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Foundry 
 
 Moulding Machines and 
 
 Pattern Equipment 
 
 A TREATISE 
 
 SHOWING THE PROGRESS 
 
 MADE BY THE FOUNDRIES USING 
 
 MACHINE MOULDING 
 
 METHODS 
 
 By 
 
 EDWIN S. CARMAN, 
 
 Mechanical Engineer 
 
 Mem. Amer. Soc. M. E. 
 Mem. Cleveland Eng. Soc. 
 
 SECOND EDITION 
 
 ILLUSTRATED 
 
t>^ 
 
 ■^> 
 
 C O P Y R I G II T 
 
 In the United States and Canada, 1020 
 
 Entered at Stationer's Hall, London, by 
 
 EDWIN S. CARMAX, Clevlland, 6. 
 
 .■ill rights resenrd 
 
 ^ 
 
 \ 
 
 e 
 
 FEB a I 1921 
 0)CU60843o 
 
INTRODUCTION 
 
 During the past years marvelous advances have be.-n made 
 in the amount of production obtained from the daily efiforts 
 of man. This is true not only in the industrial establish- 
 ments, but it is true in practically all walks of life, and 
 especially does this fact stand forth in our home life, 
 transportation, trucking, farming, merchandising and in the 
 industrial arts; it is evident in the steel mills, machine shops, 
 pattern shops and in some few foundries, especially those 
 foundries engaged in the manufacture of automobile cast- 
 ings. The increased production that is obtainable in these 
 and in many other lines of daily activities, has been brought 
 about by the utilization and application of scientific knowl- 
 edge, engineering principles and mechanical appliances. 
 
 This is a mechanical age. The hard, drudging, physical 
 effort is being taken out of labor. Labor is now, in nearly 
 all instances, being performed by the pulling of a lever, or 
 the pressing of a button. The farmer's life is easy, plowing 
 is performed by power, the wheelbarrow has become a truck, 
 the Japanese jinrikisha an automobile, the hammer and 
 chisel are replaced by lathe and planer; but to the foundry 
 in general these contrasts will not apply, as the moulding 
 in some plants is still being performed in the same manner 
 as it has been for centuries past. The mould is still made 
 in the old-style wood flask, hand rammed by the same old 
 laborious method, and very little accomplished at the day's 
 close. Instead of being fresh and vigorous, the man is 
 exhausted, the production small, and in many cases the 
 castings defective. 
 
 A new day is upon us. It is here ; we cannot change 
 it ; regardless of our individual attitude, it is here to stay ; 
 we cannot even delay its workings ; we must launch out into 
 the current of modern activities, or the current will strand 
 us upon the reef. Our individual effort will be judged 
 by the amount of work produced. There will be no place 
 for the man who is willing to work through a long, hard 
 day of drudgery in order to perform his daily work, but 
 
IV Foundry Moulding Machines and PatUrn Equipment 
 
 instead, he wlio can produce as his day's work, maximum 
 production with a mininuun of effort, will be the one who 
 stands the liighest. 
 
 The manufacturers today are not desirous of obtaining 
 a maximum production by means of exacting hard hours 
 of labor, but instead, in the great majority of industries, 
 the maximum production is obtained by mechanical means, 
 witii minimum labor. The foundry has been one of the 
 last industries to adopt mechanical means of saving hard, 
 drudging labor, and the very fact of its being late in start- 
 ing is perhaps the reason for the rapid development that 
 has been made. 
 
 Further progress will iiave been made when mord 
 attention has been given by engineers to detail casting design 
 in order to meet the foundry's requirements as to moulding 
 methods, and by the manufacturer when ordering or having 
 made patterns that are to be used by ihe foundry. 
 
 It is with a view to stimulating cooperation between 
 foundrymen. manufacturers and engineers that this book 
 is written, i heir working together will be the means of 
 producuig the world's ever increasing casting suj^plv in an 
 easier and better way. The author, believing that pictures are 
 of great value in the presentation of ideas, has endeavored, by 
 a very liberal use of engravings, to illustrate the method of 
 mounting patterns and the making of moulds l)v machine power. 
 An endeavor has been made in this book to explain tlie diffcM- 
 ent types of moulding machines together with the pattern and 
 flask equipment necessary for their use. in such a wav that 
 the reader will obtain a grouj) of fundamental conceptions in 
 regard to machine moulding that will be of value to him in 
 any line of engineering work in the foundry, and that the 
 practical foundry man will ha\e liglit shed on that most impor- 
 tant f|uestii)n, "Will it he jjrohtable to run this job on a 
 moulding machine, and if so. on what tvpe of machine?" 
 
 Chapter 1 contains much th;it is elementary in nature and 
 will be of benefit to those who are not familiar with foundry 
 terms. The practical foundryman may feel inclined to skip the 
 
Introduction 
 
 olcnientarv mattt-r. but he should lake care not to skip the state- 
 ments of tun(huiuMUal importance in rej^ard to machine mould- 
 ing. 
 
 With ad\ances coming so rapidly, the best j)ractice of today 
 becomes antiquated tomorrow and it is with a full realization of 
 this fact that some of these methods of producing castings are 
 here shown. They may be obsolete before the book reaches 
 the reader. Ilowever. a study of the methods given in this 
 book will atiford to the reader an insight into the process of 
 making moulds by machine jxnver. and if vie\\ed in this light, 
 the truths set forth are (|m'te universal. 
 
 1-Jnvi.\ S. C.XRMAN. 
 
 Cleveland, Ohio, November, 1920. 
 
VI Introduction 
 
 Preface to the Second Edition 
 
 The lirst edition was. as far as the writer is informed, the 
 first attempt of an author to publish a work covering the sub- 
 ject of machine moulding. It was felt, however, that the first 
 edition did not sufficiently cover all of the many details and 
 ramifications of the art of machine moulding, and therefore, in 
 the second edition such details are covered more completely. 
 
 Investigation has shown that many of our colleges, insti- 
 tutes and technical and trade schools desire to give to the stu- 
 dent a training in up-to-date foundry methods but are unable 
 to do so because of a lack of sufticient data on hand with which 
 properly to prepare a thorough course of study, and it is with 
 a view to supplying these needs that Chapter I has been added. 
 This chapter treats the fundamentals of machine moulding, 
 being both elementary and advanced theory and practice. 
 
 The book will also be appreciated by those in the industry 
 who are desirous of changing their methods from hand to 
 machine moulding; also by the manufacturer w^ho is desirous 
 of having his organization furnished with a complete treatise 
 which shows in detail the methods of pattern mounting and 
 machine moulding. 
 
 Edwin S. Carman. 
 
 Cleveland. Ohio, November, 1920. 
 
Table of Contents VII 
 
 Table of Contents 
 
 CHAPTER PAGE 
 
 I General Moulding Principles 1 
 
 II The Theory of Jolt Ramming 31 
 
 III Roll Over Jolt Moulding Machines 40 
 
 IV Roll Over Jolt Moulding Machines for Large Size Moulds 58 
 
 V Roll Over Jolt Machine for Medium Size Moulds 70 
 
 VI Roll Over Jolt Machines for Small Size Moulds 92 
 
 VII Jolt Moulding Machines in Brass and Aluminum Foundries 106 
 
 VIII Plain Jolt Moulding Machines 114 
 
 IX Air Operated Squeezer Machines 132 
 
 X Jolt Stripper Moulding Machines 148 
 
 XI Pattern Equipment 161 
 
 XII Flask Equipment 188 
 
 XIII Machine Moulded Cores 203 
 
 XIV Foundations for Jolt Ramming Moulding Machines 209 
 
 Index 222 
 
A Study in Contrasts 
 The man guides the tool. Here the man furnishes the power 
 
 to push the tool. 
 
 Machine Power vs. Human Muscular Power 
 
 The mechanic of today has an easier and better job than the 
 
 laborer of yesterj'ear. 
 
Hard Work! Tiring and Slow! 
 
 The machine does it quickly 
 and accurately. 
 
 The Old Method — Five minutes 
 to draw the pattern and one 
 hour to repair the damage done. 
 
 The New Method — Five seconds 
 after the lever is thrown over — 
 ready to set cores. 
 
5TTOM PLATE 
 
 Rf\M \JPRUNN£RCOFE 
 
 Fig. 1. Plan and Sections of a Well Designed Mould, Explaining the 
 Terms Used in the Following Chapters. 
 
CHAPTER I 
 
 General Moulding Principles 
 
 The foundry industry is rapidly changing from a basis of 
 performing labor by hand power to a basis of performing labor 
 by mach.ine power. This is evident in all phases of foundry 
 work. Arriving material is unloaded mechanically, the sand is 
 prepared and carried to the moulding stations by a mechanical 
 process moulds are produced by the use of air or other power, 
 the casting is handled mechanically from place to place in the 
 cleaning room where the work is done by sand blasts, pneu- 
 matic chippers and power operated abrasive wheels. To cover 
 all the labor-saving devices mentioned would require a much 
 larger volume than the present one, which is restricted to mould- 
 ing machines and their equipment. The use of moulding 
 machines with the resulting high production demands the use 
 of other labor-saving facilities in order that the other depart- 
 ments of the foundry may keep pace with the moulding 
 machines. 
 
 The pattern equipment, flasks, etc., are important items 
 that have seldom been given the proper amount of considera- 
 tion. Experience has thoroughly demonstrated that in order 
 to secure the best results, proper attention must be given to 
 e(|ui])])ir,p the machine with patterns, flasks and bottom boards. 
 In e(|'iii<ping the machine with patterns, exceptional care 
 should be exercised to secure the pattern firmly to the pattern- 
 plate, and patterns having a large flat surface should be thor- 
 oughly end strongly supported from the bottom in order to 
 remove the possibility of a springing action taking place in the 
 pattern when the mould is being rammed. If the pattern is 
 not properly supported, and a springing action takes place, the 
 mould produced will be full of cracks, and if it is the cope 
 half of the mould, it will drop out when the flask is being 
 handled. 
 
 The flasks also should be examined to see that they are 
 rigid and of sufficient strength to prevent a springing action. 
 
fi./9C£P o/v r//£ r/9gi£ of r//s />r/fcff//v£ 
 
 r»£ £i./>sfr /i/'i./9C£^ /9/7ot/n':> n£ /'/frrF/TN, 
 
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 rMf ca/'£^ ^^ /van/ />f/9a£ iv /i /ve/i/fLr ^//v/^/c/r 
 
 Mfin/v£/T £/r»£/r A/or /f0i-UAi6 ayefr lir />i.L 
 
 ofT as//vs /* r/iLse sarra/^ aav/rc 
 
 TM£ C^lC£ ^/f^s a££Af Clt>S£^. rft£ /YM'/.e' CC/IMr'£j; 
 
 Fiji. 2. Method of Makinji a Mould on the Plain Jolt Machine. 
 
General Moulding Principles 
 
 The best results have been produced by the use of flasks that 
 are cast in one piece. This is especially important when design- 
 ing the cope half of the flask, and yet in some instances it is 
 difficult to cast integral the flask and the proper bars for sup- 
 porting the sand. If it is found necessary to make use of a 
 separate bar, it should be secured to the flask by means of 
 rivets, or tightly fitted bolts, as a loose bar may prevent the 
 making of a satisfactorily rammed mould. 
 
 The above description of the equipment necessary in jolt 
 ramming applies to all machines which make use of the jolt- 
 ranmiing principle. The rapid change in the foundry industry, 
 from a basis of performing labor by hand power to a basis 
 of performing labor by machine power, has given rise to some 
 popular misconceptions. One of these misconceptions is that a 
 moulding machine is a mysterious piece of mechanism which in 
 some manner turns out finished moulds at one end of it. The 
 exact reverse of this belief is the case, however. A moulding 
 machine performs some of the operations that are performed 
 by hand moulding, merely taking the hardest part of the labor 
 out of the job and eliminating practically all of the guess work 
 and chance which go with hand labor. The pages immediately 
 following are taken up in illustrating graphically the operations 
 of the various types of machines that are used for producing 
 moulds. 
 
 Plain Jolt Machine 
 
 On page 2 is illustrated the methitd of producing a mould 
 on the Plain Jolt Machine. The six views show the successive 
 steps in the production of the mould, steps which will be readily 
 recognized by one who has made moulds on any type of 
 machine, or on the floor. The operations and the sequence 
 of operations are exactly the same as those employed by a 
 moulder in making a mould on the floor, with the single excep- 
 tion that the machine jolt rams the sand in the flask, an opera- 
 tion which the moulder would have done by hand. The machine 
 merely does a part of the hard work for the moulder. 
 
t3B 
 
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 f\ 
 
 
 s^rnrnrni \l 
 
 ! ; 
 
 V2 
 
 n 1' -1 K17 
 
 /3 Pit3r£/f£-ff TV r»£- /fou. cf£» r/)0Le 
 
 THf FLASH /S PL/)C£P l9/fOI/A/t^ TMe PfiTTSfT/^, 
 
 rH£/^jUiP M«j SS£A/ girrr£ff ^/?f r^s fforra/^ 
 3ai9Pi? cc/^^rP£ff w /vs/r/oM /W^ r/v£ ^ptcM/zvf 
 
 /i ffOLL//V6 ai'£ff r//£ /IffULff 
 
 m£ /fai/ip /J w/y ffau.£P <7i'£/r ,«*i7 nf let^uMS 
 c/i/f /rvA/ wro POi/T/ofj r,^P£C£/y£ ?'»£ moulp 
 
 THF L£)'£UAie P//VJ /iMf £/>C» 0££/V i;£PL£CT£i' 
 TH£ /tMOI//^r A/£C£SS/>Pr TO L£y£L r/^£ novLC 
 /^/</l7 /ILL r//£ P/nS i.OC^£P Sy ^/V£ L£t'£P 
 
 TH£ P/>rr£PA/ IS B£W6 PP/lirM IS/li'/A/S m£ 
 
 PmiSH£p Mfi/LP aAi r^e i.ef£L/A/6 c/>p. 
 
 Fig. 3. Method of Making a Mould on the Roll Over Jolt Machine. 
 
General Moulding Principles 
 
 Roll Over Machines 
 The next set of illustrations on page 4 shows the Roll 
 Over Jolt type of machine producing a mould. The essential 
 operations of making the mould remain unchanged and, as on 
 the Plain Jolt Machine, the machine jolt rams the sand and 
 then, after clamping the mould, instead of the moulder rolling 
 it over by his own muscular effort or by the aid of the crane, 
 he rolls it over by means of air power applied to the Roll Over 
 Machine, and after unclamping it, he draws the pattern by air 
 power on the machine rather than by muscular effort and skill 
 or by the slow and awkward method of using the crane. It is 
 easy to see that such a machine performs the hardest part of 
 the moulder's work, and substitutes for muscular effort the 
 openinp- and closing of levers and valves. I'age 6 illustrates 
 another general type of machine which accomplishes the same 
 results a'= the machine illustrated on page 4. The mould is 
 jolt rammed, rolled over by an air cylinder, and the pattern 
 drawn by air power as in the previous case. The type of 
 mechanism employed is essentially different, but the operations 
 performed are identical. 
 
 Jolt Stripper Machine 
 
 Pages 8 and 10 illustrate respectively the operation of the 
 stripper and of the jolt stripper types of machines employed 
 chiefly in making copes. Page 8 illustrates the Jolt Stripper 
 machine which jolt rams the mould and then strips it upward 
 from the pattern, while page 10 illustrates the Jolt Squeeze 
 Stripper machine which jolt rams the mould, squeezes it and 
 then strips it upward from the pattern. The essential differ- 
 ence in the two machines is that the squeezing operation added 
 to the others, eliminates hand butting which is necessary when 
 a mould is only jolt rammed. This is done to avoid the addi- 
 tional labor and to promote uniformity. Chapter X treats this 
 subject in more detail. 
 
 The illustrations previously referred to will easily demon- 
 strate to one not familiar with moulding machines, that the 
 method of producing moulds by machine power is not a radical 
 
Q^^^p 
 
 T»£ P/ITT£flN 15 MOUNTED ON THE HOLL OlfER TABLE, THE Fl,/)5M PLACED ON FIUEO 
 mTH SUNO AND JVL T RAMMED 
 
 THE MOULO HAS B££N BUTTED I7FF, THE OOTTOM BO/tffP CLAMPEO 0/v, THE Mai/LP 
 POLLED OI/EP AND THE LEfELING TABLE fTAISEO UP AGA/N5T THE saTTOM BDAAO 
 
 THE LEVELING TABLE HAS BEEN LOHTPEO THl/S OPAH/Z/VG THE PPTTEPN 
 
 Fig. 4. Method of Making a Mould on the Roll Over Jolt Machine. 
 
General Moulding Principles 
 
 departure from the old and established methods of producing 
 moulds, but that machine moulding is merely the substitution of 
 air or other power, in place of human muscles, thus doing away 
 with some of the most disagreeable tasks of. foundry work and 
 making the foundry a more pleasant, wholesome and profitable 
 field in which to work. 
 
 Squeezer Machines 
 
 The moulds referred to thus far arc all larger than the 
 class of work known as squeezer work, which on account of 
 its small size can be easily handled by one man even when 
 the flask is full of sand. Such moulds do not re(|uire machine 
 power for handling, but it has been found tliat machine power 
 can be advantageously substituted for hand power in the ram- 
 ming of the sand. Page 12 shows the sequence of operations 
 of the Plain Squeezer Moulding Machine, which is so well 
 known to everyone connected with the foundry industry, since 
 it is the oldest form of power machine. Its sole function is 
 to ram the sand by squeezing, and the remainder of the work 
 is done by hand. The Jolt Squeezer Moulding Machine, the 
 operation of which is illustrated on page 14. adds the jolt fea- 
 ture to the well known Plain Squeezer, and eliminates the hand 
 tucking which is necessary on practically all drags. It enables 
 the operator to turn out either more moulds with the same 
 efifort or the same number of moulds with less effort. Chapter 
 IX goes into this subject in greater detail, taking up the par- 
 ticular advantages gained, and the kinds of patterns on which 
 the Jolt Squeezer Machine is of great advantage as compared 
 to the Plain Squeezer IMachine. 
 
 There are types of machines other than those mentioned 
 above, but the examples discussed are typical ones which embody 
 prac'tically all of the principles that are used in the foundry 
 today. The other types of machines which have not been 
 mentioned, are dififerent combinations of the same fundamental 
 principles, and the adoption of this or that type of machine is 
 frequently a personal matter with the foundryman. 
 
r»e p/>rr£f>rt is inow/y /^ountei; on the patt£/m 
 
 PL/iT£ mc'J(Mffix'W£p gr/iM /Kcvmrtw f/rr//vs 
 
 ST/fipp/na PL /ire 
 
 mf Fi./ISff M3 B££n PL/!C£i' /fffOe'^/P TM£ 
 
 TH£ /^/>CM/f/£ ///!^ J'OLT ff/lftflf£P TH£ S/I/Vff. 
 
 oamive tmh OP£/f/rr/iw 7»£ s/u^Ai sfvfepp er 
 
 H/l/io 
 
 TH£ ffOVLP H/IS BEEN BUTTED OFF flNP THE 
 POU»ll\IS BASIN FINISMEP 
 
 THE MOi/Lff H/)S ffeS/V STfflPP£P F/fOM THe 
 
 F'/)rr£ffN Br the upward MoygMENT of 
 
 THE STPlPPlnS PL/>T£ /)NP ISNOtfCO/^PLETEO. 
 
 7ME ftPCiff /*U BEEN LIFTEP FROM 7f/£ STPIPPINS 
 PL/}T£ /fNO li SHOWN FfEHCr TO C10S£. 
 
 Fig. 5. Method of Making a Mould on the Jolt Stripper Machine. 
 
General Moulding Principles 
 
 The foregoing explanatory matter is not intended to be a 
 complete guide to the use of moulding machines ; it is elemen- 
 tary in nature and is inserted for the purpose of giving the 
 reader a broad view of the subject before taking up in detail 
 the operation of each machine. This will be done in later 
 chapters describing the machines. 
 
 Processes of Moulding 
 
 The explanations given in this chapter are not intended 
 to be complete and, in the absence of direct reference to other 
 chapters, the reader is referred to the table of contents for 
 more information on the matters which will be covered briefly 
 in the remainder of this chapter. 
 
 In order to allow the mind of the reader to dwell upon 
 the important points covered in the succeeding chapters, it is 
 necessary that a comprehensive view of machine moulding be 
 firmly established in mind so that the details will be clear 
 and no additional attention need be paid to them in the subse- 
 quent chapters. Accordingly some of the relatively minor 
 matters of machine moulding will be gone into in this chapter. 
 
 Pattern Mounting 
 
 Another of the common misconceptions in regard to the 
 use of foundry moulding machines is the idea that the mount- 
 ing of the pattern is an operation of great cost, requiring a 
 high degree of skill. While it is true that good workman- 
 ship is required in mounting patterns for machines, the state- 
 ment holds true even though the patterns are to be used 
 by hand, that good workmanship is always necessary for the 
 production of good results, and certainly, pattern mounting 
 is no exception to this rule. Any good pattern-maker may 
 easily study out the steps which are necessary in the mounting 
 of patterns for machine moulding, and with a little experience, 
 will find it very simple and not more difficult than the con- 
 sideration given to the making of the same pattern for hand 
 
/=L/)T£ /J ^v/ffiovNPea BY AN /icct//r/>r£/.r 
 FirriNs srmPfMe pl/ite 
 
 rMSn./9S/f IS PL/ICEP /iffOt/NO me P/)TT£/fN, 
 
 p/LLee mrM ^/i/yc -^/v^ •jolt pi/immsip. 
 
 TM.5 sice y/s)v if/aivs how T//£joi/££z//v& 
 ff£/iff Moyss Poffw/)/fp sTmniNe OPPTHE 
 
 .SUffPLUS S/)W/U /T/iOfES. 
 
 T»£SOl/££Z£R H£AP IS /ILL TM£ If/iy POffW/llfP 
 />NP nE MOULP H/)S JI/ST BEEN SOVEEZEff. 
 
 T»E /</0(/iiP H/)S BEEN STmPPEO PPO/t THE 
 
 P/^TTEnN Br THE UPHf/IPP MOfEfiENTOPTHE 
 
 iTRlPPINt PL/tTE /thP IS mOMfConPLCrEP. 
 
 THE COPE /J /IMPE /N /) J/M/Li9R M/iNNER 
 EXCEPT POR THE SPTE THIS yiEtV .SHOWS 
 THE PPiQS l/SEP WITHOl/r/) BOTTOfi BO/lffP 
 WITH THE COPE SET SNP THE COPE /IBOyE 
 ffEHPr TO CLOSE THE fiOULO. 
 
 Fig. 6. Method of Making a Mould on the Jolt Squeeze 
 Stripper Machine. 
 
General Moulding Principles 11 
 
 moulding. Essentially the difference between patterns made for 
 floor moulding and those made for machine moulding are as 
 follows : 
 
 In patterns made for floor moulding it is assumed that 
 the moulder is a highly skilled workman who is able to over- 
 come many moulding difficulties, and consequently it is assumed 
 that since he is working with moulding sand, which is more 
 readily fashioned than wood, he should be called upon to do 
 the extra work necessary at the expense of the patternmaker 
 who makes the pattern in the simplest manner possible, 
 simplest, that is, from the standpoint of making the pattern. 
 However, when mounting the patterns on machines, some 
 method of securing the pattern is necessary, and it is common 
 to build the pattern onto the board which forms the parting 
 of the mould. Rather than force the moulder to cut an irreg- 
 ular parting, it is now considered good practice for the pat- 
 terninaker to cut this irregular parting once and for all, and 
 to relieve the moulder of this work. An important economy 
 in the total amount of time spent in the producing of the 
 casting is thus obtained when any quantity of castings is to be 
 made, and, uniformity of method is assured, whereas different 
 moulders might . adopt diiTerent methods and every casting 
 would vary, to the subsequent disadvantage of the machine 
 shop. Mounting patterns on a moulding machine is not a 
 difficult matter, and does facilitate the making of the pattern 
 in such a way that the total amount of labor spent in the 
 pattern shop and foundry compares favorably with the total 
 amount spent in producing the casting by the old hand method. 
 
 Chapter XI on pattern equipment will present many of 
 the details of pattern mounting but it should be said in this 
 connection, that any pattern made for machine moulding 
 can be rammed by hand on the floor, rolled over by hand or 
 crane, and the pattern drawn by hand, thus demonstrating 
 the fact that machine moulding is essentially the same in 
 principle as hand moulding. 
 
^^^^M 
 
 THe COP£ H/ILP OF TH£ SVAPFLfiiH r»£ 
 P/ITr£f^N PL/^T£ /l/VO rue OR/16 HfILP Of 
 THE S/V/)P FLAiK /iR£ PLACCO INi/ePTEOON 
 
 TH£ r/igL£ OK rHC m/ichi/ve in tme o/iae/t mrio 
 
 Q QOt^ ^ 
 
 TV£ ORA6 IS FllL£0 HffTM S/tfll0 »/»NO TVCfEP 
 
 O/V THE SIPEi ^NOINR»y POCHETS STPCK/f OFf 
 /IMO THE BOTTOM gO/)RO PLACED ON 
 
 THE MOI/LO HAS Been ROLLED <?**>? THE COPE 
 PILLEO mTH JA»0 Tt/Cft£0 STRVCM ffrF /INO 
 
 THE ^ai/e£Z£ aoHRO plrc£0 oh 
 
 TH£ MOC/LO IS IVOW SOI/EEZ£P BOTH HAL^ei 
 /IT THe S/lfllE TIME 
 
 RSSI-iTEO BT THf i'/BRATOP THE COPE IS OlMfW 
 HP PRO/* THE PATTERN PLATE Pl/T A5/0£ A/VO 
 THE PRTTERN PLATE ORAtV/V UP PROn THE 
 ffRAS 
 
 THE COPE IS CLOSE ff O/V THE- ORA6 THE S/^p 
 
 PLAiH RE/IOfEO /IDIO THE P/IV/SHEO /tOt/LO 
 
 '5 ReAffy TO B£ PI RCEO ON THE PL OOP 
 
 Fift. 7. Method of Makinji a Mould on the Plain Squeezer Machine. 
 
General Moulding Principles 
 
 13 
 
 Jolt Ramming Operation 
 The jolt ramming operation is combined with various 
 other machine operations and is embodied in many types of 
 machines. It is, therefore, one of fundamental importance. 
 The importance of this operation and the theory of it will 
 be covered fully in Chapter II, and the machines performing 
 it, in subsequent chapters. At this point it might be well, how- 
 ever, to point out some features in regard to this operation. 
 
 Use of Upset 
 
 The sand, in packing down into the flask at each blow 
 of the machine, necessarily drops down into the flask, and it 
 is necessary to pile sand as high as it can be held on the flask 
 before jolt ramming. On some deep flasks it is not possible 
 to pile enough sand, and in such cases an "upset" is placed 
 around the flask for the purpose of holding more sand. 
 This upset is removed during or after the jolt operation when 
 the san-l has jolted down into the flask. An upset is shown 
 in use on page 8 at the upper right hand corner of the page. 
 When jolting down into the flask, the sand will to some 
 extent, follow the outlines of the pattern, as is clearly shown 
 l)y th<' top ilhistration on page 16, in which, at the extreme 
 right of the flask, the sand has jolted down below the top 
 of the flask, while immediately above the pattern, it has been 
 supported and is above the flask. 
 
 Fig. 8. The Use of a Gagger. 
 
 Use of G aggers 
 
 In producing the cope or 
 upper half of the mould on 
 the jolting Machine, either 
 the Plain Jolt or the Roll 
 Over Jolt, it is frequently 
 necessary to make use of gag- 
 gers. as in floor moulding 
 practice. The gaggers are 
 used in identically the same 
 way and no difficulty is ex- 
 
Tf^ coPc HALF a/=' r//e samp f-lash, rue 
 
 ^nrreff/l/ PLATE /iA/O THE OP AS HALF OF 
 THE ■SAI/IP FLASK F)/?E PLACEP IHfEPTEPON 
 THE TABLE OF THE /^ACH/HE If THE CAOEA NAnfO 
 
 THE DPAS 15 FILLEC tT/TH SAW, JOLT PAFtFtEff, 
 STPVCM OFF A/VP THE BOTTO/i BOAPO PLACEP OH 
 
 TME /^at/LO HAS BEEni POL LEO Ot^EP, THE 
 COPE FILLEO W/T» SAHO, rVCH£O,STPVCH0FF 
 PnO THE SO(/££Z£ BOPPO PLPCEO O/V. 
 
 THE fiOULD IS /VOIV SOl/EEZEC BOTH HALITES 
 /)T THE SAME TIME 
 
 PSSISTEO 3r THE i//BPATOP THE COPE li OPAtf/V 
 e/P FPO/^ THE PA 7 TERH PL P TE Pt/T Pi/OE P/HO 
 THE PPT TEP/V PLATE DPPITH CP FPOM THE 
 OPP6 
 
 THE COPE IS CL03EP O/V THE DPPS, THE 
 5/VPP PL/fS/1 PEAfOi'ElP P/VO THEF/ly/SHEO 
 /fOt/LO /S FIEPOr TO BE PLPCEO OH THE 
 FLOOP 
 
 Fig. 9. Method of Making a Mould on the Jolt Squeezer Machine. 
 
General Moulding Principles 15 
 
 periencfd in jolt ramming them by machine power. Figure 8 
 shows the usual method of setting gaggers against a bar wath 
 the foot of the "L" shaped gagger projecting into the pocket 
 of sand, which is to be carried, and which needs this addi- 
 tional support. It might be well to call attention at this time 
 to the fact that gaggers should be dipped in a clay wash before 
 being placed in the mould in order to make their use more 
 effective. 
 
 Spreading the Sand 
 Although there is enough sand in the flask it is necessary, 
 before butt ramming, that this sand be distributed evenly 
 over the flask, and this operation naturally requires a small 
 amount of time. In order to eliminate as much of this 
 time as possible, it is good practice to spread the sand from 
 the center of the flask toward the edges, by hand, during 
 the jolt ramming operation, so that at the completion of the 
 jolt ramming the sand is left in a shape such as that shown in 
 the bof.om view on page 16 which shows the sand so distrib- 
 uted that it can immediately be butted off. 
 
