The Iron Age 1944-12-14: Vol 154 Iss 24

VAN DEVENTER President and Editorial Directer BAUR Vice-President General Editorial and Advertising Offices Eost 42nd St., New York Johnson, Market Research Baur, Typography and Regional Business Managers New York Cleveland Guardian Bidg. 428 Pork Philadelphia Chilton Bidg. 1134 Otis PEIRCE LEWIS WARREN RAYMOND KAY Les Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY Executive Offices and Séth Pa., OFFICERS AND DIRECTORS MUSSELMAN, HILDRETH GEORGE TERHUNE VAN DEVENTER Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer JOHN BLAIR MOFFETT, ° ° Member, Audit Bureau every Subscription Price North America, South Amarica and $8; Foreign, $15 Single Copy, cents. Vol. 154, No. Editorial IRON AGE Face Saving Washington Technical Articles December 14, 1944 Cold Working and Forming Silicon-Manganese Spring Dynamometer Measures Friction Packings Broaching vs. Milling (Part New Design Side Blown Converter Plants Physical Properties Some Steels Carbide Featured ASME Meeting Features News Front Assembly Line Washington West Coast Personals and Obituaries Fatigue Cracks Dear This Industrial Week News Industry News and Markets Emotion Blurs Chinese Problem Iron Founders Issue Price Booklet Britain’s Reverse Lend-Lease Exceeds Billion Ohio’s Postwar Jobless Set 189,539 Tool Makers Elect Officers Surplus Act Revision Called For German Steel Plants Support Nazi War Program NAM Supports Postwar Job Program Wirebound Boxes Prevent Shipping Damage Machine Tool Market Developments Non-Ferrous Metals News and Prices Iron and Steel Scrap News and Prices Comparison Prices Week and Year Finished Iron and Steel, Steel Prices Warehouse, Semi-Finished, Tool Steel Prices Steel Pipe, Tubing, Wire Products, Prices Pig Iron and Coke Prices Stainless Steel and Prices Index Advertisers 102 116 118 120 126 130 134 140 152 162 164-165 166-167 168 169 170-171 172-173 174-175 176-177 257 ) | * 75 101 ° ° } ° ° | When cancellations are issued and cutbacks ordered will your steel inventory too high? your excess stock may prove unsuited for quick conversion other production, and decline sharply value. lowering your inventory you can help reduce the overall tonnage idle steel. Though the situation continues critical, Ryerson stocks available for prompt shipment are more than 100 per cent above 1942. This improvement Ryerson and other warehouse stocks has enabled manufacturers suggest, therefore, that you check your steel inventory, and then talk with Ryerson representative. large reserve may neces- sary. the other hand you may find your inventory can cut, and that you can protect yourself against disposal overstock sacrifice. Ryerson complete, diversified stocks include There are Ryerson plants. Facilities for cut- otherwise preparing steel areunsur- passed. promptly made cut excess reserves and maintain inventories lower working levels. CERTIFIED RYERSON STEEL JOSEPH RYERSON SON, Inc., Plants at: Chicago, Milwaukee, St. Louis, Cincinnati, Detroit, Cleveland, Buffalo, Boston, Pittsburgh, Philadelphia, Jersey City. Write for Stock List which includes complete information on: 46—THE IRON AGE, December 1944 ESTABLISHED 1855 Dec. 14, 1944 VAN DEVENTER President and Editorial BAUR and General Manage: DIX Manager, Reader Service Editorial Staff Commercial CAMPBELL Associate Editors WINTERS ALBIN JOHN ANTHONY JACK HIGHT BARMASEL Editorial Assistants SCHIEN WILLIAMS O'CONNOR MILLER News and Technical LLOYD Pittsburgh 428 Park Bidg. POST Chicago 1134 Otis MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Bidg. LLOYD Cleveland 1016 Guardian BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San 1355 Market St. Editorial Correspondents ROBERT Cincinnati DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louis JAMES DOUGLAS Seattle Face Saving Washington more reflect upon the apparent desire some our national leaders imitate the Japs adopting their practice “face saving,” the more become convinced that the “monkey men” must have something the ball. Heretofore, thought that Amer- icans were originators and the Japs were imitators; going far indeed actually reproduce blow-hole plugs the castings our machines which they copied. still believe that our American engineers and industrialists have originality thought and action maintain their leadership without copying the Japs, but evidently our War Labor Board members have not. For their award labor connection with the controversial “Little Steel Formula” perfect example face saving. More than that example chicanery the highest, perhaps should say lowest, order. Setting themselves defenders the public against the en- croaching hordes inflation, this body administrators raised one hand and said: “You shall not pass.” the other hand, pointed hole the fence and said: through that, boys, and you will find least part what you are after.” would have been far more honest and open and far more the American way putting the cards the table these men had made’ flat wage rise across the board. And that would have been much fairer the public, steel labor and those who employ that labor. would have been fairer the public, because the last analysis the public pays the bills for wage rises matter how they may disguised and regardless whether they not result increased price. Increases cost labor, being part operating cost, come out profit. And under the excess profits tax, 95c. almost every dollar steel profits now the government help finance the war. The public will have make that difference be- tween per cent the amount involved the steel cost rise and the much lower revenue received from the individual steel worker who profits it. effect, steel employers deduct 95c. from taxes, pass them steel worker, Jones, who returns 20c. Uncle Sam close the deal. Uncle Sam loses 70c. the deal but needing the money, collects from the general public. not fair steel labor since the rise discriminatory. penal- izes the older workers who because age and seniority have worked themselves into steady position the day turn and cannot, therefore, collect for either overtime night shift work. penalizes the steel employer because