The Iron Age 1944-12-21: Vol 154 Iss 25

ore VAN DEVENTER President and Editorial Directer BAUR Vice-President General Maneger a ° ° Editorial and Offices East 42nd St., New York N.Y., U.S.A. Johnson, Market Research Hayes, Production Manager. Baur, Typography and Regional Business Managers New York New York 100 East 42nd St. 100 East 42nd Cleveland Pittsburgh 1016 Guardian Bidg. 428 Park Bidg. Chicago PEIRCE LEWIS WARR Los Angeles 2420 Cheremoya Ave. Owned and Published CHILTON COMPANY (Incorporated) Executive Chestnut and Séth Sts. 39, Pa., U.S.A. OFFICERS AND DIRECTORS MUSSELMAN, President HILDRETH Vice-President GRIFFITHS Vice-President TERHUNE Vice-President BAUR Vice-President WILLIAM BARBER, Treasurer BLAIR Secretary CHASE THOMAS KANE HARRY DUFFY CHARLES HEALE Member, Audit Bureau Member, Associated Business the Industrial Arts index. Pub- every Thursday. Subscription Price Nerth America, South America and Possessions, $8; Foreign, $16 Single Copy, cents. ° Address, Vol. 154, No. IRON AGE December 21, 1944 Editorial Aim High But Have Your Gun ° ° Technical Articles Buckling Prevented Welding Aluminum Multiple Hole Punching Die Quickly Broaching vs. Milling (Part Physical Properties Some Steels ........ Glycerine Enhances Electrochemical Processes........... Shankless Twist Drill ° ° ° Features ° News and Markets Precision Bombing Feud................ Batcheller Outlines Critical Programs.................. 106 Seabees Build Shearing Financial Aids Available for Reconversion.............. 112 Cast Metais Handbook Revised.............. Machine Tool Market 138 Non-Ferrous Metals News and 140-141 Iron and Steel Scrap News and 142-143 Finished Iron and Steel, Steel Prices Warehouse, Semi-Finished, Tool Steel 146-147 Steel Pipe, Tubing, Wire Products, Prices 148-149 Pig Iron and Coke Stainless Steel and Ferroalloy Prices | q | 7 q 7 RAYMOND KAY f | | | | q | q TUNGSTEN-MOLYBDENUM HIGH-SPEED STEEL (M-2 ANALYSIS During the period WPB control, Star-Mo high-speed steel conformed Government requirements, but immediately upon re- moval restrictions, late 1943, analysis was adopted Firth-Sterling which was known Since then, all Star-Mo made has been this new composition approved leading automo- tive manufacturers and tool makers. They also adopted the designa- tion describe this type and the name for this new product —Star-Mo M-2. IRON AGE, December 1944 cations outcuts and outlasts 18-4-1 high- speed steel—a trial will prove it. STAR-MO M-2 Cheaper. The base price less than 18-4-1 steels, and addi- tion Star-Mo M-2 weighs approximately 7°/, less per foot. May quote compara- tive prices? Firth-Sterling representative will gladly tell you its value applications your plant, methods heat treatment, and practical use. x in \ AGE ESTABLISHED Dec. 1944 ° VAN DEVENTER President and Editorial BAUR and General Manager DIX Manager, Reader Service Editorial Staff Associate Editors WINTERS ALBIN JOHN ANTHONY JACK HIGHT BARMASEL Editorial Assistants SCHIEN WILLIAMS O'CONNOR MILLER LLOYD Pittsburgh 428 Park Bidg. POST Chicago 1134 Otis Bidg. MOFFETT DONALD BROWNE EUGENE HARDY Washington National Press Bidg. LLOYD Cleveland 1016 Guardian Bidg BRAMS Detroit 7310 Woodward Ave. OSGOOD MURDOCK San Francisco 1355 Market St. Editorial Correspondents ROBERT DEAN Buffalo FRAZAR Boston HUGH SHARP Milwaukee SANDERSON Toronto, Ont. RAYMOND KAY Los Angeles JOHN McCUNE Birmingham ROY EDMONDS St. Louls JAMES DOUGLAS Aim High But Have Your Gun Loaded high” good motto, but you won’t hit anything unless you have something shoot with. This statement reminds “quickie” concerning hunter and lunatic. The moron came across the hunter just the latter had shot bird which was dropping the ground. “Why waste the ammunition?” asked. “The fall would have killed him anyway.” Now, course, you who read this and who write not fall into this simple-minded category. expect have work for our meals and not have them drop from the sky without effort. But, unfor- tunately, there are many who, although they should know better, have been led believe the existence postwar Santa Claus. quite natural that this should so. the distorted economy war there are quite few manufacturers who are turning out hand- some earnings statements but whose abilities would not enable them earn dime state normal competition. Likewise, there are con- siderable number workers taking home fat envelopes whose qualifica- tions producers would not ordinarily earn them standing room well managed factory. These people may blame for being what they are but not for being where they are. Nature responsible for the first but war de- mands for the latter. And politicians and other demagogues, well number miscalled economists, are responsible for making them think that they can stay where they are and even get more for less. The employer, who has, almost spite himself, seen his plant and his business double quadruple size and earnings during the past few years likely take personal credit for the accomplishment, whereas the actual reason government credit. And the employee who listens the Washington pronouncement “jobs for everybody” naturally sees himself the job now has, with the same pay even better. What going happen these “lame duck” employers and work- ers when the crutches that support them are removed? Great expectations are fine you are willing work for them. But they cannot attained and maintained bottle fed economy with the United States Treasury acting the milkman. industry they must earned individually through constantly increasing efficiency and productivity. can have good jobs for everybody able and willing work our postwar world get our thinking straight, and take two steps the right direction. One these for our largest employer, govern- ment, set the example efficiency and economy the administration its postwar affairs. The other for our labor unions recognize individual productivity the basis for priority. — | rice ddi- For Workability With Inland Steel Steel offers designers and manufacturers the maximum workability. can formed and fabricated all prac- tical production methods, keeping shop costs down. can formed either hot cold. can easily spun extruded into many useful shapes. Steel can deep drawn such extremes the