 Butting Off 
 "Butting off" the mould has been mentioned several 
 times above. By this term is meant the hand ramming which 
 is necessary to stipplement the jolt ramming of the machine. 
 When a machine jolt rams the sand, a sufficient density of 
 sand is produced on the pattern and pattern plate, but near 
 the top of the flask the sand is not rammed so tightly and is, 
 in fact, so loose that it requires additional ramming. This is 
 done by hand and can be done very rapidly since no special 
 skill is required, as the part of the motild requiring skilled 
 ramming has already been rammed by jolting, and it is neces- 
 sary only to pack the sand tightly at the top in order to 
 support the portion of the sand adjacent to the pattern and 
 pattern plate when the mould is being rolled over, while it is 
 resting on the floor, and during the pouring operation. "But- 
 ting off" is a hand performed operation in the making of the 
 mould, and it is onlv natural that one mould will be butted 
 

 WPEff THE Pff£5SUff£ /lAlP MTl/fMLLy /)S5(/M£S /9 3H/)P£ 
 
 sucA/ /IS TM/ir SMtH//^ /)0oy£. TM/5 /s aaJ£cr/o/i^/)aiswrH/>T 
 
 \ /'=K'J/7V«W <?/^ T/i£ S/lAi:? 
 ^ X B££afl£ JOL T fr/>/^f1/fll6 
 
 rf//3 /VOt/Le' M/li £f£OC///!£ L£SS r/M£ rOff BUTT/ZVC 0£f r///>/V 
 
 THe MouLO sMoiv/v /looye. rws ^/ivof>/>BL£ c/ffCi//^sr/!A/c£ 
 /s iOffoei/csp ar s/'/rs/iff/A/s TNe s/^/^e f^/roM r//£ csAfre/^ 
 TO r/i£ £ifs£s Of rH£ f'L/fSfi Di/niNS rue JM.T nA/in/MS ofV/f/inoN. 
 
 Fig. 10. The Sand Should be Spread During the Jolting Operation. 
 
General Moulding Principles 
 
 off to one degree of hardness and the next mould to a differ- 
 ent degree. This difference does not appreciably affect the 
 size of the casting when it is used for ordinary work, but 
 is objectionable when extremely accurate castings are required, 
 such as those used in the automobile industry. This differ- 
 ence, slight as it is, causes trouble in jigs which are made 
 for accurate work, and makes it advisable to employ a machine 
 operation, that of squeezing, for butting off the mould. This 
 will be discussed more fully in the chapter which deals with 
 Jolt Stripper and Jolt Squeeze Stripper Moulding Machines. 
 
 Striking OiT 
 After the sand has been butted off, it is necessary to clamp 
 in position a bottom board, the same as in hand moulding. 
 This bottom board must support the sand evenly over the 
 entire surface of the mould, both during the roll over opera- 
 tion and subsequently on the floor and during the pouring 
 operation. This bottom board must be bedded onto the flask 
 correctly, and this is done in the following manner : The top 
 of the mould is "struck off" with a straight edge, either wood 
 or steel, so that the sand over the entire mould is exactly 
 level with the top surface of the flask ; a hand full or two 
 of loose sand is then scattered thinly over the surface of the 
 flask and the bottom board is placed on and worked back 
 and forth by hand until it makes for itself a solid bearing 
 over the entire mould. This extra sand is not necessary 
 because the flask is out of alignment, but because the bottom 
 board is always a little warped or burned in places, due to 
 its having been subjected to extreme heat and to water. The 
 strike off operation consists simply of scraping off the excess 
 portion of the sand, and is performed by the use of a wide 
 or a narrow bar, depending upon the size of the flask being 
 struck off. Figure 12 illustrates the use of a wide and a 
 narrow strike-off bar. In this case, since the flask is of 
 medium size, the wide strike-off bar has an advantage in that 
 the mould can be struck off in one stroke. This is not 
 true of the larger size of flasks, where a wide bar would hold 
 so much sand that it would be difficult for the moulder to 
 
(jciwral Moulding F'linciples 
 
 19 
 
 draw the bar. In such a case a narrow bar has the advan- 
 tage of cutting through the sand, loosening it all thoroughly 
 on the first stroke, and yet removing at every stroke as much 
 as it is practicable for the moulder to handle. 
 
 /^/V/W-w*- sr/f//r£ o/^F PEffAf/rs the s/i/ve? ro 
 sfiLL <?>'£/> THi/s A/ecenimr/MQ /isecoNo 
 
 Fig. 12. The Use of Wide and Narrow Strike Off Bars. 
 
 The clamping of the pattern, flask and bottom board 
 together, needs no comment here and the rolling over is also a 
 very simple operation and needs no further comment. 
 
 Pattern Drawing Operation 
 Removing the pattern from the rammed sand is performed 
 in essentially the same manner on the machine as on the floor, 
 namely, the pattern is lifted vertically, or as nearly vertically 
 
5.1 
 
 
 
 
General Moulding Frinciplei 
 
 21 
 
 as possible, from the sand. The details, however, vary greatly 
 in the two cases. In floor moulding the pattern is rapped 
 i)ack and forth and from right to left by using a maul or 
 hammer on the rapping pin. which is inserted in a plate built 
 into the pattern for this particular purpose. This rapping 
 damages both the pattern and the mould and also makes 
 the mould over-size. The pattern is then drawn by the aid 
 of lifting hooks which are attached to plates built into the 
 patterns and. accompanied by additional rapping, the moulder 
 lifts the pattern as nearly vertically as possible. Contrasted 
 to this method, the machine operator opens a valve, which 
 places the vibrator in operation, and then opens another valve, 
 which places in operation an air cylinder, which either draws 
 the patiern upward from the mould or the mould downward 
 from the pattern. 
 
 The Vibrator 
 
 The vibrator, which is a device similar to a pneumatic 
 hannner, is shown diagrammatically in h'igure 14. It is attached 
 either to the ])attern or to the table of the machine to which 
 
 
 ^/NT/IHE 
 
 
 
 •isijz. '/. '/f y(^P////M////<'////y^W/ 
 
 V/^/r 
 
 
 ^ Kj|.|||||||||iJ|| 
 
 ii 
 
 1^ 
 
 ^ 
 
 r :z ],.. 
 
 ^i^r^'Z-i YV/A///////////////////////y 
 
 y/}/-'. 
 
 
 
 
 Fig. 14. Diagram of an Air Operated Vibrator. 
 
 the pattern is rigidly fastened. In either case the reciprocat- 
 ing action of the vibrator produces a series of shocks which 
 are transmitted to the pattern. These shocks are of such 
 
General Mould ing Principles 23 
 
 small intensity that no measureable enlargement of the mould 
 takes place, and yet the friction of rest existing between the 
 pattern and sand is overcome, as is also the friction of rest 
 existing between the various parts of the machine which 
 accomplish the pattern drawing. The action of the vibrator 
 accomplishes perfectly the result for which it is designed, 
 and has the advantage of not damaging the pattern. 
 
 0\crhanging Projections 
 The drawing of the pattern assumes a pattern which, in 
 the trade term, "has draft." This means that the pattern is 
 of such a shape that it can be drawn vertically up ou* of the 
 mould, leaving behind it the sand of the same shape as the 
 pattern, without tearing or breaking the edges of the sand. 
 The design of many castings is such that the pattern has 
 overhanging projections which cannot be drawn from the sand 
 in the usual manner, and special methods nuist be employed 
 in such cases. Two means are generally employed — first, the 
 overhanging projections of the pattern may be made loose, 
 so that when the main pattern is drawn this auxiliary portion 
 of it remains embedded in the sand of the mould, and is 
 drawn separately in another direction into the cavity left by 
 the withdrawal of the main pattern. This method is illus- 
 trated on page 18 which shows the sequence of operations in 
 ramming up a mould from a pattern containing a loose piece, 
 and the subsequent removal of the loose piece, leaving in the 
 mould a cavity of the desired shape. 
 
 Cores 
 
 A second method of ]:)roducing such a casting is by the use 
 of a core, which is a separate block of sand, that has been 
 baked veith a binding material and is hard so that it retain.s 
 its shape and can be placed in the cavity of the mould after 
 the pattern has been withdrawn. Extra allowance must ha 
 made on the pattern for the core which will be introduced 
 into the mould later. This portion of the pattern is known as 
 the coreprint because it leaves an impression which wull be 
 
General Moulding Principles 
 
 tilled bv the core. Page 20 shows the method employed in 
 making a casting by means of a core which is set into the 
 mould after the pattent has been withdrawn. It can readily 
 be seen that this core must have sufficient bearing surface upon 
 which to rest, and must be anchored firmly in place so that it 
 will not float loose when the mould is poured. In this case 
 the projections at the top and the bottom of the core are used 
 for locating and for holding it tirmly while the mould is being 
 poured. Sometimes cores are the only method of solving prob- 
 lems similar to the one discussed above, but there are many 
 uses for cores other than as a substitute for a loose piece on 
 the pattern. Cores are frequently used where a rather thin 
 body of sand would be washed away by the flow of metal 
 into the mould ; to produce holes in the side walls of castings ; 
 to support heavy cores which must be set later ; to receive the 
 impact of metal which falls vertically thru a portion of the 
 mould ; and for other purposes. 
 
 Ram Up Cores 
 
 The term "ram-up core" is frequently heard in the 
 foundry and occasionally a mistaken view is held that a ram 
 up core cannot be rammed on a jolt machine. Page 22 illus- 
 trates clearly one of the many uses of the ram up cora. It 
 derives its name from the fact that it is placed on the pat- 
 tern and remains there while the sand is rammed, whether 
 this is done by hand ramming or machine ramming. When 
 the pattern is drawn the core is left firmly embedded in tlie 
 sand of the mould for any one of a number of purposes. 
 On page 22 a ram up core is shown in use for the purpose 
 of supporting the concentrated weight of a heavy core, which 
 otherwise would have crushed the green sand at this point. 
 
 Inserted Cores 
 
 Another form of core of similar purpose is the "inserted 
 core" which is of such shape that it cannot readily be rammed 
 up on the pattern due to overhanging projections, which would 
 cause trouble bv breaking of^", and also would require hand 
 

 9^ 
 
 
 £| 
 ^^ 
 
 St- 
 
 Sl< 
 "-I 
 
 
 V .. ^, /a I 
 
 
 
General Moulding Principles 
 
 27 
 
 tucking beneath them. The method of inserting such a core 
 is shov.-n on page 24. wliich shows clearly that the mould 
 is jolt rammed, a hole is dug down to the loose piece, which 
 is then removed and the inserted core set in place, the ramming 
 being completed by hand. This kind of a core is correctly 
 called an "inserted core," but is of the same general class 
 as a ram up core. 
 
 Covering Cores 
 The term "covering core" is frequently used in the 
 foundry and page 26 illustrates the method of its use in a 
 casting where the covering core also serves as the cope half 
 of the mould. The illustrations on that page are self-explana- 
 tory and need no further comment here. 
 
 Cjating 
 Reference has been made to the pouring of the mould 
 and to the flow of metal into the mould. The passageways 
 provided for the metal to enter the mould are known as the 
 "gate," and the making of them is known as the operation 
 of gating. The term, "gate," 
 includes the pouring basin 
 into which the metal is 
 poured directly from the la- 
 dle, and all parts of the pas- 
 sageway leading from the 
 pouring gate to the cavity 
 forming the casting. In 
 Squeezer work it is cus- 
 tomary to refer to the ver- 
 tical portion of the gate as 
 the "sprue," and to the hori- 
 zontal portion of the gate as 
 the "rimner." Other spe- F'g- 18. Diagram of Swirl Gate. 
 cial names are applied to gating, indicating the method em- 
 ployed to prevent dirt and slag in the iron from entering 
 the mould ; thus the names "skimmer gate," "strainer gate" 
 and "swirl gate" are practically self-explanatory. The typical 
 mould illustrated in Fig. 1 contains a strainer gate which 
 
28 Foundry Moulding Machines and Paitern Equipment 
 
 consists essentially of a strainer core placed in the g"atin_ij^ 
 system at some convenient point, a strainer being a core per- 
 forated with a nnmber of small holes which permit the passage 
 of the iron bnt keep out the sla;,^ and dirt. I'he swirl gate 
 is illustrated in Figure 18. In this gale the iron is led into 
 a circular basin which it enters at an angle, causing the iron 
 to rotate rapidly in the basin. Any slag or dirt floating on 
 it will collect in the center, and the clean iron is drawn 
 from the outside edge. The basin into which the iron is 
 poured from the ladle is so shaped that, to some extent, 
 it insures the entrance of clean iron into the mould. /\.n 
 aluminum pattern is used to form pouring basins of uniformly 
 correct shape. The views on page 8 illustrate the method 
 of usiri'^ it and the typical mould in Figiire 1 illustrates the 
 shape of the basin and its position in the finished mould. In 
 using it. the iron is poured into the larger of the two depres- 
 sions until it flows over into the smaller one and down the 
 gate. The basin is kept full of iron by rapid pouring, and the 
 slag accumulates on the top. allowing clean metal to enter the 
 gate. When first starting to pour, a small amount of slag 
 is likely to be carried down the gate before the basin is fuil 
 and tliis slag may get into the casting and cause trouble. 
 In order to prevent this, some foundries place a small piece 
 of thin sheet metal over the gate entrance. This holds back 
 the metal until the slag has had time to rise, and insures only 
 clean metal entering the uKutld. The sheet metal then melts, 
 admitting the iron. 
 
 The point at which the iron is introduced into the mould. 
 and the rate of flow of the iron as determined bv the size 
 of the gate, the height of the pouring basin above the point of 
 entrance, and the fluidity of the iron are matters of great im- 
 portance in securing a good casting. Oifficultv has been ex])eri- 
 enced in a number of cases in wliich the castings were bad 
 until some change was made in the gating system, after which 
 good castings were obtained. 
 
 Although the subject of gating is one of great importance. 
 it is a subject upon which very little can be said from a 
 
General Moulding Principles 29 
 
 llieoretical staii(l])()iin. and the subject remains the exclusive 
 Tield of the skilled and exj)erienced moulder, when machine 
 moulding as well as when hand moulding. This point should 
 be noted, however. The tyi)e of pattern emj)loyed on mould- 
 ing machines, being mounted on a permanent plate, readily 
 adapts itself to the use of a gate pattern l)uilt onto the l)oard 
 in such a way as to be a permanent part of the pattern ecjuip- 
 nient. thus insuring uniformity of gating, and after experiment- 
 ing to secure the best gate, it then becomes an automatic matter 
 tliat each subsequent mould has the best gate, whereas the 
 most skillful of moulders, in cutting each gate individually, will 
 vary slightly from time to time. The result of past experi- 
 ence in gating seems to be a sort of intangible knowledge which 
 takes the form of judgment, which has not been expressed 
 by a definite set of rules. 
 
 Moulding Sand 
 
 The proper moulding sand is an absolute essential in pro- 
 ducing moulds either on the floor or on the moulding machine. 
 The selection of moulding sands is rapidly assuming the aspect 
 of a definite science of sand grading, and some important 
 research work along this line has recently been done. The 
 major portion of this information has been published in the 
 Transactions of the American Foundrymen's Association, vol- 
 ume XXI, page 19, and the tests for grading moulding sand 
 are briefly recapitulated here as follows : 
 
 1. A general microscopic test which provides general 
 information in regard to the chemical composition of the sand,, 
 size of the grains, their shape and the amount of bond. This 
 test eliminates those sands which are readiK- recognized as 
 unsuited to motilding purposes. 
 
 2. Rational chemical analysis of the sand gives directly the 
 quartz, clay and feldspar contained in the sand. The per- 
 centages of these various elements determine the fusibility of 
 the sand, and consequently determine whether or not it can 
 be subjected to the heat of the molten iron. 
 
30 Foundry Moulding Macliinrs and Pattern Equipment 
 
 3. The fiiK'iH'ss of the sand is determined by the per- 
 centage ot the total passing thru a succession of screens of 
 20, 40, 60. 80 and 100 meshes to the inch, respectively. A 
 coarse sand ma}- be used for heavy work while a fine sand 
 is required for finer work. In addition to this, there also exists 
 the factor that a sand composed about one-half of relatively 
 large grains and the other iialf of relatively small grains will 
 not vent well, because the small grains will so completely fill 
 the spaces between the large grains that the gases will not 
 have sufificient room for escape. 
 
 4. The transverse strength is tested on a specimen of the 
 sand prepared and tested under standard conditions. This 
 takes the shape of a bar 1" square. Ay^" long, supported A" 
 apart and broken h\ the application of a weight at the center. 
 This test is made with from 5% to 7V2% moisture and a 
 second test with 10% moisture. 
 
 5. The crushing strength is measured on a standard V* 
 square block of sand 2I/2" high. 
 
 6. The permeability to air is measured on a 2" square 
 block 1" thick prepared under standard conditions with a 
 given quantity of air forced thru the sand. This test checks 
 to some extent the information obtained in test No. 3. 
 
 7. The strength of the clay bond present in the sand 
 is measured by the percentage of dye absorbed per unit of 
 clay in the sand. It is readily seen that this is not a test of 
 the amount of clay present, but of the strength of the clay 
 which is present. 
 
 These seven fundamental tests for moulding sand form 
 the basis of proper sand selection and their importance should 
 not be overlooked. In the absence of laboratory facilities, a good 
 magnifying glass will furnish much valuable information in 
 regard to the properties of the sand, provided the significance 
 of what is seen is fully understood. Many sand troubles 
 may be avoided by the use of a good magnifying glass. 
 
CHAPTER II 
 
 Theory of Jolt Ramming 
 
 Recent foundry development has produced no one opera- 
 tion which is more fundamental than the jolt ramming opera- 
 tion. It accomplishes the ramming of the mould in a more 
 satisfactory manner than the squeezer machine and is applica- 
 ble to all sizes of moulds from the smallest to the largest. The 
 theory explaining the jolting action of a machine in ramming 
 the mould is of such fundamental importance that a chapter 
 is here devoted to it. The importance of this operation is 
 emphasized by the fact that practically all machines, having 
 more than one operation, incorporate the jolt operation for 
 ramming the sand in the mould. Common examples are the 
 jolt Roll Over Pattern Draw Machine and the Jolt Squeeze 
 Stripper Machine. 
 
 Every foundryman is familiar with the skill required in 
 the production of a hand rammed mould ; with the exactness 
 of ramming which nuist be obtained over the pattern of vary- 
 ing shaj^c and at varying depths in the flask. .\ perfect cast- 
 ing requires perfect ramming — a thing that is very hard to 
 attain in practice. The least defect in the ramming causes 
 swells, scabs, blow-holes, or run-outs. When such a task is 
 undertaken by hand-ramming, trouble is experienced in secur- 
 ing a mould with a surface of uniform hardness and without 
 the adjacent hard and soft spots, which, when the metal is 
 poured, cause the gases to flow along the surface of the mould 
 to the soft spots instead of entering the surface of the sand 
 without flowing. 
 
 It is obvious that the moulder cannot, without exceptional 
 skill, produce with his small tamp a surface of even strength 
 and texture without setting up initial strains in the body of 
 the sand. The pouring of the hot metal against the rammed 
 sand weakens the binding elements and releases the strains 
 caused bv uneven ramming, allowing; the sand to flow in the 
 
Foundry Aloulding Machines and Pattern Equipment 
 
 path of least resistance until it becomes of uniform hardness, 
 sufficient to withstand the pressure of the metal. This move- 
 ment of the sand is one of the causes of the rough, uneven 
 surfaces that are usually seen on the castings produced by 
 hand-rammed moulds. In contrast with the above described 
 hand method, in the mould that is produced by jolt ramming 
 on a machine, the iron will lie properly and the gases, with- 
 out flowing, will immediately enter the sand, jolt ramming is 
 accomplished by lifting the table, pattern, flask and sand a 
 short distance and then allowing them to drop and contact 
 with an anvil which stops and reverses the table, pattern, an(3 
 flask but allows the sand to continue in its descending coin"se, 
 producing a pressure in the sand, especially in that sand lying 
 nearest the pattern and pattern plate. By repeated machine 
 blows the sand is caused to flow to the bottom of the mould 
 and to pack into the flask corners and around the pattern in 
 a uniform manner, the jolting action o^ the machine causing 
 the grains of sand to flow in the direction of least resistance, 
 and, therefore, the mould is packed in an even and uniform 
 manner and without setting up unequal strains between the 
 various particles of sand or between the several parts of the 
 mould. 
 
 The development of the jolt ramming method of moulding 
 has produced a machine that will jolt ram a mould complete 
 in from 5 to 30 seconds of time, operating with a stroke of 
 V to 2" in length, and at a rate of 150 to 250 strokes per 
 minute. One should not lose sight of the fact that jolt ram- 
 ming the mould properly, is only the first operation performed 
 on the mould, and that it is easy for the moulder to introduce 
 the variable human element in the latter stages of the work; for 
 instance, a mould which has been jolt rammed may be im- 
 properly butted off; the pattern may be hand drawn so crudelv 
 as to dan^age the surface of the mould, requiring a great 
 amount of slicking and patching. These variations introduced 
 in the latter phases of making the mould will eliminate some 
 of the advantages of jolt ramming. This constitutes a verv 
 strong reason in favor of the machine which not onlv jolt rams 
 
Theory oj J oil Ramming 33 
 
 the mould but which performs the subsequent operations of 
 butting off, rolhng over and drawing the pattern, with an 
 accuracy and uniformity equal to that of the jolt ramming. 
 
 Since the saving in time effected by means of jolt ramming 
 is usually not more than 50 per cent of the whole, it is advisa- 
 l)Ie that more time be saved by using a machine that not only 
 jolts but also rolls the mould over and draws the pattern from 
 the sand. These operations are being performed by machine 
 power in from 10 to 60 seconds of time, producing a mould 
 that has rot been distorted or broken, and leaving the patterns 
 undamaged by rapping. 
 
 Ramming Requirements 
 
 The requisites of ideally rammed moulds, then, are as 
 follows : 
 
 (a) Uniformly rammed sand. 
 
 (b) Correct density in various parts of the mould. 
 
 (c) Uniformity of various moulds made from the 
 same pattern. 
 
 These lequirements necessitate the use of a suitable grade of 
 moulding sand, properly prepared. 
 
 Taking these points and considering them separately, we 
 find that the jolt ramming of a machine produced an equal 
 force over the surface of the pattern and pattern plate and this 
 equal force, acting against the equal resistance of the sand, 
 produces an equal result over the entire pattern. The ma- 
 chine, then, normally produces a mould which is of uniform 
 density throughout, whereas a moulder, after nuich training, 
 can only approximate this desired condition. 
 
 The second point — correct density — is subject to the same 
 influences. The machine can readily be adjusted to give a 
 harder or softer blow, which, coupled with the number of 
 blows, will ram the mould to any desired density within given 
 operating limits. A moulder, on the other hand, attempts to 
 match his skill against the machine in producing a proper den- 
 sity of sand and invariably comes out a poor second. 
 
34 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 The third point — unifoniiity of dilTercnt moulds made 
 from the same pattern — is of great imjiortance to the user of 
 castings. Accurate weighing shows that the castings produced 
 near the end of tlie day hy hand labor are heavier, due to soft- 
 er ramming on the part of the tired moulder. The difference 
 will amount to an appreciable sum in the first cost of the 
 castings to the user, and probably even more expense will be 
 incurred in the machine shop, for these oversize castings give 
 trouble in jigs and on the layout plates. 
 
 It lias been found that to produce a machine that will 
 quickly jolt ram a mould in the manner described in the pre- 
 ceding paragraphs, there should be no pause in the upward 
 action of the stroke, but, on the contrary, the upward action 
 of the stroke should start rapidly and at the instant of table 
 contact with the anvil, in order to prevent the moving parts 
 from coming to rest at the end of the slight rebound stroke 
 due to impact only. If this impact rebound is allowed to ex- 
 pend itself before the table again starts on its upward stroke 
 bv means of the air power, the ])ressure on the sand is then 
 released, and instead of being compressed the sand itself re- 
 bounds and retards or destroys the packing action. Machines 
 that do not make use of this pressure require a longer time 
 in which to pack the sand. 
 
 FiS-19. Indicator Tests F*g- 20- 
 
 Indicator cards taken from such a machine are as shown 
 in l-'iguies 19 and 20, in which the extreme width of Fig. 19 rep- 
 
Theory of Jolt Ramming 
 
 3.J 
 
 resents the pressure required to lift the table with equipment, 
 and the extreme width of the shaded portion of Figiu-e 20 rep- 
 resents the pressure in the cyhnder at llie time of eontact. 
 Since the indicator diagram ( I'^ig". 20) shows that the pres- 
 sure in the cyhnder at the time of contact is only one-half 
 of the amount required to lift the load, it is obvious that the 
 moving parts will rebound, and that, without sufficient pres- 
 
 Fig. 21. 
 
 Fig. 22. 
 
 sure in the cylinder, the moving parts will, when the force of 
 the rebound is spent, settle back again until sufficient air is 
 admitted to the cylinder to obtain the pressure required to 
 again lift the load. 
 
 The indicator cards shown in Figures 21 and 22 are taken 
 from a machine having a balanced piston type valve, so con- 
 structed as to close the exhaust ports, thereby trapping the 
 air in the cylinder and also admitting line air to the cylinder be- 
 fore the falling load has contacted with the anvil. This pro- 
 
36 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 duces, iindtT ilie ])iston. a high pressure, j^reater even than 
 line pressure. I'his high pressure is present just hefore the 
 piston contacts at tlie bottom of the stroke, and prevents the 
 moving parts from settling back again after the rebound at 
 the beginning of the stroke. Upon contacting, the table re- 
 bounds ?nd then proceeds steadily upward under full line pres- 
 sure, maintaining the packing force generated in the sand by 
 
 Fig. 23. 
 
 the impact. This force, by remaining upon the sand longer, 
 naturally produces more packing efifect on it. 
 
 The width of the shaded portion ol" iMgure 21 represents 
 the air pressure required to lift the load; the width of the 
 shaded portion of I""igure 22 re])resents llie pressure developed 
 by the downward movement of the piston acting upon the air, 
 at atmospheric pressure in the cylinder, after the exhaust is 
 closed, and also upon the admitted compressed air ; the re- 
 sulting pressure is from 10 per cent to 20 per cent higher than 
 the pressure ref[uired to lift the load, and takes place at a point 
 in the stroke just liefore contact is made, and therefore, 
 cushions the blow so that the force of the blow is not trans- 
 mitted to the base and fovmdation. the contact being necessarv 
 only to cause a (juick antl decisive reversal of the moving 
 parts. 
 
 There are no heavy strains set up in the falling parts as 
 would otherwise be the case if the whole load were allowed to 
 fall with the full force of gravity. The action obtained in the 
 
Theory of Jolt Ramming 
 
 moving parts is rapid, and at the time of contact with the anvil 
 these parts arc resiHently reversed in their (Hrection of travel, 
 while the sand, being loose and semi-litiuid, continues its down- 
 ward movement without reliounding and without again becom- 
 ing loose in the flask. 
 
 Design 
 
 The design of a machine cai)able of i)roducing the re- 
 sults noted in the preceding paragraphs has been accomplished 
 only by overcoming many obstacles. The chief difficulties en- 
 countered have been the unpacking forces on the sand, and 
 the irregularity of action. L'npacking forces on the sand are 
 produced at two ditTerent ])(_)ints in the cycle of operation. 
 
 1st. At llie rebound after the striking blow. (This has 
 already been covered in preceding paragraphs.) 
 
 2nd. At the top of the stroke. 
 
 If, when the air is cut off at the top of the stroke, the pis- 
 ton, tabic and flask decelerate more rapidly than gravity de- 
 mands, then the sand will tend to decelerate less rapidly than 
 the flask, and the result wall be a tendency of the sand to move 
 upward in the flask. ])roducing on the sand an unpacking force 
 which will partially destroy the ramming that has already been 
 accomplished. Any mechanical defect which causes the pis- 
 ton to be retarded unduly after the air has been cut off, will 
 produce this result. A tight piston, either thru poor fitting 
 or binding, will produce this trouble. 
 
 Fig. 24. 
 
 Figures 24, 25 and 26 show the result of tests wdiich will in- 
 dicate the existence of an. unpacking force, either at the top 
 
38 Foundry Moulding Machines and Pattern Equipment 
 
 or at the bottom of the stroke, aiul which will serve the furth- 
 er purpose of indicating any irregularity which might be pre>- 
 ent in the action of the machine. Any of these defects would 
 show in the test curve of the machine, and should, of course, 
 be investigated and eliminated. l-"igures 25 'and 26 show, re- 
 spectively, a machine working properly and one working irregu- 
 larly. 
 
 Indicator card diagrams taken on foundry moulding ma- 
 chines may seem, at first sight, to be rather out of place, but 
 by the aid of these cards all of the guess work in regard to the 
 
 "^ 
 
 
 
 
 
 
 
 
 
 
 ' V 
 
 "T" 
 
 "T" 
 
 "T" 
 
 IT 
 
 T 
 
 V 
 
 V 
 
 V V 
 
 "X 
 
 Fig. 25. 
 
 ~T~^v \^~^^ 
 
 ^^^^T' 
 
 "V \r 
 
 Fig 26. 
 
 setting ot valves, as well as the design of valves, can be elimin- 
 ated. In correcting difficulties existing in the operation of the 
 machine, the indicator cards are used in much the same way 
 as those taken on a Corliss engine — a study of the card reveal- 
 ing the difficulty and a subsequent card showing its elimination. 
 There are adjustments necessary on a jolt machine in a studv 
 of which the indicator cards are of valuable assistance. The 
 length of stroke, the force of blow, and the amount of com- 
 pression are the variable features. The factors afi^ecting 
 these adjustments are as follows: .Size of the flask and 
 ])attern. grade of sand, nioistiu'e of sand, the bond of the 
 
Thfory of Jolt Ramming 39 
 
 sand, the density to be attained, and the metal to be poured 
 One should not get the false impression than an indicator card 
 is necessary every time one of these factors is changed. On 
 the contrary, the indicator cards are never used in the found- 
 ry where trial settings quickly bring the proper results. The 
 use of the indicator cards is confined to those who are mak- 
 ing a laboratory study of the action of the machine, with a 
 view of improving the machine, or of solving the extremely 
 difficult cases which are not liable to be quickly solved by the 
 guess method. They are also used to secure uniformity in 
 manufacture. 
 
 Summing up tlie jolt ramming machine, the jolt operation 
 is fundamentally, basic and important. It substitutes machine 
 power for hand power in performing a large portion of the 
 work done on each mould, and means an even more import- 
 ant difi'erence in the quality of the castings produced; due, 
 however, to the fact that its achantages cannot be utilized to 
 the fullest extent when the subse(|uent operations are perform- 
 ed by hand, it becomes of the utmost importance to supple- 
 ment jolt ramming with machine operations for the remain- 
 ing step.^ in making a mould. The ste])s in the operation are 
 as follows : 
 
 1. jolt Ramming. 
 
 2. iUitting Ott. 
 
 .S. Rolling over (if necessary). 
 4. Drawing the Pattern. 
 
 The most advantageous maciiine. of course, is one which 
 performs al! of these oiterations. 
 
40 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 27. A lypical Moulding Machine of the Roll Over .lolt Type. 
 
CHAPTER III 
 Roll Over Jolt Moulding Machine 
 
 The Roll Over Jolt Moulding ^lachine performs the 
 three most fundamental operations in making a mould. It 
 jolt rams the sand, rolls the mould over and draws the pat- 
 tern, all by machine power, thus eliminating practically all of 
 the hand work in connection with the making of a mould. 
 
 In considering the construction and operation of the ma- 
 chine, the subject naturally divides itself into three main head- 
 ings, viz.. 
 