imposes tremendous accounting burden which will keep the presently undermanned staffs working for months come, going over shift time cards back the retroactive date determine who worked each shift, how long and how much each man has coming him. Furthermore with the over- lapping shift system vogue solve transportation difficulties, will hard determine when the day shifts end and the night shifts begin. Face saving generally expensive thing, and too bad that our War Labor Board establishing American practice. e | | | 7 | VAN CAMP 4 Better Steels are Coming— from the Tests War Hour after hour, month after month, Inland metallurgists study not only the needs for this war steel, but also the requirements victorious America— the America that will turn again peace- time developments the crafts, and the sciences—new developments that will prove again that free peoples set the pace for others follow. Coming out the tests war are finer steels—steels that will set new safety and speed transportation. will help bring the newest advancements swift communications into most homes the land. Steels that will bring new conceptions beauty, convenience, com- fort, and utility—all prices that can afforded the average American. Yes, you can look forward the day when steel from Inland, now flowing 100 per cent into war products, will help build > greater America. INLAND STEEL COMPANY Dearborn St., Chicago Illinois Sales Offices: Cincinnati Detroit Kansas City Milwaukee New York St.Louis St. Paul per per allc pote muni ago holc outs pin- mat: the app. lat tak jet - 4 gen alt \ b News FRONT 1944 Automobile manufacturers forecasting the price passenger cars estimate per cent increase over prewar prices for materials alone. Because the extras, for example, steel prices are anywhere from per cent. Another major increase costs labor which about per cent. The combination labor and material price increases, therefore, somewhere around per cent the wholesale price automobile. doubtful whether OPA will Strikes and labor shortages have been blamed for every war shortage, actual potential, over the past several years, but current lack artillery and mortar munition traceable primarily lack proper estimation future needs. Army officials are being criticized for this lack vision, but late ago most observers could not visualize such return slugging holds sway. year ago industry spokesmen were privately wondering the very large stocks shells would ever used. sight appear very inaccurate. The new bombsight actually (not just publicity outs) permits bombing from 30,000 ft. major deterrent for suc bombing that when bomb bays are opened for the the inrush frigid air cools all the various sizes control cables thereby throwing the matic pilot far off pre-set sights. conquer this the steel industry has just developed steel control cable the same coefficient expansion aluminum alloy, thereby eliminating differenti expansion and contraction between the cables and the airframe. The Hughes (originally with Kaiser) flying boat ready for trial runs. plywood job (the hull plies), has twice the wingspread Superfortress. Culver City will have dismantled for transfer The Elliott Co., Jeanette, Pa., has completed the first gas turbine marine made this country. delivers 2000 net hp. and very compact. Gas turbines which take off all power mechanically promise wide application railway and marin applications. Such motors are very similar jet motors for aircraft, although latter uses all net power jet rather than mechanically. Most aircraft the future will likely use gas turbine with part the powe taken off mechanically for propeller and the remainder the power employed jet. the Pacific Northwest, the region noted for its huge electric generators, are finding themselves rationed the amount electric current they use. There shortage power, however, but only squeeze where private power companies are reluctant purchase more from Bonneville than their power pool mitment. The Tacoma Narrows bridge, the one that blew down windstorm four years ago will rebuilt when materials and labor are available. The Pierce County (Tacoma) Toll Bridge Authority recovered $4,000,000 from insurance and salvaged $250,000 has $3,200,000 remaining assets including anchorages, approaches and other The loss the time its failure was estimated $6,500,000. the 2430 terminations valued $2,763,000,000 process with the Navy some 274 contractors whose terminations involved $2,333,000,000 had filed Claims. Largest cuts the Navy program have come the destroyer escort program although terminations submarines, torpedoes and mm. guns and ammunitions have been substantial. The only programs the Navy which are lagging are rockets and mm. ammunition. China's wide-eyed friends who are beating the drum for huge industrialization program immediately following the war are losing sight the complicated problems involved such plan. Not only the complicated political situation deterrent its tion, but the Japanese conquest some China's most productive regions, the transportation and skilled labor combine force conclusion that the job partially industrializing China one far beyond the comprehension most Western people. The new bombsight used Superfortresses makes the Norden 4 a 4 4 J 4 J experience Lock Washer Co. with silicon- for spring washers for industrial and railway use goes back the year 1931, which time the writer was still con- nected with eastern steel company. The material produced the steel company for lock washers was hot- rolled shapes, roughly equivalent size in. in. rounds. Depend- ing chemical analysis, size, finish- ing temperature and cooling rate, the as-rolled hardness was found vary between 265 and 305 Brinell. Knowing that the process manufacture the steel had undergo rather severe cold working such coiling around arbor, severing (shearing), and some cases even forming, was only natural as- sume for both supplier and consumer that this hardness was too high. The first and most logical step, therefore, was try anneal the steel. From previous experience with different grades spring for the same application, annealed struc- tures