manufacture steel cartridge cases. can machined, sheared, bent, seamed, welded, and brazed. And steel available extreme ranges sizes and shapes, and chemical analyses; this offers wide scope the design parts, and also simplifies shop procedure, reducing wastage the minimum. For half century Inland has been studying the needs industry, working with designers and production men, make steel more useful—to give the workability that simplifies production and assures economical fabrication. From such close contact with field problems, Inland has given industry Ledloy, the lead bearing, faster machin- ing steel—Hi-Steel, the low alloy, high strength steel exceptional the galvanized sheet which withstands severe forming—Paint-Tite, the specially treated galvanized sheet which paint and enamel readily adhere—and many other kinds steel that offer numer- ous advantages the designer, the production man and the consumer. Inland engineers and metallurgists are your service help you design, select steel, and fabricate products for today for the post-war period. INLAND STEEL COMPANY Dearborn St., Chicago Illinois Sales Offices: Cincinnati Detroit Kansas City Milwaukee New York St.Louis St. Paul prog stru tary Matc forg evic > seve bar pet bly wit clo nes Paul News part the Navy program spend $100,000,000 month for rocket ammunition, Rheem Mfg. Co. has taken over large section the Basic Magnesium Inc. plant Vegas, Nev., for the production rocket projectiles and mortar shells. DPC making the necessary alterations and leasing the building. The Army and Navy are furnishing approximately $3,000,000 worth machine tools and other pro- duction equipment. Official estimates indicate that the overall revision shell and gun production programs will cost $250 million, and the mortar program $500 million, including struction facilities. The match shortage may credited great part military demands. The tary has, for instance, taken over the entire output book matches from the Diamond Match Co. Chico. million book matches were dropped over the Philippines the time the in- vasion with the cryptic message, "MacArthur returning". Molybdenite being employed with considerable success for the lubrication forging dies and for other applications which heat involved. There some evidence that performs better than graphite, which it, great degree, resembles. process for preparing aluminum for electroplating has been developed the Enthone Co., New Haven, Conn. Rack bulk work cleaned, then dipped the "Alumon" solution, which produces active alloy base which can subsequently copper Silver plated. And: Claims are made that the plated aluminum can soldered and subjected severe distortion without flaking. defiance recent price increases cement producers southern California, Henry Kaiser's Permanente Cement Works has unexpectedly reduced its prices 20c. barrel. The per cent reduction was effected stimulus postwar building and struction activity and dispel inflationary tendencies. Outsiders hint some petitive angle may involved. new type cargo ship designed another company will soon start down the bly line the Dallas plant North American Aviation, Inc. The plant will build Mustangs and AT-6 Texans. The company's Kansas City plant will undertake major sub-contract connection with the new ship addition its present B-25 program. release 6000 workers for "must" item production, the WPB has announced the five plants producing machine guns for Army Ordance. The plants affected were working .50 caliber machine guns which are ahead schedule. Machine Co. building 18,000 ton hydraulic forging press, largest ever installed this country. While intended primarily for the forging nesium, may also used aluminum other metals. die forging press over 10,000 ton capacity has heretofore been available for production light metal forgings this country. DPC plant will built subsidiary Wyman-Gordon, Worcester, house this new project. Production research work the press will available any agency having large forging problen. Combining qualities strength and toughness superior any the aluminum alloys used until recently claimed the Aluminum Co. America for its new Alclad alloy for airframe skins. Designated 75S, this alloy contains approximately per cent aluminum, with magnesium, zinc and copper. forming 75S, bend radii must increased and different allowance required for springback. The use glycerine the electrodeposition molybdenum compounds allows broadening permissible current densities and greater variations. The character the deposit improved that becomes more dense, more resistant abrasion and more adherent. | Avoiding LTHOUGH vealed difficulty dimpling for rivets, the introduction 75S-T the aircraft industry February, 1944, fabrication problems. Shallow joggles formed hand, and lightening holes and dimples formed with standard tooling, fractured with alarming reg- ularity. the microscopic examination this material before fabrication, was apparent that its microstructural quality did not compare favorably with that the conventional Alclad Residual stresses and stringer inclusions were observed many the cross-sections examined. as- sumed that these conditions were re- sponsible for many the fractures the severely deformed areas. The grain structure was not uniform most gages, and could not identified equi-axed. Grains were considerably longer the direc- tion rolling, affording structure more sensitive shear failure bending. comparison the grain structures 200 diameters shown Fig. comparison the micrographic structures two Alclad aluminum alloys the bend radius dimpled in. sheet, Left, there satisfactory grain orientation, complete recrys- tallization and average constituent size, suitable for average forming requirements. Right, Alclad 75S-T, grains are elongated and sensitive shear failure, and there considerable residual strain from rolling. This structure not suitable for average forming 200 diameters magnification after Keller's etch. TABLE Tensile Test Averages Alclad 75S-T 73,450 78,775 12.0 70,325 76,150 13.4 70,275 76,375 13.2 72,800 12.0 79,550 12.5 67,750 0.081 74,125 12.5 63,500 72,300 However, was possible estab- lish the following radii for straight deg. flanges Alclad 75S-T which would assure