 1. Jolting. 2. Rolling Over. 
 
 3. Pattern Drawing. 
 
 Each of these divisions can be still further subdivided into 
 the subjects of operation of the machine and construction of 
 the machine. In taking up each of these subdivisions, in or- 
 der, we have first 
 
 Jolting Operation 
 
 The jolting mechanism, as built into the Roll Over Ma- 
 chine, is very similar to that of the Plain Jolt Machine, which 
 will be described in detail in Chapter VIII. The essential 
 parts consist of a cylinder and a piston supporting a table, and a 
 valve for the proper control of the air to secure the jolting mo- 
 tion. Alany refinements are worked into the parts, such as liners 
 in the cylinder, special oil grooves and oiling devices on the 
 piston, special striking j)ads, safety limit stops, and valves of 
 various designs, ranging from a simple sleeve valve to special 
 valves designed and used for this ])urpose only. 
 
 The jolting operation introduces severe strains in all parts 
 of the machine and necessitates types of construction which 
 would not otherwise be necessary. It also necessitates steel 
 parts in some cases where otherwise cast iron would be sufifi- 
 cient. Ill Figure 27 the jolting cylinder is in the center of 
 the machine with the jolt valve to the left of it. In Figure 28 
 the jolting mechanism is at the left. In Figure 29 the jolting 
 mechanism is at the right side of the machine. 
 
42 
 
 Foundry Moulding Macliini-s and Pattern Equipment 
 
 Fig. 28. An Air Operated Roll 
 Over Jolt Moulding Machine. 
 
 The time re(|uired for hand ramming is approximately 
 50 per cent of the total time required in floor moulding, and the 
 jolt ramming feature of the machine practically eliminates this 
 time, as the machine will jolt ram the mould in from 5 to 30 
 seconds, and it can he "hutted off" in less than a minute on 
 medium size moulds. The advantage of the lime saved is 
 important, hut it is not the only benefit. The bettering of 
 the quality of the castings obtained is a direct consequence of 
 the uniformity of the jolt ramming operation. This applies 
 to the accuracy of the shape of the casting as well as to the 
 accuracy of reproduction. 
 
Roll Over Jolt Moulding Machine 43 
 
 Roll Over Operation 
 
 The roll over operation saves a large amount of time on 
 each mould, although it does not contribute directly toward 
 the production of a higher quality of casting. The saving 
 in time, as compared to rolling over by the crane, is due to 
 the following f actt~>rs : 
 
 1. There is no waiting for the crane. 
 
 2. The clamps and wedges used ni nilling over arc al- 
 ways accessible, since they are always in the same 
 ])lace and the workmen have standardized their 
 method of operation. This is contrasted with floor 
 moulding, where each mould is rolled o\er on a new 
 location and clamps and wedges must be moved 
 froni p^'icc to ])lace as demanded. 
 
 3. Standardized clamps for bottom boards require less 
 time and are adopted as a part of the machine equip- 
 ment, whereas they woubl not be standardized for 
 floor work. 
 
 4. The actual speed of rolling over is greater, due to the 
 stability and steadiness of the machine. 
 
 5. A suitable place for the rolled over mould is always 
 available on the machine, whereas in floor moulding 
 a portion of the floor must lie leveled off for each 
 mould. 
 
 The roll over operation is accomplished in the different 
 designs of machines by various methods, based upon various 
 mechanical principles. The machine illustrated in Figure 23 
 rolls about a center located in the center of the machine at the 
 highest point. Two arms reach down inside of the vertical 
 members, extending thence horizontally to the left, where the 
 pattern plate and flask are mounted. The roll over power is 
 developed by an air operated cylinder which pulls down on a 
 lug extending to the right from the roll over center, and in 
 this way rolls the pattern and flask upward and over until the 
 tiask is directly over the leveling device seen at the extreme 
 right of the photograph. It is readily seen that the principle 
 
44 
 
 Foundry Moulding Machinfs and Pattern Equipment 
 
 employed is that of a lever having a force applied on one 
 end and the weight acting on the other. 
 
 The- machine illustrated in h'igvn'e 29 operates on the same 
 general principle, and is shown with the table in a partly raised 
 and rolled over position. In this case, however, the axis of 
 rotation is on a line which is about at the floor level. An aux- 
 iliary axis of rotation is located at the end of the movable arms, 
 and the table rotates about this axis also. 
 
 Fig. 29. The Mould is Finished and the Table is Returning 
 to its Original Position. 
 
 The machine illustrated in I'ii^urc 31 rolls over about the 
 center of gravity of the nuiuld. The center of rotation is 
 the trunnion shown at the extreme left of the machine. 
 
 The machine illustrated on page 40 also rolls over about 
 the centei of gravity of the mould. The force is "developed 
 
Roll Over Jolt Moulding Machine 
 
 4,1 
 
 by the cylinder shown hi the right foreground near the bot- 
 tom of the machine, and is transmitted to the trmmions sup- 
 porting the roll over table, causing them to rise. As the table 
 rises it automatically rolls over before it reaches the top of its 
 stroke. This rotation takes "place about the approximate cen- 
 ter of gravity of the mould. 
 
 The methods of operating some of the typical types of 
 roll over machines are as follows : 
 
 The machine illustrated in l-'igure 28 is controlled by the 
 valves in the center foreground. The table is shown in the 
 jolting position at the left, and is ready for the pattern to be 
 placed upon it. After the pattern has been placed on the 
 table, the flask is placed on the pattern plate, filled with sand 
 and jolt rammed by the action of an air cylinder. The mould 
 is then rolled over. This is accomplished by a piston pulling 
 down on the lug which is shown extending to the right and 
 upward from the center support of the machine, and causes 
 the table at the other end of the lever to roll over. As the 
 table leaves the horizontal position at the beginning of its roll 
 
 over movement, the 
 pattern is automat- 
 ically locked to the 
 roll over table by 
 an air operated de- 
 vice. The opening 
 of another valve 
 causes the piston 
 ill the cylinder 
 shown at the lower 
 right hand corner 
 of the illustration, 
 to r i s e, carrying 
 with it the four 
 leveling pins, which 
 are shown. These 
 pins are air oper- 
 ated and take up 
 
 Fig. 30. Showing Clearly the Method of 
 Pnttern Mounting Employed. 
 
46 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 any irregularities in tlic thickness of the liottom hoard, 
 after v. hich they are locked and the clamps are removed 
 from tin; flask, allowing the flask to he supported on its 
 bottom board by the leveling pins. The leveling table is 
 now dropped vertically downward, leaving the pattern attached 
 to the roll over table, which is rolled back to its original posi- 
 tion at the left, ready for the making of the next mould. 
 
 Fig. 31. A Machine with Hand Roll Over and Power Jolt Mechanism. 
 
 Ano'her tv]:)ical roll over machine is shown on page 40. 
 The metiiod of making a drag mould on such a machine is as 
 follows : 
 
 The i)altern is assumed to l)c mounted on a plate with 
 suitable means for fastening to the roll over table of the ma- 
 chine which is shown in the illustration at the upper left hand 
 side. The flask is placed around the pattern, filled with sand, 
 and jolt rammed. While jolt ramming, the sand is spread 
 from the center to the edges of the flask, so that the butting 
 off operation can l)e immediately and c|uickly performed. The 
 
Roll Over Jolt Moulding Machine 47 
 
 bottom board is next bedded on and clamped to the mould, 
 after which the mould is rolled over by air power operating a 
 piston in the cylinder, shown at the lower right hand corner 
 in the illustration on page 40. This motion is transmitted to 
 the trunnions supporting the roll over table. As these trun- 
 nions rise vertically, the table rises with them and a pair of 
 chains, whicli are coiled about the semi-circular ends of the 
 table, retard the movement of one side of the table, causing it 
 to roll o\er. The le\eling car is then pushed underneath the 
 roll over table, the table lowered tmtil the bottom board de- 
 presses each of the pins a slight amoimt. the pins are locked 
 and the clamps are removed, leaving the weight of the flask 
 supported by the leveling car. and the pattern e(iuipment sup- 
 ported by the roll over table. .\ided by the vibrator, the pat- 
 tern is drawn vertically upward from the mould, which is then 
 pushed cut on the leveling car. and the table is rolled back to 
 its initial position, ready for the making of the next mould. 
 
 The series of operations discussed for the two machines 
 above are typical of the various types of Roll Over machines, 
 and while minor differences in the operations will e.xist, due 
 to differences of design and construction, yet the fimdamentals 
 have been stated above. It is well to bear in mind that these 
 machin'.'s have three major functions. 
 
 1. The Jolting of the ^lonld. 
 
 2. Rolling it over. 
 
 3. Drawing the jiattern. 
 
 Roll Over Construction 
 
 The construction of the various parts of the roll over ap- 
 paratus varies, of course, as widely as the methods employed. 
 Some factors are, however, common to all of the methods. 
 These are as follows : 
 
 1. The action of the jolting feature of the machine de- 
 mands heavy, strong parts which will have a long life 
 under hard service. 
 
4S Foundry Moulding Machines and Pattfrn Equipnu-nt 
 
 2. Since the machine operates in practically a shower of 
 dirt and dust, all working parts must be protected from 
 the action of the sand. Parts which cannot be to- 
 tally enclosed in sand proof chambers should have ev- 
 ery protection applied to them in the way of tight fit- 
 ting bushings and proper design of parts so that sand 
 will shed away from such places rather than accumu- 
 late and wear in. 
 
 3. 'J'he subsequent accuracy of the pattern drawing opera- 
 tion depends absolutely upon the accuracy of the posi- 
 tion of the roll over table at the completion of rolling 
 over. It is most important, therefore, that the table 
 shall be properly aligned, and that all working parts 
 shall be carefully fitted so that great accuracy is 
 obtained in the final position of the table. 
 
 4. It is of importance that the parts of the roll over 
 n.echanism should be so designed that they will require 
 a minimum of air consumption for the operation, and 
 so that undue weight will be avoided. 
 
 I^attcrn Draw ing Operation 
 This operation is very important from two viewpoints — 
 it is a valuable source of time saving, both directly and indi- 
 rectly, and it promotes, in a great measure, the higher quality 
 of castings produced. The pattern drawing operation as accom- 
 plished en the Roll Over type of machine, usually requires about 
 5 to 30 seconds and when this is compared with the lengthy proc- 
 ess employed in floor moulding, the gain in the direct time 
 saved becomes at once apparent. Indirectly also, time is 
 saved in that the pattern drawing operation is accurate to 
 within an amount less than the taper of the pattern, so that 
 the sand in the mould is left undamaged, and need not be 
 slicked and patched. These useless operations of slicking and 
 patching require a great amount of time when the pattern is 
 drawn b}' hand, as there is always more or less damage done 
 to the mould in that case. These operations of slicking and 
 patching are a total loss of time, and the machine, in eliminat- 
 ing them, saves time. 
 
Roll Over Jolt Moulding Machine 49 
 
 'JMic method of accomplishing the pattern draw varies in 
 the different designs of machines. It is immaterial whether 
 the roll over ta])le is moved upward away from the leveling 
 tahle. or whether the leveling table is moved downward from 
 the roll over table — the result accomplished is the same. In 
 all cases the pattern is supi)ort('d bv the roll over table and 
 the mould must l)e supported b\ the leveling table, which is 
 either movable or stationary, and is provided with some means 
 of equalizing the variations or inequalities of the bottom board. 
 Ordinary wedges or depressable pins are commonly u.sed for 
 this purpose. 
 
 The machine illustrated on page 40 draws the pattern 
 by lifting it upward from the flask. The machines illustrated 
 in Figures 28. ,^1 and M all draw the pattern by lowering the 
 mould away from the stationary pattern. 
 
 The principal points of interest are not in the method of 
 accomplishing the movement, but rather in the accuracv with 
 which the roll over table is held at right angles to the line of 
 pattern draw, and in the accuracy with which the flask is 
 brought to exact right angles with the line of pattern draw be- 
 fore its weight is released from the roll over table and 
 allowed to rest on the leveling table. One of the greatest diffi- 
 culties is in deflection of the roll over table or of the leveling 
 device. If, when the mould is released from the roll over 
 table, the decrease in weight supported by it causes the table 
 to spring slightly, the pattern will move in the sand, and will 
 break up the mould before the pattern draw is even started. 
 The same conditions will exist if the weight of the flask causes 
 the leveling table to deflect, for if the pattern, attached to the 
 roll over table, remains stationary and the mould should tip 
 slightly the result wotild be a damaged mould. It is essential 
 that the pattern be moved in a straight line, and the accuracy 
 of the straight line motion is necessarily destroyed by any 
 looseness in the fit of the bushings located in any of the mem- 
 bers causing this motion. Accordingly, too much care cannot 
 be taken with the design of bushings and bearings and with 
 the accuracv with which thev are fitted. 
 
iiO 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 The question of removing the finished mould from the ma- 
 chine is usually considered in the design of the leveling tahle. 
 In some cases the leveling table is provided with wheels and is 
 run out from under the roll o\er table. This method is used 
 in the niachine illustrated on page 40. In other cases, such 
 
 Fig. 32. A Portable Roll Over Jolt Machine for Small Moulds. 
 
 as the one illustrated in I'igtu't' 2S. tlie leveling; table remains 
 stationary, and the roll over table returns to its original posi- 
 tion, far enough removed from the leveling table position to 
 allow the crane to take away the finished mould witliotit inter- 
 fering with the operation of making the next mould. 
 
Roll Over Jolt Moulding Machine 51 
 
 The advantages of machine pattern draw, as contrasted to 
 hand pattern (h'aw are far reaching, extending in fact from 
 the foundry all the way to the niacliine .^hou and to the as- 
 sembly floor where the casting is finally used, and also even 
 to the Treasurer's Department which no longer pays for over- 
 weight castings. 'J'he j)attern is drawn in a])proximately 5 to 
 30 seconds and this is in contrast to the old method of drawing 
 a pattern where it iinist first be rapped, which damages it 
 seriously, and which w ill damage the mould seriously before the 
 jiattern is drawn. 
 
 Machine Moukicd Castinirs 
 
 Hand made castings vary from 5 per cent to 15 per cent in 
 weight with corresponding variation in shape, whereas, machine 
 moulded castings are identical as to weight and shape. In rough 
 work, where great accuracy of shape is not a requirement of the 
 parts, the variation in hand made castings is not a serious det- 
 riment to their use. On the other hand, the reiiuirements for 
 certain grades of castings are so exact that hand made castings 
 do not measure up to the recjuired sjiecifications. and in such 
 cases the uniformitv of machine castings is of greater import- 
 ance. The outstanding examples of this latter class of cast- 
 ings are those used in the automotive industry. As a rule, 
 these castings are used by the thousands and the machine shops 
 are specially equipped for the handling of each casting, with 
 jigs and tools designed for it and with piece wor'-c lates set 
 and procedure systemized to the last degree. In such cases 
 a slight additional amount of metal here or there will seriously 
 interfere with the use of the accurately fitting jigs, and will 
 decrease the speed of the workman who is on a piece-work 
 rate. Small metal allowances are also the rule, as for in- 
 stance, in the embloc cylinders which have usually a 3/16 
 thickne-s of wall and 3/16 thickness of water jacket. The 
 variation allowed is very minute and the overall allov/ances of 
 variation in the castings are always so small as to be neg- 
 ligible. 
 
Foundry Moulding Machines and Pattrrn Equipment 
 
 The Making of a Drag Mould on the Floor Contrasted 
 with the Roll Over Jolt Moulding Machine 
 
 Below is set forth a detailed comparison between the 
 making of a mould by hand on the floor, and on the Roll Over 
 type of machine. In comparing the operations, the viewpoint 
 in mind should be the amount of physical labor necessary to 
 perform each operation, the amoiuit of time consumed, and 
 the quality of the work done. 
 
 Floor 
 
 T\\Q Pattern Plate 
 A flat reinforced pattern 
 plate of suitable size is placed 
 on a leveled portion of the 
 foundry floor. 
 
 Pattern 
 
 ^Ihe drag half of the pat- 
 tern, asswmed in this case to 
 be a split pattern, is laid on 
 the board in the location that 
 is desired. 
 
 Flask 
 
 The flask is placed on the 
 pattern plate surrounding the 
 pattern and in such relation to 
 the pattern that there will be 
 sufficient room for gating and 
 sufficient sand thickness be- 
 tween the pattern and the flask. 
 
 Facing Sand 
 
 On all heavy and high grade 
 work, facing sand is used ; oth- 
 erwise moulding sand is rid- 
 dled onto the pattern. 
 
 Machine 
 
 Pattern 
 
 The pattern, mounted on 
 the pattern plate, is attached 
 to the roll-over table of the 
 machine. 
 
 Flask 
 
 'J1ic flask is placed on the 
 pattern plate, the pins locat- 
 ing it. 
 
 Facing Sand 
 
 On all heavy and high grade 
 work, facing sand is used ; 
 otherwise moulding sand is 
 riddled onto the pattern. 
 
Roll Over Jolt Moulding Machine 
 
 53 
 
 Floor 
 
 Sand 
 Sand is put inlo the llask 
 either by hand shovelinj^'. l)y 
 grab buckets, or from an over- 
 head l)in. 'I he method em- 
 ployed depends on the size of 
 the ti;i>k and on shop equip- 
 ment. 
 
 Ramming 
 
 The mould is rammed either 
 by hand or by a pneumatic 
 rannner. whicli is substantial- 
 ly the same size as the hand 
 ramnu'r. but is operated by a 
 '^mrdl air cylinder. This oper- 
 ation consumes approximately 
 50% of the total moulding 
 time, and introduces the vari- 
 able luuuan factor into the 
 density of the ranuned sand. 
 This operation also constitutes 
 a large part of tin- hard physi- 
 cal labor of the foimdrv and 
 contributes a large share to- 
 wards making it such an im- 
 4^1easant ]')lace in which to 
 work-. 
 
 Striking Off 
 
 Steel bars are better prac- 
 tice than wooden ones for 
 striking oflf the flask. .\ wide 
 strike off bar has been found 
 to be very advantageous on 
 small and medium size flasks. 
 
 Machine 
 
 Sand 
 
 ."^and is ])ut into the flask 
 eiilier 1)\- hand shoveling, by 
 giab buckets, or from an over- 
 head bin. The method em- 
 ployed de])ends upon the size 
 oi" the flask and on shop 
 e(|nipment. 
 
 Ramming 
 
 The mould is rannued by 
 jolting, accomplished by power 
 and controlled by a valve. The 
 butting otT is done bv hand. 
 
 Striking Off 
 
 Steel bars are better prac- 
 tice than wooden ones for 
 striking oiiP the flask. A wide 
 strike ofi:' bar has been found 
 to be very advantageous on 
 small ;ind medium size flasks. 
 
Foundry Moulding Machines and Pattern Equipment 
 
 Floor 
 
 Bottom Board 
 
 The bottom board is fitted 
 into place by scattering a hand- 
 ful or two of sand over the 
 surface of the mould and 
 working the board back and 
 forth over it to obtain a uni- 
 form bearing at all points. 
 
 Clamping the 
 Bottom Board 
 
 "C" clamps are employed, 
 being tightened by means of 
 wedges. The clamps must be 
 moved from one location to 
 another on the floor as the 
 moulds are put up. 
 
 Rolling Over 
 
 The rolling over of a mould 
 involves the use of a crane 
 on mediimi and large size 
 moulds, and frequently calls 
 for the assistance of several 
 other men besides the moulder 
 and helpers working on the 
 mould being rolled over. The 
 danger of a damaged mould, 
 due to the shifting of the bot- 
 tom board, is always present. 
 Delays while waiting for the 
 crane, or for other workmen, 
 are common. Extra space is 
 always required in an already 
 busy foundry. Hiis nuist be 
 cleared especially for the pur- 
 
 Machine 
 
 Bottom Board 
 
 'Jlie bottom board is fitted 
 into place by scattering a 
 handful or two of sand over 
 the surface of the mould and 
 working the board back and 
 forth over it to obtain a uni- 
 form bearing at ;ill points. 
 
 Clamping the 
 Bottom Board 
 
 Either "C" clamps or spe- 
 cial clamps are used. 
 
 Rolling Over 
 
 Power applied to the ma- 
 chine automatically rolls the 
 mould over. 
 
Roll Over Jolt Moulding, Machine 
 
 55 
 
 Floor 
 
 pose. After rolling over, the 
 bottom board is undamped. 
 
 Drawing the Pattern 
 
 The pattern is first rapped 
 by means of a rapping pin 
 inserted into the rapping plate 
 which has been built into the 
 pattern for the purpo.^e. Tiie 
 pin is rapped back and forth 
 and from left to right with a 
 hammer or mallet, loosening 
 the pattern in the sand so 
 that it may be withdrawn with 
 as little damage to the mould 
 as possible. The lifting han- 
 dle is then inserted in the plate 
 provided in the pattern and the 
 pattern drawn as nearly 
 straight upward as possible, 
 taking care not to damage the 
 mould any more than can be 
 avoided. 
 
 Slicking and Patching 
 
 Some damage is invariably 
 done in drawing the pattern, 
 and the moulder now slicks 
 over these places and patches 
 up any broken corners or sur- 
 faces. These two operations 
 are very detrimental to the 
 shape and size of the casting, 
 and also impede the escape 
 of the gases at the time of 
 pouring. In addition, this op- 
 
 Machine 
 
 Drawing the Pattern 
 
 The vibrator is placed in 
 operation and the machine 
 draws the pattern. 
 
 SHckine and Patching 
 Not required. 
 
56 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Floor 
 
 cralioii frc(|ucntly consumes 
 mure time llian any dihcr one 
 operation connected with mak- 
 ing- moulds, and as the time 
 tluis sj)enl is a total loss, the 
 inefficiency of such a meth- 
 od is |»reat. 
 
 Prepariiiir \o\ 
 the Next Mould 
 
 Machine 
 
 Preparing for 
 the Next Alould 
 
 Tlie pattern ])late. wed!.';es. TIk- machine upon complet- 
 
 clamps. ]);itterns. rajipiui;- and ini^ one mould, is re.ady for the 
 slicking;' tools nni^t now all he makin,c^ of the next, 
 moved to the next locrition on 
 the foiuKlrv floor. This in- 
 volves a lari^e aniomit ol time 
 spent in levelini;' the place on 
 the tloor u])on which to woi-k 
 and in movin".;' small tools and 
 e(|nipment : all of this time is 
 non-productive. 
 
Roll Over jolt Moulding Machine 
 
oS 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 1?TWlnaii a- 
 
 Fig. 34. A large Roll-Over Jolt-Moulding Machine, with Foundations 
 
 Cut Away to Show the Construction Underneath 
 
 the Foundry Floor. 
 
CHAPTER IV 
 
 Roll Over Jolt Moulding Machines For 
 Large Size Molds 
 
 Large moulds, as referred to in this chapter, will be con- 
 sidered to include moulds of from 3,000 to 20,000 pounds in 
 weight. Manufacturers commonly rate their machines in terms 
 of the maximum load and the maximum flask sizes. Flasks 
 ranging in length from 72" to 150" are usually regarded as of 
 a size requiring large Roll Over Machines. 
 
 The principles of construction and operation of the large 
 Roll Over Jolt Machines have already been covered in the 
 preceding chapter, and the reader is referred there for details. 
 
 The handling of the large size moulds with their attend- 
 ant heavy equipment brings up the question of the crane 
 equipment necessary for handling of patterns, flasks, bottom 
 boards, moulds, setting cores and closing moulds. The use of 
 a crane for so many operations would seem to necessitate an 
 exceptional amount of crane service but when the number of 
 moulds produced per day is considered, it will be seen that a 
 large machine requires about the same amount of crane atten- 
 tion as a medium size machine. The machine does not add to 
 the demands upon the crane, but rather lessens them. For 
 instance, a foundry may be employing a number of floor mould- 
 ers, all being served by the one crane. In changing over to 
 machine moulding, say, for example, two moulding machines 
 would be used to put up the same total number of moulds, using 
 fewer men but the same crane. This crane would now be 
 be relieved of rolling the moulds over and of drawing the pat- 
 terns, these operations being performed by the machines. 
 
 The output of large machines, measured in tonnage pro- 
 duced, does not vary greatly from the output of medium size 
 machines as the greater weight per casting is just about evenly 
 offset by the smaller number of moulds produced. When the 
 figure is reduced to a "tons per man" basis, it increases some- 
 what with the size of the machine used. 
 
(in 
 
 Foundry Mnuldiivi Mo.chinrs and J-c.ltnn liijui pw.riil 
 
 Fig. 35. Tunnel Segment Mould — 
 Lower or Drag Half — Made on a Rull- 
 0\cr Jolt Machine. In the view shown 
 above, the machine is roiiini: over the mould 
 after it has been jolted and bottf)m board 
 clamped. 
 
 .\fter the rolline-(j\er operation is com- 
 pleted, the mould is lowered on the run-out 
 car, shown in the rear, clamps rcmo\-cd and 
 pattern drawn from the mould. 
 
 'The lower \ iew shows the completed 
 lower half or drair mould before the cores 
 
Roll Over Jolt Moulding Machiiifs for Large Size Moulds 
 
 C.l 
 
 Fig. 36. Tunnel Seg- 
 ment Mould — Upper 
 Half or Cope — Made on 
 a 42 "xJ)?" plain jolt-moulJ- 
 ing machine. 
 
 Tunnel Segment Casting 
 Weighing 1500 Pounds. 
 
 Used in making tunnel linings for 
 the New ^'ork subway system. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 Increase 
 
 Without Machine 
 
 2 
 
 <» 
 
 7 
 
 
 Cope— 42 ".\t)7 " Plain [oh 
 
 
 9 
 
 14 
 
 
 Drag— 42 "xD?" Plain Jolt 
 
 2 
 
 100% 
 
 Cope— 42"x97" Plain Jolt 
 
 Drae— 42"xl('6" R. 0. Jolt 
 
 « 
 
 9 
 
 *141 
 
 570% 
 
 * With sand conveying system. 
 
Foundry Moulding Machines and Pattern Kquipmenl 
 
 t^-J? 
 
 'm 5 
 
 Fig. 37. Railway Truck Frame Steel Casting— Weight 470 Pounds. 
 
 The standardization of railway equipment has resulted in large quantity pro- 
 duction of the various castings. 
 
 The production figures given below are based on using two machines of the 
 Roll-Over Jolt type — one for the lower or drag half and the other for the upper or 
 cope half of the mould. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 Increase 
 
 Without Machine 
 
 
 9 
 
 15 
 
 
 
 
 
 Cope— 42"x97" Plain Jolt 
 
 Drag— 42"x97" Plain Jolt 
 
 5 
 
 9 
 
 *40 
 
 166% 
 
 Cope— 42"xl06" R. 0. Jolt 
 
 Drag— 42 "x 106' R. 0. Jolt 
 
 . . . . 7 
 
 9 
 
 *120 
 
 470% 
 
 *\\ ith sanJ conveying system. 
 
Roll Over Jolt Moulding Machines for Large Size Moulds 
 
 63 
 
 The shipbuilding industry has 
 not attained the quantity pro- 
 duction shown on the preceding 
 pages, yet a very great saving can 
 be made by the use of moulding 
 machinery on smaller quantity 
 production as is shown in the 
 following tabulations. 
 
 The production figures given 
 below are based on making the 
 cope and drag moulds on the 
 same machine. 
 
 Fig. 38. Marine Engine Cylinder 
 Head — Weight 2400 pounds. 
 
 
 PRODUCTION 
 
 
 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 
 Increase 
 
 Without Machine 
 
 4 
 
 9 
 
 1 
 
 
 Cope— 72"x72" Plain Jolt. . . 
 Drag— 72''x72" Plain Jolt. . 
 
 '.'.'.'.'.'.'.'... 4 
 
 9 
 
 2 
 
 100% 
 
 Cope— 60 "x92"R.O. Jolt.. 
 Drag— 60"x92" R. 0. Jolt. . 
 
 .'.'.'.'.'.'.'.'.. 4 
 
 9 
 
 3 
 
 200% 
 
«4 
 
 Foundry Moulding Machini-s and Pattern Equipment 
 
 Fia. 39 
 
 Marine Engine Column — Weight 4000 pounds. 
 
 \\ here the quantity of castings required from one pattern is not sutiiciont 
 for continuous production, or even for a full da\'s produciicjii. an\- number of 
 different patterns can be used during the da}'. The clianging of the pattern on 
 the Roll-Over Jolt-Mouldinp Machine requires onh- a few minutes ot tin;e. 
 
 The production figures given below are based on making the cope and drag 
 moulds on the same machine. . 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 
 Moulds 
 
 % 
 
 1. 1 crease 
 
 Without Machine 
 
 4 
 
 () 
 
 1 
 
 
 Cope — 42"x<)7" Plain ]o\\. 
 
 
 {) 
 
 •) 
 
 
 Drag— 42"x97" Plain Jolt 
 
 4 
 
 100% 
 
 Cope— (id "xl .■)()" R. O. Jolt . . . 
 Drag— ()()"xl.")()" R. (). Jolt. 
 
 4 
 
 <» 
 
 .") 
 
 4(M)% 
 
Roll Over Jolt Moulding Machines for Large Size Moulds 
 
 m 
 
 A large number of machine tool 
 castings are adaptable for machine 
 moulding, particularly on the Roil- 
 Over Jolt type of machine. 
 
 In some instances, wliere a 
 casting does not readily lend itself 
 to machine moulding, a slight 
 change can be made in the design 
 without impairing its utility or 
 strength. thereb\- making it 
 possible to mould on machines. 
 
 /<»■ 
 
 
 
 '>*Z7e9 
 
 /2" 
 
 
 
 305-m"v 
 
 
 
 T 
 
 
 
 ^.W^ 
 
 
 / 1 
 
 ^^5( ) 
 
 
 { o 
 
 U'^^ 
 
 ^ 
 
 . — .1 
 
 Fig. 40 
 
 Planer Housing lasting — Weight 
 5000 Pounds 
 
 The production figures gi\en below are based on making the cope and drag 
 moulds on the same machine. 
 
 PRODUCTION 
 
 Method of Mouldin? 
 
 No. 
 .Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 T ^° 
 Increase 
 
 Without Machine 
 
 4 
 
 1» 
 
 1 
 
 
 Cope— 72"x72" Plain Jolt 
 
 Drag— 72"x72" Plain Jolt 
 
 4 
 
 <» 
 
 •> 
 
 100% 
 
 Cope— 66"xl.')()" R. O. Jolt 
 
 Drag— 66"xl.'J0" R. 0. Jolt 
 
 .... 4 
 
 1< 
 
 .") 
 
 400% 
 
66 
 
 Foundry Moulding Machines and Paltern Equipment 
 
 Milling Machine Column. 
 
 Weight of Casting — 
 
 700 Pounds 
 
 A 4o"x72" Roll-Over Jolt-Moulding 
 Machine made both the upper or cope 
 half and lower or drag half of the 
 mould for producing this casting. 
 
 The production figures given below 
 are based on making the cope and 
 drag moulds on the same machine. 
 