showing but small percentages Cold Working and Forming SARTORIUS Metallurgist and Engineer Test, National Lock Washer Co., Newark, lamellar pearlite were not even The aim the steel com- pany was obtain maximum soft- ness together with completely spheroidal structure. order ac- complish this, that time gener- ally accepted annealing methods were tried, (1) “prolonged heating temperature just below the lower limit the transformation tempera- ture range with slow cool- ing (2) heating temperature above the transformation range and then, after holding suitable time, cooling very slowly the hardness 200 210 Brinell and coarsely spheroidized structure were readily obtained. However, much the disappointment everybody concerned, the steel thus annealed (spheroidized) was found ex- tremely brittle and entirely unsuit- transformation diagram for SAE 9260. Austenitizing temperature, 1650 deg. F.; critical temperature, 1380 deg. F.; prior condition, Steel analysis: 0.57 0.72 Mn, Laboratory, Crucible Co. America. 1400 1.89 Si, 0.20 Ni, and Cr. Courtesy Eastern Research Seconds 50—THE IRON AGE, December 1944 Minutes Hours m e able for any cold-working operations. Evidently, might have been ex- pected with per silicon steel, the long annealing cycles had caused graphitization. All further attempts produce satisfactory ductility annealing were abandoned and for the years following, silicon-manganese spring steel shapes were ordered and sup- plied the natural, i.e. hot-rolled condition. This was the status when, 1937 the writer became associated with the National Lock Washer Co. was soon realized that ordering this grade steel certain chemical specifi- and maximum hardness 285 Brinell desired, was assurance for its satisfactory performance with regard cold-working. Particularly during the winter months seemed that breakage coiling certain bundles steel was most prevalent. The problem coiling was thus at- tacked first since resulted lower production and increase manu- facturing cost. the case with quite few cor- (high-silicon valve steel), heating only moderate temperatures greatly improved the cold working character- istics SAE 9260. After getting equipped with steam heated chambers holding approximately 5500 ing the hot-rolled shapes uniformly elevated temperature 130 deg. 180 deg. F., further difficul- ties were experienced with breakage coiling. Severing (shear cutting) also was greatly facilitated per- forming this operation immediately after coiling and while the steel was still hot. pointed out previously, only small percentage the material re- ceived would give any trouble processing. Therefore, assume that certain lot steel could coiled and severed cold but that—through the cumulative effect cold working— became too brittle for forming. this case, second “conditioning treatment” restore ductility was found apply. Heating over wide 1000 100 Silicon-Manganese Spring Steel temperature range of, say, 1100 deg. 1800 deg. and quenching air water would “recondition” the steel entirely such degree that forming could done without any danger cracking. This treat- ment might best called stress re- lief since does not result any change hardness microstructure. Finally, the hope annealing (spheroidizing) this grade steel given entirely. When Payson, Chief Research Metallurgist, Eastern Research Laboratory, Crucible Steel Co. America, published his modern conception annealing based TTT was felt that here might the answer these problems. Fol- lowing closely the underlying princi- ples Payson’s work, the following three experimental cycles were ar- rived at: (A) Heat 1450 deg. F., hold for hr., cool fast 1325 deg. F., hold for hr., and air cool. (B) Heat 1450 deg. F., hold for hr., cool fast 1325 deg. F., hold for hr., cool fast 1275 deg. F., hold for hr., and air cool. (C) Heat 1325 deg. F., hold for hr., raise temperature 1450 deg. F., The full annealing without graphitization silicon-manganese spring steels has resulted definite advantages the cold working and forming this grade steel. hold for hr., cool fast 1325 deg. F., hold for h., cool fast 1275 deg. F., hold for hr., and air cool. While there was found very little difference hardness (212 Brinell) both cycles and showed appreciable amount elongated carbides; cycle resulted completely and coarsely spheroi- dized structure and the steel thus an- nealed showed excellent cold-forming properties. determined chem- ical analysis any serious graphitiza- tion did not Graph. 0.012 (Cycle 0.015 Annealing large scale proved equally successful. Summarizing, may thus said that there are three ways which overcome any possible cold-process- ing difficulties that might experi- enced with silicon-manganese spring steel: Hot-rolled Annealed (1) elevated tempera- ture (130 deg. 180 deg. F.) (2) Stress relieving (1200 F., water quench). (3) Full annealing. Since, the writer’s knowledge, SAE 9255 (60) widely used the automotive well the railroad field, was felt that the experiences described herein might some benefit many other industries. Full annealing without graphitization should interest those engaged cold-drawing rolling this grade steel. preprint the Report Committee E-8. Payson, “The Annealing Steel,” series articles which appeared Ace during June and July 1943. Austin, Penn State College; and Fetzer, Carpenter Steel Co., “Fac- tors Controlling Graphitization Carbon Temperature,” Paper presented National Metal Con- gress, Dynamometer Measures Friction Packings method for mea- suring the friction hydraulic piston packings against the cylinder wall has been devised inserting Dillon traction dynamometer between the loading mechanism and the piston setup shown the illustration. ized leading manufacturer air- craft equipment called upon recently make tensile tests the magne- sium supporting structure pilot’s seats. Because the odd size and shape the units, conventional test- ing apparatus could not used. mounting the seat the floor and sus- pending block and tackle from overhead support, Dillon dynamom- eter placed series with the seat and block read the direct load pounds that ultimately ruptured the magne- sium