more than per cent rejections: was also possible establish the following table dimensions for jog- gles 75S-T which would free cracks severe strains: Radius, In. Depth 0.051 0.064 0.072 0.081 0.156 0.102 Length impling Failures the Ratio 3.8 6.3 6.1 5.9 5.4 6.2 6.1 Forming Equipment rolls rolls brake brake J | 0.040 0.051 0.064 0.072 0.081 0.091 0.120 | | Gage | | | 0.040 0.051 0.072 0.081 — 38—THE IRON AGE, December 1944 New Aluminum Alloy-Alclad 75S-T ° ° ° Process Douglas Aircraft Co., Segundo, Cal. ° ° ° Dimpling Study The first step studying the dim- pling characteristics Alclad 75S-T sheets was make tensile tests all sheets used. The averaged results the tests can seen Table and will noted that the strength and toughness this mate- rial greatly exceed comparable prop- erties Alclad All dimpling was done with Doug- las standard 100 deg. male dies. The female dies used with them were un- used Douglas standard dies having included angle 110 deg. and worn dies currently use the shop. the latter instance was hoped establish range tolerances for female dies. can observed from the photomicrographs shown Figs. dimples produced with used dies were quite unsatisfactory. Good definition could not obtained ex- cept the expense severe circum- ferential cracking the dimpled hole and cupping the sheet. Cracks and internal strains were developed dimpling with new fe- male dies conforming Douglas standard dimensions. “Canning” cupping the sheet made impos- sible produce flat panel. The quality the dimples was poor and unacceptable for use. Where large constituents accompanied stringer type defect were observed the microstructure the dimpling areas the sheet, severe cracking usually parallel the di- rection rolling and following the stringer defect. However, shearing occurred the more defective areas. The radial cracking the dimples produced with standard dies was se- vere and could readily seen. How- ever, circumferential fracturing the radius the dimple was not al- ways transmitted the ¢ladding and, for the purpose the investiga- tion, microscopic examination the dimpled areas was required. Experimental female dies incorpo- new Alclad alloy for airframe skins developed the Aluminum Co. America has combination strength and toughness superior any the aluminum alloys used until recently the aviation industry. The alloy, designated 75S, contains approximately per cent aluminum, with magnesium, zinc and copper. its heat treated condition, general less readily fabricated than Alclad the principal aircraft skin material now use. forming, bend radii must increased, and different allowance required for springback. The results investigation into modification dimpling procedure for flush riveting are presented the accompanying article. Accelerated corrosion tests have indicated that Alclad 75S-T re- corrosion well Alclad 24S-T. However the former more affected slower quenching rates and diffusion, particularly the thinner gages. Stress corrosion cracking Alclad 75S-T not likely because the electrolytic protection afforded the cladding. None has been observed date after year’s seacoast exposure highly stressed, plastically deformed samples. Comparative typical properties Alclad 75S-T and 24S-T are follows: Alclad 75S-T Tensile strength, lb. per sq. in. 77,000 64,000 Yield strength, lb. per sq. in. 67,000 43,000 Shear strength, lb. per sq. in. 46,000 40,000 comparison guaranteed minimum properties for the aluminum alloys 24S-T and 75S-T indicates that modification the heat treat- ment the former alloy, strength values approaching that the latter obtained, but only the expense ductility: Tensile Strength Alloy Lb. Per Sq. In. 60,000 24S-RT 66,000 24S-T81 64,000 75S-T 72,000 Yield Strength Elongation 56,000 5.0 65,000 3.0 62,000 8.0 rating series modifications the included angle, diameter and radius were developed determine whether the dimpling defects could relieved variation any the three di- mensions from standard, moved less critical areas. Larger radius dies produced dimples with poor definition and resulted cupping the sheet, which rendered them unsuitable for use dimpling for flush riveting, sizes. Dies which the included angle increased from the standard 110 deg. 2—Position bend radius dimpled sheet where all photomicro- graphs dimpling study were taken. 112 deg. produced dimples. Internal strains were mini- mized and were removed the lowest satisfactory extremity the dimple. Cracking was avoided most gages. Definition was good, and cupping, warping canning the sheet was negligible. The metallurgical phases the in- vestigation were concerned with the microstructural quality the Al- clad sheet, examination for dimple defects, and guide the development proper tooling. The development proper die design was facilitated comparing changes the micro- structure the dimpled areas die design was modified. was also possible observe the movement areas containing defects and strains and, modification die design, direct their movement less critical positions. Measurements were made the thickness the core material the base the dimple sections taken THE IRON AGE, December 1944—39 end the ng ent e ys- ng | - : ~ { clad 75S-T sheet taken the bend radius. These specimens were 0.051 in. thick, and 3/16 in. dies were used for dimpling. tion 35X. 40—THE IRON AGE, December 1944 q Iv n, n tory Strain Frac¢ ed AS 4 0 ® AVOIDING DIMPLING FAILURES 4—Photomicrographs dimpled Alclad 75S-T sheet taken the bend radius. These specimens were 0.064 in. thick, and 3/16 in. dies were used for dimpling. tion 35X. ° LEFT Standard female dimpling die, section taken across the grain. There slight frac- ture the outer bend radius and some strain critical bend There are stringer de- fects the center the sheet. This gage exhibits extreme elonga- tion the and residual stresses from Fair definition dimple, and cupping sheet. Coin 0.016 in. LEFT Standard female dimpling die, sectioned with the grain. Two stringer defects cen- ter strain. suited moderate forming. Fair definition and cupping sheet. Coin 0.015 in. LEFT Large radius female dimpling die, sectioned across the grain. Con- siderable strain less critical areas. Core de- fects and rolling stresses, but fractur- ing. Poor definition, and severe