 Fig. 41 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 ■ Quan. 
 Moulds 
 
 Increase 
 
 Without Machine 
 
 4 
 
 9 
 
 4 
 
 
 
 
 
 Cope— 54"x66" Plain Jolt 
 
 Drag — 54"x66" Plain Jolt 
 
 4 
 
 9 
 
 8 
 
 100% 
 
 
 
 
 Cope— 45 ''x72 " R. 0. Jolt . . . 
 
 
 9 
 
 14 
 
 
 Drag— 4.5 "x7J" R. 0. Jolt 
 
 4 
 
 2.50% 
 
Roll Over Jolt Moulding Machines for Large Size Moulds 
 
 (u 
 
 A Milling Machine Base Cast- 
 ing made on a Roll-Over Jolt- 
 Moulding Machine having an over- 
 all flask capacit}' of 45" in width by 
 72" in length. This machine is cap- 
 able of jolting and rolling over half 
 moulds up to 4, (KM) pounds in weight. 
 
 i_ 
 
 & 
 
 1_J 
 
 ^ 
 
 n 
 
 ^ 
 
 1 X ) 
 
 
 cpr 
 
 fe 
 
 u 
 
 
 -r^ 
 
 S4 
 " 872 •»« 
 
 » 
 
 
 
 
 ^u 
 
 Fig. 42 
 Weight of Casting^l040 Pounds. 
 
 The production figures given below are based 'm makiui; the cope and dra^r 
 moulds on the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 
 Increase 
 
 Without Machine 
 
 .... 3 
 
 9 
 
 4 
 
 
 
 
 
 Cope— 54''x66" Plain Jolt 
 
 Drag— .54"x66" Plain Jolt 
 
 3 
 
 9 
 
 S 
 
 100% 
 
 Cope— 45 "x7''" R. O. Jolt. . . 
 
 
 9 
 
 18 
 
 
 Drag— 45"x72" R. 0. Jolt 
 
 3 
 
 350% . 
 
68 
 
 Foundry Moulding Ma< hinrs and Paftrrn Eijuipment 
 
 
 
 
 
 ^^■/f 
 
 "t 
 
 -^ , 
 
 
 
 
 
 ^ -' 
 
 1 
 
 
 
 44" 
 
 
 5" --- 
 1 27'"*'*"' 
 
 \ 
 
 
 
 
 
 -^^ij/e 
 
 
 
 
 
 ' 
 
 /^ 
 
 
 ^l 
 
 
 
 
 
 
 
 
 I 
 
 
 
 
 
 
 
 
 1 
 
 
 
 
 
 
 
 t 
 
 
 
 / 
 
 J 
 
 \, 'ifri i'»'l»w>ii*-ni>iOii««l»ii»iiii'»^-..^^. -ti^tMa^i^ii^^. 
 
 Fig. 43 
 
 Milling Machine Table Casting — Weight 500 Pounds. 
 
 A 4.'j".\72" Roll-Over Jolt-Moulding Machine made the moulds for producing 
 this casting. Its simplicity in design makes possible a large production by hand 
 moulding, yet a very large increase has been obtained by machine moulding, as 
 noted in the following tabulation. 
 
 The production figures gi\cn below arc based on making the cope and drag 
 moulds on the same machine. 
 
 PRODUCTION 
 
 Method of Moiildinp 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 
 Increase 
 
 Without Machine. . . 
 
 3 
 
 <> 
 
 11 
 
 
 
 
 
 Cope — 42 ".\();)" Plain Jolt 
 
 
 i) 
 
 IS 
 
 
 Drag— 42"xfi()" Plain Jolt 
 
 W 
 
 64% 
 
 Cope— 4.") "x72 " R. (). Jolt 
 
 Drag— 4.") "x72 " R. (). "jolt 
 
 ... . 3 
 
 9 
 
 32 
 
 190% 
 
 
 
Roll Over Jolt Moulding Machines {or Large Moulds ()0 
 
 Fig. 44. A Large Roll Over Machine Used in the Core Room. 
 
70 
 
 Foundry Moulding Machines and Paltrrn F.'juiptr.rnt 
 
 Fig. 45 A Roll Over Jolt Moulding Machine Suitable for Making 
 Medium Size Molds. 
 
CHAPTER V 
 
 Roll Over Jolt Moulding Machines For 
 Medium Size Moulds 
 
 Medium size moulds are considered to include those rang- 
 ing in weight from 1,000 to 3.000 pounds, and from 44" to 
 64" in length. Such a class of work requires a crane for han- 
 dling flasks and moulds, hut the hottom board and cores can 
 usually be handled by hand. The machine illustrated on page 
 70 is a machine l)eli)nging to the class which produces medium 
 size movilds. 
 
 Medium size moulds, being of moderate weight, demand 
 a production of a large number of moulds per day, in order 
 to keep the figure of "pounds of iron per man per day" as 
 high as it should be. Since high production is important, it 
 is advisable to touch on a few points in regard to the methods 
 of producing the cope and drag moulds. 1liis is solved in a 
 wider variety of ways on this type of machine than on any 
 other. The simplest method is to produce drag moulds in 
 the forenoon, change patterns in the middle of the day, and 
 then to produce cope moulds to go with the drags. The 
 disadvantage of this method is that production is limited, and 
 that the drag moulds, which remain on the floor for several 
 liours before being closed, are liable to physical damage, set- 
 tling dust and drying out. It is the practice in some shops 
 to avoid the undesirable feature of having drag moulds sit on 
 the floor for several hours by making six or eight drag moulds, 
 changing patterns, making six or eight cope moulds and then 
 repeating the cycle. This requires very rapid methods of 
 changing patterns, or too much time will be lost in making 
 the changes. The most obvious remedy, where larger pro- 
 duction is desired, is the em})loyment of two Roll Over 
 Machines, one producing copes, while the other produces drags. 
 Hie drag moulds are then closed as rapidly as they are made, 
 and a verv desirable ct)mpetition is established between the 
 
Foundry Mould inf, Mr.chiiifs and Pattern Equipment 
 
 crews of the draj^- and c()])C' niachiiu's. and, at limes, between 
 the coro setters and the machine crews. The utiHzatinn of 
 the competitive spirit is an excellent aid to production. 
 
 A variation of this method, in large quantity production, 
 is the use of a Roll Over Machine for the dratjs and of a 
 Stripper Machine for the copes. When using a Roll Over 
 Machine for making copes, the crew operating the cope 
 machine have a harder task than those operating the drag 
 machine, on account of their having to form a gate in the 
 cope, and also because of the frequent necessity of setting gag- 
 gers in the cope. This condition is, however, reversed when 
 a Stripping Plate Machine is employed for making the cope, 
 as the crew operating the cope machine can then easily pro- 
 duce n^oie moulds than the crew operating the Roll Over 
 Machine, making drags. In fact, it has been found possible 
 for a single Stripping Plate Machine to keep up with two 
 Roll Over Machines making drags, and this unit of three 
 machines provides a highly ef^cient disposition of men and 
 machines, resulting in a high production. The competitive 
 spirit which is introduced into the work can be used to good 
 advantage. 
 
 All the methods discussed thus far have dealt witli 
 the mounting of one pattern, or at least of only one flask on 
 a machine, using a machine of the proper capacity and size. 
 An alternative method frequently employed is the use of a 
 machine large enough to accommodate two moulds side by 
 side, ''he machine shown in h'igure l.il ])r()duces both a cope 
 and a drag half at each operation, since the cope and drag 
 patterns are mounted side by side on the Roll Over Table. 
 This same method is employed in conjunction with the Strip- 
 ping Plate Machine. I'igure 132 illustrates tht nKumting of 
 two dr;i'^ ]")attcrns side bv side on the table of the Roll ( )ver 
 Jolt Moulding Machine. A small Stripping Plate Machine 
 opei'atcs twice as fast as the Roll Over Machine and i)r()duces 
 enough copes for all of the drags. 
 
 There remains one other method which is sometimes 
 employed as an aid to production when the pattern is symmet- 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds T'.i 
 
 rical about both center lines, that is. the center Hne joining 
 the pins and the hne perpendicularly bisecting this line. The 
 same pattern may then be used for making both cope and 
 drag moulds. In some cases where one half of the gate is 
 mounted on the plate, the mould becomes essentially non- 
 symmetrical about the principal center line and requires care 
 in closing, as the cope mcnild must he turned end for end 
 before closing. In order to avoid the possibility of closing 
 the mould improperly, it is best, in all cases, to endeavor 
 to keep the pattern and gates symmetrical about both center 
 lines. 
 
 Fig. 46. A Medium Size Roll Over Machine. 
 
Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 47 
 
 Automobile Cylinder with Upper Half of Crank Case 
 cast en bloc— Made on a Roll-Over Jolt-]\IoulcHng Machine. 
 
 This view shows the pattern drawn frtan the mould, 
 which is deposited on the run-out car and ready for the 
 crane to remove to the foundrv floor for setting the core. 
 
 After sufficient drags ha\"e ])een made t(T begin core- 
 setting, the drag pattern is remo\ed from the machine and 
 the cope pattern substituted. 'I'his changing of pattern con- 
 sinnes al)i)ut fi\e minutes in time, as only four l)()lts are 
 used in securing it to the roll-o\ er table. 
 
 Foundries producing these castings in large quantities 
 find it advisable to tise two machines in producing the 
 UK^uld — one to be used in making the cope half and the 
 other the dratr half of the nmuld. 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds "o 
 
 Fig. 48 
 
 Automobile Cylinder en bloc. Weight 175 Pounds. 
 
 The production figures given below are based on making the cope and the 
 drag on the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Machine 2 9 2 
 
 Cope— 36"x4S" Plain Jolt ^ 
 
 Drag— 36"x48" Plain jolt 2 9 4 100% 
 
 Cope— 34"x64" R. O. Jolt ^ 
 
 Drag-34"x64" R. O. Jolt 4 9 4S 1100% 
 
Foundry Moulding Machines and Pctlern Equipment 
 
 An Automobile Truck Wheel 
 
 Produced in a Steel 
 
 Foundry. 
 
 Beginning work in the morning, 
 10 to 15 drags are made, permitting 
 the core-setter to start work. The 
 drag pattern is then removed from 
 the machine and the cope half of the 
 mould is made. Rotation in this 
 manner makes possible the closing 
 of the mould before the floor is com- 
 pletely filled. 
 
 If the quantity is sufficient, it is 
 advisable to use two machines, one 
 for the cope and one for the drag. 
 
 Fig. 49 
 Weight 240 Pounds. 
 
 The production figures given below are based on making the cope and dras 
 moulds on the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 Without Machine 
 
 Cope— 42"x6()" Plain Jolt. 
 Drag— 42"xti()" Plain Jolt. 
 
 Cope— 34"x()4" R. O. Jolt. 
 Drag— 34"x64" R. O. Jolt. 
 
 No. 
 Men 
 
 Quan. % 
 
 Hours Moulds Increase 
 
 9 IS 100% 
 
 45 400% 
 
Roll Over Jolt Moulding Machin es for Medium Size Moulds JJ, 
 
 Remarkable progress is being made 
 on tractor work and the large quantity 
 of castings required makes machine 
 moulding a necessity. 
 
 A pair of 34"x64" Roll-Over Joh- 
 Moulding Machines were used in 
 obtaining the production noted below, 
 one making the cope half and the other 
 the drag half of the mould. 
 
 Fig. 50 
 
 Tractor Sprocket Wheel — 
 Weight 115 Pounds. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 Increase 
 
 Without Machine 
 
 6 
 
 9 
 
 30 
 
 
 Cope— 36"x4S" Plain Jolt 
 
 Drag— 36"x48" Plain Jolt 
 
 '.'.'.. 6 
 
 <) 
 
 GO 
 110 
 
 100% 
 
 Cope— 34"x64" R. 0. Jolt 
 
 Drag— 34"x64" R. 0. Jolt 
 
 8 
 
 8 
 
 208% 
 
 
 
 
 
 
78 
 
 foundry Moulding Machines and Pattern Equipment 
 
 Fig. 51 
 
 The Upper Half of Liberty Motor Aluminum Crank Case — made 
 
 on a 34''x70" Roll-Over Jolt-Moulding Machine. 
 
 The large production noted in the tabulation below was obtained with a 
 pair of these machines, one making the upper or cope half and the other the lower 
 or drag half of the mould. 
 
 Weight of Casting 100 Pounds. 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Mouldinp Men Hours Moulds Increase 
 
 Without Machine 8 9 1ft 
 
 Cope— 42"x60"' Plain Jolt 
 
 Drag— 42 "x60" Plain Jolt K 9 :V2 100% 
 
 Cope— 34"x(70" R. O. Jolt 
 
 Drag— .34"x70" R. O. Jolt S 9 102 540% 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds 
 
 Fig. 52. 
 Weight 230 Pounds. 
 
 Steel Casting of a Lower Ball Race for 6 Ton Armored Truck. 
 
 Made on a 32''x54" Roll-Over Jolt-Moulding Machine. A dense and 
 uniform casting is very essential in work of this kind. Loss from defective 
 castings is reduced to a minimum by machine moulding, thus making a 
 saving in labor and metal and also increasing the production. 
 
 Production based on using one machine for both the cope and the drag half 
 of the mould. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 
 Increase 
 
 Without Machine 
 
 3 
 
 9 
 
 20 
 
 
 Cope— 24"x36" Plain Jolt 
 
 Drag— 24"x36" Plain Jolt 
 
 ...'. 3 
 
 9 
 
 32 
 
 60% 
 
 Cope— 32"x54" R. 0. Jolt 
 
 Drag— 32"x54" R. 0. Jolt 
 
 '..'.'. 3 
 
 9 
 
 45 
 
 125% 
 
so 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Milling Machine Drive Pulley. 
 
 Weight of Casting 150 Pounds. 
 
 Fig. 53 
 
 Production based on using one macliine for both tiic cope and tlie drap half 
 of the mould. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 Vc 
 Increase 
 
 Without ^lachine. . . ... 
 
 . . 3 
 
 9 
 
 20 
 
 
 
 
 
 Cope— 24"x:}6" Plain Jolt 
 
 Drag— 24"x36" Plain Jolt 
 
 '.'.'.'. 3 
 
 9 
 
 32 
 
 60% 
 
 Cope— .32".x54" R. 0. Jolt 
 
 Drag— 32"x-)4" R. 0. Jolt 
 
 3 
 
 9 
 
 45 
 
 125% 
 
Roll 
 
 Over Jolt Muulding Marliiii,-s j<>r Maiium Sizr Moulds S^ 
 
 Casting Used in the Shipbuilding 
 Industry. 
 
 L^<:^ 
 
 !::;> 
 
 v-^^ 
 
 
 cZ^=r~ 
 
 ^^ 
 
 1 
 
 r^ 
 
 .. 
 
 
 J- 
 
 Towing Chock. ^^ eight 
 500 Pounds. 
 
 Fig. 54 
 
 Production based on using one maciiinc for both tiu- cope and the drag half 
 of the mould. 
 
 PRODUCTION 
 
 fvjo Quan. % 
 
 Me thod of Moulding Men Hours Moulds Increase 
 
 Without Machine "^ _11__— 
 
 Cope— 36"x48" Plain Jolt ,^(u 
 
 Drag -36"x48" Plain Jolt 4 9 S _m)^_ 
 
 Cope— 34"x64" R. O. Jolt .^c» 
 
 Drap-34"x64" R. O. Jolt 4 9 jg_ ^"^/^ 
 
82 
 
 Foundry Moulding Machines and Patti-rn Equipment 
 
 Casting Used in the Ship- 
 building Industry. 
 
 Fig. 55 
 Combination Mooring Timberhead. 
 
 Production based on usiiit; one machine for both tlic cope and tlie drag half 
 of the mould. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 
 Increase 
 
 Without Machine 
 
 4 
 
 9 
 
 5 
 
 
 Cope— 42"x60" Plain Jolt 
 
 Drag— 42"x60" Plain Jolt 
 
 4 
 
 9 
 
 9 
 
 80% 
 
 Cope— 34"x64" R. 0. Jolt 
 Drag— 34''x()4" R. 0. Jolt 
 
 4 
 
 It 
 
 22 
 
 340% 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds 
 
 H3 
 
 Shipbuilding Industry 
 
 
 
 
 
 
 
 
 
 
 
 =^=^ 
 
 
 
 OASnUGa RBO'D 1 
 
 MACHItrS UOUlDIIfG 1 
 
 HAJfD MOTTLDINO 
 
 3A7IWS 
 
 
 
 Kama 
 
 ^Tunt 
 
 R.O. 
 Maoh. 
 
 Out- 
 Put 
 
 Ho. 
 Uen 
 
 0o8t 
 
 Eaoh 
 
 Out- 
 Put 
 
 no. 
 
 Man 
 
 foet 
 Eaoh 
 
 TaluB 
 
 H 
 
 Uan 
 Doya 
 
 
 le" Bits - 
 
 600 
 
 46"x72" 
 8 bz 
 
 30 
 
 4 
 
 t .70 
 
 2 
 
 2 
 
 t6.25 
 
 $2730. 
 
 86 
 
 520 
 
 
 Core 
 
 2400 
 
 32"x64" 
 
 140 
 
 S 
 
 .066 
 
 16 
 
 1 
 
 .376 
 
 693. 
 
 
 
 
 TOTtt 
 
 
 
 
 6 
 
 
 
 3 
 
 
 3423. 
 
 ==— 
 
 636 
 
 
 9* Bite - B 
 
 IBOO 
 
 45"x7E" 
 2 tx 
 
 36 
 
 4 
 
 .60 
 
 3 
 
 2 
 
 3.50 
 
 5220. 
 
 83 
 
 992 
 
 
 Oor« 
 
 7000 
 
 32''x64" 
 
 140 
 
 & 
 
 .066 
 
 
 
 36 
 
 2 
 
 4 
 
 .33 
 
 7000. 
 
 
 1288 
 
 
 6" Bit - A 
 
 600 
 
 34"x64'' 
 
 40 
 
 3 
 
 .413 
 
 6 
 
 £ 
 
 1.76 
 
 802. 
 
 76 
 
 156 
 
 
 
 lEOO 
 
 E2"x37" 
 
 160 
 
 1 
 
 .04 
 
 25 
 
 1 
 
 .24 
 
 240. 
 
 63 
 
 40 
 
 
 TOTAL 
 
 
 
 
 4 
 
 
 
 3 
 
 
 1042. 
 
 
 196 
 
 
 Mooring Rings 
 Dwg. H-62 #4 
 
 1200 
 300 
 
 34"x64" 
 
 40 
 
 4 
 
 .526 
 
 9 
 
 6 
 
 s.eo 
 
 4462. 
 
 86 
 
 850 
 
 
 Core ^d 
 i'o 
 
 2400 
 
 E2"x37" 
 
 lOO 
 
 S 
 
 .12 
 
 18 
 
 1 
 
 .33 
 
 
 
 
 
 TOTAL 
 
 
 
 
 
 
 
 II 509 Z. 
 
 J — LJ!!1 
 
 J 
 
 Fig. 56 
 
 Tabulation showing production by machine and by hand moulding on a 
 number of ship castings. The total value of saving by machine moulding on the 
 quantity noted amounts to $16,359.00. 
 
 The total amount of labor by hand moulding. 
 The total amount of labor by machine moulding 
 
 Saving in labor 
 
 .3,767 man days 
 . 691 " " 
 
 3,076 " " 
 
 Average percentage of saving. 
 
 .81% 
 
S4 
 
 Fouiidrv Moulding Machints and Pallt-rn Equipment 
 
 Shipbuilding Industry 
 
 CA3TIS03 RSJ'D VACHIira MOPLDIKO 
 
 Hjun) 
 
 MOULDING 
 
 3AVIS8 
 
 Rams Uach 
 
 Out 
 Put 
 
 No 
 Uan 
 
 OOBt 
 
 Bach 
 
 Out 
 Put 
 
 HO 
 Men 
 
 Coat 
 Gaoh 
 
 Value 
 
 « 
 
 Uan Days 
 Far Uo. 
 
 Driving Coller 
 fae" «la. ) 
 
 32"xM* 
 
 40 
 
 2 
 
 .26 
 
 3 
 
 1 
 
 3.50 
 
 3.24 
 
 93 
 
 294 
 
 Windlan Side 
 
 3£"t64" 
 
 £4 
 
 2 
 
 .44 
 
 3 
 
 1 
 
 3.60 
 
 3.06 
 
 87 
 
 166 
 
 Several Snail Bl- 
 
 tcTs; Ash 5UE 
 
 Baffle Pitta; Dis- 
 charge Valve - 
 Chest Liner 
 
 32"x64" 
 
 or 
 2£"t37" 
 
 40-60 
 
 of any 
 of 
 these 
 
 2 
 
 .21 
 to 
 .26 
 
 4 
 to 
 6 
 
 2 
 
 1.76 
 to 
 2.62 
 
 1.54 88 
 to to 
 2.36 90 
 
 620 
 
 Fig. 57 
 
 Total saving per month. 
 
 Total saving in labor 
 
 Average percentage of sa\ing . 
 
 . . . ..1|;S,;i47.0() 
 
 070 man days 
 
 .89% 
 
 CASTINGS BiSl'D 
 
 MACHIUE MOULDIRG 
 
 HAHD MOULDING 
 
 SAVING 
 
 None 
 
 R.O. 
 Mach 
 
 Out 
 Put 
 
 Ho 
 Men 
 
 Cost 
 Saoh 
 
 Out 
 Put 
 
 No 
 Men 
 
 Cost 
 Bach 
 
 Value 
 
 i 
 
 Van Days 
 Per Mo. 
 
 Housing Slides 
 
 34"x64" 
 
 40 
 
 3 
 
 .41 
 
 4 
 
 1 
 
 1.60 
 
 1.09 
 
 73 
 
 182 
 
 Winch Head 
 
 (Cstg. 24" dla. Bot. 
 
 ( " 18" " top 
 
 34"l64" 
 
 40 
 
 3 
 
 .41 
 
 2 
 
 2 
 
 6.26 
 
 4.84 
 
 92 
 
 962 
 
 Anchor Chain 
 Stopper 
 
 34"x64" 
 
 12 
 
 3 
 
 1.38 
 
 1 m 
 
 1-2/3 
 days 
 
 2 
 
 7.00 
 
 6.62 
 
 80 
 
 338 
 
 Fig. 58 
 
 lotal saving per month. 
 
 Total saving in labor 
 
 Average percentai:e of saving. 
 
 $S, 070.04 
 I JV.'.A man days 
 
 84% 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds 
 
 S5 
 
86 
 
 Foundry Moulding Machines and Pattern Equipvient 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds 
 
 87 
 
88 
 
 Foundry Moulding Machines and Pattern Equipment 
 
Roll Over J oil Moulding Machines for Medium Size Moulds 
 
 89 
 
90 
 
 Foundiy Moulding Machines and Pattern Equipment 
 
Roll Over Jolt Moulding Machines for Medium Size Moulds 
 
 91 
 
92 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 66. A Small Roll Over Jolt Machine Showing the Foundation. 
 
CHAPTER VI 
 
 Roll Over Jolt Moulding Machines for 
 Small Moulds 
 
 The good results produced from the use of Jolt Moulding 
 Machines on the large and medium size work, creates a demand 
 for a l«'lt Moulding Machine that will quickly handle the many 
 small i)atterns adaptable to jolt moulding. The machine 
 should be small, self contained and protected from sand and 
 grit. It should not require a pit in which to set, nor should the 
 falling sand from the flask obstruct its working. The different 
 operations of the machine should be performed in the simplest 
 manner possible and without consuming an excessive amount 
 of time. Especially is this true of the operations other than 
 the jolting of the mould, as when these operations are com- 
 pared with the operations of a moulder making a mould on 
 the floor, it is evident that he does not spend much time in 
 clamping the bottom board onto the flask, or in the rolling 
 over of the mould, and, therefore, these operations when 
 performed on the machine and considered from the stand- 
 point of time alone, require the utmost speed in the operation 
 of the machine. However, there enters at this point an ele- 
 ment not thus far considered, i.e., while the moulder when 
 making the mould on the floor, can perform a few of the 
 individual operations in the same time, or even faster than 
 the machine, nevertheless, the performing of these operations 
 throughout the entire day consumes the vitality and strength 
 of the moulder, and it is a fact that in the latter part of 
 the day his operations are neither as uniform nor as accurate 
 and certainly are not nearly as speedy as they were at the 
 beginning of the day's work; while the operations performed 
 by machine power are constant throughout the entire day and 
 demand very little effort on the part of the operator. 
 
 There was a time, now past, when these most vital points 
 did not require the consideration that must now be given them, 
 for at that time there was an abundance of skilled manpower 
 
94 
 
 Foundry Moulding Machines and Pat'ern Equipment 
 
 available, workmen could be had to perform these tasks at 
 a low rate of wages, and in order to secure a livelihood the 
 workman produced a large day's work at the expense of break- 
 ing down his health and strength. Conditions, however, have 
 changed and those days have seemingly passed forever, as the 
 
 Fig. 67. A Portable Roll Over Jolt Machine for Small Moulds. 
 
 workman has come to a position where he is satisfied that 
 he should produce the necessities of a livelihood without the 
 hard work which in the past has been so necessary to maintain 
 a satisfactory foundry production. He is beginning to realize 
 that the manufacturer and foundrvman should furnish him 
 
Roll Over Jolt Moulding Machines for Stnall Moulds 9.7 
 
 with machines that will perform the heavy and drudging part 
 of the day's work, without exacting the maximum of his 
 effort, and that will yet produce equal or greater results than 
 those obtained by the old time methods. 
 
 For producing the smaller size of what has been termed 
 "Small Moulds," there has been a demand for a Roll-Over 
 Jolt Moulding Machine mounted on wheels, either operating 
 on the foundry floor or on Tee rails, placed in the foundry 
 floor in such a manner that the machine can be conveyed 
 from one end of the floor to the other. The claim is made 
 that a greater production can be obtained with less effort on 
 the part of the operators, since the distance that the moulds are 
 carried from the machines to the floor, is less than when the 
 machine is permanently located ; others maintain that the 
 machine permanently located has an advantage over the port- 
 able machine, claiming that the time and energy consumed 
 in moving the machine are equal to that required in carrying 
 the moulds the short distance further. This again is largely 
 a matter of individual preference, and should be determined 
 by the conditions in the foundry in which the machine is to be 
 used. Many foundries, using this particular type of machine 
 for small work, prefer to set it in a permanent location under 
 the chute of a sand-conveying system, which has been found 
 to be a highly desirous installation in foundries producing 
 castings in large quantities, while others prefer to make use 
 of the available sand-cutting machines, in bringing the sand, 
 after it has been tempered, from the floor into a pile alongside 
 the moulding machine, where it is then readily shoveled into 
 the flask before the mould is made. 
 
 The numerous castings and foundry floors shown in this 
 chapter will give a good idea of the production obtained and 
 will suggest to the reader the great possibilities of machine 
 moulding when applied to this class of work. 
 
 The castings produced by this type of machine are true 
 to pattern, uniform in weight and, when they are machined 
 by the use of jigs, have a decided advantage over the ones 
 made by hand ramming. 
 
9G 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 i.^ 
 
 (U <D 
 
 > J= 
 
 o ^ 
 
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 H 
 
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 "ob 
 
 
 
 
 
 
 £ 
 
 
 
Roll Over Jolt Moulding Machines for Small Moulds 
 
 97 
 
9S 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Automobile Cylinder Head. 
 
 Weight 38 Pounds. 
 
 
 Fig. 70 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 
 PRODUCTION 
 
 
 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 
 Moulds 
 
 Increase 
 
 Without Machine 
 
 3 
 
 9 
 
 30 
 
 
 Cope— 20"x27" Plain Jolt. . . 
 Drag — 20"x27" Plain Jolt. . . 
 
 ......... 3 
 
 9 
 
 60 
 
 100% 
 
 
 
 Cope— 22"x37" R. 0. Jolt. . 
 Drag— 22"x37" R. 0. Jolt. . 
 
 ......... 3 
 
 9 
 
 200 
 
 567% 
 
Roll Over Jolt Moulding Machines for Small Moulds «« 
 
 Steel Casting Bracket for 6 Ton 
 Armored Truck. 
 
 Weight 50 Pounds. 
 
 Fig. 71 
 
 Production based on making both the cope and the drag half of mould on 
 the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 % 
 
 Increase 
 
 Without Machine 
 
 3 
 
 9 
 
 11 
 
 
 Cope— 20"x27" Plain Jolt 
 
 Drag— 20"x27" Plain Jolt 
 
 3 
 
 9 
 
 22 
 36 
 
 100% 
 
 p<-.T-i«. '">'"> "y"^?" R O Tolt 
 
 
 9 
 
 
 Drag— 22"x37" R. 0. Jolt 
 
 3 
 
 227% 
 
100 
 
 Foundry Moulding Machines and Pattirn Equipment 
 
 Steel Casting Sprocket for 6 Ton 
 Armored Truck, 
 
 Weight 125 Pounds. 
 
 Fig. 72 
 
 Production based on making both the cope and the drag half of mould on 
 the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 Increase 
 
 Without Machine 
 
 3 
 
 9 
 
 10 
 
 
 
 
 
 Cope— 20"x27" Plain Jolt 
 
 Drag— 20''x27" Plain Jolt 
 
 .... 3 
 
 9 
 
 IS 
 
 80% 
 
 Cope— 22"x37" R. 0. Jolt 
 
 Drag— 22"x37" R. 0. Jolt 
 
 '.'.'.'. 3 
 
 9 
 
 32 
 
 220% 
 
Roll Over Jolt Moulding Machines for Small Moulds 
 
 101 
 
 Fig. 73 
 High Pressure Steam Trap. 
 
 Weight 61 Pounds. 
 
 Production based on making 
 both the cope and the drag half 
 of mould on the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Quan. % 
 
 Hours Moulds Increase 
 
 Without Machine. 
 
 18 
 
 Cope— 20"x27" Plain Jolt. 
 Drag— 20"x27" Plain Jolt. 
 
 50% 
 
 Cope— 22"x37" R. O. Jolt. 
 Drag— 22 "x37" R. O. Jolt . 
 
 133% 
 
102 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Timberhead Casting 
 
 Used in the Shipbuilding 
 
 Industry. 
 
 Fig. 74 
 
 Production based on making both the cope and the dra^ half of mould on 
 
 the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Machine 3 9 21 
 
 Cope— IS "xl 8" Plain Jolt 
 
 Drag— 18"xlS" Plain Jolt :} 9 3(i 71% 
 
 Cope— 22''x37" R. O. Jolt 
 
 Drag— 22".x:57" R. O. Jolt 3 9 4S 131;% 
 
Roll Over Jolt Moulding Machines for Small Moulds 
 
 103 
 
 Cleat Casting 
 
 
 
 r^ 
 
 
 Used in the Shipbuilding 
 
 ( 
 
 
 y 
 
 
 Industry. -> 
 
 L 
 
 -h- 
 
 
 \ ^ 
 
 
 1 ' 
 
 
 
 
 ~T^ 
 
 
 If 
 
 
 
 
 ^Oti^-m. 
 
