yg c ik rth SIGN OF | a , WN OA Rai iceEel,« A. W. WRIGHT 1916 1293 01692 8461 LIBRARY Michigan State University ; _{~ - + *2-~REE Sans. PLACE IN RETURN BOX to remove this checkout from your record. TO AVOID FINES return on or before date due. DATE DUE DATE DUE DATE DUE 1996 c/CIRC/DateOue.p65-p. 14 Design and estimate of a proposed Machine Shop for the Mitte and Merrill Keyseater Co. Saginaw, Michizane A Theais Submitted to The Faculty of MICEIGAN AGRICULTURAL COLLEGE A. We Mri gnte CeNe Winstone Candidates for the degree of Bachelor of Science. June, 1916-6 THESIS Page 1 History of the Plant and Object of this Tnesis. The Plant of the Mitts and Merrill Keyseater Company is situated upon the river front at Saginaw, Michigan. It's location is ideal for acquiring raw materials and for shipping the finished products, vdecause of the water way, and the railroad which operates along the street parallel to the river and on the other side of the plant. The criginal shop was very small and the output consisted cf repair work upon river steamers and farm machinery. As time went on, the conditions changede Lumbering ceased and with it went the majority of river steamers. Hence, the firm had to turn to other pursuits. They invented and perfected the Mitts and Merrill Keyseater. Gradually, the far. machinery trade dropped off and the entire ocutput changed to higher class machinery. They purchased some property across the street from the original shop and put up a modern foundry. Other buildings had to be built, such as a blacksmith ehop, lumber sheds etc. These were all crouded to-gether in the small available space. The result of such unsystematic building has given the firm shops, which are not scientifically located. It necessitates a loss of time and efficiency to have to transport so much of the materials from one building to another, and often, back again. Floor space is at a premium. Stock rooms are hard to find and the interior is not well lighted. In spite of this, however, they are doing a great deal of business. Careful and good management hes done wonders. With the size of tne output, the quality and variety of the 40413+ Page 3 Rear view of shop Front view of fou ndry a oe “MOY product in@reased. At tre present time they are building several sizes of Keyseaters ani special iwachines;samall keyseat millers, voring mills,and hogs,cr refuse zringing nacnines, fcr sawmblls and rubber fuctories. All cf these machines are hégh class and tre firm has a well estsatlished reputation. The time is rive, therefor2, for a new set of working conditicns and the object of this thesis is to study the old and design tie new.To the best of our abilitv, we are emnloying scientific and medern princip2@e in the design. We are obtaining the most reasonable prices and selecting the most practical and econovie installation that we can get. Thre data herein comviled was obtained fro: many sources and we hereby acxnowledze our indebtedness to the following persons and firm who have been so kind as to furnigeh us cratis tie 3tea3tiastics that we neede 3. Phillip ¢.Nit‘s The Griscomb Russell Co. Willian J. Winsto: The inurray CO-5 Hdrbert W. Merrill Tre Fitzburg Co. Dean Geo. W Bissell Tne Busch Sulzer Eros. Ajis. Chalmers Co. The Mc Intosh Seymour Co. General Electric Co. “The Shepard Crane Co. The Brown Crane Co. The Northern Engineering Co. Michigan Light and Power Co. The Firm hac now acquired the property adjacent to the foundry. It is 204'%138" and haz s°veral houses Property to be Boiler house Page 4 removed Building to be removed Rear view of foundry View of Saginaw river es eee, Page 5 and buildings upon it which will have to be torn downe Upon this property, we propose to place a new shop and office building. The specifications for the same will appear later. We have this fundamental fact and requisement to base Our calculations upon, that the present boiler house be used and that electric drive be used upon the machines. We keep in mind the character of the work that is to be done and as one of us has worked for several months in the plant, we feel that we are eapable of determining the most systematic rotation of operations and the best arrangement of departments that can be used. This problem is merely an estimate upon our part however, and we expect to be subjected to disaproval and changes by those, whose experience and older judgement enable them to find the faults