cupping. Coin in. ° RIGHT New female dimpling die design, sectioned with the grain. tudinal slip center sheet and slight trans- verse strain. Good defi- nition and overall flat- ness sheet. Coin 0.018 in. Large radius female dimpling die, sectioned with the grain. Less strain than across grain section. Slight longi- tudinal slip and rolling stresses present. Poor definition and cupping sheet. Coin 0.019 in. New female dimpling die design, sec- tioned across the grain. Material de- fects, rolling stresses, and slight strain neor critical bend area. Good defini- tion and flatness. Coin 0.019 in. + — an Standard female dim- pling die, section taken across the grain. Severe fracturing bend area. Material quality fair, orien- tation grains improved. Less residual strain from rolling. Fair definition dimple. Slight cupping skeet. Coin 0.010 in. 5 J . gre 5—Photomicrographs dimpled Alclad 75S-T sheet taken the bend radius. These speci- mens were 0.040 in. thick, and 5/32 in. dies were used for dimpling. Magnification 42—THE IRON AGE, December 1944 pre: tic abl; tha coil ang dial pro low sat sho plo pre low riv 4 e : 40% x Q q across the grain and with the grain. most specimens, coining com- pression the sheet was more dras- tic sections taken with the grain than those across the grain. The amount strain was also appreci- ably greater. was found, moreover, that controlling the degree coining opening the included die angle, was possible permit the diameter the die enlarged sufficiently the bend radius provide proper definition and flatness the sheet when using relatively low riveting machine pressure. The satisfactory female die design shown Fig. The machine em- ployed was Chicago Pneumatic No. 219 pedestal type riveter. With ram pressure lb. minimum, the fol- lowing gun pressures mended for various gages Alclad 75S-T using several common sizes rivet: Riveting Gun Pressure, Lb. 0.032 in.| 0.040 0.051 0.064 in. Conclusions Improvements will undoubtedly made the manufacturer Alclad 75S-T regard grain size, orien- tation grains and annealing prac- tices which should serve improve its uniformity and response fabri- cating methods. Nevertheless, rivet- Carbon Flue known uses carbon and graph- ite deriving from their chemical re- sistance the action practically all corrosive fluids, unique applica- tion carbon for controlling corro- sive and explosive gases developed and installed the new laboratories the St. Lawrence loys Metals, Ltd., Beauharnois, Que. Construction the new laboratory required that gases from furnaces and testing tables the basement dis- sipated through brick chimney run- ning through the center the building. overcome the corrosive action the gases ordinary chim- ney brick and avoid explosion hazard the gases were indiscrim- Note: Standard Douglas lines 6—Douglas designed female dimpling die for Alclad 75S-T. Phan- tom lines indicate the dimensions the Douglas standard dimpling die used for Alclad ing dimples formed accordance with the following gage limitations and female die design are acceptable for use and may considered free from excessive strains fractures: Limited Gages Rivet 75S-T, In. AN426-4F AN426-5F 0.032 0.040 0.025 0.032 0.040 0.051 The Comparator method recom- mended for inspection all female dies. precision check their dimensions, rejections will mini- mized and production hours saved. Accuracy female die di- mensions accordance with the new design very largely determines the quality the dimples 75S-T and will serve prevent rup- turing. Inspection should adequately informed the neces- sity for careful inspection all dimpled assemblies Alclad 75S-T sheet circumferential cracks may very easily overlooked. Fatigue tests -show that Alclad 75S-T dimpled and riveted panels compare favorably with the conven- tional Alclad 24S-T fabricated with standard dimpling sets. While success has been reported hot dimpling this Alclad sheet, was considered that there would difficulty establishing the critically controlled procedures required for Female Dimpling Die Dimensions Included Bend Diameter Angle Radius In. In. 0.253 0.321 0.387 treatments. Less difficulty ‘anticipated with the modified tooling recommended. reasonable as- sume that the modified female dies could also used satisfactorily for dimpling Alclad 24S-T, that dupli- cate dimpling tools need not stock- all riveting machines. The author wishes acknowl- edge the assistance given Newton, riveting consultant, and LeBarge, riveting specialists Douglas Aircraft Co., carrying out the tests and accumulating test data. Dispersal Corrosive Gases inately released, two in. i.d. flues corrosion resistant carbon pipe were built into the chimney carry two groups gases and protect the brick- work. Use two flues kept separate those gases that might produce explosion permitted mix. Metal hoods mounted over the testing tables and furnaces and connected the horizontal carbon tubes carried am- monia, hydrochloric acid, ether and ethyl acetate gases into the No. flue. sulfuric, acid gases and chlorine fumes were directed into the No. flue. The gases are exhausted through the flues mechanical means. minimize condensation and backdrip acid solutions that might caused rain snowfall the flue openings, roofed chambers with side outlets were built carbon brick. The bottom each flue consists slanted carbon disk covered with built-up layer carbon cement. Any acid solutions formed will flow out through small carbon pipe spillway when carbon opened. Each the ft. carbon flues formed threaded lengths carbon pipe. Joints are sealed with car- bonaceous cement with the female threads the upward position, thus providing added protection against seepage. According reports re- leased St. Lawrence Alloys Metals, Ltd., the exhaust system highly efficient, and the gas fumes originating the laboratory are un- detectable the floors above. THE IRON AGE, December 3 | | A / ow | n. } | | ap expansion special jigs which hold the work flexibly being used place preheating, still retained small work. ducts still retain the flat base after welding has been done jig with the con- trolled expansion feature. The inventor the sys- tem, Arthur Brown, shown checking duct surface plate. MECHANICAL place preheating for the con- trol