Slocam

Life, simplicity, success

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Knowledge from the Tools: ARC FORCE

ARC FORCE is an common feature found in modern MMA-stick inverter welders that increases welding amperage (heat) as the arc voltage decreases, thereby stabilizing the arc.

ARC VOLTAGE is the voltage that exists between the electrode and the earth (work lead) during the welding process. Arc voltage is proportional to the arc length, i.e. As the arc length decreases the arc voltage also decreases.

The Arc Force setting is the maximum percentage of the set amperage the actual welding amperage may increase by. E.g. 100 Amps @ 20% Arc Force may increase to 120 Amps maximum.

For the welding of new/clean mild steel and vertical up welding, I use an Arc Force of around 20% percent.

Otherwise, painted and/or rusty steel and sometimes for corner fillets or 'back penetration', I'll use an A/F of 50%.

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Engineering Icons - Sergei Korolev

SERGEI KOROLEV

The Chief Designer of the Soviet space program, leader of the OKB-1 team, mentor to Yuri Gagarin and protégé of Andrei Tupolev. Korolev both managed and contributed to projects including Sputnik, Vostok 1, Soyuz, and the rocket that has a 68-year history of putting things into space, the R7 Semyorka.

The following is an outline of his extensive career.

Vocationally trained as a Carpenter in 1913.

1924 - Personally designed a glider called the K-5 and constructed it with assistance from the OAVUK society.

Accepted into the Bauman Moscow State Technical University in 1926.

1929 - Gained diploma in aircraft design by producing a practical aircraft design within 12 months whilst being mentored by Andrei Tupolev.

1930 - Worked with Andrei Tupolev at the Central Aerohydrodynamic Institute (TsAGI).

1931 - Founding member of GIRD - Group for the Study of Reactive Motion.

1933 - GIRD merged to form RNII - Jet Propulsion Research Institute.

1938 - Imprisoned during the Great Purge at Lubyanka.

1939 - Transferred to Siberian Gulag gold mine in the Kolyma area.

1940 - Transferred to NKVD Sharashka penitentiary to work under Andrei Tupolev.

Commissioned into the Red Army after release from Sharashka TsKB-29 and is sent to Germany to study V2 rocket technology in 1945.

1946 - Korolev is placed in charge of OKB-1 with Vasily Mishin assigned as Korolev's deputy.

1953 - OKB-1 starts design work on the R7 Semyorka, the world's first ICBM.

August 1957 - The R7 Semyorka rocket makes first successful test launch.

October 1957 - Korolev and OKB-1 launch Sputnik 1 using the R7 rocket.

1960 - OKB-1 begins design work for the Vostok programme.

1961 - Vostok 1 carries the first human into space, Yuri Gagarin.

1964 - Design work on the Soyuz spacecraft begins.

1966 - Sergi Korolev dies during routine surgery. OKB-1 is renamed TsKBEM with Mishin succeeding Korolev as Chief Designer.

1968-72 Vasily Mishin and Korolev's team work with Dmitrievich Kutnetzov to design world's first operational closed-cycle rocket engine, the NK-33.

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Engineering Icons - Sir Harry Ricardo

HARRY RALPH RICARDO

Pioneer of internal combustion and innovator of sleeve valve engine design. Ricardo also described the knock-inhibiting qualities of water-methanol injection in his groundbreaking volume on high-speed engines in the decades before World War II.

He also consulted on the sleeve valve Rolls-Royce Crecy engine, which would have bridged the gap between the jet and internal combustion engine.

1904 - Starts research with Bertram Hopkinson whilst at Trinity College, Cambridge.  

1906 - Graduates with a degree from Trinity, Cambridge. Gains first patent for a 2-stroke engine, upon graduation establishes a company to sell the engine.  

1911 - The Two-Stroke Engine Company fails.  

1915 - Establishes new company "Engine Patents Ltd" whilst an engineer for the Department of Mechanical Warfare. Designs 150 hp six-cylinder petrol engine for the Mark V tank.  

1917 - Mark V tank engine modified to produce 260 hp.  

1918 - Appointed technical director to the Air Ministry.  