supports. These dynamometers have come into use some steel plants por- table scales for weighing odd lots steel, thereby saving the expense crane scale operator. The instrument manufactured Dillon Co., Inc., 5410 West Harrison Street, Chicago weighs lb. oz. and measures Dillon traction dynamometer measure the amount friction encoun- tered the hydraulic piston packings against the cylinder THE IRON AGE, December 14, — SWIDLO Head Engineer, Production Engineering Department, Springfield Armory part the Garand semi- automatic rifle called the “Han- dle, Operating Rod” slender component nearly in. long, shown forging and finished part Fig. conventionally minded process engineer ideal exam- ple for milling machine method manufacture, inasmuch being nar- row requires comparatively short cuts. However, careful study was made revealed that the first Broaching vs. Milling milling operations, previously adopted before any hope was entertained the writer for new methods and for the procurement new machine tools, could combined into eight broach- ing operations. With the exception two for last two operations all broaching fixtures for this component are hydraulically operated and are equipped with elec- tro contacts which interlock with the starting circuit the machine 9—Rough forging and finished operating rod handle for the Garand semi- automatic rifle. analysis the machining this component was chosen illustrate tooling problems broaching long, slender part. order prevent possible down move- ment the ram the component not properly located clamped. Since the component long and slender very difficult produce absolutely straight forging eco- nomically that the work could supported every point under the cut. Therefore was found necessary make the first operation roughing cut, known Operation 10, that broaching bedding spots the right hand side, shown Fig. 10. This performed the right hand ram 5-ton, in, Cincinnati duplex vertical surface broaching machine. The forging located the fixture endwise, stopping against hardened block and supported the rear end the handle and underneath with hardened blocks four places. There are two clamps which apply pressure four points opposite the sup- porting places. One clamp equipped with swivel jaw compensate for irregularity the forging. The forging made 8745 steel, normalized Brinell hard- ness, with maximum stock re- moved 0.169 in. The important part this operation broach all locating pads line that the next cut will properly supported. The chip load per tooth the rough- ing broach teeth 0.004 in. gradually decreasing 0.001 in. the finish- ing teeth. Locate Section roughing cut the operating rod handle that broaching bedding spots the right hand side, designated Oper. 10. Sketch shows the cuts made. Fixture left. ° ° ° ° ° SUPPORTING BLOCKS SS 52—THE IRON AGE, December 14, 1944 Manufacturing Rifle Parts The left hand table the same machine equipped with fixture hold the forging while Oper. 15, “broach left side, rear end and spots tube section,” being performed. The sketch the cut and photo- graph the fixture are shown Fig. 11. The forging located endwise from inside the finger bar and supported and elamped the same way the previous operation. backed against the spots cut Oper. 10. The maximum amount stock removed 0.161 in., with chip load per tooth the roughing inserts 0.003 in.; middle inserts, 0.002 in., and third inserts, 0.0016 in. The finishing broach insert has chip load 0.001 in. the 14th tooth, with the bal- ance the teeth removing chip only 0.0005 in. thick. order insure acceptable finish and reduce possi- ble chatter, the broad broach inserts have teeth with deg. shear angle. The forward and return speed the ram ft. per min. with in. stroke, giving production 167 pieces per hr. Complete setup the machine both fixtures and broach holders for Oper. and shown Fig. 12. Fig. illustrated the fixture and the next cut, known Oper. 20, “broach bottom side and tube sec- tion ends.” The fixture mounted the left hand table second max. rernoval consists broaching the left side, rear end and spots the tube section the operating rod handle. the second part five-part article, the author takes the details broach tooling for long, slender part. Comparative data milling operations produce the same daily output are given. 5-ton in. Cincinnati duplex verti- cal broaching machine (see Fig. 15). The part supported the fixture surface broached previous op- eration and located against the same sur- faces used support the forging the first operation. (Oper. 10). Two clamps apply pressure hold the component securely the fixture spots broached first opera- tion. The maximum stock removed from the rear end the tube section 0.192 in., and from front end, 0.168 in. Since the cut starts this point the trimmed edge, the chip load per tooth the roughing broach in- serts 0.004 in., grad- ually decreasing 0.001 in. the finish- ing teeth. However, the broad serts cutting the han- dle bar and removing only 0.060 in. stock begins cut chip the width the component and there- fore have chip load the roughing this view are mounted the swiveling table in. stroke duplex broaching machine. Oper. performed the right; Oper. 15, the left. THE IRON AGE, December 14, 1944—53 4 > 4 Fy AN? \ 4 he \ § ~ 3 $ HYDRAULIC VALVE CONTROL LEVER, setup for perform- ing Oper. and in. ver- tical duplex broaching machine. Oper. accomplished with the tools and fixture the left, Oper. 25, the right. Li 4 max stock stock rem stock removal 1G. 13—The third operation, called Oper. 20, performed this fixture. The cut consists broach- ing the bottom side and the tuke section ends. This fixture shown the left the table Fig. fourth broaching operation the operating rod handle performed this fixture. The cut for Oper. that broaching the top side insert only 0.002 in., the middle insert 0.0015 in., and the first 17. teeth the finishing broach 0.001 in., with the last seven teeth removing chip in. thick. Since the component comparatively narrow hammering effect, re- sulting poor finish, these broad inserts that cut along the bot- tom side are given 30-deg. shear angle (see Fig. 15). The right hand table the same machine equipped with ture hold the com- ponent while Oper. 25, that broaching the top side and in. ra- dius, performed. This cut and the fix- ture are illustrated Fig. 14. The compo- nent located the fixture endwise the rear end the finger and in. radius. 