the buckling commonly encountered welding sheet alumi- num has been developed the Vultee Field Division Consolidated Vultee Corp., Calif. has been long buckling can prevented preheat- ing aluminum parts temperature more than 950 deg. However, has been found impractical keep large sheet metal assemblies preheated the course lengthy torch weld- ing job. Arthur Brown, employed Vultee special assignments, has designed devices which substitute for the preheating process relieving the stresses set local heating and expansion. The basis Brown’s procedure can illustrated simple welding experiment. circle sheet alumi- num placed fire brick has torch applied the center. The heated area the periphery remains constant. The ex- pansion forces flow metal out along the plane the material, which resisted unyielding cold peripheral portion. Hence, the metal forced take the difference expansion arching. Now, new cut made from the edge the center will noticed that most the expansion has been relieved the 44—THE IRON AGE, December 1944 EXPANDER TOGGLE LINKAGE CLAMPS 2—The trunnion jig used retain the upper and lower parts the duct provided with individually springed fingers which exert adjustable external pressure the surfaces parts being welded permitting movement the expanded metal definite plane. Note the webbing which supports the upper half the part, not shown. cut, which opens and allows preset open approximately in. periphery expand, thus per linear ft. weld order close dating the centrifugal flow expand- seam without causing overlap ing material. condition. This expansion characteristic Fig. are shown ducts, designed taken advantage butt welding bolted the leader plate laying the butt weld seams open for which buckling con one end and welding from procedure utilizing the principle closed end. The weld bead, that is, outlines above has been successfully the expanded area, travels down the adopted. The base the duct must seam and upon cooling remains perfectly square and flat, condi- tension. Accordingly, the metal which previously was obtained inward and the hand working, sometimes mucb gressively closed. The gap hour per unit. some CLAMPS BASE CLAMPS | ose ned Welding Aluminum stances was also necessary re- lieve corner with and fishmouth patch. Balanced Pressures Handworking practically elimi- nated using the ball bearing trun- nion jig, shown Fig. The con- struction the jig such that making weld joggling avoided permitting the heated parts slip the plane passing through the edges. place the conventional rigid clamp, individually springed fingers acuated single clamping handle exert adjustable pressure the surfaces the parts being welded. Against the external pressure the fingers WEBBING ADJUSTABLE FINGERS SPRING CLAMP 3—To overcome buckling the aluminum due the difference expansion heated area and surrounding cold BASE GAP fore commencing close seams may noted gap (about 3/16 in.) has been set (A), the meeting point the two seams one which shown already welded. Welding started the crown where the seam practically closed and finished (A). Sometimes gap will remain which can handled adjusting the webbing attain the de- sired abutment edges and making tacks. With this setup has sible turn out average ducts daily with only minor straight- ening operations following the weld- ing. has been the experience Vultee that although EXPANDER area metal, V-gap preset (A) before commencing weld the seams. The expander handle controls internal structure which exerts pressure against the outside fingers order obtain desired abutment the edges. internal expanding box struc- ture, the pressure which ad- justed the expander handle. amploying webbing screen place solid backing plate, heat more likely retained the aluminum instead being lost conduction the jig frame. The method leaving V-gaps be- 4—Preheating prior welding, economical for small parts, being accomplished welding shown fixed posi- tioner with turntable. Heat from the thick steel block, maintained the welding torch, absorbed the aluminum plate. Con- trolled expansion the tube permitted. have been placed this work fre- quent intervals, has not been neces- sary permanently reject unit during the past year. Where small parts are involved still practical preheat the pieces prior welding. Controlled expan- sion can used here also. Fig. shows welding jig fixed table type positioner which thick block steel (insulated from the turntable temperature about 1000 deg. prior welding. top, the block contoured the shape the flange aluminum tubing, the plate being held the block means clamp and tooling pin. The heat the block, maintained process the welding torch, preheats the aluminum plate which, being held the top and bottom, free ex- pand sidewise. The tube belonging this assembly located round gate the end internal brace the top and screen core the bottom. N if QUESTIONNAIRE SUPERVISORY JOB SPECIFICATIONS OUR FOREMEN are preparing job descriptions supervisory positions. You can help obtain clear-cut breakdown your own duties and responsi- bilities filling out this Before putting the specifications into effect, will course, over the material with you point point. Name: Department Division Position Held: Name Your Supervisor: His Title: AUTHORITY Who gives you your orders and instructions? How you receive your orders? Verbally Writing any other persons departments give you orders and in- structions? Name specific persons and departments What kind orders and instructions you get from each the above? How often? HEN survey reveals that fewer than per cent the supervisors have full under- standing their duties and respon- sibilities, easy see why many foremen feel uncertain about their business futures. Such sur- vey has just been completed the field staff the Labor Relations In- stitute, 1776 Broadway, New York 19, whereas, employers, have spent large sums money over long period years job specifications for pro- duction workers, per cent all foremen questioned have “blue- print” govern their jobs. Wherever such analyses foreman jobs and duties have been made, each super- visor knows exactly where his au- thority begins and ends. That, turn, serves correct one the most serious obstacles better labor rela- tions all