1919 - Bridge Works established at Shoreham. Conceives "Turbulent Head" for petrol engines to increase combustion chamber flame speed.  

1918-21 - Builds variable-compression test engine to research irregular combustion problems, innovating with Henry Tizard and David Pye the octane rating system for measuring petrol quality.  

1922-23 - Publishes seminal work "The Internal Combustion Engine" in two volumes.  

1927 - Formation of Ricardo Consulting Engineers.

1929 - Awarded Fellowship of the Royal Society.

1931 - Devises combustion swirl chamber for high-speed diesel engines.  

1936 - Begins work on the Rolls-Royce Crecy, a sleeve valve 2-stroke direct injection petrol V-12 engine.  

1941 - Assisted jet engine pioneer Frank Whittle in designing a barometric fuel control system and improving combustion chamber design.  

1939-45 - Consulted by various firms during World War II including Bristol, Napier and Rolls Royce.  

1948 - Knighted for his work in internal combustion engineering.

1964 - Retires from active work at Ricardo Consulting Engineers, aged 79.

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The Apprentice Striker

12/07/22: Acting striker for blacksmith Adam (ex. Maritime board, NSW) with 10-lb. sledge. Forged 3 pinch bars with 40mm tip from 20mm spring steel rnd. bar.

Yellow heat, jump 25mm dia., 3-4mm reduction,

normalize 2-ft, oil harden, Blue temper.

1 per hour cold.

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Engineering Icons - Sir Joseph Whitworth

JOSEPH WHITWORTH

The fitter's fitter, an engineer of practical ideas that were to become standard practice throughout the world.

Where Henry Maudsley conceived the machine-tool to produce parts of sufficient quality and accuracy in the required quantity to meet demand, Whitworth continued.

He identified two elements absolutely crucial to precision workmanship - a true plane and power of measurement. Coining the statement "you can only make what you can measure".

At the same time he endeavored to improve the construction of machine tools,  to this end he is credited with doing away with flimsy architectural designs and originating the box structure design found in lathe beds. Whitworth made machine tools which were of the quality and size required to make the mechanical components comprising the industrial machinery of the period. Hence a large portion of the machinery which embodied the industrial revolution in England had components made on Whitworth machine tools.

When exhibiting his latest development in measurement, Whitworth exclaimed the definition of comparative measurement and laid down the fundamentals of workshop metrology: "We have therefore in this mode of measurement all the accuracy we can desire; and we find in practice in the workshop that it is easier to work to the ten-thousandth of an inch from standards of end measure, than to the one-hundredth of an inch from the lines on a two-foot rule. In all cases of fitting, end measures of  length should be used, instead of lines."

The following is a small outline of Whitworth's extraordinary calibre.

1821 - Around the age of 17, runs away from his uncle's cotton mill in Derbyshire. Finding work with Creighton & Co as a mechanic.

1825 - Begins working at Maudslay & Field in London as a bench fitter.

1827 - Innovates the 'three-plate method' for originating true surface plates through scraping by discovering the correct sequence of comparing and working the plates.

1841 - World's first screw thread standard: Whitworth proposes his thread standard in a paper to the Institute of Civil Engineers, 'Whitworth thread' was generally adopted in England by 1860.

1844 - Proposes adoption of decimal fractions in engineering workshop practice and is attributed with introducing the thou, being 0.001 of an inch.

1850 - At this time, Whitworth was the pre-eminent maker of machine tools due to his tools having sufficient size, strength and precision to meet the demands of industry. Thus introducing a standard of design only exceeded later in the 20th century.

1856 - Exhibits bench micrometer capable of discerning differences of one-millionth of an inch to the Institute of Mechanical Engineers in Glasgow, making the exclamation on metrology in the workshop stated above.

1868 - Founds the Whitworth Scholarships.

1870 - Develops fluid compressed steels for armament manufacture.

1874 - At the close of his career, Whitworth converts his Manchester business to a stock company and issues most of the shares to his workmen.