 3- 
 7«-m«i. 
 
 
 
 . 1 
 
 / 
 
 ^ 
 
 
 
 
 • 
 
 1 
 
 Fig. 75 
 
 Production based on making botli the cope and the drag half of mould on 
 the same machine. 
 
 PRODUCTION 
 
 No. 
 Method of Moulding Men 
 
 Without Machine 3 
 
 Cope— 18"xl8" Plain Jolt 
 
 Drag— 18"xl8" Plain Jolt 3 
 
 Cope— 22"x37" R. O. Jolt 
 
 Drag— 22"x37" R. O. Jolt 3 
 
 Qvian. 
 Hours Moulds 
 
 36 
 
 60 
 
 100 
 
 % 
 
 Increase 
 
 67% 
 
 180% 
 
104 
 
 Foundry Moulding Machines and Pattern Equipment 
 
Roll Over Jolt Moulding Machines for Small Moulds 
 
 105 
 
 o 
 
 a 
 
 
1U(J 
 
 Foundry Moulding Machines and Paltern Equipment 
 
CHAPTER VII 
 
 Jolt Moulding Machines in Brass and 
 Aluminum Foundries 
 
 The jolt moulding machine, having had its early devel- 
 opment in the iron and steel foundries, was slow to be 
 accepted as a machine which would produce the proper type 
 of moulds for brass and aluminum castings. Conditions for 
 
 making aluminuni 
 castings are greatly 
 different from those 
 for iron and steel. 
 A different grade of 
 sand is used, and an 
 entirely different den- 
 sity of ramming is de- 
 sired. For a long 
 time it was believed 
 that a jolt machine 
 could not satisfactori- 
 ly ram sucli a movild 
 Fig. 79. Liberty Motor Crank Case^ on account of the 
 
 Upper and Lower Half. hardness cf the blow 
 
 which was associated with many early designs of machines. 
 The mechanical handling of the equipment is a proposition 
 entirely different from the methods employed in grey iron 
 foundries. Pouring progresses continuously throughout the 
 day, and a comparatively small number of flasks and small 
 amount of sand are used over and over during the day ; in 
 fact the sand in an aluminum foundry sometimes heats up as 
 much as 40 degrees Centigrade during the day, due to its 
 being used and re-used. Perhaps it required the stress of war 
 conditions with the necessity for a large production with a 
 minimum amount of labor, coming simultaneously with the 
 problem of the Liberty Engine, to cause the foundry industry 
 seriously to try the jolt machine on aluminum castings. 
 
108 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 When the American engineers designed and began build- 
 ing the Liberty Motors in quantities for Government aero- 
 planes, it was with a full realization of the possible difficulties 
 that would be encountered before all of the many details were 
 perfected and the engine pronounced a success, both from 
 the viewpoint of reliability of operation and of the practica- 
 bility of its adaptation to manufacturing methods. The 400 
 H. v., which the motor was to develop, required materials, in 
 
 Fig. 80. Pattern Mounted on Roll Over Jolt Machine. 
 
 fact demanded materials, that would be almost perfect in their 
 metallurgical (jualitics and of the highest grade of workmanship. 
 
 Of the many different parts of the engine, the crank- 
 case is one that received a considerable amount of attention, 
 as failure in this particular part practically meant complete 
 destruction of the engine. The inspection, therefore, was care- 
 fully made and the materials held strictly to the specifications. 
 
 The aluminum foundries, with the true Yankee spirit, 
 began with a determined effort to produce castings that would 
 
Jolt Moulding Machines in Brass and Aluminum Foundries 
 
 109 
 
 pass inspection and fulfill all 
 requirements of the specifi- 
 cations. After the casting 
 had been successfully pro- 
 duced, free from defects, 
 the next qiiestion that con- 
 fronted the foundry was that 
 of production to meet the 
 enormous requirements de- 
 manded by the Government's 
 program. The same deter- 
 mination that produced the 
 casting successfully from the 
 Fig. 81. Jolting the Drag Half metallurgical standpoint, also 
 of the Mould. solved the problem of pro- 
 
 ducing the quantities required per day. The Roll Over Jolt 
 Mouldin*: Machine was, after due consideration, decided upon 
 as being the one best adapted to produce the moulds. 
 The views in this chapter were made in the plant of The 
 Aluminum Castings Company, Cleveland, Ohio, U. S. A., and 
 show the process of moulding and casting the Liberty Motor 
 crank cases. An inside and an outside view of the casting 
 is shown in Figure 79. These views show clearly the construc- 
 tion of the casting, both of 
 the top and bottom half. It 
 will be noticed that the cast- 
 ing has many exceedingly 
 thin sections, as well as a 
 moderately heavy section at 
 the front end. Also that the 
 side walls are practically ver- 
 tical, making the drawing of 
 the pattern a matter demand- 
 ing great accuracy. The pat- 
 tern mounted on the pattern 
 plate and attached to the 
 table of the moulding ma- 
 chine is shown clearlv in 
 
 Fig. 82. Butting Off the Cope 
 Half of the Mould. 
 
no 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 83. Drag Half of Mould Ready for Setting Cores. 
 
 Fig. 84. Drag Half of Mould with Cores Set. 
 
Jolt Moulding Machines in Brass and Aluminum Foundries 
 
 111 
 
 Fig. 80. It will also be noted in this view that a finished drag 
 mould is on the leveling car of the machine. The bottom 
 boards used are seen standing against the foundry wall at the 
 extreme left. 
 
 In Figure 81 the flask is being filled with sand from the 
 bins overhead, which are a part of the sand-conveying system 
 with which this plant is equipped. On this size flask two bins 
 were used in order to fill the flask more quickly. 
 
 In Figure 82 the jolting operating of the cope half of the 
 flask is completed and the workmen are "butting off" the loose 
 sand on top of the mould, an operation which can be performed 
 in eight to ten seconds of time. 
 
 Too nnich emphasis cannot 
 be placed upon the necessity 
 of providing the proper flask 
 e([uipment when attempting a 
 large production. By analyz- 
 ing the flask shown in Figure 
 8,S. it will be seen that the 
 flask \ised is one especially 
 adapted to their work. The 
 flask is made of aluminum, 
 and the trunnion piece has 
 been cast separately and pro- 
 vided with dove-tailed slots at 
 each end ; the purpose of 
 these slots is to receive the 
 
 Fig. 85. Making Cores on a Small 
 Jolt Machine. 
 
 loose pieces that are used as handles in case it is desired to carry 
 the flask without a crane. Bolts are used for securing this trun- 
 nion piece to the flask. The pins are located on the side rather 
 than on the end, permitting shorter trunnions. This figure also 
 shows a splendid detail of the drag half of the mould, after the 
 pattern has been withdrawn and the mould set on the foundry 
 floor. 
 
 By referring to Figure 84, this same drag half of the mould 
 is shown with cores set and ready to receive the cope. There 
 are six separate cores used in the body of the mould, practically 
 
11: 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 86. 
 
 tlie same in construction, and 
 all made on a small Plain Jolt 
 Moulding Machine, as shown 
 in Figure 85. These cores 
 were produced by first plac- 
 ing in the bottom of the core- 
 box, a dry-sand slab in which 
 has been placed suitable hold- 
 ing lugs to which the carrier 
 handles are attached. The 
 core-box was then filled with 
 green sand and jolt-rammed. 
 The shape of the core de- 
 manded the hinge type of box 
 which permitted the swinging 
 
 A View of the Moulding 
 Floor. 
 
 of the box from around the core, after which it was carried to 
 the green-sand core racks. 
 
 In Figure 86 may be seen a row of moulds, part of which 
 are completed and ready for pouring, while others at the far- 
 ther end of the row are "shaken out" and ready for cleaning. 
 The small core referred to above is here seen with the lifting 
 handles in place, standing beside the drag half of the mould 
 appearing in the foreground. 
 
 Figure 87 shows a close up 
 view of the distant end of 
 the row of moulds in the 
 preceding view. The sand 
 has been shaken from the 
 moulds, and the castings ap- 
 pear as thev are before being 
 sent to the chipping and 
 cleaning rooms. The remark- 
 able production obtained by 
 the use of moulding machines 
 on this casting is exceptional, 
 as eight men produced 102 
 
 moulds per day, the cope and j... „, r^. ^ ... ^, 
 
 ^ • ^ Fig. 86. The Castings as thev 
 
 drag being made on different Appear When Shaken Out. ' 
 
Jolt Moulding Machines in Brass and Aluminum Foundiies 113 
 
 machines. The best resuhs obtained under former condi- 
 tions was the production by eight men of 16 moulds per 
 day. It should be noted also that the production from the 
 hand ramming method resulted in a scrap loss of 30%, while 
 the scrap loss from the moulds made on the Roll Over Jolt 
 Moulding Machine was less than 10%. 
 
 The success of the Roll Over Jolt Machine in making the 
 Liberty motor crank case castings has called the attention of the 
 progressive brass and aluminum foundrymen to the use of the 
 machine, and in the comparatively short time that has elapsed, 
 machines have been installed in a large number of shops. 
 
 No radical departures are made from the practice followed 
 in iron foundries. The finer sand used is more fluid and 
 demands less packing force to produce a given density than the 
 coarser sand used in iron work ; also, a much lower density 
 is used for aluminum work, since the liquid pressure exerted 
 by an aluminum casting is only one-third that which would be 
 exerted by an iron casting from the same pattern, and the 
 density of the sand should be proportional to this pressure. 
 The adjustable valve for controlling the jolt stroke is set for a 
 very light blow and from four to ten jolts is considered good 
 practice. 
 
 One by one the superstitions in regard to the jolt machine 
 are being dispelled. Some foundrymen hesitated for a long 
 time before attempting copes on a jolt machine, but no one has 
 doubt on this subject any longer. Others hesitated on account 
 of the damage, from the shock of the machine, to moulds 
 already on the floor, but this is a subject which has also dropped 
 from popular interest. The belief that the machine was not 
 suitable for aluminum work has now been successfully pushed 
 into the background, and this type of machine is well on its 
 way toward filling the universal field which it is destined to 
 occupy. 
 
114 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 I ' 
 
 Fig. 88. 
 
 A Large Plain Jolt Moulding Machine with the Foundation 
 Shown in Phantom. 
 
CHAPTER VIII 
 Plain Jolt Moulding Machines 
 
 Development 
 
 In the early development of the jolt ramming method of 
 moulding, the Plain Jolt Machine was built essentially in the 
 same form as we know it today. These early experiments 
 extended over a period of about fifteen years, and resulted in 
 the development of a machine which had proven satisfactory 
 for the production of large varieties of castings. 
 
 Reference has been made to the tendency in the foundry 
 to consider that the use of moulding machines must be accom- 
 panied by a complete change in the type of patterns used. This 
 mistaken belief has caused many foundrymen to think that they 
 did not possess the necessary knowledge required to re-equip 
 their patterns for machine moulding. 
 
 The facts are that any pattern whicli has been made for 
 floor moulding can be used on the Plain Jolt Machine and also 
 on the Roll Over Jolt Machine. The knowledge necessary for 
 the use of patterns on machines is not complicated and can 
 easily be acquired by any foundry man. Many foundrymen, how- 
 ever, u:?e Plain Jolt Machines when they should be using Roll 
 Over Jolt IMachines, and many others are producing moulds 
 on the floor when they should be using machines. Under the 
 economic stress which exists and which will continue to exist, 
 the adoption of labor-saving devices will be in some measure 
 forced upon those who. at present, are not making full use of 
 them. 
 
 Production 
 
 The Plain Jolt Moulding Machine performs only the one 
 operation, viz., jolt ramming; replacing hand ramming. It is 
 evident, therefore, that the ultimate time saving which may be 
 accomplished by this machine is the saving of the time expended 
 in this one operation. Studies show, that in floor moulding 
 the average time required for ramming is approximately 50% 
 of the total time required for making the mold. 
 
116 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 This time is reduced to a very small amount by the Jolting 
 Machine, which jolt rams the mould in 5 to 10 seconds, leaving 
 only the butt ramming operation which does not require careful 
 and expert work, and which can be performed in from 15 
 seconds to 5 minutes, depending upon the size of the mould. 
 The time of rolling over is not aflfected, nor is the amount of 
 time required to draw the pattern. 
 
 Fig. 89. A Plain Jolt Machine of Rigid Construction. 
 
 Quality of Castings Produced 
 
 The influence of jolt ramming on the quality of the cast- 
 ings is as marked as is its influence on the amount of produc- 
 tion. Ninety-five per cent of all defective castings may be 
 traced to two causes: 1st — unequal ramming; 2nd — slicking 
 and patching due to a faulty pattern draw. Most of those 
 troubles arising out of improper ramming are eliminated on jolt 
 rammed moulds, as the sand is packed practically uniformly and 
 
Plain Jolt Moulding Machines 117 
 
 evenly over the surface of the pattern and pattern plate. After 
 the mould is jolt rammed, however, there remains the hutting 
 off operation to be performed by hand. 
 
 This prevents the ramming operation from being quite as 
 fast as it otherwise would be, and also introduces a slight 
 human variation in the density of the rammed sand. The 
 limitations of the usefulness of the Plain Jolt Machine should 
 be mentioned here. 1 lie ideal iiioitldiiu/ macliinc is one Schick 
 mccJianically pcrforjiis all of flic operations of making a mould 
 with a uiiiiiinitin ainoiint of time and effort and with a ina.vi- 
 mnm of accuracy and exact repetition. The Plain Jolt Ma- 
 chine fc'.lls short of this ideal in that there remains to be done 
 by hand — 
 
 1. Butting off. 
 
 2. Rolling Over. 
 
 3. Drawing the pattern. 
 
 Design and Construction 
 
 As we know it today, the Plain Jolt Moulding Machine 
 is simple and rugged in construction. Simplicity of construc- 
 tion does not mean, however, that there are no problems affect- 
 ing the design of the machine or the construction of it. Sub- 
 jected as it is to the hardest use with a minimum of attention, 
 the Plain Jolt Machine is expected to have a long life of useful 
 service, maintaining its accuracy throughout its life. 
 
 One of the principal factors affecting the accuracy of the 
 machine is the relation of the piston diameter to piston length. 
 If the piston is too short in relation to its diameter, it will tend 
 to lean in the cylinder toward the side which is more heavily 
 loaded, and will thus cause a slapping action of the table when 
 it strikes, particularly if the impact surface is of a large area 
 and is located around the cylinder at the top. Adequate length 
 of piston is necessary, as increasing the length of the piston 
 decreases the angle at which the table might lean from the 
 horizontal. 
 
 In years past much has been said regarding the merits of 
 the bottom or center strike type of machine, as compared with 
 
118 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 the top strike machine, in which a large area of the table con- 
 tacts with the base of the machine. Much can be said regard- 
 ing the merits of the two ditlferent types ; nevertheless, there 
 is today no controversy, as both are producing moulds satis- 
 factorily. 
 
 The working action of the Jolt Moulding Machine is such 
 as to cause a vibration throughout its different parts. This 
 vibration, of course, becomes exaggerated when the machine is 
 
 Fig. 90. The Machine Shown Here is Mounted with the Top of the 
 Table Level with the Floor. 
 
 made up of many different castings. It has been found exceed- 
 ingly difficult to bolt together the different parts of a machine 
 in a manner that will withstand the severe vibration produced 
 in the bolted members. Where bolts are used, it has been 
 found that the best type of lock washers are not sufficiently 
 strong ond rigid to hold the parts in place, and, therefore, if 
 bolts arc a necessity, a method should be employed that will 
 
Plain Jolt Moulding Machines 
 
 119 
 
 absolutely prevent the loosening of the bolt; for if only a few- 
 bolts loosen, and the remaining bolts hold tight, an exceptional 
 strain is produced on those that are holding, thereby causing a 
 breakage of the casting or of the bolts. Modern tendency is 
 toward a machine designed with as few parts as possible, elim- 
 inating the bolted construction, and using in its place a design 
 that will withstand the severe vibration caused by the jolting 
 action. 
 
 Fig. 91. A Small Plain Jolt Machine of Simple Construction. 
 
 Since the action of the Jolt jVIachine in operation is severe 
 and very much like the action that is used in breaking up scrap 
 iron for the cupola, it is obvious that a machine that will with- 
 stand the repeated blows of jolt-ramming should be of a mas- 
 sive an'l heavy construction, preventing as much of the blow 
 as possible from reaching the different parts. 
 
 In order to produce an economical operation by the con- 
 sumption of the smallest amount of air, it is well to examine 
 critically the many different syles of valves on Plain Jolt Mould- 
 ino- Machines. It is essential, in order to conserve the com- 
 
120 Foundry Moulding Machines and Pattern Equipn ent 
 
 pressed air, that there be some means of controlling the amount 
 used, and also to shut off the inlet port of the machine during 
 the exhaust stroke. If the air inlet is permitted to remain 
 open during the exhaust stroke, a large amount of air is use- 
 lessly consumed by its blowing thru the machine and into the 
 exhaust. 
 
 While the jolt ramming of a mould is a comparatively 
 simple operation, yet considerable difficulty has been encountered 
 in years past, in the ramming of the moulds required in found- 
 ries producing castings from various metals. The stroke 
 required, on Jolt Moulding Machines, that will economically 
 and properly pack the sand of a steel casting mould, varies 
 considerably from the stroke that is required to produce the 
 mould into which is to be poured iron, brass or aluminum. In 
 addition to the varying degree of hardness required in the 
 mould, there are the factors introduced by the use of the differ- 
 ent grades of sand that are required in making the mould. 
 To meet these varying conditions, it is well to have a machine, 
 the stroke of w^hich can be adjusted to suit the requirements. 
 The stroke, however, when once set for a particular foundry, 
 rarely, if ever, requires further adjustment. The adjustable 
 featue of the stroke, which, of course, is obtained by adjusting 
 the valve on the machine, is, many times, a decided advantage 
 when difficult copes are to be made, which in many instances 
 require a long stroke with a sharp, quick blow, while in the 
 majority of moulds a shorter stroke, with lesser blow, will 
 accomplish the results in the same time and without the same 
 amount of detrimental action to the machine and pattern equip- 
 ment. 
 
 In the early years of moulding machine operation, there 
 existed in the minds of foundrymen the feeling that the ma- 
 chine, when once installed in the foundry, should operate and 
 give entire satisfaction without being cared for by a competent 
 mechanic. They did not realize the importance of keeping the 
 machine properly oiled and free from sand obstruction. There 
 
Flain Jolt Moulding Machines 121 
 
 should be in every foundry operating moulding machines, a 
 mechanic with sufficient mechanical knowledge to inspect the 
 machine properly and to keep it in good working condition. 
 
 The pattern and flask equipment is another important item 
 that has not been given the proper amount of consideration. 
 Experience has thoroughly demonstrated that in order to se- 
 cure the best results, proper attention must be given to equip- 
 ping the machine with patterns, flasks, bottom boards and oth- 
 er necessary auxiliaries. In equipping the machine with pat- 
 terns, care should be exercised to secure the pattern plate 
 firmly, and patterns having a large flat surface should be thor- 
 oughly and strongly supported from the bottom, in order to 
 remove the possibility of a springing action taking place in the 
 pattern when the mould is being rammed. If the pattern is 
 not properly supported and a springing action takes place, the 
 mould produced will be full of cracks, and if a cope, will be 
 likely to drop out when the flask is being handled. 
 
 The flasks should also be examined to see that they are 
 rigid and of sufficient strength to prevent a springing action. 
 The best results have been produced by the flasks that are 
 cast solid in one piece in the small sizes and are of securely 
 bolted construction in the larger sizes. This is especially im- 
 portant when designing the cope half of the flask, and yet in 
 some instances it is difficult to cast integral the flask and the 
 proper bars for supporting the sand. If it is found neces- 
 sary to make use of separate bars, they should be secured to 
 the flask by means of tightly fitted bolts, as a loose bar will 
 prevent the making of a satisfactorily rammed mould. The 
 above description of the equipment necessary in jolt ramming 
 applies not only to this particular chapter, but to all machines 
 which make use of the jolt ramming principle. 
 
 The following pages illlustrate the increased production 
 obtained by the use of the Plain Jolt Moulding Machine on a 
 variety of different kinds of moulds. The increase of produc- 
 tion in each case is given and it will be noticed that this in- 
 crease averages about 100 per cent. 
 
122 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 92. Generator End Frame made on a 54"x66" Plain 
 Jolt-Moulding Machine. 
 
 The cope and the drag half of the mould ara both made on this machine. 
 
Plain Jolt Moulding Machines 
 
 123 
 
 Fig. 93. A Floor of Generator End Frame Moulds Made on the Plain 
 Jolt Machine Shown in the Foreground, at the Plant of 
 
 THE WESTINGHOUSE ELECTRIC & MFG. CO. 
 Cleveland, Ohio, U. S. A. 
 
124 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Generator End Frame Casting. 
 
 Weight 210 Pounds. 
 
 Fig. 94 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Machine 2 9 6 
 
 Cope— 54"x66" Plain Jolt 
 
 Drag— 54"x66" Plain Jolt 2 9 12 100% 
 
 A Roll-Over Jolt-Moulding Machine would give an increase in production of from 400 to 500%. 
 
Plain Jolt Moulding Machines 
 
 125 
 
 m 1.143 
 
 y$^^^^y^x^;;ms;^ii^i^^s>!^■y^^ 
 
 Fig. 95 
 Steel Casting Press Cylinder. Weight 610 Pounds. 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Machine 4 9 2 
 
 Cope— 54"x66" Plain Jolt 
 
 Drag— 54 "x66" Plain Jolt 495 \5Q% 
 
 A Roll-Over Jolt-Moulding Machine would give an increase in production of from 300 to 400%. 
 
126 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 96 
 Railway Truck Bolster— Steel Casting. Weight 430 Pounds. 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 No. 
 Men 
 
 5 
 
 '.'.'.'.'..'.'. 5 
 
 A Roll-Over Jolt-Moulding Machine would Rive an increase in production of from 300 to 400% 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 Moulds 
 
 T ^^ 
 
 Increase 
 
 
 5 
 
 9 
 
 12 
 
 
 
 
 
 Cope— 42"x97" Plain Jolt 
 
 Drag— 42"x97" Plain Jolt 
 
 '.'.'.'. 5 
 
 9 
 
 30 
 
 150% 
 
Plain Jolt Moulding Machines 
 
 127 
 
 ^ 
 
 7a 
 
 m'lSai 
 
 vrnM^/^^MmMm/'m/m/ ' /' 
 
 i 
 
 Standard 
 
 Open Hearth 
 
 Ca^t Steel Char^in^ Box 
 
 TheWcllman-Sedver-Morrf^an Co., Clcvcland.Ohio 
 
 Fig. 97 
 Weight of Casting 1210 Pounds. 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Mat;hine 4 9 2 
 
 Cope— 54"x66" Plain Jolt 
 
 Drag— 54 "x66" Plain Jolt 4 9 6 200% 
 
 A Roil-Over Jolt-Moulding Machine would give an increase in production of from 300 to 400%. 
 
12S 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Base and Cylinder Cast 
 Integral. 
 
 Weight 1700 Pounds. 
 
 Fi-'^-^ 
 
 Fig. 98 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Hours 
 
 Quan. 
 
 Moulds 
 
 % 
 Increase 
 
 Without Machine 
 
 4 
 
 9 
 
 
 2 
 
 
 
 
 
 Cope — .54"x66" Plain lolt 
 
 
 9 
 
 
 4 
 
 
 Drag— .'i4"x6(i" Plain Jolt 
 
 4 
 
 lOO^c 
 
 A Roll-Over Jolt-Moulding Machine would give an increase in production of from 500 to 600%. 
 
Plain Jolt Moulding Machines 
 
 129 
 
 ^/8" 
 
 Fig. 99. Side Frame Casting. 
 
 Weight 800 Pounds. 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Machine 4 9 2 
 
 Cope — 54"x66" Plain Jolt 
 
 Drag— 54"x66" Plain Jolt 4 9 4 100% 
 
 A Roll-Over Jolt-Moulding Machine would give an increase in production of from 400 to 500%. 
 
130 
 
 Foundry Moulding Machines and PatUrn Equipment 
 
 Fig. 100 
 
 Truck Center Casting for Locomotive Crane. 
 Weight of Casting 1680 Pounds. 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 No. Quan. % 
 
 Method of Moulding Men Hours Moulds Increase 
 
 Without Machine 3 9 1 
 
 Cope — 54"x66" Plain Jolt 
 
 Drag— 54 "x66" Plain Jolt 3 9 2 100% 
 
 A Roll-Over Jolt-Moulding Machine would give an increase in production of from 400 to 500%. 
 
Plain Jolt Moulding Machines 
 
 131 
 
 Fig. 101. Large and Difficult Table Casting. Weight 1500 Pounds. 
 
 Production based on making both the cope and the drag half of the mould 
 on the same machine. 
 
 PRODUCTION 
 
 Method of Moulding 
 
 No. 
 Men 
 
 Quan. % 
 
 Hours Moulds Increase 
 
 Without Machine. 
 
 Cope— 54"x66'' Plain Jolt . 
 Drae— 54"x66" Plain Jolt. 
 
 100% 
 
 A Roll-Over Jolt-Moulding Machine would give an increasejn production of from 500 to 600%. 
 
132 
 
 Foundry Moulding Machines and Pattern Equipment 
 
CHAPTER IX 
 Air Operated Squeezer Moulding Machines 
 
 Primarily, the air operated squeezer type of moulding ma- 
 chine was designed to replace the old laborious hand method 
 of bench moulding of light work. The question of producing, 
 rapidly and economically, large numbers of small castings from 
 one pattern, is one that cannot be lightly viewed as a subject 
 of little importance ; this fact is evident from the varied and 
 interesting devices designed to facilitate the squeezer class of 
 foundry work. The first development in the art of squeezer 
 moulding produced a single pattern with its match of green 
 sand; next, a single gate; then the improving of the green 
 sand match by the substitution of fireclay or oil sand for the 
 delicate green sand ; further development produced a match 
 board similar to the modern match plate. The various plates 
 were first used for hand ramming on the bench, but soon a 
 squeezer machine came into favor, and was extensively use<l 
 throughout the United States of America. 
 
 The original type of air operated squeezer was designed for 
 one purpose, that of squeezing the mould, as its name implies, 
 and this type, subject to its limitations, is still doing efficient 
 and rapid work. With the plain squeezer type of machine, 
 the most common and most extensively used form of pattern 
 is the match plate type, although the vibrator frame and hard- 
 sand match are also frequentl}- used. 
 
 Combination Jolt Squeezer 
 
 Later it was found that a great many patterns belonged in 
 the squeezer class of work, as the weight of the casting was 
 such as could be produced by squeezer moulding, but the 
 depth of the patterns seemed to prevent their use, as the 
 squeezing failed to pack the sand properly at the bottom of 
 the pattern and firmly against the match plate ; to meet this 
 difficulty a machine was designed that embodies the principles 
 of both the squeezer and the jolt machines. This machine is 
 in appearance the same as a standard air operated squeezer, 
 
Vi4 
 
 Foundry Moulding Machines and Pctlern Equi-pment 
 
 but is in reality a Jolt Squeezer Moulding Machine. It has, 
 nK)unte(! within the large squeeze piston, a small jok cylinder. 
 in which operates the jolt piston carrying the table of the ma- 
 chine, usually cast integral with the piston. Xo changes are 
 required to use either feature of this dual machine, hence a 
 deep mould may be jolted to pack a deep recess, by a slight 
 pressure of the knee against an air inlet valve. A few jolts 
 of the mould settles and begins the packing of the sand in the 
 recess of the pattern and the corners of the tiask. after which 
 the mould is squeezed in the usual manner. ])acking the remain- 
 der of the sand in the flask. This featm-e of double utility 
 
 Fig. 10.^. An Air Operated Squeezer Moulding Machine with the 
 Mould in Position for Squeezing. 
 
 is also an effective means of preventing what is known as a 
 "ram-ofif". an annoyance caused 1)\- the sand, after being tucked 
 against the side of the pattern or into a depression, being 
 pushed r.way again by the squeezing action of the Plain Squeez- 
 er Machine. These machines are used not only in the Stand- 
 ard design, but also with other special attachments, for exam- 
 l)le, a stripping or pattern drawing device, and when so equip- 
 ped is commonly known as a Split Pattern Machine. These 
 machines are used for a heavier class of work, such as fly- 
 wheels for small gas engines, valve and pipe fittings, gears, and 
 for such patterns as require stooling. They are usually operated 
 
Air Operated Squeezer Moulding Mr. chines 
 
 135 
 
 in pairs ; the drag pattern mounted on one machine and the 
 cope pattern on the other. llie addition of this device does 
 not in any way interfere witli the usual operation of the ma- 
 chine as a standard squeezer. 
 
 -^ 
 
 Fig. 104. A Split Pattern Machine 
 
 Operation of the Jolt Squeezer Machine 
 
 In detail the operation of the Jolt Squeezer type of mould- 
 ing machine is as follows : The cope flask is placed up side 
 down on the table of the machine ; the pattern plate is placed 
 on top of the flask with the drag side up and the drag half 
 
130 Foundry Moulding Machines and Pattern Equipment 
 
 of the flask placed in position. The pins which are fastened 
 in the drag half of the flask will align, and hold in alignment, 
 the three parts just mentioned. The drag half of the flask is 
 now filled with sand in the usual manner, and a conveniently- 
 operated knee valve allows the operator to jolt the mould at 
 the same time that he reaches for the bottom board. The jolt- 
 ing is performed very quickly, it having been found from 
 experience that from 5 to 20 blows are generally sufficient. As 
 soon as the jolt operation is completed, the operator places the 
 bottom board on the mould, and proceeds to roll the complete 
 
 Fig. 105. An Air Operated Squeezer Moulding Machine with the 
 Pattern Drawn from the Mould. 
 
 flask over, utilizing the forward edge of the table to hold the 
 bottom board in position during the operation. The cope half 
 of the flask is now filled with sand and the squeezer head pulled 
 forward into position, and the valve handle controlling the 
 squeezing operation pushed down, causing the table to rise and 
 to squeeze the mould against the pressure head. Both halves 
 of the mould ru-e squeezed at one operation, but only the drag 
 half of the mould has been previously jolt rannned. In squeez- 
 ing the mould, a pop valve is used which automatically releases 
 ihe pressure when it reaches a certain ])redetermined value; 
 tbe squeezer licad is pushed Ixuk. the scjueezer board removed, 
 and. after cutting the sprue, the cope half of the mould i= 
 
Air Operated Squeezer Moulding Machines 137 
 
 drawn upward from the pattern plate, guided by the pins at 
 either end, and loosened by the vibrator which is placed in 
 operation by a conveniently located knee valve. After setting 
 the cope on a table provided at the left, the operator draws 
 the pattern from the drag half of the mould, utilizing the vibra- 
 tor to prevent sticking. 
 