along the line. Here typical job specification prepared the Institute’s manage- ment engineering division: POSITION: Foreman, milling de- partment PLANT: Cleveland DIVISION: generator DEPARTMENT: Milling machine PERSONAL CODE: ADC963Z 46—THE IRON AGE, December 21, 1944 DATE ESTABLISHED: December 22, 1942 SIMILAR JOB TITLES: Super- visor, milling machine dept.; fore- man, small parts milling machines Line Authority—Accepts direct supervision from division manager. Correlates and collaborates with planning department (tools and methods), time study department, production control department, plant engineering department, safety engineer, recruiting and em- ployment division and industrial re- lations department, cost department and inspection department. Directs and supervises subordinates such assistant foreman, group leaders, operators, shop stewards, etc. II. Responsibilities Management: Gets out maximum production quality standards and minimum cost. Responsible for departmental production performance; has full departmental authority. Subordinates: vision assistant foreman, setup men, group leaders, milling machine operators and Standards performance, quan- tity and quality: Maintenance Analyzing The Job Relatively few companies have ap- plied the techniques job evaluation supervisory positions, according recently completed survey. typical supervisory job specification outlined herein. COOL Director, Labor Relations Institute, New York quality standards shown prints. Responsible for speci- fications during process and completion. schedules: Manhours Machine operation Good housekeeping Enforces safety. production Personal Characteristics Re- quired: Education: High school equivalent, with technical train- ing desirable. Ability read complex required; should have thorough basic un- derstanding and working ability mathematics, such arith- metic and algebra. Experience and background: Ability all around pro- duction man required, either acquired apprenticeship training actually doing the work. (This order that may correlate and function with and understand other de- partmental requirements). least two years production group leader (lead-man as- sistant foreman). ° 5s =e JOB DETAILS What are your: Daily Duties—(list completely) Weekly Duties Monthly Duties Miscellaneous Write out the names and jobs the people who work directly under you: Name Should have working knowl- edge production methods, machine setup, intra depart- ment production scheduling, department equipment and machine layout. Knowledge characteristics various metals and alloys machined. Must have completed in- plant training courses Job instruction training Job methods and work simplification Safety policies and meth- ods Supervisory and execu- tive training labor relations, policies and methods. Physical Characteristics: Good health required as- sure regular attendance and provide ability withstand overtime and rush production demands. Should have mature judg- ment secure confidence subordinates. Personal Contact Requirements: public contacts required. time spent Job Duties Quality Quantity partment? employees and have ability discuss grievances with em- ployees and union shop stew- ards. Must render decisions and secure acceptance em- ployees. Must have ability in- struct methods and tech- niques and secure employee acceptance when changes are desirable. Must rate employees fairly for merit, either for increased pay for reclassification promotion. Must have ability discuss ratings with the em- ployees, secure their accept- ance and cooperation and sug- gest means for improvement. Must capably represent the interests the department employees management, and secure acceptance. Must able present and discuss problems coordina- tion work his depart- ment with other departments, both “line” and “staff,” and presentation secure acceptance and cooperation; must capably represent the in- What standards you use check Employee efficiency Give brief description the physical working conditions your department, such long hours, heat, noise, vibration, What technicai qualifications are necessary What educational background needed? What other qualities you think are important? terests his department supervisory meetings. Must able analyze the operational problems his department and present factual evidence basis for discussion such prob- lems with the plant manager and other top executives, and secure acceptance. Ability analyze production costs, inspeetion reports and production scheduling. Reports for (1) work process, and (2) completed units, Job Analysis Suggestions Preparing job specifications this sort something that almost every personnel department equipped do. advisable have such work done under the close supervision company executive who has op- erating knowledge the plant. The foremen themselves can great assistance analyzing their respec- tive duties through the use ques- tionnaire like the one reproduced herewith and participation this work will give them added sense (CONTINUED PAGE 57) THE IRON AGE, December | - run your de- , | | type unit showing the relationship components the self-contained punch assembly and die assembly. notably aircraft sheet metal parts, makes highly desirable punching system. Such system be- comes valuable when can lead the release experienced die makers ultiple Hole Punching Die and die setters and the use their place any good mechanic who can put the assembled type die into opera- tion often the same day that pattern handed over for produc- tion. See article, Subpress Dies for Aircraft Fabrication,” Aug. 27, 1942, 52. The new Wales “CD” hole punch- ing system developed the Wales- Strippit Corp., North Tonawanda, Y., utilizes unit consisting two parts, punch assembly and die assembly. These are independent and self-contained for quick mounting templates and thence die sets direct die sets for long runs. This unit differs from prior unit* devel- oped this company which the punch and die assemblies were com- bined single holder that could ickly Assembled press brake rail. illustrated the cutaway view, Fig. the punch assembly consists holder that retains the punch, stripping spring and guide rela- tionship the separate die assembly which consists holder with