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• After the molding sand mixture has been packed and compacted
around it, the pattern is withdrawn and molten metal is poured into
the mold cavity which remains.
• After the metal has solidified and cooled, the casting is separated
from the sand mold. The sand castings are easily recognized due its
sand-like texture imparted by the sand mold.
• As the accuracy of the casting is limited by the green
sand making process, there is always some sand
residues on the surface of the castings to be removed.
3: This 'half mould' is then inverted, the board removed and the
upper half of the split pattern is located accurately on its lower partner.
4: A parting agent (traditionally French chalk) will often be dusted over the area
where the sand in the drag will contact the sand to be poured into the cope.
5: Provision will be made for the 'runner' and 'riser'. The runner is to allow the molten
steel to enter the mould. The riser is allow the air to escape. In this case exothermic
sleeves are being used to keep the puddle of steel in the runner and riser hot longer
and thus ensure a complete fill as the molten steel cools and thus contracts.
6&7: Sand mixed with a binder is now poured into the flask that forms the cope. The wooden frame on top of the upper
flask is there to increase the depth of sand on the top half of the mould and thus increase the volume
of metal contained within the puddle. Having a good head of molten metal assists in ensuring a complete fill.
8: The two parts of the mould are separated and the pattern is withdrawn by screwing a tool
into the lifting plate. The moulder is seen applying the threaded tool to the lifting plate
between the two dowels. The dowels ensure the two halves of the pattern align accurately.
9: Final preparation of the mould is made before the core is accurately located within
the mould supported on its core prints.
12: The core can be seen in place awaiting closure of the mould.
13: The two halves of the mould are brought together. A dowel and corresponding
hole at each end of the two parts of the flask ensure the cope and drag align.
14: Steel of the correct mix is prepared in an electric furnace.
15: Pouring from the furnace to a crucible that will be taken to the mould
by means of an overhead crane
16: The pour from crucible to mould. Note full safety equipment worn by the foundry man.
Molten steel is to be treated with great respect!
17: The filled moulds are now left to cool. With a casting
this size the mould will be opened tomorrow.
18. One very nice pair of taper-shank buffers ready for machining before being fitted to
4566. Coincidentally the pattern makers number the patterns uniquely by using their
initials followed by a sequential number. Gordon Woodruff made these patterns, hence
the GW21appearing on the moulding equipment.
• Patterns
From the design, provided by an engineer or designer, a skilled
pattern maker builds a pattern of the object to be produced, using
wood, metal, or plastic; other materials such as expanded
polystyrene.
The metal to be cast will contract during solidification, and this may be
non-uniform due to uneven cooling. Therefore, the pattern must be
slightly larger than the finished product, a difference known as
contraction allowance. Pattern-makers are able to produce suitable
patterns using 'Contraction rules' (these are sometimes called "shrink
allowance rulers" where the ruled markings are deliberately made to a
larger spacing according to the percentage of extra length needed).
Different scaled rules are used for different metals because different
metals / alloys contract by differing amounts.
Pouring
• Paths for the entrance of metal, during the pouring
(casting) process into the mold cavity constitute the
runner system and include the sprue, various feeders
which maintain a good metal 'feed' and 'runners', and in-
gates which attach the runner system to the casting
cavity. Gas and steam generated during casting exit
through the permeable sand or via the riser, are added
either in the pattern itself, or as separate pieces.
Molding box and materials
• A multi-part molding box (known as a casting flask, the top and
bottom halves of which are known respectively as the cope and
drag) is prepared to receive the pattern. Molding boxes are made in
segments that may be latched to each other and to end closures.