0250 bar and supported the surface broached Oper. (Fig. 11) and gaged against surfaces broached the preceding operation. Two clamps, one wide one with two swivel jaws, applies the pressure the points broached first cut. The maximum stock removed 0.060 in., and the chip load per tooth preceding cut, that is, wide inserts cutting long surfaces have chip load the start cut 0.002 in., and the last finish- ing teeth remove chip 0.0005 in. thick. These teeth have deg. shear angle for the same reason. The for- ward and return speed the ram ft. per min., with in. stroke, giving production 167 pieces per hr. Complete setup the ma- chine both fixtures and broach holders for Oper. and shown Fig. 15. The last broaching operation the long bar known Oper. 30, “broach right side, finger bar tip and spot tube section,” illustrated Fig. 16, with fixture holding the component place. This operation really one finishing the surfaces out the first broaching operation for locating spots only, except that END LOCATING BLOCKS locate, SUPPOATING BLOCAS VALVE > = q i WIDE CLAMP WITH . NARROW CLAMP TwO SWIVEL JAWS 54—THE IRON AGE, December 1944 16—The fifth broaching operation the oper- ating rod handle known Oper. 30, that WIDE CLAMP WITH SWIVEL JAW BLOCKS broaching the right side, finger bar tip and spot the tube section. The fixture mounted the right the table the machine shown Fig. 18. sixth broaching operation, known Oper. 40, consists broaching 0.540 in. radius the tube section. The fixture shown mounted the left the table the machine shown Fig. 4. 50 -0.0/0 the piece inverted. (Compare with Fig. 10). The fixture mounted the right hand table third 5-ton, in. Cincinnati duplex vertical broaching machine. The component located the fixture between stops endwise, supported surfaces broached Oper. and gaged located against surfaces broached the cut shown Fig. 11. Two clamps, one which has swivel jaw compensate for variation thickness the handle bar, hold the component securely the fixture. Since this surface was partially broached the first cut, the stock removal not uniform and some places much 0.218 in. has removed. The first roughing teeth narrow surface where the forging was trimmed and since the surface consists three spots ap- proximately in. long 0.160 in. deep, the chip load per tooth the start cut 0.005 in. and gradually decreases 0.002 in. this depth. From this point, the surface becomes approximately in. long and the chip load per tooth reduced 0.0015 in. first, gradually decreas- ing 0.0005 in. chip removed the finishing teeth. this case SUPPORTING, END LOCATING BLOCK LOCATING BLOCK HAND OPERATED CLAMP wide cut, the shear angle the broach in- serts also deg. The operation component form milled and drilled the known Oper. 40, “broach 0.540 in. ra- dius.” The cut and fix- ture are shown Fig. 17. can seen, the component held the fixture vertically, being located two sides the long bar and held horizon- tal, operated clamp. The tube sec- tion being broached supported previous- broached locating points and held down with vertical, hy- draulically operated clamp. This fixture mounted the left hand side the table the same machine used the previous operation. (TURN PAGE) > HYDRAULICALLY ACTUATED CLAMP HYDRAULIC VALVE CONTROL LEVER SUPPORTING BLOCK formed this in. duplex broaching machine. The fixture for Oper. the right, for Oper. the left. THE IRON AGE, December = and broach holders for performing Oper. (left) and Oper. (right) are shown mounted in. stroke duplex Hydro-Broach. d The maximum stock has been form milled and the 0.391 are removed 0.080 in. diameter hole drilled, the roughing teeth drill the hole first order bro required the drawing showing ver the location the in. radius. The broaching this radius and remove small chips tube section, designated Oper. broaching 65, performed the left hand the avoid breakage duplex vertical broaching teeth and secure good machine. The fixture designed des The forward hold two components, shown with bro and return speed sketch the cuts Fig. 19. ram ft. per min. with in. stroke, giv- ing production 160 each case the component located plugs and has support under each cut. The hand operated clamps hold pieces per hr. work the bar section. The fixtures and two spring operated plungers serve holders for Oper. two purposes; first, they facilitate and are shown Fig. mounted the machine, After the tube sec- tion the component loading and unloading, and second, they hold the component against the rear end the tube section, locating stop. These plungers are locked with knobs shown the top cuts for Oper. 65, broaching in. radius the left side the operating rod handle and in. flat the right side. - ACTUATING HANDLE FOR LOCKING BARS ACTUATING LEVER deg. chamfer and 3/32 in. radius the operating rod handle, this special fixture with V-block Locate Section A-A 56—THE IRON AGE, December 14, 1944 / HAND OPERATED CLAMPS fixture before the hand clamps are applied. interesting note that for machining the in. radius, cylindrical broach inserts four sections are mounted the broach holder the vertical ram. This type broach insert very economical cuts only with one-fifth its circumfer- ence, and when one sector becomes dull there made revolve each section deg.; therefore, the tool life this type broach five times longer than partial section the radius. This design saves time resetting broach inserts after resharpening, be- sides simplifying the procedure BROACHING Description Operation Machine Used sharpening. The maximum amount stock removed 0.090 in. and the chip load per tooth the roughing broach 0.002 in., gradu- ally decreasing 0.0005 in. the last seven teeth the finishing broach. The right hand side the table the same machine equipped with fixture hold the operating rod handle while Oper. 70, “broach deg. chamfer and 3/32 in. radius,” performed. The