built-in slug clearance chute, die and pilot pin. The corresponding pilot pin the punch assembly part the punch. All parts these units are interchangeable and are removable Since the type “CD” units have uniform shut height, only one adjust- ment the press ram required, regardless the number hole patterns. Methods Mounting form multiple hole punching die, these units may mounted easily 2—For template mounting pair templates required, one for mounting the punch assemblies and one for mounting the die assemblies. the left, template setups are ready mounted the die set press brake. the right, Wales "CD" units are shown set punch straight line, staggered, scattered and individual group patterns. IRON AGE, December 21, 1944 —— BS ¥ ire order line the punch setup with the die setup, locator rings are temporarily placed around the four corner die assemblies. the case template mounting, one template required accommodate all the punch assemblies and another for the die assemblies, Fig. Among the advantages cited for these mount- ing templates are the ease drilling pilot and mounting holes, transferring and from the press and bolting the die set. The sequence operations for mounting type “CD” units to. the templates first clamp the tem- plates together and lay out the hole pattern directly the top template, transfer the pattern from master template. Holes 0.375 in. diameter are drilled and reamed through both templates accommodate pilot pins. Two mounting holes for both the punch and die assemblies are drilled and countersunk through both tem- plates (0.302 in. diameter drill) locat- ing both mounting holes with drill jig Standard 5/16—18 flat head machine screws with nuts are used secure the punch and die assemblies the templates. Before the templates are bolted the die set necessary make sure the alinement punches and dies through the use special parts called rings, Fig. four these rings sufficient, which are placed over the dies the assemblies occupying approximately the four corners the template. The coresponding corner punch guides the upper template are fitted into the respective locator rings. Upper and 4—Punch and die assemblies the Wales units are being mounted direct die set, which more econ- omical for long runs. gage rods clamped convenient die holders are aid for accurate locating the work the die set. lower templates are thus linked to- gether correct alinement this manner the templates are bolted the die set. After the ram has been raised, the rings are removed and the die ready for operation. For unusually long runs has been found more economical mount the “CD” units the die itself. The method previously described for mounting the units the templates applies the mounting onto die sets, Fig. The drilling two mount- ing holes and one pilot hole for each die assembly and punch assembly required. Each pair tapped mount ing holes are located drill jigs from the pilot pin hole. For quick accurate locating the work during feeding operations, work stops with adjustable gage rods are clamped the die holder, Fig. eliminate sagging the work, feed rails, made 10, 20, 30, and in. lengths, are for bolting templates the same manner the die assemblies. They may located wherever support required the work. Wales type “CD” units are available four sizes—1%, 1%, 1%, and in. holder widths punch THE IRON AGE, December F sts 7 22—Rough forging and finished trigger housing for the Garand semi-automatic 0.30 cal. rifle. the machined form, this piece thin walled shell. the name implies, the trigger housing the Garand rifle houses the hammer and ham- mer releasing mechanisms, that the trigger, sear and safety. This compo- nent appears such design that would lend itself milling and profiling methods machining. will seen later, however, use two duplex broaching machines has replaced millers considerable saving capital investment and di- rect labor. The forging made X1340 steel and weighs 1.6 while the completed part merely shell with thin walls, weighing only oz. The forging and finish compo- nent are shown Fig. 22. VERTICAL VERTICAL SUPPORT IRON AGE, December 21, 1944 Except for intermittent milling op- eration remove excess stock in- side the plate, the first four cuts are broaching operations. Here again, due the very irregular form and difficulties holding the component rigidly enough, only broach minded engineer would attempt process this component the broaching method. The first operation serves establish locating surfaces 23—Oper. trigger housing consists broaching the edges size and the bed- ding surfaces. Hand clamped fixtures are used all four opera- tions this part. Broaching vs. Milling ° ° ° SWIDLO Head Engineer, Production Engineering Department, Springfield Armory for the several following cuts and later these surfaces are removed entirely. This operation, known Oper. “broach edges size and bedding surfaces”, shown Fig. 23, performed 5-ton, in. Cin- cinnati duplex vertical broaching ma- chine, with work holding fixture mounted the left hand table and broach holder the left hand side ram. The forging located the fixture four spots, indicated Fig. 23, “locate” and clamped hori- zontally against the left side two points. The forging also supported sides -+4, Must line within and clamped vertically against the point marked “stop.” From the illus- tration can seen how the forging held with two manually operated clamps against supporting blocks. the same figure there also shown forging after this operation com- pleted. Maximum stock removal 0.125 in. requires comparatively heavy chip load per tooth. this case the first and second roughing broaches have CLAMP or we 0.005 in. chip load per tooth, while the first tooth the finishing broach re- moves 0.003 chip, gradually de- creasing 0.001 in., with the last five teeth straight. The next machining operation milling, remove excess stock from the middle portion the front end, and has performed regardless the methods used the following cuts. After excess stock removed the component goes back the same broaching machine for Oper. the right hand table this machine mounted fixture hold the com- ponent while Oper. 1A, “rough broach top and deg. angle,” formed. This operation illustrated Fig. 24. The forging