 There is now a completed drag half of the mould sitting 
 on the bottom board on the table of the machine, and a cope 
 half of the mould on the table at the left, and all that is neces- 
 sary is to close the two, remove the flask and set the mould 
 in its place for pouring, on the floor. For a graphical explana- 
 tion of this process the reader is referred to i)agc 14 oi Chapter 
 I, where the different steps are illustrated by sketches accom- 
 panied by explanatory notes. 
 
 The method of making a mould on the Split Pattern 
 Machine is very similar, except that only one half of the mould 
 is made at one time, and the unnecessary steps are omitted. 
 The Split Pattern Machine frequently substitutes a mechanical 
 lifting device for drawing the mould from the pattern, operated 
 either by hand or by air. 
 
 Operation of the Plain Squeezer Machine 
 
 The Plain Squeezer Machine, without the jolt operation, has 
 the following sequence of operations in making a mould. The 
 cope half of the flask, pattern, and the drag half of the flask 
 are placed on the table in the order named; the drag half of the 
 flask is hlled with sand, the corners and edges tucked by hand; 
 the bottom board is placed on the mould and the mould rolled 
 over without squeezing; the cope half of the flask is then filled 
 with sand, the squeezer board placed on top and both halves 
 of the mould are squeezed simultaneously. The remaining oper- 
 ations are identical with those of the jolt squeezer machine. 
 
 It can readily be seen that on the plain squeezer machine, 
 the pressure developed on opposite sides of the pattern plate is 
 equal, and a comparatively thin plate will be satisfactory, espe- 
 cially since this pressure is applied slowly. On the Jolt Squeezer 
 
i:}S 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Machine, however, the drag half of the mould is jolted before 
 the cope is filled with sand, and the pattern plate should have 
 sufficient strength to withstand the forces exerted on it. 
 
 In comparing the Plain Squeezer and the Jolt Squeezer 
 types of machines, it is well to bear in mind the following facts: 
 The Jolt Squeezer Machine eliminates the hand tucking which 
 is necessary to supplement squeezing on deep moulds, but it 
 requires a much more substantial pattern plate. Due to the 
 elimination of hand labor, the Jolt Squeezer Machine will turn 
 out a r,lightly larger quantity of moulds per day, and in this 
 way will pay for the increased investment. Another factor, 
 ^vhich is too fre(iuently overlooked, is that by eliminating some 
 
 Fig. 106. An Air Operated Jolt Squeezer Movilding Machine 
 Showing a Deep Drag which was Jolted. 
 
 of the manual labor, the foundry worker's task is made a more 
 desirable one, and his attitude toward the foundry is much 
 better. 
 
 The standard types of Air Operated Squeezer Moulding 
 Machines are usually mounted on wheels. The advantage in the 
 use of this construction is that, if desired, the machine can be 
 moved along the side of the sand heap on the working floor, or 
 it can be permanently located, and the sand piled in a heap 
 beside it. 
 
^4ir Operated Squeezer Moulding Mcchincs 139 
 
 Another style of air operated squeezer is that known as the 
 Sand Straddler, which is mounted on wheels having a wide 
 span. This machine is designed to straddle or span the sand 
 heap, the sand being piled in long rows, but shorter than the 
 length of the moulding floor, to permit placing the first moulds 
 and to allow working space. As the floor is filled with moulds, 
 the machine is pushed ahead, the sand being taken from beneath 
 the machine. 
 
 Design 
 
 In air operated squeezer machines of any size or type, 
 should be found incorporated the following principles : All 
 working parts should be fully enclosed or shielded against sand 
 and grit ; the place for moulding sand is either in the mould 
 or on the floor, hence the contours of the exposed members of 
 the machine, as far as possible, should be of the inverted "V" 
 design so as to shed the falling sand ; simplicity of operation 
 is essential to its proper working under the conditions usually 
 existing in the foundries ; pistons should be provided with cast 
 iron piston rings and proper oiling facilities; the strain rods 
 carrying the pressure head should be adjustable for height, to 
 meet the conditions existing due to varying height of flask 
 used ; tiie pressure head and strain rods should be counter- 
 balanced ; the operating valve should be in a convenient location 
 at the right of the operator and below the working position of 
 the table ; this operating valve should be automatically locked 
 except when the pressure head is in the squeezing position ; 
 there should be a release pop valve, releasing the pressure in 
 the cylinder when the mould has been squeezed to a predeter- 
 mined densit}', there should also be a pressure gauge, a blow 
 valve, a riddle bracket, and a shelf for holding the cope half 
 of the mould while drawing the pattern from the drag half 
 which is still left on the table of the machine. These features 
 make of the machine a self-contained and independent unit. 
 
 Production 
 
 The- following photographs. Figures 107 and 108 show the 
 production of the squeezer machines. It is easy to see that 
 
140 
 
 Foundry Moulding Machines and Pattern Equipment 
 
Air Operated Squeezer Moulding Machines 141 
 
 they produce moulds in large quantities, but such vague gener- 
 alities are not acceptable to practical foundrymen. Production 
 ranges from 50 to 250 moulds in a working day, depending 
 upon the following conditions : 
 
 1. The size of the flask. 
 
 2. The number of cores to be set. 
 
 3. The difficulty of pattern draw. 
 
 4. The mounting of the pattern. 
 
 Considering these factors in detail: The first of these is 
 the size of the flask. It is readily seen that a larger flask, being 
 heavier, will fatigue the operator more than a smaller flask, 
 since he must handle each flask several times during the opera- 
 tion of making each mould — first, when he places it on the table 
 with the pattern in between the two halves; second, when he 
 rolls it over with the drag half full of sand; third, when he lifts 
 the cope half from the pattern plate; fourth, when he places 
 the cope half back onto the drag half; fifth, when he removes 
 the flask from the mould; sixth, when he places the finished 
 mould on the floor. In all of the above cases, the greater 
 weight of the larger size is the principal factor, except in the 
 sixth case, namely setting out the finished mould on the floor; 
 here another factor enters into the element of difficulty of han- 
 dling: This is the shape of the flask or the relation of the 
 width to the length. A mould 14" x 14" will be more difficult 
 to handle and will be more tiring to the operator than a mould 
 10" X 20", although the 10" x 20" mould is the heavier of the 
 two. This is because the long narrow mould may be held 
 closer to the body, whereas the square mould must be held 
 further from the body, making it very much more difficult to 
 handle and much more tiring. 
 
 The second consideration, the number of cores to be set, is, 
 of course, self-evident. The more cores there are to be set, the 
 more will be the time required, and the smaller the number of 
 moulds that can be expected from one man. 
 
 The third, the difficulty of pattern draw, affects the speed 
 with which the cope can be drawn up from the match plate, or 
 the match plate from the drag mould, or both, and in this way 
 
1-12 
 
 Foundry Moulding Machines and Pattern Equipment 
 
Air Operated Squeezer Moulding Machines 143 
 
 a pattern with a difficult draw will decrease the number of 
 moulds which can be produced per day. 
 
 The fourth, the mounting of the pattern, is most important 
 and deserves more attention than the others. 
 
 Pattern Mounting 
 
 The method of mounting the pattern should be given exten- 
 sive study, as it is here that the greatest advantages in produc- 
 tion are possible. The rule in seeking for quantity production 
 is to make the pattern so that the patternmaker lias eliminated 
 as mitcl: of the moulders' icork as possible. The rca-^on tor this 
 rule is almost obvious. Any operation which can be eliminated 
 in the foundry will be that much time saved over and over 
 again as many times per day as there as moulds made, and 
 this saving of time, large in the aggregate, will more thrm off'set 
 what might seem at lirst to be a large ex})enditure of time in 
 the pattern shop. 
 
 X'iewing the construction of the pattern in this light we 
 have the one extreme, the simple, loose pattern which is some- 
 times used in an emergency, but which requires a skillful 
 moulder to bed the pattern into a green sand match, and to cut 
 the parting by hand. Since this is only an emergency method 
 of producing moulds the first method to be considered is the 
 use of ilie gated pattern with a follow board or match. This 
 follow i>oard may be either of wood or of hard sand, and 
 enables the moulder to lay the pattern on the follow board, 
 which takes up the irregularities in the shape of the pattern, to 
 ram up ihe drag half direct and then, after making the parting, 
 to ram up the cope half. The gates are introduced in the 
 mould without the necessity of the moulder cutting them each 
 time. The next step forward in pattern equipment is the 
 vibrator frame, Avhich allows the use of a vibrator instead of 
 hand rapping. 
 
 The match plate is the next forward step in producing 
 moulds on the squeezer machine. It eliminates entirely the 
 handling of a follow board and eliminates the making of a 
 parting and the ramming of green sand against green sand. 
 
Foundry Moulding Machxnes and Pattern Equipment 
 
 rl'' ;^1^ 
 
 >Xi 
 
 ** ^-.^'i^ 
 
 -J-'J""mf\^**^'^ 
 
 ■iHl*.J^V\ 
 
 V t * • 
 
 
Air Operated Squeezer Moulding Machines 145 
 
 allowing both halves of the mould to be rammed directly against 
 a metal plate. Chapter XI, on patterns will explain more fully 
 the differences in the construction of the various kinds of pat- 
 terns. Their use is as follows: 
 
 The Use of Match Plates and Vibrator Frames 
 
 The use of a match plate on an Air Operated Squeezer 
 Machine requires in addition to the match plate, a flask parting 
 compound, a tubular sprue cutter, a quantity of bottom boards, 
 a cope board and the vibrator. The cope half of the flask 
 is placed on the table of the machine, and upon this the match 
 plate — the cope side being turned downward. The parting sub- 
 stance is then dusted over the drag side of the match plate, and 
 sufficient sand riddled into the flask to completely cover the pat- 
 tern. Sand is then taken from the sand heap to fill the flask, 
 and the flask is "struck off," using the bottom board for a 
 "strike,"' and the bottom board is placed in position on the 
 mould. The bottom board must be about ^" smaller all around 
 than the inside of the flask. The mould is now rolled over, and 
 the operation is repeated to fill the cope flask. Instead of a 
 bottom l>oard, however, a cope board is used, which is similar 
 to the bottom board, but has a button secured to the face of it, 
 serving to locate the position of the sprue. The pressure head 
 is then drawn forward, the operating valve handle pressed 
 down and held until the relief or "pop" valve operates. The 
 squeezing is then complete. The pressure head is next pushed 
 back, and the cope board removed. The .sprue is cut by means 
 of a brass tube sprue cutter, at the point indicated by the 
 impression of the button secured to the cope board. The vibra- 
 tor is then started by pressure of the knee on an air inlet valve, 
 and the cope half is drawn off and set on the shelf at the left 
 side of the machine. The vibrator is again applied, and the 
 match plate of patterns is withdrawn from the drag half of the 
 mould; the match plate is then placed on the pressure head. 
 
 The vibrator frame type of pattern is moulded in a similar 
 manner. The pattern, in its hard match, is placed on the table 
 of the machine, the drag flask set in place, and the sand riddled 
 
14C. 
 
 Foundry Moulding Machines and Pattern Equipment 
 
Jir Operated Squeezer Moulding Mrchines 147 
 
 into the flask, which is then filled and struck off. The bottom 
 board is then placed, and the mould is rolled over. The match 
 is then removed and replaced by the cope flask. The pattern 
 and the sand in the drag flask are dusted with parting com- 
 ])nund, c'md the cope is tilled with sand, in the same manner as 
 the drag. The cope board is placed on the top, the pressure 
 head drawn into position, and the squeezing o])cration performed 
 as befo-2 described. The cope board is tiien removed and the 
 sprue cut. The pattern is vibrated while the cope half is drawn 
 ui)ward and is vibrated again as it is drawn from the drag. 
 The impressions of the strips holding the pattern in the frame 
 must be stopped off with sand, after which the mould is closed 
 and placed on the pouring floor. 'J'he ordinarv gated pattern 
 is handled in the same manner as the vibrator frame, except as 
 there is no means of attaching a vibrator to the pattern, it is 
 rapped thru the sprue, as in ordinary bench moulding, and a 
 draw spike is used for lifting the pattern from the drag half 
 of the mould. . 
 
148 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 111. A Jolt Stripper Moulding Machine. 
 
 Fig. 112. A Jolt Squeeze Stripper Moulding Machine. 
 
CHAPTER X 
 
 Jolt Stripper Moulding Machines 
 
 Tlvj iiiacliines classihcd under this lieading arc those 
 which joh rain the mould, and then strip the i)attern from 
 llic mould, and those which jolt ram, sciucezc and then strip 
 the mould. In both cases the strii)])ini^ oi)eration may mean 
 either liftiui,^ the mould upward from a stationary pattern 
 or dropping the pattern downward from a stationary mould. 
 Figure 113 shows a stationary tyi)e of machine used on small 
 work which embodies the lirst mentioned principle, that of 
 lifting the mould upward from the pattern. This type of 
 machine is further illustrated in iMgure 114. which shows the 
 stripping plate in the raised position and the mould lifted 
 from the plate and turned up for inspection. The last men- 
 tioned tvpe of machine, viz.. the one that draws the pattern 
 downward from the stationary mould, is illustrated in Figure 
 115, which shows a small .stationary hand operated machine. 
 It is readily seen that the roll over operation is not incorporated 
 in anv of these machines and that its normal use. therefore, is 
 for making the cope halves of the mould, although the drag 
 halves are frequently produced on these machines. In such 
 cases the drag half of tlu 
 flask is barred like a cope 
 half. The Jolt Stripper Ma- 
 chine is frequently used in 
 connection with Roll Over 
 Machines, the one making 
 the cope half of the mould, 
 and the other the drag half 
 In such cases the Jolt Strip- 
 per Machine is alv.ays more 
 rapid in operation than the 
 Roll Over Machine and in 
 some instances it has been 
 found possible for one Strin pj^. ^j, a Small Jot Stripper 
 
 per machine to sutiply th.e Machine in the Foundry. 
 
150 
 
 Foundry Moulding Matliinrs and Pattern Eqmpment 
 
 Fig. 114. A Jolt Stripper Machine 
 with tlie Table Raised. 
 
 cope halves of the moulds for 
 the total number of dra^ 
 halv^es made on two Roll 
 Over Machines. The choice 
 of the Jolt Stripper Machine 
 for producing cope moulds is 
 usually made as a result of 
 one of two factors ; first, the 
 pattern is of such intricate 
 sliape with such thin projec- 
 tions of sand, that the ordi- 
 nary jiattern drawmg opera- 
 tion would damage the mould. 
 In such cases a stripping 
 plate is necessary for the 
 making of good moulds. In 
 the second case the Jolt Stripper Machine is used with patterns 
 which could also be used to produce moulds easily by any other 
 method, but on account of the large quantity production the 
 advantages of the greater speed of the Jolt Stripper Machine 
 more than offset the increased cost of pattern mounting. 
 
 The mounting of the strip- 
 ping plate, pattern plate and 
 pattern with regards to each 
 other varies in the practice 
 of different foundries. Figure 
 116, page 151, illustrates the 
 two most common methods. 
 The bottom view show^s a 
 method suitable for use with 
 patterns which have already 
 been made, and which can be 
 mounted directlv on. the spe- 
 cial pattern plate, but this Fia- 115. A Hand-operated Machine 
 
 ^ ^ Which Strips the Pattern 
 
 special pattern plaie must be Downward. 
 
Jolt Stripper Moulding Machines 
 
 151 
 
 of the shape of the pattern, so that the total amount of work 
 to be done on the pattern equipment is about the same in each 
 case. The location of the pins is also decided differently by dif- 
 ferent toundrymen and Figure 116 shows two of the common 
 methods in use. In the top view, the pins are attached to the 
 stripping plate, and the finished moulds after they have been 
 stripped, must be lifted off the pins ; while, in the bottom 
 view the pins are attached to the pattern plate, and when the 
 stripping operation is completed, the finished mould can be lifted 
 off of the stripping plate without the trouble of disengaging it 
 from the pins. This method is referred to by foundrymen as 
 stripping the pins, and is preferable whenever conditions warrant. 
 
 The gate is frequently mount- 
 ed on the upper side of the 
 stripping plate and when this 
 is the case the mould must be 
 lifted vertically from the 
 stripping plate. The use of 
 pins attached to the stripping 
 plate is usually advisable in 
 such cases. Fig. 114 shows 
 the plate with the gate con- 
 structed in this manner, but 
 the pins are stripped so that 
 the moulder must exercise 
 care not to damage the mould 
 when lifting it from the strip- 
 ping plate. When using pat- 
 
 Fig. 116. Two Methods of Arrang- 
 ing Patterns and Stripping Plates. 
 
 terns of very intricate shape, where the body of sand is sur- 
 rounded by portions of the pattern and is of such shape that it 
 needs support, the method employed is known as "stooling." In 
 this method of moulding, the pendant or hanging sand is sup- 
 ported by the stool, while the flask with the mould is withdrawn 
 from the pattern. This will be explained more fully in the fol- 
 lowing detailed description. 
 
loli 
 
 Foundry Moulding Machines and Patlirn Jiijuipintnt 
 
 'I'd illustrate this nutliod of iiKmldint;:, I''i.i,airc 120 shows 
 a jolt squeeze stripping plate moulding machine, which is 
 especially adapted to this particular ty]>e of work. 
 
 ^-B 
 
 Fig. 118 
 
 Fig. 119 
 
Jnll Stripper Moulding Machines 15.'} 
 
 Fio-urc 117 is a cross section drawing of the drag of an 
 aiUomol)ilc- tlywiicci i)aiu-rn. while Figure 1 U> show> a cross 
 section of the cope pattern. 'Jhe casting produced is shown 
 in outline in Figure 118. It is o!)vious that the sand between 
 the rim and hub of the drag half of the mould, and also the 
 ])odv of hanging .sand in tlie coi)e will reiiuire supports when 
 strippiuij- the ])attern from the mould. The drag and cope 
 l)attern ecpiipments consist of sub-plates .\. which are bolted 
 and doweled to the jolt table. The Stripping plate P>. by 
 means of which the Hask is lifted or drawn from the pattern, 
 and which rests on the sub-plate .\. is elevated by means of 
 ])ins at each end of the sub-])late. as well as at the rim of 
 the flywheel C\ as the same ])rinciple is applied to both the 
 cope and the drag moulds, it is necessary to describe only the 
 drag part of the i)attern. The sub-jjlate has a central projec- 
 tion extending u])ward and forming the hul) of the flywheel, 
 and the corej^rint of the hub core. 
 
 TIk- rim of the flywheel i)attern consists of a ring with 
 a nuiltii)le number of downward extending lugs, by means of 
 which it is securely fastened to the sub-plate A, each lug 
 extending thru the holes in the slri])ping plate 1>. 
 
 Tho hub and rim of the pattern should be cast integral 
 with or bolted to the sub-plate, and remain stationary while 
 the stripping plate 1> is being lifted, thus strii)ping or drawing 
 the mould from the hub and rim. The pendant ])art of the 
 mould is supported by stripping plate W during this operation. 
 
 It will be noted that the stripping plate lifts the flask 
 and at the same time strips the hub of the pattern from 
 around the center of the hub and the inside and the outside 
 of the flywheel rim. 
 
 To ])roduce good moulds and consecpiently sound castings 
 it is necessary not only to be able to strip this type of pattern, 
 btit also to make sure that the sand is sectu'ely held in posi- 
 tion by the stool plates, while the mould is being lifted from 
 the stripping plate. It is also necessary to provide a means 
 to instire the sand being secttrely held while the motdd is 
 carried ;'nd placed on the ]iouring floor; this is accomplished 
 
154 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 by casting ribs on the flask, as shown by the dotted lines in 
 FigH-ire 117. The section of these ribs should be tapered, the 
 point next to the pattern decreasing to a size about Y^", and as 
 close to the pattern as will permit a uniform ramming of the 
 sand over the entire surface of the pattern. The distance 
 
 Fig. 120 A Jolt Squeeze Stripper Machine. 
 
 between these ribs and the pattern should be not more than 
 I/2". It is important that the ribs referred to be substantial, 
 so as to avoid vibration which would destroy the mould while 
 being jolt rammed. 
 
Jolt Stripper Moulding Machines 
 
 155 
 
 The Jolt Squeeze Stripper Machine 
 
 There are also Jolt Stripper Machines which have the 
 squeezer operation embodied in the machine, and a discussion 
 of the ^.dvantages to be gained by their use is in order here. 
 The addition of a squeezer head and a squeezing cyhnder 
 
 Fig. 121. A Jolt Squeeze Stripper Machine with the Stripping Plate 
 in the Raised Position. 
 
 naturally makes the machine more expensive and does not 
 add materially to the speed of operation, since it is possible 
 to butt off the mould by hand in about the same length of 
 time that is required to pull the squeezer head forward. 
 
Foundry M'luldiiiii Mtjcliiiifs cud Ptiltrr)! Equ-ipmnU 
 
 s(|ueczc' the mould and then push the sciueezcr head back 
 ai^ain. 'I'he a(l\anlage. therefore, is not primarily one of speed, 
 hut ratlur one of (|ualily. In ramming the sand ])y jolting 
 and hand hutting oiT. a varial)le human element enters into 
 tile deiisilv of the sand in the mould, it is natural, as the 
 (lav progresses and the fatigue of the worker increases, that 
 he should ram the sand softer, or if he is an unusualK' con- 
 scientious worker and realizes the tendency of soft ramming, 
 lie will prohabK- overdo the matter and ram the moulds 
 harder than he did earlier in the day. In either e\-enl the 
 result is non-uniform rannning of the day's moulds, and in 
 the dillVrent ])ortions of the same moidd. These variations 
 are slight and })roduce onl\- a relati\ely slight ditference in 
 the shajx' and weight of the castings. On work which it is 
 not necessarv to hold to exact linn'ts, the dit^'erence might 
 ne\er ])n/ve serious, hut the ])atterns mounted on stripping 
 ])late machines are generall}' used in large <|uantities and the 
 machine shops are ecpiipped to handle them rapidly. Con- 
 sider for instance the automobile piston illustrated in Figure 
 114 'i'hese ])istons are made entirely in green sand and are 
 hutted (IT hv hand. Slight variations in the density of the 
 sand cause slight variations in the outside size of the i)iston 
 at the head end. This causes more metal to be turned off 
 and increases the machining time. The machinist is able to 
 do more ])ieces per hour when the pistons are perfectly round 
 and are furnished with the minimum amount of finish metal 
 0:1 then I. h'igure 1.^2 illustrates a ])attern which e.xemplities 
 another ])hase of the importance of uniform rannning. The 
 ])att('rn tliere shown pi'oductd one half of th.' symmetrical call- 
 ings. 'i"he u])])er point of the jiattern was used as a jigging 
 l)oint and the jigs were made to locale from this portion 
 of the pattern. It was found that when jolt rannning and 
 hand butting off. the distance from one ])oint to the other 
 on the rough casting varied from 1/64 to l/vi2 of an inch. 
 'Jdiis caused nnich trouble with the jigs, and eventually was 
 overcome 1)\- the use of Jolt .Scpieeze Strii)per Machines. 
 
Jolt Stripper Moulding Machines 157 
 
 'ilu'sc examples arc tyi)ical of practically all jMhs mounted 
 on the Jolt S(iueeze Stripper Machines, since they are all 
 produced in large quantities and the machine shoj) is e(iui])ped 
 with accurate jigs for handling them. 
 
 In th.eor\- as well as in ])ractice, the addition ol the 
 s(|ueezing ojjcration to the jolt ramming operation makes for 
 unifornnt\ oi results. Not only is each mould identical with 
 each other mould, hut also the density of ramming is uniform 
 from too to hottom of the mould. I'Mgure 126 illustrates graph- 
 ically the reason for this fact. A jolt rammed mould is 
 densest at the ])attern plate, decreasing to such a small den- 
 sit\' at die top of the flask that hand hutting otT is recjuired, 
 while the mould which has only been squeezed is generally 
 accompanied hy the reverse effect, that is, the mould is denser 
 at the s(|ueezer hoard and sotter turther 1 rom the S(|ueezer 
 hoard, requiring, in fact, some hand tucking near the pattern 
 and jiattern plate in most cases. The mould which has been 
 jolt rammed and squeezed conihines the good ])()ints of both 
 and eliminates the hand work of both. The jolting takes 
 the place of liand tucking arotmd the })attern. and the squeez- 
 ing supplements the jolting ()])eration so that hand butting off is 
 eliminated. The total result of the two ojx'rations then is 
 to produce a mould, the density of which is jiractically imiform 
 from top to bottom as well as over the entire surface of the 
 jxittern and j)attern plate. 
 
 In the tyj)es of machines ])reviouslv mentioned, it is 
 always necessary to ])erform some of the operations by hand 
 On the Jolt Squeeze Stripper Machine, however, the machine 
 performs all of the essential ojierations, and the operator 
 merely controls the machine. The natural result is that the 
 100% i)Ower machine ])roduces a larp-cr nnmlier of satisfac- 
 tory moulds than those types of machines which require som 
 steps to be performed by hand. 'Jdiis type of machine pos- 
 sesses, therefore, not only the highest ability to produce cast- 
 ings of uniform size and shape, but also to produce them in 
 the largest quantities. The.se advantages offset the disadvan- 
 tage of the higher cost of the special patterns, pattern plate 
 
158 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 122. Placing the Flask 
 Around the Pattern. 
 
 Fig. 123. Squeezing the Mold. 
 
 Fig. 124. Stripping the Mold. 
 
 Fig. 125. Lifting the Finished 
 Mold from the Machine. 
 
Jolt Stripper Moulding Machines 1^ 
 
 and stripping plates which are necessary, and of the time 
 required for changing patterns which involves, of course, 
 changing the stripping plate also. These disadvantages, how- 
 ever, are not present when the machine can be kept con- 
 stantly at work at full capacity on one pattern, for then pat- 
 tern changing becomes unnecessary and the greater pattern 
 expense is distributed over such a large quantity of moulds 
 that it really becomes a low figure when expressed in terms of 
 pattern cost per casting produced. 
 
 Operation 
 For those who are not familiar with the method of pro- 
 ducing moulds from the Jolt Squeeze Stripper type of Mould- 
 ing Machine, the four views on the opposite page depict four 
 stages of the operation. The upper left hand view shows the 
 operators about to place the special cut flask around the pat- 
 tern on the stripper plate. It will be noticed that the squeezer 
 head is pushed back out of the way, and does not interfere 
 with the locating of the flask. The second illustration, in the 
 upper right hand corner, shows the squeezer head pulled 
 forward into the squeezing position and the table raised in 
 the act of squeezing. In moving forward, the squeezer head 
 strikes off the surplus sand which remains above the top 
 of the flask after it has been jolt rammed, and the squeezing 
 operation compresses this sand the amount of the squeezing 
 stroke, in this case about 2". The squeezer head is so 
 adjusted that at the completion of the squeezing operation 
 the sand is level with the top of the flask. The figure at the 
 lower left illustrates the next operation in producing the 
 mould. The squeezer head has been pushed back, the vibrator 
 placed in operation and the mould stripped upward from the 
 pattern. It will be noticed that the flask pins are fastened 
 to the pattern plate so that they are stripped as well as the 
 pattern, thus permitting the finished mould to be lifted from 
 the stripping plate more rapidly, as it need not first be disen- 
 gaged from the pins. The lower right hand figure shows 
 the two operators removing the finished mould from the strip- 
 ping plate which is ready to be returned to its initial position. 
 
100 
 
 Foundry Mouldinti Macliinrs and Pattern Equipment 
 
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 r J(1 
 
 ^fl^ 
 
 s_^ 
 
 ^u£ 
 
 XtiA 
 
 f^ 
 
 
 
 
 
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 ~ 
 
 
 7d 
 
 fWi«: 
 
 f tf 
 
 ^ 
 
 
 
 
 
 
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 L 
 
 
 
 
 
 
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 V 
 
 
 
 
 
 
 
 
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 V^ 
 
 
 
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 'y 
 
 
 
 
 
 
 
 
 
 
 V 
 
 N 
 
 k / 
 
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 ^ 
 
 V 
 
 
 
 
 
 
 
 
 
 
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 r^ 
 
 
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 \ 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 M£/a^r OF F14SK 
 
 Fig. 126. A Curve Showing Graphically the Density of Ramming 
 
 Produced as a Result of Both Jolting 
 
 and Squeezing. 
 
CHAPTER XI 
 Pattern Equipment 
 
 The nuijority of patterns originally made lor floor mould- 
 ing can be mounted for use on Moulding Machines. In some 
 cases it will he necessary to provide cores or loose pieces to care 
 for overhanging lugs, but it is nevertheless true that the great 
 majority of the patterns made for tloor moulding can be moimt- 
 ed for machine moulding. On the other hand, a more satisfac- 
 tory tyj)e of pattern construction may be had by originally con- 
 structing the pattern together with the plate. The building 
 of the pattern at the same time the plate is built, offers as ad- 
 vantages, if both are made of wood, rigidity and strength of the 
 pattern, which means less pattern upkeep and longer pattern 
 life. Patterns made for machine moiniting, that is, for Plain 
 jolt or Roll Over type of machines, sometimes cost more and 
 sometimes less, but, on the average, cost about the same, 
 vvhethe'- made for floor or machine moulding. 
 
 Too often the design of the pattern is left entirely to the 
 l)aitern maker, who. in deciding the type of pattern to be 
 made, is in reality determining foundry practice. There are 
 many pattern shops which make a specialty of patterns for 
 machine mounting. 
 
 These pattern makers, wlio are specialists in their line, 
 are better titted than anyone else to decide upon such ques- 
 tions as the method of moulding, and they are fully com- 
 petent to design and mantifactiu'e equipment which v/ill give 
 satisfactory production when used with moulding machines. 
 On the other hand, there are pattern shops which have not, 
 as yet. made a study of the moimting of ])atterns for machine 
 motilding. and who are not in direct touch with the foundry 
 in which the patterns are proposed to be used, ft is um'air 
 to these i)atternmakers to expect them to produce the best 
 designs of patterns when they are not familiar with such fac- 
 tors as the number of castings to be made, the portions which 
 are to l)e machined or jigged, or the available foimdrv equip- 
 
Kil 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 ment, including, junong other items, the available moulding 
 machine for producing the moulds. It is to the interest of 
 the producer of the castings to see that his patterns are prop- 
 erly designed for the most economical production in the foundry 
 as well as in the machine shop. It is the manufacturer also 
 who knows the quantity of castings desired from each pat- 
 tern, and since this determines the amount of study and 
 time which may justifiably be spent upon a pattern, it is an 
 important factor which should be utilized to its fullest extent. 
 The essential fact to bear in mind is, that the making of 
 the drawing, making of the patatern, and the making of the 
 castings are not separate, unrelated steps but that each one is 
 related as in a chain, joined to the link on each side of it, and 
 that the process of transferring the designer's ideas from his 
 brain to finished product is in reality one operation. 
 
 Fig. 127. Correct Mounting of a Fragile Pattern on a Pattern Plate. 
 