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Genesis - Portsmouth Block-making

PORTSMOUTH DOCKYARD BLOCK MILLS

The block mills embody the first purpose designed and integrated system for mass production. *AND* the original machinery was in operation for 122 years!

The block-making machinery was conceived by Marc Isambard Brunel whom consulted and subsequently engaged Henry Maudslay in the year 1800 on the making of such machine-tools.

Three sets of machines were required, each to produce a different size of block, totaling 45 machines. Making the machines completely engaged Maudslay for six years, as they were nearly entirely hand made by chisels, files and scrapers. The resulting work was in every way a tribute to the dexterity of the craftsmen involved.

By 1808 the block mills were in operation, allowing 10 men to make 130,000 blocks in that year alone, and averaging 160,000 blocks in following years.

The original block-making machinery was in use until around the 1930s, production from the block mills ceased in the 1960s when some original machines were still in use! !

Link: More details on the blocks and mills themselves

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Key Thinkers - Ben Franklin

BENJAMIN FRANKLIN

At age 20, Franklin drafted his 13 virtues which he practiced throughout his life. Franklin explored civic and personal virtue publishing his wisdom in Poor Richard's Almanac. Through his insights, Benjamin Franklin pioneered Deliberate Practice through his writing method of Deconstruction and Reconstruction. Among other things he was also not far off originating the 'Pay It Forward' concept.

Some other interesting facts:

Started apprenticeship as a printer.

1728 - Franklin establishes printing house with Hugh Meredith.

1733 - Publishes Poor Richard's Almanack.

1737 - Appointed postmaster of Philadelphia.

1747 - Retires from printing.

1746 - Began experiments with electricity. Franklin's experiments focused on electric charge, culminated in discovering the principle of charge conservation.

1752 - Invented the lightning rod.

1775 - Franklin becomes the first US Postmaster General.

1776 - Represented Pennsylvania in the Committee of Five becoming a drafter and signee of the Declaration of Independence.

And that’s only some of the story...

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RAAF Fitters, Papua New Guinea 1944

source: Australian War Memorial

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Engineering Icons - Dr. Goddard, PhD

ROBERT HUTCHINGS GODDARD

Goddard co-creates the foundation of rocket science when in 1919 the Smithsonian Institution publishes Goddard's monograph, A Method of Reaching Extreme Altitudes. This along with Tsiolkovsky's work forms the foundation of rocket science.

1908 - Recieved B.S. degree in physics from Worcester Polytechnic Institute.

1910 - Recieved M.A. in physics from Clark.

1911 - Completed his Ph.D.

1912 - Invented beam deflection vacuum tube, predating Lee De Forest.

1912 - Originated the mathematics and physical principles fundamental to rocket flight.

1913 - Seriously ill with tuberculosis, not expected to survive.

1914 - Goddard is granted his two landmark patents describing multi-stage rocket engines with solid propellant and, solid fuel or liquid propellant rocket engines.

1915 - Employed de Laval nozzles in rocket engines which achieved internal efficiencies greater than 63%.

1916/1917 - Built and tested the first ion thrusters.

1918 - Demonstrated the first rocket-powered, recoilless light infantry weapon precursor to the "bazooka".

1919 - The Smithsonian publishes Goddard's report, A Method of Reaching Extreme Altitudes.

1926 - Launches world's first liquid propellant rocket.

1930 - Charles Lindbergh finds Goddard funding through the Guggenheim Foundation. Goddard and his family move to Roswell. Roswell workshop is constructed.

1932 to 1934 - Return to professorial position at Clark University.

1935 - Liquid-fueled, gyroscopic guided A-5 rocket launched to 4800 feet.

1936 - Designs and launches world's first rocket with multiple combustion chambers and nozzles, the L-7.

1940/41 - Goddard's P-series rockets use propellant turbopumps.

During the war, Goddard was contracted by the US Navy to develop Jet-Assisted Take-Off (JATO) engines before dying in 1945 at age 62.

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The Fitter

"What is Fitting?"

