the root. The tap root diameter should held 1.070 in. for the same reason. This allows cutting lubrication flow between the tap and the thread. With the minor diameter tap, the tap root only rakes off the built-up thread and thus avoids losing the minor dimension. the sixth and final position, the shell cut off and slides down leather chute ready for spot inspection and then the next ma- chining operation. For the secondary operations centering, drilling, chamfering, facing and reaming the tracer cavity, chucking machine used rather than drill press, enabling all op- Position band 0003-0005 finish size and Position and stamp erations handled one com- plete and very fast cycle (See Fig. 2). Following the simple notching and banding operations—the latter requiring plug gage check determine the bore cavity has collapsed under banding pressure, the band turning and stamping operations are performed No. Brown Sharpe automatic screw machine. Here, the shell hand-injected into ball bearing head, Fig. which timed will insert the shell into the collet when the cam moves the head forward. When the shell inserted into the collet, ro- tation started. The ball bearing head stays position, acting center support and revolving its bearings. Cam set furnish the required end pressure for rigidity. circular, carbide- tipped forming tool, mounted the front cross slide moves form within 0.003 0.005 in. size, and then backs out. this mo- ment, the stamping tool the rear slide comes stamp the serial number, then moves back, and the forming tool again comes forward finish the band and remove the rise caused the stamp. When finishing completed, the cam op- erated loading head shell removed, and new one in- serted the head for injection into the collet. Coolant Refrigerated interesting phase this op- eration the use one the company’s standard milk cooling Conomatic for (1) drilling the tracer cavity, turning band and facing base; complete drilling and stamping; and (3) forming band and chamfering. This tool layout combines the operations shown tooled Figs. and 52—THE IRON AGE, July 1942 Load and eject -—— - - - | -Stamp ° ° Carbide Form and countersink machining operations the 37-mm. shell are performed this six spindle Acme-Gridley, rebuilt into bar machine this job. Shell progressively rough formed, drilled, oand seat formed, faced, shaved, tapped, burnished and cut- off. minor control tap used the fifth position permit lubrica- tion between the tap and thread and relieve cutting pressure the tap root. the copper rotating band No. Brown Sharpe automatic ball bearing holder the turret inserts shell into the collet when the cam moves the turret forward, then acts center support during turning. Between rough and finish forming, stamping the serial num- ber performed from the rear cross slide. Although not shown the standard milk cooling chine hooked the right, keep temperature the cutting oil deg. Before the cooler was attached, operators hands were slightly from the heat gener- ated turning. the ary operations centering; drilling, chamfering, and reaming the tracer cavity and facing the end, new Bri- tain-Gridley four spindle chucking machine used the job one fast cycle. 2 ¥ 3 q | units, which are part the reg- ular line products made this plant. the start production, when the cooler was not used, the heat generated from forming the band and from spindle friction created build-up temperature. With the ordinary milk cooler hooked the coolant system, the plain light viscosity sulphur- less machine oil kept uni- form temperature deg. The operator has difficulty whatsoever handling the steel now and scrapped shells are sur- prisingly low minimum. Sulphur- ized oils cannot used because they discolor the copper-base band. Both operations now handled the chucking machine and the Brown Sharpe could performed one cycle No. Conomatic shown Fig. the first position, the tracer cavity would drilled, the band turned, and the base faced. the second po- sition, drilling would continued and the serial stamping completed. Third, circular form tool would form the band and end tool would chamfer the cav- ity. Shell leaded hand into the injector which automatically injects into the collet. The remaining operations the OPERATING SEQUENCE 37-mm. SHELL (a) Rough form shell and drill (b) Semi-finish and drill (c) Form band-seat, face end, finish drill required depth (d) Shave shell, recess, chamfer and size minor tap dimension Burnish, knurl band seat, tap minor dimension Cut off Center, drill, chamfer, ream and face tracer cavity Notch Band Turn band and stamp Wash File off burrs and sharp edges Company inspection Government inspection Degrease Paint inside diameters Paint outside diameters shell are routine. Following the band forming, the shells are washed with compound, leaving oil film prevent rust. Burrs and sharp edges are then removed formed speed lathe. The shell gripped its powder cavity. q IRON AGE, July 1942 and the shell supported inter- nally steel bars inserted the arbor. This same set-up can used for polishing off any rough- ness this stage with emery cloth. Careful Inspection Complete company inspection now takes place. home-made motor-driven thread checker checks the threaded minor diameter. Gages are set progressively. out- side dimensions are checked Sheffield electric gage. Then gov- ernment inspectors take over and following their OK, degreasing and painting takes place. gravity type ferris wheel home-made de- sign holds the shell such man- ner that internal diameters are degreased simultane- ously. hand operated fixture used paint inside the large and small cavities one cycle auto- matically. Finish outside painting done rotary disk automati- cally. handling from the first step the last, loading station provided each operation. Shells are kept trays each which holds pieces, and each loading station will accommodate about two day’s production, thus avoiding tie- ups due breakdowns. Gages set progressively for company inspection girls. the ex- treme right, home driven thread check- visible. All out- side dimensions are checked Shef- field electric gage, not shown this view. | — OMBINATION riveting machines, designed and built the premises, are be- ing used Douglas Aircraft Co. speed fabrication airframe subassemblies. The first machine this kind was built 1938 and there are now five use the Long Beach (Cal.) plant. Two the units are illustrated Fig. With this equipment, possible drill and precision countersink the hole, insert the rivet hand and set without moving the sub- assembly from its original