the castings after pickling, and the burned sand and scale coming from the castings, will go into another receptacle, where the sand and scale may be retained and the water flow into the sewer.

A very efficient method of accomplishing these results is in use in the new foundry of the Brown & Sharpe Manufacturing Company, Providence, R. I., and with some necessary modification it is shown on an enlarged scale in the plan Fig. 119, and in vertical, longitudinal section in Fig. 120. The pickling beds are built of 2-inch plank, supported on timbers 4 x 6 inches, placed not over 4 feet centers, and have at both sides and at the upper end a plank 8 inches high. This bed is lined with sheet lead of sufficient thickness to not be easily cut through by laying castings upon it.

Very heavy castings may rest upon pieces of board laid upon the lead for its protection. The lead should not be thinner than an eighth of an inch for ordinary uses. The pickle bed inclines toward the drainage system a quarter of an inch to the foot. The pickling solution or wash water dripping from the castings upon the pickling bed flows to the lower end, and upon a narrow tilting table A, which directs its course as may be desired. In the position shown on the right of the drawing it will run the pickling solution into a transverse conduit, from which it flows into the pickle trough, where it may be dipped up to put on other castings. When the castings are sufficiently pickled and it is desired to wash them, the hose is brought into use and the tilting table A is placed in the position shown on the left in Fig. 120, and the wash water flows into the settling chamber. Considerably above the bottom of this chamber a drainage pipe leads to the sewer. All sand or scale which passes down from the washing process drops to the bottom of the settling chamber, from whence it is cleared out as often as necessary through the manhole between the car tracks, as shown. A cast iron plate covers the settling chamber, supporting the car tracks passing over it, as well as the manhole

cover.

Near the pickling beds is located the pickling vat, in which small castings may be immersed until sufficiently pickled, then placed upon the pickling beds to drain and be washed. This is constructed of planks and lined with lead, the same as the pickling beds. Concrete construction may be used if desired.

An overhead trolley and hoist should be placed over the pickling beds, for removing castings from the cars and transferring them to the bed on the right or left, as may be desired, and back to the car when they are finally washed. Another similar overhead trolley should be placed in the center of the room for lifting castings to and from the floor and cars. These two trolley beams may be connected if desired, and run as one system.

The hoists may be operated by compressed air, in the same manner as those in the foundry proper. If the sand blast process is to be used for cleaning

castings it will be necessary to enclose a space of sufficient size in which to operate it, in order to prevent the disagreeable dust created by its use, provided the high velocity usually used is to be arranged for. There is, however, a sand blast apparatus made in Germany which uses a very coarse sand at a comparatively low velocity, which appears to be a success, and does not require to be operated in a close room.

The core room is provided with benches on two sides, and the usual form of core oven, which is fired from a pit formed in the floor of the foundry proper, by which arrangement the entire height from the core room floor is utilized for the cars upon which the cores are arranged and run into the oven from the floor level. The core oven may have its entire front closed with sheet iron doors, running up out of the way; and upon the inner sides of the oven walls a series of supporting bars, permitting cars to run in, one above the other, their front ends being suspended on overhead trolley beams when they are drawn out. By this means the upper portions of the core oven may be better utilized and smaller lots of cores may be run in and baked at a time; or, the oven may be divided by a vertical partition and one side used for a large car, filling the entire space, and the other side arranged with shelf-like cars or racks, for small lots of cores. Separate doors should be provided to close each section so as not to expose one section to cold air when cores are to be put in or taken out of the other. By this arrangement much more work may be baked than if the whole front is to be opened at once. The doors may swing upon hinges if there is a lack of height for lifting doors, although the latter, properly balanced, form a very convenient arrangement, and not in the way when the doors are opened.

The flask room requires no special arrangement or equipment beyond the car track and its cars for carrying flasks to and from the molding floor, unless a very considerable number of the flasks are of small and medium sizes, when they might be conveniently stored upon a gallery floor, which might extend nearly around the room. Flasks could be quickly and conveniently passed to and from this gallery by means of a pneumatic hoist. By this means the storage capacity of the room could be increased at least 50 per cent, perhaps more. The alcove arrangement of flasks is very convenient for the purpose of easily reaching any size flasks needed. Thus, groups of two piles of flasks, backs together, may be piled up to any convenient height, with a passage between these groups, flasks of similar size forming each pile when possible. A little study of this arrangement will save much unnecessary labor in handling the flasks when wanted.