"Fitting, in its broadest sense, signifies the union of the various portions of which a mechanism is composed. But it embraces more or less of the preliminary preparation of parts, as well as their subsequent union. It also includes the repair and reconstruction of all classes of engineers' work. It deals with the smallest and most delicate machines and models, and the largest and most powerful engines, cranes, and pumps, and all the thousand and one forms in which mechanism occurs. It embraces the manipulation of all the common metals and alloys, together with a practical knowledge of:

Material properties and thier special uses;

Approximate strengths of ropes and chains, beams and elements;

Methods of aligning and hoisting heavy castings, forgings, and parts of machinery;

The nature, and properties, and behavior of water, steam, gas, and air.

The practice of the trade presupposes good physical health, able to stand the extremes of outdoor winter temperature, the scorching heat of summer, and the close atmosphere of boiler sheds and stoke-holds, for a jobbing fitter never knows where he may be sent to work at an hour's notice. In short, the fitter stands as the visible embodiment of the engineer.” - Joseph G. Horner, "Introduction," in Principles of Fitting, 4th ed., 1919, pp. 1-2

Fitters at LMS Horwich works 1919 © National Railway Museum and SSPL

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Shop layout: Benches

Whether servicing steam locomotives or building Porsche 550s, you need the right "bench-space" in the right place.

Determining workshop layout usually begins with establishing which tasks are to be performed where. In a perfect world 5S methodology would be implemented from this stage on, but that's fuel for another post.  

Where what is done is governed by infrastructure. Can a 50-man assembly line be put in a backyard garden shed ?

Infrastructure floor plan determines positioning of benches. In turn bench location and orientation effects work space flow.

Benches are generally laid out in two configurations:

Wall side

Benches are placed along walls, or bays..

Possible access and egress to workshop from both ends,  well suited to stages\stations in assembly lines.

Suited to smaller areas.

Prone to lighting issues.

Island

Benches placed away from walls, central in shop area.

Generally requires more floor space.

Easier cleaning.

Benches may be worked at from all sides.

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The “Old Breed”

The "Old Breed" was forged in the "Banana Wars" during the first decades of the last century.

Prime examples of "Old Breed" Marines include

ROY GEIGER

Veteran of Nicaragua, 1912.

Qualified as Marine aviator.

Veteran of World War I, 1918.

Veteran of Haiti, 1919-1921, 1925-1927.

Pioneer of close air support tactics.

Commander of Cactus Airforce, 1942.

Only Marine officer to ever command a field army, 1945.

CHESTY PULLER

Veteran of Haiti, 1919-1924.

Veteran of Nicaragua, 1928-1931, 1932.

Commander of "Horse Marines" in Peking, 1933-1936.

Commanded 1st Battalion 7th Marines at Guadalcanal, 1942.

Commanded 1st Marine Regiment in two wars,   at Peleliu in 1944 and in Korea, 1950.

Most decorated US Marine in history.

DAN DALY

The blueprint to which all subsequent   "Gunny" sergeants are made.

Awarded two Medals of Honor in separate actions,   and recommended for a third during the Battle of Belleau Wood.

“The fightinest Marine...ever” - Maj. Gen. Smedley Butler

Veteran of the Boxer Rebellion, 1900.   Awarded the Medal of Honor for single-handedly   holding an position during a night-attack against   hundreds of rebels at the American Legation in Peking.

Veteran of Haiti, 1915.   Again awarded the Medal of Honor for retrieving his   platoon's machine-gun from the bottom of a river.

Veteran of World War I, 1918. Awarded Navy Cross and DSC instead of another Medal of Honor during the Battle for Belleau Wood for extinguishing a fire in an ammunition dump then five days later, proceded to capture an German machine-gun position unassisted with only hand grenades and a pistol. Continuing throughout the battle to bring in wounded under fire.

The "Old Breed" really embraced the professional conduct of combat being the epitome of the 'Marine' if there can be such.

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(Below) Buckton planing machine of same design operated by a precursor of myself, William “Sloky” Slocombe at Walkers Ltd. The table (middle slab bit with square holes) measures 8ft long and 5ft wide, the total length of the machine would have been 16 feet.

Records indicate Sloky’s planer was probably circa 1895. The miniature I operate dates from 1909, hence myself being given the Slocam handle :|