in our argumente Motive tnits AT PRESENT. The boiler house is bullt of reinforced concrete contaning Wickes boilers of horse power, accessories, and a large coal bunker. The boilers furnish steam for a 50 H.P. corliss engine, which operates the machines. They also furnish heat oy means of a plenum forced air system,for all the buildings. There ig no complaint to make concerning these bollers as they have given exceptionally good service. The capacity is enough to take care of any immediate changes so that we need not design any new installations. Puce § The fifty horse-power Corliss engine was built fo yty years ago by the Bartlet Machine Co.,Saginaw, Michigan. © .ted with a speed of 90 R.P.M., tne engine operated at that speed for many years. Lately, because of the addition of many large machines in the snop, the speed was increased to about 120 RPM. Notwithstanding this unusual condition, the machine continues to give good service , which is a credit to itle makerge It works beyond economic capacity, though, so that we féel that there is a great need of change. Upon April 7th and 8th, we ran a five hour test upon the engine and obtained many carde showing the working conditiom From these we plotted a curve, I.H.P. to time in hours. This is shown on the next page. There are some discrepencies in the curve because of the difficulties encountered in making the cards, and the fact that we could not take them as often as necessary to give a true representation of the varying loade The peak is due to the running of one of the hogse The cylinder of this large Hog weighs two tons and it requires a great deal of power in starting. This machine was run for our benefit, although it had been tested beforee Almost every day, one of these machines 1s put upon the block and the test extends for approximately twh hours. The starting and stopping for balancing would have given an entirely different curve. The peaks would have been numerous and close to-gether and the curve would then cover the worst conditions that the engine is required to carry STEAL ENGITE TEST. -Corliss Stean Engins Pieton diameter— Stean pressure-----------~----— 138 lds. St rok e--~-----~-.------- - -- 30 inchese 10 inches. Piston rod dicmeter 111/16 inches Rated RP. .—— 90. Running Re? ott e ween 116 e Horse pover (indicated)= plan/33000 - 225 29. 921416_ horee power constant (head end) = 33000. EH. P. conetant (head end) =.00595 horse nower constant (crank end) = @: 5 25 _3.1416-3.14)6 1.5) 33000 ae H. P. constant (crenk end) = .00578 Horse power (indicated) Time HeEs C.Es Total I.H.?. ReP.ve 7:25am 28.60 31.80 60.40 115 7240 48.00 42.70 90.70 114 8:45 25.55 34470 49.25 130 8:56 26 70 23.95 50.65 113 9:12 38.95 320.10 47.05 115 9:15 27.18 21.40 A258 114 9:34 31.20 18.60 49.80 120 9:58 31.00 26.90 57.90 118 10:00 22320 27.90 50.10 112 10:15 39.00 24.40 53.40 116 10:45 28 .20 20.70 A890 114 11:30 26.20 22.20 20.00 118 11:32 18.30 14.50 30.80 116 11:34 14.40 15.50 _89 .90-- 118 = 39.90 H.P. is line shaft load alone. The everage Horse Power with ott line sheft end with out the Peak load. 54.629 Page & The two points upon the curve at 61 and 57 H.?. were ootained when the elevator and the trip-hammers were working. Had more cards been taken, there would be a great many of these points so that the average load of 52.5 H.P. would have bean higher. There were several reasons for getting this curve. It shows us that the engine is working with a great overload. It shows that about 40 H.P. were required to start the heavy Hogee This can be used to advantsge in estimating the size of motor to install for the express purpose of testing these machines. It gives the governing range of the engine to install and the horse-power necessary in case we decide in favor of an enginee It shows the overload that thw engine would have to carry without overheating and burning out. It shows the line shaft load of 30 H.P., which is our duty to lower as much as possible. And as a concise way of showing the load conditions, this curve is the best method that could be usede There is one small vertical engine in the shop which is used to drive the fan for the heating system. It requires &® little steam and it was necessary to consider,only the steam used in the Corliss. A small motor can be used economically to replace that. The power in the foundry consists of one 30 H.?. motor and one 10 H.P. motor. The current for these is bought