position. Drill spindle and rivet “bucker up” are carried the end long tubular arm which can ro- tated indexed deg. bring one the other turret tools into the work position. This movement effected foot treadle the left. The riveting gun located below the table and automatically when the buck brought down into position. The entire tubular head with motor drive the rear sup- ported vertical post which can moved and down inside the main column the machine. This vertical movement governed Douglas Designed Aircraft Riveters the foot treadle the right. This arrangement leaves the operator’s hands free position the work under the drill and feed the rivets into the prepared holes. Since the work not moved, the rivet re- mains line with the gun and buck when the head indexed. The driving motor mounted Combina- tion drilling and riveting machines Douglas design. Movement the treadle the right brings the bucker into position and the pneu- gun mounted under the table. Drilling spin- dle left has been indexed deg. from its work posi- tion. BELOW 2—This group Douglas pneu- matic squeeze rivet- ers throat depth can handle wide variety sub- assembly operations. vertically the back the col- umn and drives the drill spindle single V-belt carried through the tubular arm driven pulley. can seen, these machines are constructed almost entirely welded tubing. Aside from single hole drilling, attachable fixtures have been de- signed for such specialized func- tions drilling, countersinking and riveting two three holes varying size simultaneously, the example attaching riveted wing nuts. Several special bucks have also been devised for differ- ent jobs. Douglas has also built battery pneumatic squeeze riveters its own design, Fig. There are now eight use the Long Beach plant. Each these machines 10,000 per sq. in. Throat depth in. These machines are welded plate construction com- bination with bolting. Control the pneumatic ram foot pedal and there separate pedal for retracting the lower operating arm in. for insertion channel work. The upper buck adjust- able for stock varying thickness. The machine can used with at- tachable dies for dimpling and for pierce and die operations. THE IRON AGE, July 1942—55 = 4 | From Linoleum Air outstanding example con- working peacetime concern that the Armstrong Cork Co. Lancaster, Pa. Normaily manufacturer linoleum, resilient tile, insulating fire brick, glass containers, and hundreds other products for home and industry, Armstrong to- day engaged turning out shells various calibers, aluminum air- plane parts and number other items essential the armed forces the Before the end 1942, high percentage the productive ca- pacity the company’s various fac- tories will devoted the manu- facture war materiel. this transition, factory truck drivers 56—THE IRON AGE, July 1942 yesterday are helping produce wing tips for bombers; linoleum inspectors are operating precision machines shell production line; paint mixers are turning out shot for small cannon; clerks are making bomb racks. Obviously, one the major problems facing Armstrong its conversion war production the instruction inexperienced work- BELOW ON-METAL working peacetime employ- ees the Armstrong Cork Co. have been taught run preci- sion lathes turn out shells for the war program. The men above are the nose threading operation. ers the skills required for the operation the many precision machines used the manufacture shells and other armaments. Un- usual the fact that the company indirectly began preparing for this emergency several decades ago. that time, policy training men ties was adopted. the interven- ing period, Armstrong each year has interviewed senior students many colleges schools, and has maintained ex- tensive training program for those accepted for employment. All fac- tory supervisors receive initial training course, attend monthly conferences under the direction experienced officials, and also re- turn the home office Lancaster every three for post-gradu- ate work. result, the company has con- siderable trained personnel which being used nucleus for ex- panding its war work. addi- tion, Armstrong well staffed with competent supervisors who non-metal working plant, Armstrong Cork Co., converts shells, shot, aircraft stampings, bomb racks, etc. are able teach men how op- erate centering, drilling, knurling tapping presses, and turning lathes—found shell production line—as well many other precision tools used manufacturing armaments. Engineering and technical skills ployee training the conversion non-metal working factories war production. respect, Armstrong again found that cies long standing were invalu- able connection with its change- over war work. The company for many years has maintained large engineering staff design most the special machinery and certain the tools used its fac- tories. its large and shop and toolroom, machinists and ABOVE RIGHT ERE woman operator who has been trained op- erate drill press shell produc- tion line the Arm- strong Cork Co.. RIGHT huge draulic presses have been converted the Armstrong Cork Co. stamp THE IRON AGE, July 1942—57 =i tool and die makers produced these precision built items. Consequently, skilled technicians available design and install metal working machines and tools needed produce war materiel, and where possible, convert peacetime fa- cilities war production. Starting Shell Manufacture soon Armstrong engineers had installed their first shell pro- duction line, men were called from their regular peacetime learn the various volved making shells. For the instructing other workers, are em- ployees with service records with the company excess years each. all their years with Armstrong prior its conversion war work, these veterans had been engaged solely with various cork manufacturing operations. The need for special employee training was not confined only shell manufacturing. When Arm- strong engineers succeeded con- verting huge linoleum presses stamp out aluminum plane parts, was apparent that training classes aircraft assembly would have airplane wing tips stamped out converted linoleum presses one the many domestic factories the Cork Co. most part, these workers had had previous machine tool experi- ence. Under the direction su- pervisors, they operated every ma- chine the line until they had mastered each production detail. They were then assigned spe- cific tasks for which they were best suited. And after completing their training, they were also available help instruct other employees called learn the job making shells. Thus the company