The wash room is located in one of the outer corners of the foundry proper, as shown in Fig. 115, and has adjoining it the water-closets, and next to these the lockers for the use of the employees. The water-closets should

be so arranged as to be flushed automatically, and a continual supply of running water be provided for the urinals. The washing sinks are of cast iron and arranged with an individual supply of water from a pipe running along above them. One of these sinks is shown in perspective in Fig. 121. By

FIG. 121. Cast iron Washing Sinks, with Individual Supply of Water.

this method of water supply each man may have clean water, and still the expense of separate wash bowls is avoided. The plentiful supply of fresh water is nearly always appreciated by the men, although the author once knew of a shop in which a similar arrangement for their cleanliness was made and the men refused to use it, preferring to wash in the common pool of not overclean water in which all the rest of the force did the same. It has been said

WATER CLOSETS

TTTTTTT

that "there is no accounting for taste," and this may be a case in point. Certain it is that the well-meant efforts of shop owners and managers are not always appreciated by the employees.

The lockers are of expanded metal, and are of the usual dimensions for such use, that is, 12 inches deep, 18 inches wide, and 72 inches high. The width might be decreased to 15 inches and still provide ample room. They are placed in rows facing each other, with the two rows in the center back to back, for economy of space. In the plan just described it will be noticed that the lockers, the wash room and the water-closets are each separated from the other. In some respects this is not as convenient as it will be to have the lockers arranged in the wash room. Such a plan is shown in Fig. 122. The

amount of space and the expense necessary are about the same in either case, but the latter arrangement will probably be preferred by the employees generally, as being more convenient to have their lockers near where they are to wash up, and it will cause less confusion in running back and forth from one to the other, at a time when every one is in a hurry to wash, dress, and get out in the shortest possible time, and the capacity of the wash room is usually taxed to its fullest extent.

WASH SINK

CHAPTER XXII

THE FORGE SHOP

Its present restricted sphere. Improved facilities. Case-hardening and tempering. The addition of machine tools to its equipment. The proper location of the forge shop. Its special construction. Transportation of stock and material. Coal and bar stock storage. Foreman's office. Portable scale. Forge fires. The down-draft system. Construction of forges. The blower. Blast pipes. Arrangement of blast apparatus. Steam hammers. Drop presses. Special heating furnaces. Annealing and case-hardening furnace. Detailed description. Cutting-off machine. Power hack saws. The cold saw. Heavy shear. Heavy turret lathe. The forge lathe. Work benches. Steam supply. Compressed air. Electric motor drive. Jib crane. Overhead trolleys. Pneumatic hoists. Bar stock storage rack. Shop rack for bar stock. The wash room. The water-closets. The lockers. Compactness of the design.

It is undoubtedly true that since the very general introduction of turret lathes, forming lathes, and the large variety of similar machines now in use in almost every machine shop making any pretense to modern equipment and up-to-date methods of doing work, the forge shop has lost considerable of its importance as one of the indispensable departments upon which the machinist of former times very largely depended for much of his material for the better classes of work. The introduction of steel castings, malleable iron castings, and other similar materials, superseding in many cases the old-time forgings, has also been an important factor in the same direction, and has decreased the cost of materials of complicated form, and at the same time provided the machinist with materials which have admirably answered the purpose as to strength, and lessened the amount of machining necessary for their practical

use.

And yet, while the forge shop may have decreased in the matter of importance in the making of forgings, there will always remain the demand of the machine shop for a certain amount of strictly machine forgings of iron and steel which cannot be met by any other material. Many great and important advances have been made in forging by use of improved hammers, by dies in connection with them, and by the process of drop forging, yet there is a large demand for forgings requiring the services of the skilled machine forger with his expertness in hand forging, as well as his technical knowledge