located the fixture the previously broached surface, resting vertically top the lower clamp shown Fig. 24. Upon placing the forging into the fixture this manner, turning the knob seen the left side, the operator forces the work means horizontal clamp against one side previously broached. Since the dimensions produced the first broaching operation within 0.005 in. necessary work from the left side order avoid accumulation tolerances and able produce the component within the required limits. turning the seen the left Fig. the vertical supporting clamp draws the work against locating blocks, thus holding the work surfaces broached the preceding operation. The release lever actuates cam the fixture which permits serrated self-adjusting supporting plunger RELEASE LEVER third example the application broaching compo- nents the Garand Mr. Swidlo describes the broach tooling and fixture design for machining part that finally whittled down thin walled shell. the fourth part the article, will analyze the tooling small, fragile part. move forward under spring pressure until the rough forging contacted. Cam construction inside the fixture such that the plunger will not recede under pressure the cut. The lever seen the right actuates the vertical clamp forcing the work against the lower stop and self-adjusting serrated supporting plunger. Since side broaching starts 9/16 in. from the bedding surfaces, provision made the four-section broach in- serts insure stock removal 0.450 in. The first three sections, with teeth each, remove chip 0.006 in. thick. The last finishing broach in- fixture, Oper. performed. consists broach- ing the top the trigger and the deg. angle. against broach tool loads featured. ° ° serts have chip load the first tooth 0.005 in., with gradual de- crease 0.001 in., the last two teeth being straight. The forward and re- turn speed the ram ft. per min., with in. stroke, giving production from each ram 170 pieces per hr. Complex Clamping Required The following operation known Oper. “finish broach left side, deg. angle groove and deg. angle,” and performed the left ram second 5-ton, in. Cincinnati duplex vertical broaching machine. The component located the fix- ture the surfaces marked “Loca- tion” Fig. and clamped and supported the following manner. The plunger (not shown) forces the work against the left side locator that the forging located sur- faces broached Oper. using the same side for gaging Oper. 1A. (Fig. 24). The lower horizontal clamp forces the forging into the fixture and the same time supports ver- tically. The plunger and the clamp are operated the lever shown the back fixture through combi- THE IRON AGE, December Clamp Gage loc. | oF HORIZONTAL SELF - ADJUSTING AND SELF -LOOUNG SUPPORTING PLUNGERS LOWER CLAMP AND VERTICAL SUPPORT nation racks, pinions and wedges which hold the work securely position while the cut made. Two self-adjust- ing and self-supporting plung- ers operated the top lever counteract the created the cutting tools the thin wall the forging. These plungers cannot recede under pressure due angle the supporting plungers and spring actuated locking plung- ers which set wedging action when plungers contact the work. Table Broaching os. SELF - ADJUSTING SuPPoORT PPER Self support TABLE Operations the Garand Trigger Housing ° 25—Oper. finish the left side, deg. angle groove and the deg. angle, performed this fixture. The cuts taken are shown the sketch. The upper clamp and self-adjusting support actuated the knob shown the right function follows: order permit loading, the clamp carrying the knob swings verti- cal pivot, but when its loaded posi- tion shown, the entire mechanism has horizontal movement permit the clamp hold work rigid its natural position without any distor- tion. When the clamp adjusts itself the work position the entire me- chanism clamped securely single movement the knob. The maximum metal removal 0.110 in. the groove. The chip load per tooth the roughing broaches 9.005 in., decreasing 0.001 in. per tooth all finishing broaches cutting the side and deg. angle. 2 276 +0005 Clamp Support Locate ENLARGED VIEW BROACHING Mach. No. Opers. Pes. Produce Produce | edges size and Cincinnati edges finish bedding surfaces duplex size and mill vertical bedding surfaces broach Oper. 1A—Rough Same 171 Oper. 2A—Rough broach top mill top, sides, broach left side milling sides, top, deg. angle, duplex groove, and angle deg. angle broach part finished each pass broach right side deg. angle, deg. angle 52—THE IRON AGE, December 944 MILLING No. Mach. Opers. Produce Produce Machine Per 1000 1000 Pes. miller Cincinnati miller B&S miller ips LEFT SIDE LOCATOR sar ist pass wit the op co a di INSIDE WEDGE OUTSIDE WEDGE BLOCK VERTICAL SUPPORT The right hand ram the same machine equipped with fixture and broaches perform Oper. “finish broach right side, deg. angle groove and deg. shown Fig. 26, the component located its left side and the deg. surface broached the pre- ceding operation. The com- ponent held the fixture with two wedge blocks which force against side sup- port and the deg. locator which the same time takes pressure created the cutting tools. The lever shown the back the fixture operates both wedge blocks, which contact the surfaces marked “adjust- able supporting the sketch. The inside wedge block holds the forg- ing rigid manner, while the out- side wedge block permitted float slight amount take variations due both surfaces not being exactly alinement with each other. addi- tion this type clamping there swinging clamp which holds the part against the left surface broached SUPPORTAND 80° SWING CLAMP ACTUATED trig- ger guard hous- ing partially sup- ported wedge blocks while Oper. performed. This consists finish broaching, the right side, the deg. angle groove and the deg. angle. ° ° ° the previous operation and applied against the hollow part the com- ponent, indicated word “clamp” the drawing. This swinging clamp narrow enough clear the cutting tools. Vertically, the component supported with hardened block the point marked “stop.” The amount metal removed the same the previous cut and the chip load per tooth the rough- ing and finishing tools also the same. Forward and return speed the ram ft. per min