cut and fixture are shown Fig. 20. The component located endwise from the rear end finger bar and held between two V-block plates actuated two TABLE Comparative Table Broaching vs. Milling the Operating Rod Handle the Garand Semi-Automatic Rifle No. No. Mach. Produce Produce Oper. 5-54 in. bedding spots Cincinnati right hand side duplex broach Oper. 15—Broach left side, rear end and spots tube section Same Oper. 20—Broach 5-54 in. bottom side and Cincinnati tube section ends duplex vertical broach Oper. 25—Broach Same top side and in. radius Oper. 30—Broach 5-54 in. right side, finger Cincinnati bar tip and spot duplex tube section vertical broach Oper. 40—Broach Same 0.540 in. radius Oper. 65—Broach 5-54 in. 142 in. radius left Cincinnati side and right side duplex vertical broach Oper. 70—Broach 142 deg. chamfer Same and in. radius Oper. 1—Rough mill left side Oper. 5—Finish mill left side rear, tube section and finger bar Oper. 4—Mill bottom side and tube section ends Oper. 6—Finish mill top side Oper. 14—Profile radius tube section Oper. 2—Rough mill back cam and finish mill right side Oper. mill end tube section Oper. 8A—Rough mill 0.550 in. radius Oper. mill 0.550 in. radius Oper. 12—Profile radius left and right sides tube section Oper. 27—Mill 0.05 in. deg. land miller Cincinnati Hydromatic Cincinnati Hydromatic profiler millers shown the right the photo, through pinions and racks. Both plungers, after pressing the work in- the V’s, are locked the tapered ends two round bars clamped hand, can seen top the fixture. This operation quite simple and does not require further com- ment, except state that the amount material removed the lo- cation the 3/32 in. radius nearly 7/32 in, and smooth surface re- quired this section subject hammering, alternate load and any tool marks tears are the beginning fatigue cracks. The forward and return speed the ram ft. per min. with MILLING No. Mach. No. Opers. Pcs. Produce Produce Machine Per 1000 1000 Pes. Used Hr. Hr. Per Hr. Cinncinnati Hydromatic 2-18 in. nm Cincinnati miller No. B&S miller miller profiler Cincinnati miller THE IRON AGE, December 14, es- ler ing us. ind the er. ind in. ing ith ted ach old nd, are Net | in. stroke, however, since one fixture, double type, requires two loading and unloading with two manually oper- ated handles and two knobs handle, the net production per hour much lower comparison with previous cuts, but reached 142 pieces. Fixtures and broach holders for Oper. and are shown Fig. 21. summary broaching vs. milling op- New Design Side Blown Converter Plants the time the expansion converter plants Great Brit- ain, the supply ores suitable for the manufacture hematite irons suddenly became precarious. came necessary reassess the rela- tive importance the silicon and car- bon reactions the process. Fassotte reported the British Iron and Steel Institute the results ex- periments the combustion low silicon irons and the operation verter plant. view the small amount sili- con contained the irons used these experiments, the temperature increments over 350 deg. ob- tained could only explained the fact that the carbon combustion was essentially carbon dioxide reaction. this respect, the side-blown con- verter appears work differently from the bottom-blown type where the passage gases through layers metal rich carbon favors the production carbon monoxide. The function the silicon reaction now appears its true perspective. essentially kindling agent. Its principal purpose side-blown con- verter practice make the dif- ference between the temperature the iron introduced into the converter and the temperature which the car- bon reaction starts freely. The experimental work the following conclusions: warranted (1) the side-blown converter the bulk the carbon transformed into carbon dioxide, provided there ade- quate blast volume. 9° (2) Irons containing from 2.7 per cent carbon upwards, with only negligible silicon content, duce temperature increment over 390 deg. (3) The carbon dioxide reaction capable making the difference between iron temperature of, say, 2642 deg. and the steel tempera- ture required the steel foundry. (4) Silicon the iron can dis- pensed with, provided the metal 58—THE IRON AGE, December 1944 erations the operating rod handle, indicating the machine used, produc- tion per hour, number machines and operators required produce 1000 parts hr. can seen from this table there are only four broaching machines and four opera- tors required. milling methods were retained, however, then milling machines and operators would required the same amount sufficiently hot the beginning the blow. well known fact that the affin- ity carbon for oxygen increases with temperature and becomes par- ticularly pronounced temperatures exceeding 2642 deg. If, therefore, iron were supplied the converter sufficiently hot for the carbon reac- tion start immeditely, then silicon could dispensed with, with the con- comitant elimination the hematite and ferrosilicon from the cupola tuting for heat chemically produced the converter the silicon com- bustion, heat physically imparted the iron prior the conversion proc- ess. achieve this end furnace had introduced between the and converter which the iron could brought the tem- perature which the carbon reaction starts. large enough such fur- nace would also act mixer and reservoir for hot metal, which would make possible operate the cupola independently fluctuations the demand for steel and secure great- uniformity the iron and effi- the converter operation. designing the cupolas care was taken provide them with deep wells order favor carbon pickup, the charges were composed steel scrap only. The metal pro- duced the cupolas has approxi- mately the following composition: 2.7 3.2 0.05 0.2 Si; 0.3 0.7 Mn; 0.11 0.18 and 0.03 0.07 After has been desulphurized, the iron transferred the mixer, the temperature being 2336 deg. The rotary mixers have capacity tons, but may reach tons, the degree wear the linings. They are fired anthracite and the calorific input such that the iron can raised the required temperature the rate tons per hr. The fuel