 Pattern Materials and Construction 
 
 Patterns are divided into two general classes, wood and 
 metal. The material used in the making of a metal pattern 
 may be brass, aluminum, white metal or iron, depending, of 
 course, upon the size, and whether or not the pattern in 
 moulding is to be handled or fastened to the table of the 
 machine. Metal patterns are made from master patterns, 
 
Pattern Equipment 163 
 
 which, for machine mounting, should be provided with the 
 necessary ribs to reinforce any weak portion of the pat- 
 tern. It is well, also, where possible, to provide suitable lugs 
 or bosses (preferably inside the profile of the pattern) for 
 fastening the pattern to the pattern plate, although in some 
 instances the pattern and pattern plate are cast integral. The 
 necessity for rigidity of construction cannot be too strongly 
 emphasized in the making and mounting of patterns that are 
 to be used for jolt machine moulding, as the pattern that is 
 so made as to permit a springing action to take place while 
 the machine is being jolted, will cause a vibration that will 
 prove very detrimental to the proper packing of the sand, 
 and if such a pattern is used, the mould will be full of cracks 
 or other imperfections. Therefore, considerable stress must 
 be laid upon the importance of properly reinforcing the fiat 
 surfaces of the pattern in such a manner as to prevent 
 vibration. 
 
 The pattern should not be designed until the style of the 
 moulding machine for producing the mould has been deter- 
 mined, after which, consideration should be given to the proper 
 size of flask. In determining the size of flask that should 
 be used in connection with the moulding machine, it is well 
 to keep in mind the fact that a machine rammed mould, 
 made in a suitable flask, does not require as large an amount 
 of sand between the pattern and the flask as has been the 
 common practice in the foundries making use of a more 
 fragile type of flask, or in those making use of the ordinary 
 v/ood flask. 
 
 It should also be noted that a larger castiniT can be 
 made in the same flask on the moulding machine than on the 
 floor. The decreased sand allowance between t-ie pattern 
 and the flask is possible because the motion of the machine 
 is more smooth and regular in rolling over than is the roHing 
 over by crane, where the flask is frequently balanced on one 
 vomer as it is being rolled over. 
 
 It is well to point out the necessity of considering the 
 advisability of producing the mould in a rectat!?:i'!ar liask, 
 
I (14 
 
 Foundry Mouldinf, Machiiu's and Pattern Equipment 
 
 i. c. wliflht'i" iir nui \\\c (|u;uiliu- <il castiiij^s to l)f ukkU- ironi 
 the paltcrn is such as would warrani llic iiiakii\j uf a llask 
 of a special shape, foUowiuji^ the outline of the pattern, com- 
 monly Inown as a "cut" flask. This matter of llii' (lesijru 
 cf flasks is covered more tullv in Chapter X I 1 . 
 
 Metal Patterns and Pattern Plates 
 As has heen pointed out. when niountin_<i;- jialterns which 
 are to Ix' used on jolt moulding machines, extreme care should 
 he taken to see that the ])attern is thoroughly reinforced 
 and free from all i)ossil)ilitv of a springing action taking 
 ])lace in the ])attern itself while the mould is heing jolted. 
 ]*atter;is tor use on this l\i)e of machine, and from which 
 
 Fig. 128 
 
 Fig. 129 
 
 Fig. 130 
 
 a large (|uantitv of castings are to he ])roduced. are usually 
 made of metal and mounted on iron ])lates. The thickness 
 of the jilates should not he decided until afti'r determining 
 the height, in order that thc\- mav conform to the moulding 
 machine on which tlu-v are to he used. Where it is possihle, 
 lhe\- should he made dee]) and hollowed out in the hack, also 
 reinforced 1)\' rihs riuming in hoth directions, and. if the plate 
 
Pattern Equipment 
 
 165 
 
 can be irade of sufficient height, holes should be provided on 
 the sides, suitable for attaching clamps to hold the bottom 
 board and flask to the plate while the mould is being rolled 
 over. 
 
 Figures 128, 129 and 130 clearly illustrate the high state of 
 at^^ainment in the art of pattern making. The patterns are of 
 a design requiring the highest grade of workmanship, in order 
 to produce the profiles which will maftch and maintain the 
 uniformity of section that is required in this particular type 
 of casting — the section in many cases being not more than 
 3/16" in thickness. 
 
 In Figure 131 are shown tlie cope and drag halves of a 
 metal pattern, mounted side by side upon the table of a Roll 
 Over Jolt Moulding Machine. A careful study of this view 
 will convince the reader that this style of operation is econom- 
 ical where the pattern is of a length to permit its being 
 used in this manner. In the view here shown it will be noted 
 that sufficient blocking has been provided below the pattern 
 plates to make the top of both cope and drag halves of the 
 flask the same distance from the table of the machine. 
 
 The location of the pattern on the pattern plate, when 
 the two are made separate, is worthy of much study, since 
 improper location will result in a mismatched cope and drag. 
 This defect will cause an undue amount of chipping, or, if it is 
 bad enough, will scrap the casting. In matching cope and 
 drag halves on separate plates, the only safe procedure is to 
 work from the pin centers, which 
 must be drilled before the pat- 
 tern is mounted. This is necessary 
 because a center line can be drawn 
 thru the pin lioles more accu- 
 rately than the j)in holes can 
 be located on the center lines. 
 The center line adjoining the 
 two pin holes is perpendicular- 
 ly bisected, and these two cen- 
 ter lines then form the basis of a Pig_ j^j 
 
166 Foundry Moulding Machines and Pattern Equipment 
 
 system of measurement by wliich the two halve? of the pattern 
 are similarly located. 
 
 Machine moulding is so thoroughly a part of the auto- 
 mobile industry that very little comment is necessary upon the 
 manner in which patterns are made, and the views which 
 show automobile castings are used only for the information 
 of those other foundrymen who are not familiar with the 
 progress that has been made in the automobile foundries. 
 
 Fig. 132. Two Metal Patterns Mounted Side by Side on a 
 Roll Over Jolt Machine. 
 
 W'ood Patterns and Pattern Plates 
 
 Therefore, in order to show the use of the jolt moulding 
 machine in plants other than the specialty foundries, and the 
 gain to be made from their universal use in foundries, illus- 
 trations are shown and a full description given of the method 
 of making and mounting wood patterns upon wood plates ; 
 also of the practice in some foundries, where a universal 
 plate is used and patterns of all shapes and sizes are mounted 
 on the plate, in order to till the standard size flask provided 
 for the statidru-d pattern plates that have been adopted. 
 
Pattern Equipment 
 
 167 
 
 FigTjres 133, 134, 135 and 136 show several patterns mount- 
 ed on wooden plates. They also show the condition of the 
 patterns after hundreds of castings have been made. These 
 patterns were used on a medium size Roll Over Jolt Moulding 
 Machine. 
 
 Fig. 133 
 
 Fig. 134 
 
 The group of patterns shown in Figures 168 and 169 is 
 illustrative of the best method of making patterns for use on 
 Jolt Squeezer Moulding Machines. These patterns were orig- 
 inally laid out and made for jolt moulding; the patterns and 
 plates have been constructed together (the patterns being 
 built solidly into the plate) making both the plate and the 
 pattern more durable than when made separately and fastened 
 together by means of bolts or screws. It has been fully dem- 
 onstrated by cost records that a pattern of this description 
 can be made at a cost not exceeding that of making the same 
 pattern for floor moulding, and that the life of the pattern is 
 
 onjjcr. 
 
 Fig. I.i5 
 
 Fig. 136 
 
168 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Jobbing foundries are confronted with the necessity of 
 making use of patterns which the customer sends them and 
 which are usually made for floor ramming. If the foundry- 
 man desires to make the moulds on a moulding machine, it is 
 necessary to provide plates upon which he can mount the pat- 
 tern. This situation has been met in some foundries by the 
 use of master pattern plates made either of steel or of wood ; 
 if made of wood, they are usually edged with metal cleats 
 
 Fig. 137. A Wood Pattern on a Wood Plate with the Core Box 
 on the Right. 
 
 upon which the flask is to rest. These cleats also protect the 
 wooden plate. These master plates are provided with center 
 lines which make it a simple matter to align the patterns that 
 are placed thereon. 
 
 These center lines are used to locate one half of a set 
 of dowel pins, the other half being mounted in the loose pat- 
 tern, which will be placed on the plate temporarily. While 
 this method docs not ofifer the advantages that are ofifered 
 by building the plate and pattern together, namely, rigidity of 
 construction and consequent low pattern upkeep, yet in job- 
 bing shops it is a profitable method of handling work in 
 those cases where the pattern is furnished and only a few 
 castings are to be made. 
 
Pattern Equipment 
 
 169 
 
 From the views shown in Figures 138, 139, 140 and 141, it 
 will be seen that there can be mounted on the plates many 
 different shapes, styles and sizes of patterns, the object being 
 always to fill the plate with patterns in order to make use of 
 
 Fig. 138 Fig. 139 
 
 all the available space in the flask. The views of the plates 
 shown in Figures 140 and 141 especially emphasize this possi- 
 bility, as there are several different styles of pattern poured 
 from one gate. The patterns shown in these figures, with 
 the exception of the gear, are so-called "flat back" patterns, 
 requiring no part of the pattern in the cope. By referring 
 to Figure 141 it will be noted that the cope-plate, standing 
 alongside the drag plate, is provided with a depression that 
 
 Fig. 140 Fig. 141 
 
 aligns with the gear shown on the drag plate; this depression 
 produces the proper shaped cope half of the mould for the 
 ffear. 
 
170 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 The plate shown in Fignre 140 is well covered by n 
 number of small patterns, all of them being shallow. It will 
 be noted, however, that on the floor adjacent to the pattern 
 plate are patterns having a greater depth. By taking off the 
 patterns now moulded on the board these deeper patterns 
 may be easily mounted and located by means of pins. The 
 particular plates shown in these four figures were made to be 
 used in connection with a Roll Over Jolt Moulding Machine. 
 
 Fig. 142 Fig. 143 Fig. 144 
 
 Comparison of Machine and Floor Patterns 
 In order to bring more clearly before the reader the 
 possibility of the great saving to be made, by making the pat- 
 terns for machine moulding originally, there are showai in the 
 following views the casting to be produced, the pattern as it 
 was made for use on the moulding floor, and also as it \vas 
 later mounted to be used on either the Plain Jolt or the Roll 
 Over Jolt Moulding Machine. 
 
 Figures 142 and 143 (combined) show a casting difficult 
 to make, and the manner in which the pattern was made for 
 
 Fig. 145 
 
Pattern Equipment 
 
 171 
 
 hand ramming on the moulding floor. Observe the "stop- 
 off" piece used in order to hold the shape of the pattern 
 while the mould was being rammed, which was difficult to do 
 regardless of the stiffening member. 
 
 Fig. 146 
 
 Figure 144 shows the manner in which a new pattern was 
 later mounted on pattern plates for use on Jolt Moulding 
 Mathines. The difificulty experienced in the producing of a 
 casting straight and true to pattern was entirely eliminated 
 by the use of the pattern plates. 
 
 Figures 145 and 147 show large and difficult castings. Fig- 
 ures 146 and 148 show patterns as they were originally made 
 for use either on the floor or on Jolt Moulding Machines. 
 However, it was possible to make only the drag half of the 
 mould on the machine when using the patterns without mount- 
 ing them on pattern plates. This was accomplished by placing 
 the drag pattern flat on a plate on the table of the machine, 
 and after jolt ramming the drag half, the flask and pattern 
 
 ^^^^iS- 
 
 Fig. 147 
 
172 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 were rolicd over and placed on the foundry flot)r, and the cope 
 half of the pattern was rammed by hand in the usual way. 
 
 Figure 149 is still another view, which again emphasizes 
 the advantage to be gained by mounting the patterns on pat- 
 tern plates, especially fragile patterns. 
 
 In the early days of ma- 
 chine moulding there was de- 
 veloped a method of mount- 
 ing patterns known as "shell 
 patterns." Such patterns 
 when mounted for machine 
 use were usually made for the 
 production of castings in large 
 quantities, the cope and drag 
 halves being mounted on sep- 
 arate machines — usually the 
 drag on a roll over type of 
 machine, and the cope on a 
 stripping plate machine. The 
 method devised was such as 
 to make use of the shell pat- 
 tern for either cope or drag 
 ])late. The views shown in 
 Figure 150 are of the cope 
 
 and drag patterns mounted 
 
 Fig. 149 
 
 P^""'"' '_3> 
 
 Fig. 150 
 
Fatlern Equipment 17.'? 
 
 on a stripping plate and roll over machine respective- 
 ly. The pattern here shown is a jacket of a hot water 
 gas heater, with the shell varying in thickness from 
 ]/%" to 3/16". The shell pattern was used for the cope 
 plate, while a white metal match was made from the shell 
 pattern, and used for the drag plate. Foundries producing 
 stove castings generally make use of this method of pattern 
 niDunting, the details of which are well known to the industry. 
 
 Patterns for Squeezer Machines 
 
 There are several different methods in use for the mak- 
 ing and mounting of patterns to be used in connection with 
 air-operated squeezer machines. Some of these methods are 
 applicable in one case while others are preferable in different 
 cases. The various methods of mounting patterns for use on 
 the Squeezer Machine are as follows : 
 
 Method of Mounting 
 
 Pattern Cost 
 
 ProditctionOhtained 
 
 Tlard Sand Match 
 
 Small 
 
 Small 
 
 Vibrator Frame 
 
 Medium 
 
 Medium 
 
 :\retal Plate 
 
 Cjreatest 
 
 Greatest 
 
 Suppose that a loose pattern is received at a foundry 
 with an order for castings. If only one or two castings are 
 desired it is possible for a skillful moulder to make these up 
 directly from the loose patterns, using a green sand match, 
 but if any quantity is desired one of the methods mentioned 
 above will be used. 
 
 Hard Sand Match 
 
 In mounting the patterns for producing a small quantity of 
 castings the gated style is used with a hard sand match. The 
 pattern, or patterns, are mounted together, joined by metal 
 strips which also serve to form gates in the mould. Figure 
 151 illustrates such a method of mounting four patterns together. 
 It can easily be seen that a follow board must be used with 
 this style of pattern; the most commonly used follow board 
 is a hard sand match. 
 
174 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 The material used in niakini,^ the hard sand malcli varies 
 although the following formula has been found to give satis- 
 faction : To eight parts, by weight, of boiled linseed oil, 
 add by weight, one part of yellow oxide of lead. A suffi- 
 cient amount of the mixture is added to new moulding sand 
 (which should be baked to insure it being thorouirhlv drv") 
 
 
 aOSkSlirialMMiHr 
 
 Fig. 151. Upper Left— Hard Sand Match; Right— Gated Pattern; 
 Lower Left — Drag Mould; Right — Cope Mould. 
 
 to make it the consistency of well tempered moulding sand. 
 The gated pattern is placed in the flask and the drag and 
 cope rammed in green sand. The cope is then removed and 
 replaced with a wood frame, previously prepared for containing 
 the match preparation. The surface of the drag and of the 
 pattern are then dusted with suitable parting material, and a 
 new cope rammed up in the match frame, using the match 
 material. The surface of the match is then made even with 
 tlie frame, and a bottom board secured in place with screws. 
 'I he mould is next rolled over, and the green sand drag 
 
Pattern Equipment 
 
 17."> 
 
 removed. The pattern can then be drawn, and any portion 
 of the match that has been injured by the drawing of the 
 pattern can be repaired. The match should then be set aside 
 in a warm place for about twelve hours and allowed to become 
 hard and dry ; shellac may be applied for the purpose of 
 further waterproofing. A gate of patterns, together with the 
 hard match and a mould made from the patterns, is shown 
 in Figure 151. 
 
 Fig. 152. Upper Left— Drag Mould; Right— Cope Mould; 
 
 Lower Left — Hard Sand Match; Right — Pattern Mounted 
 
 in Vibrator Frame. 
 
 \ ibrator Frame Patterns 
 
 Since the gated pattern must be wrapped thru the sprue it 
 is not as rapid in use as is desired, and a modification is intro- 
 duced in the shape of a vibrator frame, wdiich is illustrated in 
 l-"igin-e 152. The vibrator frame, in addition to the pattern 
 and gates, consists of a frame, to which the vibrator may be 
 attached. 
 
176 
 
 Foundry Moulding Machines end Pcttern Equipment 
 
 f 
 
 In attaching vibrator frames to the gated patterns, it is 
 necessary only to fasten the two together firmly ; no allowance 
 in the height of the pattern is necessary to compensate for 
 the thickness of the vibrator frame. 
 
 Match I^latcs 
 
 ^Nlatch plates consist essentially of a metal plate, the 
 opposite sides of which form the cope and the drag half of the 
 mould respectively. Flat plates 
 may have the pattern or pat- 
 terns attached by means of 
 dowel pins with suitable fast- 
 ening, both halves of the pat- 
 tern first being drilled at the 
 same time, and then one halt 
 of the pattern being used as 
 a jig to drill the plate. Other 
 forms of plates are cast of an 
 aluminum alloy, and the pat- 
 tern and plate are cast inte- 
 gral. Figiu-e 153 illustrates 
 the first mentioned variety of 
 match plate. A thin steel 
 plate is cut to the desired 
 shape, and the opposite halves 
 of the split pattern are mount- Fig. \Si. 
 
 ed on opposite sides of the plate and aligned by means of 
 thru dowel pins. The gate is then fastened on and the plate is 
 
 completed. Figure 154 shows 
 the method of using the fin- 
 ished plate. This method is 
 a very satisfactory one when 
 the parting line is straight 
 and the patterns to be mount- 
 ed are simple, but when the 
 patterns are of irregular 
 shape, requiring an irregular 
 Fig, 154. parting line, with hollowed 
 
 I I I I 
 
 III] 
 
 
 1 i I 1 
 
 I I I I 
 
I'attern Equipment 
 
 177 
 
 out surfaces on either the cope or the drag, it then becomes 
 an ahnost impossible matter to machine a plate of the reqviired 
 shape, and the most satisfactory practice is the casting of the 
 plate and pattern all in one piece. Figure 135 illustrates a 
 plate of this nature. 
 
 In this manner the plate becomes essentially a fin on the 
 casting, as the plate is usually made by ramming up a mould 
 
 Fig. 155. Upper Left— Cope Mould; Right— Cope Side of Plate; 
 Lower Left— Drag Side of Plate; Right— Drag Mould. 
 
 and separating the two halves by a distance equal to the thick- 
 ness of the plate. The procedure of making the plate is a 
 simple one, and in view of the universal use of the match 
 plate, the process is shown in detail on the following pages. 
 The match plate is readily seen to be a reproduction of 
 the gated pattern with the plate cast as a part of the pattern, 
 the plate occurring at the desired parting line. A very help- 
 ful way of considering the match plate is to consider it as a 
 fin occurring at the parting line, of a thickness previously 
 determined, and confined to the shape desired. 
 
178 . foundry Moulding Machines and Pattern Equipment 
 
 Fig. 156. The Gate of Patterns and the Hard Sand Match Used in 
 Producing the Match Plate Are Here Shown. 
 
 Fig. 157. The Gate of Patterns is Placed on the Match and an Extra 
 Length of Green Sand Built On. 
 
Pattern Equipjnent 
 
 179 
 
 Fig. 158. The Drag Flask is Placed on and Clamped, Ready 
 for Rolling Over. 
 
 Fig. 159. The Hard Sand Match is Removed, Leaving the 
 Pattern Bedded in the New Drag Half. 
 
180 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 160. The Cope is Placed on and Rammed in the Usual Manner . 
 
 Fig. 161. The Cope is Removed but the Pattern is Not Drawn 
 at this Time. 
 
Pattern Equipment 
 
 181 
 
 Fig/162. Wood Forms Are Used to Shape the Ends of the Plate and 
 Form the Pin Ears. 
 
 Fig. 163. The Mould is Now Complete and is Ready for the Pattern 
 
 to be Drawn. 
 
1S2 Foundry Moulding Machines and Faltern Equipment 
 
 Fig. 164. The Pattern Having Been Drawn, the Mould is 
 Closed and Clamped. 
 
 Fig. 165. Pouring Must Take Place Rapidly Due to the Thin Sections. 
 
Fattt-rn E(fuipmn\l 
 
 1S3 
 
 Figt- !<><>• The C>ope Side of the Match Plate. Note the 
 Method of Gating. 
 
 Fig. 167. The Drag Side. These Two Views Show the Plate 
 Just as it is Shaken Out. 
 
184 Foundry Moulding Machines and Pattern Equipment 
 
 An alloy coniposerl of 
 
 Zinc 15 per cent 
 
 Copper 3 per cent 
 
 Aluminum 82 per cent 
 
 is frequently employed for match plates used on a Jolt Squeezer 
 Mouldino- Machine. These plates must be made thick enough 
 to have sufficient strength to resist, without deflection, the 
 impact of Jolt Ramming. A second alloy used for the same 
 purpose is 
 
 Aluminum 69 per cent 
 
 Zinc 31 per cent 
 
 Both of these alloys have a shrinkage of about 5/32" per foot. 
 The standard No. 12 Aluminum Alloy composed of 
 
 Copper 8 per cent 
 
 Aluminum 92 per cent 
 
 is used for match plates which will be used on Plain Squeezer 
 Machines, but is not strong enough for match plates to be used 
 on Jolt Squeezer Machines. 
 
 In casting match plates there are two difficulties which 
 must be carefully avoided. The first is poor gating, which may 
 allow some portions of the plate to solidify before metal has 
 reached all portions of the plate, and the other difficulty is 
 unequal shrinkage in the cope and drag halves of the plate. 
 Gating is a very difficult problem, and it should be remembered 
 that a large thin plate must be successfully run in a very short 
 period o' time. The lower illustration on page 165 shows the 
 mould being poured from three ladles. This is neccssar\-, as the 
 metal must enter from both sides of the plate simultaneously 
 and meet at the center. A long runner is made, extending the 
 full length of the pattern plate, with numerous openings from 
 the runner into the casting, so that the metal can enter the 
 casting thru the entire length at the same time. \\'hen casting 
 comparatively large hubs of metal in connection with tliin sec- 
 tions, it is advisable to use an aluminum core which is set into 
 the mould on chaplets, and has new metal all around it. This is 
 accomplished by making a mould from a wood pattern and cast- 
 ing it in plaster of paris. The heavy .section, which is to be 
 cored out, is then cut away from the other portions of the pat- 
 
Pattern Equipment 
 
 185 
 
 tern and shaved a uniform amount of either 3/16" or 1/4". 
 This plaster core is then used as a pattern and reproduced in 
 aluminum which is set into the mould on chaplets, and which 
 allows a uniform thickness of 3/16" or 1/4" of metal to be 
 poured around it, burning in the chaplets and eflfectually pre- 
 venting shrinkage of the large hub on the pattern. 
 
 Fig. 168. A Group of Wood Patterns on Wood Plates. 
 
 The use of brass chills on the cope surface will also solve 
 many difficulties encountered in unequal shrinkage of copes 
 and drags. 
 
 Figure 170 shows graphically the total pattern and moulding 
 costs of producing various quantities of castings from the 
 different types of patterns used on squeezer machines. Since 
 
 Fig. 169. These Wooden Patterns Were Built on the Plates. 
 
186 Foundry Moulding Machines end Falter n Equipment 
 
 the varying factors of pattern and labor cost will be different in 
 each fotnidry, the exact ligures will not hold true except for one 
 foimdrv. However, the general shape of the curves are the 
 same in all cases. The height of the curve at its starting point 
 on the extreme left indicates the cost of the pattern and its rise 
 as it progresses toward the right is due to labor and fixed 
 charges on tlie moulding machine and pattern equipment. In 
 drawing up such a curve for his own use, a foundryman will 
 determine the average cost of his patterns made by the various 
 methods, ihe average labor cost of jiroducing moulds by the 
 various methods and his own hxed charges. He will then be 
 able to read from his chart the most economical type of pattern 
 to be made and used for any given ((uantity of castings. 
 
 Patterns for Stripping Plate Machines 
 
 The patterns used with this type of machine are sur- 
 rounded by an accurately fitting stripping plate, which is so 
 closely fitted that there is not room for satid to get in between 
 it and the pattern. This requires that the stripping plate be 
 fitted to the pattern by hand, and in considering patterns for 
 these machines, the stripping plate should be regarded as a part 
 of the pattern equipment. It is for this reason that the cost of 
 pattern equipment on the stripper machine is high, and that 
 more skill is required to make them. Two general types of 
 patterns for stripping phite machines are illustrated in Figure 
 116. A.ri additional method of handling difficult patterns 
 is by means of "stooling." A description of this method is 
 given in the chapter on Jolt Stripper Machines on jiage 152. 
 The contents of this chapter emphasize throughout the necessity 
 of planning the style and construction of the pattern at the 
 same time that the method of moulding, and the quantities, are 
 being planned. The only too common practice of sending a 
 blueprint to the pattern shop, with instructions to deliver the 
 jjattern to the foundry, is essentially wrong. The Planning 
 Department should take care of the production of the casting 
 from its beginning in the mind of the designer, throtigh the 
 Drawing Room. Pattern .Shoj). h'oundry and to its linal destina- 
 tif»n. 
 
188 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 171. A Group of Typical Small Flasks of Good Design. 
 
CHAPTER XIT 
 Flask Equipment 
 
 Of exceptional importance to the successful operation of 
 moulding- machines is the providing of suitable flasks. It is 
 a waste of time and money to attempt the production of good 
 moulds on moulding machines without giving the proper con- 
 sideration to flask equipment. There are many difficulties 
 encountered with the ordinary flask equipment in use in the 
 foundries producing moulds by hand ramming methods and 
 much loss is occasioned by the use of flasks that are burnt, 
 or that have become loosened by the severe handling incident 
 to foundry practice. Flasks in this condition should not be 
 used, even in hand-moulding, and the time consumed in addi- 
 tional care, as well as the loss occasioned by their use, would 
 more than offset the loss incurred by scrapping the old flasks 
 and making new ones. Those foundries that are accustomed to 
 the use of wood flasks only, find it rather difficult to see imme- 
 diately the necessity of changing their viewpoint to coincide with 
 modern founding. It had been their practice to nail together 
 roughly a set of flasks for almost every pattern that was to be 
 used, tliii king that the cost of wood flasks was small when com- 
 pared with that of iron flasks. Little attention was given this 
 subject nor were many attempts made to standardize the flask 
 ecjuipment in order to reduce to a minimum the stock of flasks 
 necessary to carry on the foundry operations. 
 
 The introduction of moulding machines has made possible 
 the standardization of flasks in such a manner as to reduce 
 the cost of flask equipment below that of the old style methods, 
 so that a better and more durable flask can be made. Such 
 flasks, when made of grey iron or of steel shapes and given 
 the propel consideration in handling, are practically indestructi- 
 ble and, therefore, in the end, are the most economical that can 
 be made. 
 
 Design of Flasks 
 The subject of flask equipment is vitally important in order 
 to bring those who are inexperienced in foundry moulding 
 
\w 
 
 Fou>idr\ Moulding Machine} and Pattern Equipment 
 
 machine operation, to a full appre- 
 ciation and realization of the im- 
 l)ortance of good flask equipment 
 in producing moulds by machine 
 methods ; and therefore, the fol- 
 lowing views are shown to illus- 
 trate the styles of flasks that are 
 largely used in moulding machine 
 production. The shape and size of 
 the flasj^ arc the first things which should be determined in con- 
 siderinfj the design. While the ordinary rectangular flask is com- 
 monly used in the majority of cases, nevertheless it is frequently 
 advisable to make what is known as "cut flasks," that is, flasks 
 which follow, to some extent, the contour of the pattern. Figure 
 172 illustrates a rectangular flask, containing one casting per 
 mould, und represents ordinary practice in iron flask desigii. 
 
 Kift. 172 
 
 Fiji. 173 Fig. 174 
 
 Contrasted to this. l-"igure 173 and Figure 174 illustrate the 
 design of a cut flask for producing two of these same castings 
 per mould. It will be noticed that the corners are cut away, sav- 
 ing expense and weight of iron, and the handling of extra sand . 
 also, thct the block of sand shown in the center of Ingure 173 
 has a double use, that is. it serves to support the mound of sand 
 necessary when making each of the two castings, whereas in Fig- 
 ure 172 the mound of sand is used only once. It is easy to see 
 that the weight of flask equipment to be handled is less per cast- 
 ing in the case of a flask designed as shown in Figure 173, and 
 also tJTit tlie amount of sand to be handled per casting is less. 
 
Flask Equipment 
 
 191 
 
 The shape and dimensions of the flask having been decided 
 upon, iho material of which it is to be constructed is the next 
 consideration. Formerly, wooden flasks were preferred rather 
 than iron flasks, in many foundries, and the process of changing 
 to the more satisfactory iron flask has been rather .slow. Today, 
 however, grey iron and rolled steel flasks are quite commonly 
 used and the satisfaction which has attended their use is well 
 known t() the foundry industry. 
 
 Fig. 17.S. 
 
 Soine txpical iron flasks 
 are illustrated in Fi^nu'es 
 175. 176. 177. 178. 180. 
 181 and 182.- In adopt- 
 ing a standard design of 
 flask, to be used in a variety of sizes with jolt ramming 
 machines, the following designs are submitted as representing 
 the result of satisfactory use. Figure 179 is a drawing suitable 
 for use 111 making flasks ranging from 20" to .W" in length, and 
 
 Fig. 176. 
 
v.r2 
 
 Foundry Moulding Machines and PatUrn Equipment 
 
 REAM-J 
 
 OOOOOOOOO 
 
 ooooooooo 
 
 5—1- 
 
 LENG TH OF FLR SK 
 Z0TO4-0 INCHES 
 
 J^^ 
 
 ii 
 
 PROVIDE. COPE FLftSKS WITH 
 A RETAINING SAND LEBGE 
 
 CROSS SECTION OF FLA5K UNDER 25 INCHES IN WIDTH 
 
 
 CR0S5 SECTION OF FLf\5K FROM aSToAO INCHES IN WIDTH 
 
 F 
 
 ,^ 
 
 <i 
 
 CROSS SECTION OF FLASK OVER 15 \NCHES IN HEICKT. 
 
 Fig. 179. Standard Drawing for Flasks, 20" x 39" in length. 
 
Flask Kquipmcnl 
 
 193 
 
 of appropriate widths and moderate heights. It will be noticed 
 that the flask is fully dimensioned except for the inside length, 
 width and height. 
 
 Figures 183 and 184 illustrate drawings suitable for flasks 
 ranging in length from 40 to 59 inches and from 60 to 80 
 inches, of any widths and any heights. 
 
 Fig. 180. 
 
 Fig. 181. 
 
 Fig. 182. 
 
 By selecting the proper drawing and using the section which 
 corresponds to the width desired and also using the design cor- 
 responding to the height of flask desired, this set of three 
 flask drawings may be used to make any flask from 20 inches in 
 length up to 80 inches in length by 80 inches in width and of 
 any desired height. 
 
 The holes shown in the side walls of the flasks are for the 
 purpose of venting the green sand and are spaced at any con- 
 \enient distance. They may also be used in bolting the bars in 
 cope halves. 
 