from the Michigan Light and Power Coe Our design will include this power also as comming from the same source as the shop powere The following is a tabulated statement of the varoius uses , to which the power will be used. ~~ fee Page 9 A machine tool load of 25 %.P. which will be increased to at least S90 #.P. in tha next few yoars. A 30 H.P. load in the foundry. fpout five H.P. for the electric weider. Ten H.P. for electric hoists. This allows fér the number of hoists we think would be in operation at one tine. Five H.P. for ventilating fan. This makes a total of eoout 100 H.ee waick is equivalent to aoout 75 K.W. Any machine tocol addition will not materially effect tre operation of a 75 K.W. Generator. However if we decide in favor of buying the power from the HICIIGAN POVER ©CO., the addition of inachines can te wade as desired. Page 10 Buildingse We measured the property with a tape and found it to be 204 Ft. long and 138 Fte wide. Upon this we propose a building containing offices, drafting rooms, machine shops, blacksmith ahops, and a grinding roome We are designing this building on the same basse as the Potter and Johnson Coe, Pawtucket, ReI., which has a two story administratiog front, and a saw tooth roof shope In designing factory buildings, consideration eof utility, and esonomy, must be thought of first, and conditions architectural must subserviently adapt themselves to these prime requisites. The building must be designed with regard vO intake and output,adapting the arrangement to the equipment and flow of work, following the lines of least resistance as regarde both losses andi transmission avparatus and losses in activity of operators. The central monitor building gives the more pleasing architectural effect than the say tooth roof over the whole building, although the monotony of the saw tooth rocf structure is relieved by the two story administration front. The very cheapest factory building can be constructed of wood framing of just sufficient stgwength to withstand the stresses, and covered with corrugated steel siding, and tar paper or asbestos paper rocfing.e Anyone can see, however, that such a cOnstruction would be unsafe, would involve a high insurance rate, high cost for heating, and would depreciate rapidly. The next best type of building is the slow burning wood construction. Heavy timbers are used for framing, end thick flooring. It is designed, coupled with good automatic Sprinklinz system. “oe fire can gain great headway and only Page al BULlLGing cen't the surfaces cf the tinbers or certeinu ectivorzs of the bullaing Ould te destryed. In modern times, this is very expensive and has a higher fire protecticn rate than brick and steel cenetruction. Ketter than brick and though, for nost racticel purposes, is the trick and wood. It is apt te fill in most cases the requiwvenment cf thet type of building which prevents the loweet combined crarzese for intereet, depreciation and insurance, althoush it's cost is but slightly exceeded Cy construction of reifcreei concrete, which will be ¢ 4a accoupanied by still lower fire insurance rates. heinforce: concrete at one time presented difficulties in tearing down cut modern methods have done eway vith this objection. So, from all the points which we have cousicerdd, we would recommend that the Mitts :& Merrill Company use reinforced concrete in the new cCuilding. Licht. Abundsence of light is as important ae abundance of air. Vatural light skculd permeete the whole shop during all hours ét which it prevails cut:of doors, and not only WOre benches end mackines, but aveirvays and all pacsages, ehculd be lighte The saw tooth roof with the glase portion tovard the north gives the most agreable and diffused light. 9? In addition to thie there should te numercus side windors Pitted with ehades. Cxyliphtse ere generelly undesirerle Cn account of their liability to breakage of glass and ctatruction by sncwe fo much for natural lignt. Artificial light ise cest attained ty the use cf electricity. fre lamps o-: the incandescent circuit are desirestle for general illuminetion, eupplemented by incandéescents for the Page ps tO indivicuel benches and machines. The murcury ere lary is more economical tc operete then the flaming arc, Out proportionally less satisfactory, owing to the weird color effects accompaming their use. Jn large plents naving thoir ovn cower plant, the lozical thing to dc is