con- sumption lb. per ton metal. After has been superheated the iron transferred the converters work the hr. Since Springfield three times many operators would against 12. {In the third article, Mr. Swidlo will iliustrate the fixture designs for broach- ing forging that hollowed out mere shell and will give comparative performance data for milling the same batches 5600 7000 lb. The mixer continually being refilled desulphurized cupola metal, The silicon content the metal charged into the converter approxi- mates 0.05 0.2 per cent. Iron containing little 0.05 per silicon has been blown successfully and yielded steel sufficiently hot for foundry requirements. The advantages the process may summarized follows: (1) Elimination hematite and ferrosilicon from the cupola charges. (2) Reduced consumption ferro- silicon the converter. (3) Appreciable reduction blow- ing loss the converter. (4) Increased flexibility duction through reduction blowing and slagging time. (5) Longer life ings. (6) Less variation phosphorus content and final steel analysis. (7) More cupola oper- ation. (8) Reduced quantity converter slag and easier removal. The process has the following dis- advantages which must not over- looked: (1) Considerable increase capi- tal expenditure due the cost the mixers and the provision heavy change the mixer bodies. (2) Heavier structure needed support this crane and larger area re- quired the melting plant. (3) Higher coke ratios needed the cupola for charges. (4) Greater wear cupola refrac- tories. (5) Extra labor and upkeep en- tailed the operation the mixers. (6) Fuel and lining costs the the particular plant under the review, the items increased cost were more than offset the savings due cheaper charges, reduced metallic loss and improved perform ance converter refractories. mac the mal suc] and alte has pro tha me! wel con util vel the to the suc the bes di: tic hifts, as will rative same The sually metal proxi- Iron cent sfully for blow- pro- owing oper- verter dis- over- capi- the heavy re- led l-steel efrac- en- the the cost duced been investigating the proper- ties steels employed the machinery Naval vessels. Due the service conditions involved, pri- mary interest has been centered such properties notch toughness and fatigue resistance, particularly alternating torsion. Special emphasis has been placed the variation properties forgings such size that normalizing and tempering the only practical method heat treat- ment. The National Emergency were developed early the war conserve critical alloying elements utilizing such elements available from scrap and making the maximum use the alloying constituents for de- veloping hardenability. Although these steels have found fairly wide application comparatively small machinery parts permitting quench- ing and tempering, was necessary investigate them thoroughly before they could considered for use such applieations heavy forgings the Naval service. Accordingly steels are being studied the Naval Engineering Experi- ment Station Annapolis, Md. though this investigation has not yet been completed, felt that the in- formation obtained thus far may value industry. The primary purpose the inves- tigation obtain information the strength properties these large sizes, although small diameter bars are Large forgings are required for propulsion shafting and rudder stocks which must conform the physical proper- Navy Department Specification (see Table I). the Navy Department purchases steels accordance with physical properties rather than chemical requirements. all, steels representing grades are being investigated. The sizes range from in. diameter. Similar steels obtained from different sources are being tested order determine the effect manufaeturing variables. view interest these many years the Navy has ysical Properties Some Steels Although the primary purpose the data reported here was determine whether certain the steels would meet Navy Department specifications, much general information the physi- cal properties obtainable result various heat treatments, particularly specimens large sections, made available for the first time. Special emphasis has been placed the variation properties forgings such size that and tempering the only practical method heat treatment. The data originally appeared somewhat greater detail the August 1944 Journal the American Society Naval Engineers. steels large sec- tions and because inherent hardenability, nor- malizing and tem- WILLIAM STEWART Principal U.S. Naval Engineering mens with refer- ence the cross- section the forg- ings ered. addition, pering heat treat- Station the high tempera- ments were given preference over quenching and RICHARD WILEY tics some the steels were deter- Materials Engineer, mined. dures. The forg- Bureau Ships The chemical ings were normal- ized full tion and tempered except those few cases which the manufacturer performed the en- tire heat treatment the forging. The tests include the determination static tensile and prop- erties, charpy impact value, hardness, and fatigue resistance rotating flexure and alternating torsion. The hardenability was test. Temperature-expansion (dilato- metric) curves were obtained for rep- resentative steels. determining these properties the location speci- compositions all steels were deter- mined and checked acaiast the analyses furnished the manufacturer and against the range the grades ordered. Results chemica! analysis are given Table and are the average two more determinations. noted that considerable number the steels analyzed failed conform the specified analysis one more ele- ments. instances where chemical analysis indicated different grade stee] from that ordered the applicable grade designation shown paren- thesis. Two the steels were modi- fied intentionally the manufacturer. ° TABLE Physical Requirements Navy Classes and Steels Stress may and ferro- THE IRON AGE. December 14, TABLE Chemical Composition Steels Tested EES Source Designa- Size Total Chemical Hardness EES 021 013 1.40 Mfr 027 1.5 EES 031 021 1.50 EES EES Hardness measured in. From end Jominy Specimen. IRON AGE, December 1944 q (8949) (8739) ou TABLE Chemical Steels Tested EES Source | Designa- Size Total Chemical Hard EES 9450 42129 | Hardness measured 114 in, From end Jominy Specimen. Mechanical Properties Mechanical properties the steels are presented Table III. Tension tests were made standard 0.505 in. diameter threaded-end Static torsion tests were made 0.75 in. diameter specimens. Charpy im- pact values obtained from mm. square keyhole notch specimen. The fatigue tests flexure were made with the rotating cantilever type specimen. this specimen the test length conically tapered and designed that the maximum stress out from the inner fillet, and the stress varies only about 1.5 per cent over length 1.5 in. All specimens were finished method alternate longitudinal and trans- verse polishing. The surface finish this method sufficiently smooth permit examination the structure magnification 100 diameters. The test length the was kept covered with film mineral oil throughout the test. The endur- ance machines were operated continu- ously 1450 r.p.m. except for the time required remove and install Endurance tests alternating tor- sion were also made for some the steels. For the tests herein re- ported, the stress was maintained equal positive and negative from the neutral position. All tests were made 1475 stress reversals per min. will noted that general forgings in. diameter made steels the lower carbon ranges in- vestigated can normalized and drawn conform the require- ments Navy Class steels, and those the higher carbon ranges, Class HG, The average endurance ratio (ratio endurance limit tensile strength) for the steels tested rotating flexure 0.43, and the corresponding ratio for the alternating torsion tests compares favorably with endurance ratios obtained for alloy steels such per cent nickel steel, although the average ratio for the rotating flexure tests somewhat lower. this respect, the steels tested be- have more like carbon steels than alloy steels. The maximum endurance ratio was obtained for the in. stock, Material VE, the quenched and tempered conditions. For the normalized and tempered steels the best values for endurance ratio range from 0.44 general, good endurance ratios were obtained for the 1300 deg. temper. Brinell readings were taken every in. along center line for the full cross-section. Maximum and mini- mum hardness values are reported Table III the following pages. were made all the steels, but inas- much they conform general the curves already published for these steels, they are not reproduced. Like- wise the results hardness tests determine the response tempering are close enough agreement with other published results make their reproduction unnecessary. the second and concluding part the article, the authors present labora- tory test data the properties some steels elevated temperatures with view appraise their acceptability high temperature bolt THE IRON AGE, December ooo | | web x | 62—THE IRON AGE, December 1944 — | | } one | | | — | | | “ | | | Lil 0091 THE IRON AGE, December 1944—63 ad | | | | | —— | } -— —— | —— — 0091 | } | | | | oO | | | © Lice | | | ceinioin om | | ’ | | | |- q | | - = ‘ | | - | | clo! | clo Ss sis | Nim | =-\|= | | aa | 7 | = | | | = | = Sioa = } | | — 64—THE IRON AGE, December 14, 1944 a | , — — Buyyeu | ‘9 wht | ——-—]-—-+- 66—THE IRON AGE, December 14, 1944 - |” | — q | | | | = | Ss q | | | | S | | j | | | | | | | | | | | | | | | j | | | | c = t= 3 c S | Eo. 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Citing the advantages solid cut- ters over the conventional brazed tip, indicated that the solid carbide tool reground many more times, the shank material not ground away and hence remains its original strength; strains due the difference thermal expansion rates steel and carbide are eliminated, impor- tant factor the larger sized tool, and finally, grinding simpler the Carbide Milling Steel Features ASME Annual Meeting Among the 150 papers presented the annual meeting the American Society Mechanical Engineers, held New York, Nov. Dec. were number papers relating the milling steel with carbide cutters. Data the influence reduced tem- peratures cutting oils and other phases machine shop practice were also reported. differential expansion problem longer factor there either. Use solid carbide blades heavy roughing work has been made possible through improvement the physical properties cemented car- bides over the past few years. Break strengths have been almost doubled, permitting the overhang blades be- yond the steel seat and mechanical clamping various types. unit price reduction per cent over the last four years has also been factor this development. Investigation clamping pressures necessary hold the carbide tip place carefully machined recess brought out the fact that clamp all was needed con- tinuous cutting, once the cut was started. Heavy duty tools D—Depth cut BA—Bevel angle C—Chamfer cutter face T—Face cutting tooth X—Original tooth F—Length wear land face WBA—Width wear land bevel angle WC—Width wear land chamfer WF—Maximum width wear held tips were primarily developed for machining heavy alloy forgings and armor plate where the work was such that could not rotated rap- idly due out-of-balance, nor were the higher speeds available existing machines. Instead using high speeds and low feeds these jobs ordinary carbide practice, the speeds run from 150 ft. per min. and the feed from in. per rev. turning boring, with depths cut ranging in. Use heavier feed eliminates the need for chip breakers, increasing the rate metal removal for given horse- power. Use solid carbide blades and double negative rake millers has_re- sulted particularly outstanding re- sults, according Mr. Kennicott. large milling cutters the proportion carbide body less favorable than single point tool and the milling cutter must heated repeat- edly brazing instead only once. Hence the factor differential ex- wear around cutting edge carbide tip used milling steel with negative angles. Y—Outline tooth after break- down occurred and wear was recorded V—Points breakdown H—Foir hair-like lines. Many these only become noticeab