to opersute thése 1 + fe ehtg fron their own generator. Howewer, the highly fluctuating load would ordinarily csuse the lichts to flicker. This has to be overcome by some voltage regulator, the cperaticon of which is unsktlefactory, and the initial cost quite high. It hae been Guoted to ue that a voltage regulator for this size plant would cost three hundred dollars and the additional generator power would cest ee much, Trerefore we btelicve trat the shop rovld vee lighting current from the city whether or net tBey wake their own power. Considering the amount cf space to be lighted and the cost of current in the city of Seginaw, we do not teliwwe thet this expense would Le BhoeeHives (iisstirs Of secexbly floor) Lips should be is close te the ceiling as possitle su that the glere will be reduced to & minimux. Dowl-frosted laings are not so desirable es clear ltmps, tecauee the effe 4 “ s 3: ~~ - he an pp. s GC. fost end dirt cr tre rfFrestinx ctr a) ww = ey - a ” « a _ s Moe wetal veficctcrs gre far rt inferbor to glass reflectors because no light passes through themy The cebling and girders should be of a light color so that light paseing through the glass reflectors will reflect upon the floor. Tyrell says, "Lamps without reflectors are debarred on account of the glare which results, and further Since sixty-two percent more illumination is delivered upon the working surface by such lamps than clear cnes of the same size, their is no doubt which lamps are preferred". Page 43 Heating and ventilaing. Professcr Hugo A. Diemer says, "With regard to heating and ventilating, it can be safely said that the loss in labor efficiency and consequent output per man due to faulty installation will certainly be found to be enormously greater than the cost of heating and ventilating equipment". The 1 indirect pressure or hot tlast system has many advantages over direct radiation=for heating» The hot blag® system consists of heating the air in a room supplied with steam coils, and delivering it under pressure from a blower, by means of ducts neatly concealed under the floors and in the walle of the office building, and thin metalic pipes in the shop. It has the following advantages over the direct radiation system; it will heat the shop more Quickly in the morning, it will destribute the heat more uniformly, and is more easily controlled. We recommend that the heating chamber and the blower be loagted in the shop building as shown in drawing No. 2. The fan which is in use will in all probability be sufficient for the new building. It should be run by an electric motor and should be used for ventilation as well as for heatinge Clean air is a money saver. There are to methods of obtaining thate One is the coke washer and the other is the curtain spray. In the first plan, the air is drawn througha series of cages filled with coke, over which fine streams of water trickie. The coke absorbs a certain amount of dust end will serve in this way without replenishment for at least & yeare eta: ee The eecond and better plan consists of blowing air through several curtcing of fine streams of water. The drying is a accomplished by passing the alr alternately over en€ under e series of baffle slates. We recommend treat the Mitts and Kerrill O60. use the latter methcd,astney have and mlimited supply of water.Suck a cleaning cf the Gir will eliminate a large amount of the rusting of machinery and stock,ena sill make the bullding cool,light,and free from dust. The g@ide windows need rot be opened,thus preventing drsughts. In fact the best success cf tre Plenum system comes when the side winWowsere shut eni the skylights are opened. The hot eir and gasses are then forced cut of the top of tre building. Ths abliity to controll the humidity will mice the cost of heat- ing lower incese live steem froz. t:.e bcklerea is used@ . Offilce. We have been told that the firm desires to build the offi e before making the shop change. In that case the office sheuld be so plinned thattie scp could be bullt on to it in tie future There is no werygood -ijection tc waking the Office end shop buldines s’purcte and distinct “r.mezch other, and there cre several very gcod ones tis. they should be cuilt into one buildin... Firet,buildingmeterieal,such ce glosse,eashes,e«xterior brick or finely finished concrete wall will be gaved. Second, it will be very convenient te go from office to shcop.Thirdy, noise. and vibration will be entirely eliminated by modern methods of construction and the fact that the large machines ere to be ect the other end of the chop frou tne office. For example the Reo Motor Car Co. of Lansing,wich. he-the edminitrat ion tuiling and the shop to-gether. They hsve no complaint to make over the “rrangement and the noise is entirely elininated in tre office. &. - -~G@~ ~ mm ww The office should front unon Eclden Street whieh runs ecet and west. It si.culd te located centrally with respect to the reset of the building. Archetecturel design should be thought of a the discourts, we heltbve th-t the couceny ehoul? buy all cf it's light and power fro. this aoncerne Tze cost of ro er zener ted by « steam plant would be Sichiczen Coe In eny ue an 6 greater then the ecst o°fered by the power plent cvned by the “ir, tnere is a hich repeir bill e Trere ia she cost cf building such = pewer plent end dnetelling enzines snd ceneretors, which cost is eliminated. The Diesel installation is even rcre expensivee Any operatecr for a Dies2l engine has to be cn exvert in thet line and his salary ig hi:h. Fro these facts :nithe fact thet power can be bought for sbout one and one half cents per K.We/hre, we think thet the Sims can do no better than buy their powere -nf -. 4 = a ed CONCLUSION. In conclusion, we sucmit the following blue print shoving as clearly es possible, the floor nlans énd arr:ngemmt of machinery in the shop us specified heretofore. Ye feel that tris Thesis has been completed as fully es possible in the snort time evailable. It is merely < preliminary estimate and before adoption, should be more thoroughly analyzed. Ae & matter of education we feel fully repaid for the time ani work put upon the study. We acknowledge and appreciate the information which We have received from the eources stated. The librar y reference used is "Engineering of Shops and factories" by Tyrrell. Signed: C Uf - tt) valor a WU UWrtg ht Index to Drawing No.l First Floor. #1-38 " New Haven Lathe. # 8---- # 3--~- #4-—.._ ¢ 5---- % 5---. a # 8 t 9 # 10___ # 11 ___ “Ho as a Oo © Ingersol Miller. ifarvel High speed Saw. Srall automatic Saw. Prentiss drill press. Water grindstone. Elevetore Drill Press. Mitts and Merrill Keyseat Miller. 48" New Haven Lathe. Bick ford Redial Drill Press. Whitcc.2 Planer. Kinslee Planer . Bickford Radial Drill P ress. Grinder. Gordon Disk Grinder. Hog testing Elocks. “Mitts and Merrill Keyseater. 36" Boring “ill. 60" Poring Mill. Food shop. TO°99 Rand cawe 2°°°° ‘Swing Cross cut. 19°99 Rip Saw 13°°° Wood Lathe 1°°°° iultiple spindle drill 19°°°° Planere Page Seaond Floor. Gould and Eberhafdt Gaaper. “Allwaukee Shaper. Bickford and Cincinnati Drill Bresses. Garvin Millers. vDiek Grinder. Einery Grinder. Duffer. Hill Clark & Co. Drill Press. Lew. Pond Blaner. smith Machine Silk tool Co. Planer. Jones and Landert Turret Lathe. Greenerd Rroor Press. Toledo Electric Welder. Gosld and Eberhardt cear Cutter. Mitte and uerrill Keyseater. Mahning,iaxwell,and Morse Lathe . Fay and Scott Lathe. Prentiss Lathe. Lodge and Shippley Lathe. Lodge and Davis Lat:.e. American Lathe. Fay and Scott Lathe. Bradford Lathe. Le Bond Lathe. 5 y #28—-—~—Cincinnati Drill Press. INDEX TO DRAWING No.2 #1----Mitts and Merrill Boring Mill. #2——--Mitts and Merrill Keyseater. #3—-~——Coburn Boring Mill. #4—-—-Floor space for shrinking bands on cylinders and for fitting shafts to cylinders. #5----48" New Haven Lathe. #6--—~28" New Haven Lathe. #7-—--Ainslee Planer. #8—----Whitcomb Planer. #9-~-—Storage space and chipping floor and future machine spaee. #10-—~Prentiss Drill Press. #ll—--Ingersol Miller. #12--~Prentiss Drill Press. #13-—-Bickford Radial Drill Press. #14-—-Rlocks for portable Lathe to face bearings on Hog Frames. #15---Blocks for portable milling Keyseater Frames. #16---H111 Clark Drill Press. 717-—Automatic Hack—-saw. #18———Two Wheel Grinder. #19---Mitts and Merrill Keyseat Miller. #20-=-Gordon Disk Grinder. #2l———Marvel High Speed Saw. #22—-——Gould and Eberhardt Shaper. #23--—Milwaukee Shaper. #24-—-Gould and Eberhardt Shaper. #25--=Babbitting Floor. #26---Hog Tests Block. 727--—Bickford Drill Preas. #28--~Cincinnati Drill Press. — - co Ci Page Index to drawing No. 2 #29-——Bickford Drill Press. #30-—-—Lodze and Shippley Lathe. . #31——-Jones and Lambert Turrett Lathe. #33---Prenties Lathe. #35—-—--Eridford Lethe. 434~--Gremnerd arbor Preas 135—---Mitts end Merrill X