Foundry Mnuldin-' Machiyu-- a'-d Fat!rr>' E'luipmrnf 
 
 CROSS SECTION OF FLRSK OVER 20 INCHES IN HEIGHT 
 FLR5KS OF THIS HEIGHT SHOULD nIVit STIFFENING RI85 
 SPflCEO ABOUT II INCHES APART AROUMD THE FLASK 
 
 Fig. 183. Standard Drawing for Flaslis, 40"— 59" in length 
 
Flask Equipment 195 
 
 Tlie use of tlie flask pins requires some mention here in 
 order to explain clearly the reason for the four pin hole loca- 
 tions. The ideal place for the location of pins is directly 
 heneath the trunnions, but since their location at this point is 
 attended by the inconvenience of using closing pins of very 
 short length, due to interference with the trunnions, it is advis- 
 able to locate the pin holes to one side of the trunnion, care 
 being taken to keep them as close to the trunnion as is prac- 
 ticable. The location on all three of the standard drawings 
 shown is 2^" from the trunnion center, and it will be noticed 
 that one ear is provided of suitable size to take both pin holes. 
 In actual use, however, only two pin holes are used, these two 
 being diagonally opposite each other. Of course, cope flasks 
 nuist b(i drilled opposite from the drag flask and, in some 
 cases, wl^ere the same flask pattern will be used to make both 
 cope and drag flasks, the lug for all four pin holes is necessary. 
 On flasks, which are to be used only as copes or only as drags, 
 there is- a possibility of damage to the pin hole, making it advis- 
 able to use the other holes, so that, in all cases, only two holes 
 need be drilled and the other two locations are held in reserve. 
 
 While the location of both the pins and trunnions on the 
 ends of the flask is attended by many advantages in handling 
 the flask, yet in some cases it is advisable to locate the trun- 
 nions on the sides of the flasks and the pin holes on the ends. 
 In other cases, this is reversed by placing the pin holes on the 
 sides and the trunnions on the ends. 
 
 The jig shown in Figure 185 is used with the standard flask 
 drawings for drilling flasks of any length. When flasks of a 
 large range of sizes are to be drilled it is advisable to make 
 two jigs, as it is very awkward to handle a large jig on a 
 relativeh' small flask. In using the jig, the slip bushings are 
 fitted into the common hole at the end of the jig and the appro- 
 priate hf Ic at the other end. After one hole has been drilled 
 it is advisable to place a tightly fitting plug through the jig 
 and hole in order to locate the second hole accurately. 
 
 Bars used in the cope flasks may either be cast in one piece 
 with the flask, or cast separately and bolted in. When using 
 
1% 
 
 Foundry Moulding Machines and Potlrrn Equipment 
 
 l-4kJ 
 
 CROSS SECTION OF FLASK UNDER BO INCHES IN WIDTH 
 
 CROS^ SECTION OF FLBSK OVER 20 INCHES IN HEIGHT. 
 ri-RSKS OF THIS HEIQHT SHOULD HftVE STlFFtNlNC R1B5 SPRCEO 
 ABOUT It INCHES BPftRT RROUND THE FLRSK. 
 
 Fift. 184. Standard Drawing for Flasks 60" -80" in length. 
 
Flask Equipment 
 
 197 
 
 the bolted construction, attention must be paid to the fact that 
 the flask will be jolt rammed and rigidity is important. 
 
 The proper design of flask bars to facilitate the packing 
 of the sand underneath them during the jolt ramming operation 
 is of importance, as improperly designed bars frequently require 
 the use of gaggers, when correct designs would eliminate their 
 use. The bar should be located at a uniform distance of about 
 1/2'' above the top of the pattern, as it has been found that this 
 distance is great enough to allow the sand to be packed uni- 
 formly under the bar and yet small enough to hold pockets of 
 sand with a minimum use of gaggers. 
 
 Fig. 185. Jig Used in Drilling Flasks. 
 
 The complete flask illustrated in Figure 176 is used in 
 connection with the Roll Over Jolt Moulding Machine. In this 
 view may be seen the type of closing-pin used, which has proved 
 to be the best all around type of pin. Figure 186 is a 
 sketch of a closing pin. The use of this particular type of 
 
198 
 
 foundry Mculding Machines and Pcttern Equipment 
 
 r7=^ 
 
 
 
 A" 
 
 TO^UIT 
 
 TO 5U/T 
 
 FLAS/^ P/^ 
 
 closing - pin is much better 
 than the old style of fasten- 
 ing the pin in the drag halt 
 of the mould, as it prevents 
 the breakage which was so 
 common while the flasks were 
 being shaken out and han- 
 dled in the foundry and stor- 
 age yard. The right hand 
 pin is of the design common- 
 ly used to locate the flask on 
 the pattern plate. Figure 187 
 illustrates a pattern used in 
 m a k i n g flasks. It will 
 be noticed that core prints are used to locate the trunnions 
 instead of ramming them up, as is the practice in some found- 
 ries. The undercut portion of the pin ears around the pin holes 
 is seen to be cut away on the pattern, indicating that in this 
 case a cope was used in making the flask, and this portion was 
 coped out. The practice of casting flasks in open sand is not to 
 be recommended, although it can be done in some cases. 
 
 C£oa//^c ^M 
 
 Fig. 186 
 
 Fig. 187 
 
 Figure 188 shows one type of bottom board that is used 
 with grey iron flasks. The bottom board may be either plain or 
 supplied with projections, as here shown. The advantages of 
 the projections are manv, inasnuich as tlicy make it more con- 
 
Flask Equipment 
 
 199 
 
 Fig. 188 
 
 venient to release the chains 
 when carrying the mould to 
 the foundry floor as well as to 
 attach the chains after the 
 mould has been poured and 
 is ready to be taken to the 
 "shake-out" floor. While the 
 cost of providing the plates 
 with the projections re- 
 ferred to is greater than that of producing the flat plate, 
 nevertheless, when it is considered that the plate is to be used 
 continually, it is well to ascertain whether or not the time saved 
 in crane service does not far exceed the additional expense of 
 providing the extra projections on the plates. 
 
 On smaller moulds, however, which are of a size that 
 can be carried away by hand, without the use of a crane, an 
 inexpensive bottom board is made by the use of a cast iron or 
 steel plate with standard chan- 
 nel-iron riveted to its back, as 
 is shown in Figure 18^). 
 
 Rolled Steel Flasks 
 
 'Jhe descriptions thus far 
 have covered flasks that are 
 to be made of castings, either 
 grey iron or aluminum . 
 There has been a flask devel- 
 oped, however, which in mauA- 
 respects for certain sizes, is 
 better than those made In- 
 casting. This particular flask, 
 shown in Figures 190 ancl 
 191, is made of steel, the sec- 
 tion of the flask being de- 
 signed especially for produc- 
 ing rigidity, by means of ribs which are rolled into the plate. 
 
 Fig. IS") 
 
200 
 
 Foundry Moulding Machines and PatUrn Equipment 
 
 The manufacturers, realizing that there would be a large 
 demand for a light and rigid flask, have provided special rolls 
 to produce the various shapes required. The shapes are rolled 
 in long bars, and in the manufacture are shaped, by the use of 
 a large bending apparatus, to the desired size; the joint is then 
 firmly riveted. 
 
 Fig. 190 
 
 By referring to the illustration of these flasks, it WAX be 
 seen that there are light malleable castings provided for carry- 
 ing the fiask pins, as well as a light section handle casting 
 riveted to the corners. 
 
 Mention has been made of the importance of the proper 
 flask equipment. It is not too much to emphasize again the 
 fact that without the proper pattern and flask equipment, 
 machine moulding is practically an impossibility, and yet it is 
 not desired to convey the impression that the providing of the 
 
 Fig. 191 
 
Flask Equipment 201 
 
 proper patterns and flask equipment is a difficult task. The 
 fact of the matter is that the proper equipment can be provided 
 with very httle, if any, additional cost over that for producing 
 the usual equipment required for floor moulding. 
 
 Snap Flasks 
 
 As a large amount of the work produced on air-operated 
 squeezer machines is made in snap-flasks, Figures 192. 193 
 and 171 are shown to illustrate the different styles in com- 
 mon use on those machines. 
 
 The manner in which these flasks are used is clearly set 
 forth in the descriptive matter, as well as illustrated in the 
 different photographs in Chapters I and IX. 
 
 Fig. 192 Fig. 193 
 
 There is some work of such size and shape as to be 
 readily adapted to squeezer-moulding, and yet, because of its 
 weight, it cannot be successfully made in snap-flasks. Such 
 work is usually made in iron flasks of very light construction, 
 as illustrated in Figure 171. 
 
 The flask shown in Figure 175 illustrates one in common 
 vise in the aluminum and brass foundry industries. 
 
 What has been said of the above flasks and of their 
 adaptation to air-squeezer moulding, can also be said of their 
 use on the hand-rammed, hand roll-over type of machine, 
 commonly used on such work as does not readily lend itself 
 to squeezer moulding. 
 
 Flask design and construction has been discussed here in 
 such detail on account of its great importance. When hand 
 moulding, and producing from one to five moulds per day from 
 each pattern, the loss of one minute per mould, due to faulty 
 
202 Foundry Moulding Machines and Pattern Equipment 
 
 flask design or construction, is not important, as the aggregate 
 time lost is small. When machine moulding and producing 
 one hundred moulds per day from a pattern, the loss of one 
 minute on each mould then becomes an aggregate loss of one 
 hundred minutes, which is a very serious matter, indeed, as it 
 represents 20.8% of the total time of an eight-hour day. No 
 effort has been made to discuss the construction of special 
 flasks when the quantities of castings produced warrant the 
 expense. When high production is to be obtained the standard 
 flask, as described in this chapter, should be altered in any way 
 that will decrease the time of making the mould, or will increase 
 the quality of the casting. In short, the rules to be followed 
 in flask design and construction are: 
 
 Spend time and thought on flask desi(j)i. 
 
 Spend money on flask equipineut and it leill more than pay 
 for itself. 
 
CHAPTER XIII 
 Machine Moulded Cores 
 
 The exceptional demand of the automobile industry for 
 castings, in addition to forcing the use of a method that was 
 speedier than the method in use a few years ago, also made 
 necessary a way in which to produce the tremendous quanti- 
 ties of dry-sand cores that were required for the production 
 necessary to meet the demand. 
 
 There are a number of different styles of moulding 
 machines that are used to advantage in the core room. There 
 are also a number of the smaller cores that can be made by 
 hand on the bench faster than when made on moulding 
 machines. Therefore, it is the medium large, yet delicate and 
 intricate core with which this chapter will deal. 
 
 The subject of core-making is one of such magnitude that 
 the little given in this chapter appears insignificant ; it is with 
 a keen realization of this fact that the author ventures to show 
 and describe a few of the core-making operations, attempting 
 only to create in the minds of those who are not familiar with 
 the highly developed state of the art, a desire to know more of 
 the possibilities awaiting the introduction of the moulding 
 machine into the core-room. Foundries producing high grade 
 castings have adopted a rigid system of core-inspection by 
 which the various individual cores are measured by gauges, 
 having the allowable limits. In addition to the gauging and 
 inspecting of the individual core, extreme accuracy is required 
 in the satting, and therefore, to insure the core being accurately 
 set. there has been devised a system of assembly jigs in which 
 the detail cores are made fast into the composite core assembly, 
 and are held firmly in place by pouring lead into the interlock- 
 ing holes provided in the different detail cores. Therefore, with 
 this explanation, the reader is requested to refer to Figure 194, 
 
204 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 194 
 
 which ilhistrates several 
 conipHcated cores that have 
 been produced on the 
 moulding machine. 
 
 By careful study of this 
 view, it will be seen that 
 some of these cores are 
 made in one piece ; while 
 other views show several 
 cores assembled together. 
 
 
 Fig. lOS 
 
 ^ '^>!^^^B|^^^^^^^^^^^V 
 
 
 
 S^^ 
 
 
 -■.p^^^^s 
 
 Fig. 196 
 
Machine Moulded Cores 
 
 205 
 
 Handling Complicated Cores by Assembly and 
 
 Setting Jigs 
 
 iMgure 195 shows clearly 
 the manner in which the core 
 is assembled. The various 
 cores, after being assembled 
 into one complete core and 
 gauged for accuracy and then 
 placed into the mould in the 
 ordinary manner, still failed 
 to meet the requirements, as 
 it was found that a sufficient 
 accuracy could not be attained 
 ^'S- *^^ because of variation, due to 
 
 the cores straining the core-print pockets when being lowered 
 into the mould. This condition was overcome by providing 
 suitable core-setting jigs, as illustrated in Figures 196 and 
 197. Figure 196 shows, in the background, an assembly jig, 
 and m the foreground, the assembled core attached to the 
 setting jig. Figure 197 shows the manner in which the jig 
 is used while lowering the core into the finished drag half 
 of the mould. It will be seen from this view that the core- 
 setting jig is guided into place by means of the flask pins. 
 
 The style of castings which 
 this mould will turn out is 
 shown in the foreground. 
 
 The cores illustrated in the 
 ])re\-ious views were made on 
 
 l*».s 
 
 Fig. 199 
 
2U6 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 200 
 
 the moulding machine illus- 
 1 ruled in Figures 198 and 
 I'^O. l-roni Figure 198 it will 
 he seen that the core has 
 
 a'B '^-^gt^Jf/S^ |M heen rammed on the machine 
 
 Ji^-' i.iJffPBll I W '""^ ^'^^" rolled over, and the 
 
 l)aUerns and loose pieces 
 drawn from the main core- 
 box, h'igure 199 shows the 
 same core after it has been 
 lifted to the side of the ma- 
 chine, the loose pieces with- 
 clrawn and the core-box part- 
 ly rolled back in order that 
 the complicated core-box may be seen to advantage. 
 
 (jrccn Sand Cores 
 Dry-sand piston cores are produced at the rale of six per 
 operation on the machine shown in Figure 201, while in Figure 
 202, the producing of piston moulds is shown, using the green- 
 sand core method instead of the dry sand. 
 
 Figure 202 shows a mould 
 for the handling of grey iron 
 castings for gas engine pistons. 
 This is a good example of 
 green sand cores, as thev are 
 made on a moulding machine. 
 The cores are formed integral 
 with the drag portion of the 
 mould in a metal core-box. so 
 arranged as to produce foiu* 
 cores at one cycle of opera- 
 tions. This core-box is of 
 the split type and is parted 
 directly through the centers 
 of the cores. The wrist-pin 
 bosses are secured to the in- 
 side of the bo.x on a center pj^ 201 
 
Machine Moulded Cores 
 
 207 
 
 line at a right angle to the 
 parting Hne of the box. The 
 top of the box forms a flat 
 surface of sufficient area to 
 form the parting surface of 
 the mould. The members of 
 the core-box are arranged to 
 be separated in a horizontal 
 liy. 202 plane, by means of a lever 
 
 located at the back of the box. so as not to interfere with the 
 movements of the operator. On the ends of the core-box mem- 
 bers are provided tongues which slide in grooves in the upright 
 ends of the frame. A bearing strip provided at the bottom of 
 the box prevents distortion of the box while being rammed. 
 
 This core-box was mounted on a Roll Over Moulding 
 Machine and was used in the following manner : With the 
 core-box set in the position shown in the illustration, the drag 
 flask was placed on the core-box with pins on the core-box 
 properly engaging the holes in the flask ears. The core-box was 
 tiicn filled with riddled moulding sand and the sand tamped and 
 packed on the lower side of the wrist-pin bosses, after which 
 the flask was filled and rammed complete. The mould was then 
 "struck off," the bottom board clamped in place, and the table 
 carrying the core-box rolled 
 over. The leveling bars were 
 then brought up against the 
 bottom board and the auto- 
 matic leveling pins locked. The 
 bottom board clami)s were 
 next released, after which the 
 vibrator was started and the 
 members of the core-box 
 drawn apart by means of the 
 lever provided for the pur- 
 pose. The flask and cores 
 were then lowered to clear 
 the core box, and removed Pig, 203 
 
 
 , .i" 
 
 ifip 
 
 H 
 
 
 •/ •/ 
 
 «t''ri'| 
 
 i^sBi 
 
 
 1^ 
 
 m 
 
 ■-- 
 
 . " ~'" J 
 
 ^te 
 
2()S 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Fig. 204 
 
 from the machine to the posi- 
 tion shown in Figure 202. 
 
 Tunnel Segment Cores 
 'i'he tunnel segment casting, 
 fully illustrated and described 
 in Chapter IV, pages 60 and 
 61. required a large number 
 of cores to produce the bolt- 
 holes in each side of the cast- 
 ing. To meet this situation, 
 eight core-boxes were mount- 
 ed on the moulding machine 
 shown m Figure 203, which required an operation of three 
 hours to produce the rack of cores shown in Figure 204. 
 
 In the core-room of the average foundry producing general 
 castings, very little attention has been given to the possibilities 
 of producing cores on moulding machines ; yet this vast field 
 of possibilities is awaiting the foundryman who will follow the 
 lead of those now beginning 
 to realize that it is not enough 
 to make the saving possible 
 on the moulding floor, but 
 that this saving should be car- 
 ried into the production of 
 the core-room. Figure 205 
 shows a Roll- Over Jolt 
 Moulding Machine used in 
 
 Fig. 205 
 
 the production of large cores. The core boxes shown in the 
 background are all used on this one machine in one day. This 
 is a Roll-Over Jolt type of moulding machine, which jolt 
 rams the core, rolls it over, and draws the box from the core 
 by power. On the run-out car may be seen the core that 
 was produced in the box shown mounted on the machine. 
 
CHAPTER XIV 
 
 Foundations for Jolt-Ramming 
 Moulding Machines 
 
 In order to intelligently consider the proper foundations 
 for modern jolt-ramming machines, it is necessary to review 
 briefly some of the machines of earlier types. In many instances 
 it was considered necessary, to effectively jolt-ram a mould, to 
 
 Fig. 206. Plain Jolt-Ramming Moulding Machine witli only Suf- 
 ficient Foundation to Hold the Machine in Place. The Sand 
 may be Filled Around the Machine as the Working Parts 
 are Protected. 
 
 have a machine that would produce a heavy blow. This usually 
 was accomplished by building the machine with a stroke of 3 
 to 4 or even 6 inches in length. This stroke, of course, would 
 produce the heavy blow, its action was not unlike the blow of a 
 steam hammer. 
 
 In order to control the ground vibrations produced by such 
 a machine, it was necessary to provide massive foundations, and 
 in many instances the concrete was capped with several layers 
 of wood to aid in the absorption of the blow. 
 
210 
 
 Foundry Moulding Machines and Pattt-rii Equipv.rnt 
 
 The recent rapid development of jolt-ramniing machines 
 has practically reversed the early theory of design, as it has 
 been determined that it is not the force of the machine blow 
 that packs the sand, but that it is packed by the jolting table 
 being suddenly or abruptly brought to rest while the sand in 
 the flask to be packed continues its downward course, thereby 
 producing the pressure which results in the sand packing against 
 the pattern or pattern-plate. It is quite evident, therefore, that 
 
 Fig. 207. Foundry Floor View of Jolt-Ramming Power-Stripping 
 Moulding Machine with Working Parts Protected. 
 
 if the machine which has been brought suddenly to rest be 
 instantly started again on its upward stroke and not allowed to 
 pause, an increased pressiu'e of the pattern against the sand 
 will result, which causes the sand to lay and not rebound. 
 
 A jolting machine necessary to accomplish this need not 
 be miduly massive in its working parts, nor need it have a 
 long stroke, 1 to 2 inches usually being sufficient. It should 
 have means of ctintroUing the force of the blow of the table 
 
Foundations for Jolt Ramming Moulding Machines 
 
 211 
 
 Avhen contacting with the anvil base, as it is evident that 
 the weiglit of the moving table (or dead load) must not be 
 allowed to freely drop and contact with the anvil block, or it 
 will produce the unnecessary heavy blow. The up-to-date, 
 uiodern jolting machine prevents this heavy blow by providing 
 
 r 
 
 Fig. 208. Same Machine as Fig. 207, Showing 
 Simplicity of Foundvitio'i. 
 
 an air cushion under the cylinder sufficient to overcome the 
 
 violent blow caused by the dead load, allowing only sufficient 
 
 blow to accomplish the instant reversal of stroke. 
 
 A machine that accomplishes the foregoing not only will 
 
 ram a good mould in a very short time, but will do so without 
 
 excessive or detrimental vibration in either the machine, pattern 
 
 or foundation. 
 
Foundry Moulding Machines and Pattern Eijuifn.ent 
 
 '\s we now approach our subject — the machine foundation 
 — it is evident that with such a machine the extremely massive 
 foundation is not essential and, therefore, our consideration will 
 be from the standpoint of economy and accessibility. 
 
 Of first importance is the kind and nature of the soil upon 
 which the machine foundation is to be placed. A dry gravel is 
 considered the thing next best to solid rock and will safely stand 
 a load of 6,000 to 8,000 pounds per square foot. Dry ^and or 
 
 Fig. 209. A Large, 42 x 97-inch, Plain Jolt-Ramming Moulding 
 Machine, Showing Section Through Foundation and Pit. 
 
 dry sand and gravel mixed makes a very good foundation base 
 and will withstand a load of 4,000 to 8,000 pounds per square 
 foot. Clay soils vary widely ; a soft clay will flow in all direc- 
 tions even under very light load, and should not be loaded more 
 than 3,000 pounds per square foot, while a dry clay will satisfac- 
 torily stand a load of 3,000 to 5,000 pounds per square foot. If 
 the foundation is to be placed on made ground or fill, provision 
 should be made to keep the ground perfectly dry and free from 
 
Foundations for Jolt Ramming Moulding Machines 
 
 213 
 
 water. With the proper condition existing a satisfactory foun- 
 dation can be made, such condition being more desirable than a 
 wet or oozy clay soil. When the foundation is placed on clay or 
 fill, better results can be obtained by having it cover a large area 
 rather than making it of greater depth, unless the fill is of such 
 depth that the foundation may be extended through to solid soil. 
 
 Fig. 210. A 64-inch Roll-Over Jolt-Moulding Machine, Showing 
 Section Through Foundation. 
 
 It must be remembered that when we place a moulding 
 machine in the foundry Ave are actually violating the old estab- 
 lished principle of -machine installation and placing it in a 
 sand pile instead of an engine room, or other dirt and dust- 
 proof room, and yet notwithstanding this extraordinary condi- 
 tion, and without giving the machine proper care, many found- 
 rymen expect as good results from the machine in the sand pile 
 as they do from the machine that was placed in a dust-proof 
 room and in charge of an expert mechanic. 
 
214 
 
 Foundr\ Mouldivji Machines and Pattern Euuipvient 
 
 3 O 
 
 o o 
 i= ^ 
 
 C3 
 
 .2 S 
 
 C/^ -fe- 
 et 
 
 J2 
 
 •r O 
 ^ a* 
 
 0^ 
 
 CO 
 
 
 
Foundations for Jolt Ramming Moulding Machines 
 
 21.") 
 
 Fig. 212. View of Large, 42xl09-inch Roll-Over Jolt-Moulding Machi 
 
 Fig. 213. A 36xl50-inch Roll-Over Jolt-Moulding Machine, Base and 
 Foundation Shown in Phantom as it Appears Above Foundry Floor. 
 
216 
 
 Foundry Moulding, Machines and Pattern Equipment 
 
 The accompanying illustration will demonstrate that it is 
 economy to provide a foundation and setting that will give 
 ample protection to the machine, by making it impossible for 
 
 Fig. 214. Foundry Floor \iew of 42-inch Klectrically Operated Roll 
 Over Jolt-Moulding Machine, Showing Foundations in Phantom. 
 
 sand to collect on the machine or in its moving parts. They also 
 will show the advisability of providing ample space around the 
 machine so that the mechanic can easily oil, inspect and keep 
 the working parts in order, the same as he does the machine 
 placed in the engine room. The depth of the space surrounding 
 
Foundations for Jolt Ramming Moulding Machines 
 
 I'T 
 
 Fig. 215. Same Machine as Fig. 21-4, Showing Section of Foundation. 
 
 Fig. 216. This Photograpli was Taken in the Pit and Shows the Ex- 
 cellent Condition of the Base of this Jolt-Ramming Moulding 
 Machine and its Freedom from Sand, etc. 
 
218 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 the machine should be sufficient for a man to stand erect, suit- 
 able lighting facilities should be provided and a stairway or 
 ladder should lead into the pit. 
 
 The covering of the pit or foundry floor should be made of 
 2-inch matched planking and should be fitted tight against the 
 
 Fig. 217. I lUrancc Way into the Foundation Pit of a Jolt-Moulding 
 
 Machine, Showing Steps Leading into the Pit from an 
 
 Adjoining Basement Room. 
 
 machine. The trap door leading into the pit should be hinged 
 and of ample size. 
 
 The engineer or architect called upon to design and build 
 the foundry of tomorrow will do well to thoroughly consider 
 the best method of installing and maintaining the moulding 
 machines to be used, placing them in such manner as to insure 
 ample protection from dust and grit and making it easy to give 
 the machines the care and attention they deserve. 
 
Foundations for Jolt Rammiw^ Moulding Machines 
 
 219 
 
 F'ig. 218. \iew of Jolt-Raniniing Moulding Machine, Taken in the 
 Pit, Showing Construction of the Pier. 
 
 Fig. 219. View Showing Several Jolt-Ramming Moulding Machine 
 Foundations with Piers Built on the Basement Floor. 
 
220 
 
 foundry Moulding Machines and Pattern Equipment 
 
 The author's idea of a foundry that will best meet these 
 practical requirements is set forth in l-'igure 220. This illustra- 
 ti(in shows the cross-section of a proi)Osed foundry, havinj^ 
 a tunnel or basement extendini'- the full length of the mouldinef 
 
 ^ 
 
 Fig. 220. Cross-Section of the Proposed Foundry, Showing Tunnel 
 for Machine Foundations. 
 
 floor. The floor of this tunnel or basement should be at least 
 7 feet below the ceiling and the width should be sufficient to 
 allow a clear passageway on one side of the machines ; the piers 
 for the machine foundations can be placed at any time and to 
 suit anv condition. 
 
foundry Moulding Machines and Pattern Equipment 
 
 Index 
 
 A 
 
 Airplane Castings 78 
 
 Alloys for Match Plates 184 
 
 Aluminum Crank Cases 109 
 
 Aluminum Hasks 110, 111 
 
 Aluminum Foundries 107 
 
 Armored Truck Castings. . .79, 99, 100 
 
 Automobile Castings 
 
 74, 75, 76, 77, 9f), 97, 98 
 
 Floors of 85-91 
 
 Automotive Industry 
 
 Core Making In 203 
 
 State of 166, 203 
 
 B 
 
 Bedding on the Bottom Board . 19 
 
 Bottom Boards 198 
 
 Bottom Strike Machines 117 
 
 Brass Foundries 107 
 
 Butting off 
 
 Definition 15 
 
 Speed of 15 
 
 Variation 15 
 
 Care of Machines 120 
 
 Castings 
 
 Machine moulded 9^1 
 
 Center Lines on Pattern 72 
 
 Changing Patterns 71 
 
 Clamping Bottom Boards 54 
 
 Clay Wash for Gaggers 13 
 
 Competitive Spirit 71, 72 
 
 Construction 
 
 Pattern Draw on Roll Over 48 
 
 Patterns 162 
 
 Plain Jolt Machine 117 
 
 Roll Over Machines 47 
 
 Continuous Pouring 107 
 
 Cope on Roll Over Machines 71 
 
 Cope on Stripper Machines .... 71 , 149 
 
 Core 
 
 Assembly 204 
 
 Covering 25, 26 
 
 Green Sand 206 
 
 Inserted 24, 25 
 
 Production 203 
 
 Ram-up 22, 25 
 
 Setting Jigs 205 
 
 Core Machines 69, 1 1 1 , 203-208 
 
 Core Print 23 
 
 Crane Equipment 5*) 
 
 Crank Cases 
 
 Floor of 85 
 
 Production of 113 
 
 D 
 
 Deflection of 
 
 Leveling Tables 49 
 
 Patterns 163 
 
 Roll Over Tables 49 
 
 Density of Ramming 160 
 
 Design of 
 
 Flasks 163, 189 
 
 Jolt Machines 37, 117 
 
 Patterns 161 
 
 Squeezers 139 
 
 Vibrator 21 
 
 Development of 
 
 Plain Jolt Machine 115 
 
 Squeezers 133 
 
 Diagram of Vibrator 21 
 
 Equipment 
 
 Crane 59 
 
 Flask 7, 188-202 
 
 Pattern 161-187 
 
 F 
 
 Facing Sand 52 
 
 Flask 
 
 Bars 121, 195 
 
 Construction 198 
 
 Design 121, 163, 189 
 
 Drawings 191 
 
 Jigs 195 
 
 Pins 195, 197 
 
 Flask Equipment 188-202 
 
 Flasks 
 
 Aluminum 110, 111 
 
 Cut 164 
 
 Grey Iron 191 
 
 Rectangular 190 
 
 Snap 201 
 
 Steel 199 
 
 Floors, views of 85, 91, 104, 105 
 
 Follow Board 143, 173, 174 
 
 Form for Pouring Basin 27, 28 
 
 Gaggers 
 
 Use of 13 
 
 Clav Wash for 13 
 
Index 
 
 223 
 
 Gate Pattern \Xi 
 
 Use of 147 
 
 Gate, Swirl 27 
 
 Gating 27 
 
 (jcnerator Castings. . . .122, 123, 124 
 
 Gravity, center of, in rolling over 45 
 
 Green Sand Cores 206 
 
 Green Sand Match 133 
 
 H 
 
 Hand Ramming 
 
 Difficulties of 31 
 
 Requirements of 31 
 
 1 land Roll Over on Squeezers 136 
 
 Hard Sand Match 133, 173, 174 
 
 H>draulic Machinery Castings .... 125 
 
 I 
 
 Ideal Moulding Machine 117 
 
 Impact of Machine 34, 41 
 
 Inspection of Machines 120 
 
 Indicator Tests 34 
 
 Cards 35-36 
 
 When used 38 
 
 Inserted Cores 24, 25 
 
 Inverted "\'" Construction 139 
 
 J 
 
 Jobbing Foundry Methods 168 
 
 Jolt Machine 
 
 Design 37 
 
 Plain 114-131 
 
 Time sa\ed b}' 33 
 
 Jolt Ramming 
 
 Cushioning of 35 
 
 How accomplished 32 
 
 Length of Stroke 32 
 
 On Roll Over Machine 41 
 
 Rate of Blows 32 
 
 Recess 134 
 
 Theory of 31 
 
 Time required 32 
 
 Jolt Squeezer Machine 
 
 Advantages of 138 
 
 Construction 134 
 
 Design of 139 
 
 Operat'on 135 
 
 Production on 139 
 
 Jolt Squeezer Stripper Machines. . 
 
 Advantages of 155 
 
 Operation of 159 
 
 Speed of 155 
 
 Jolt Stripper Machines 148-163 
 
 Functions of 149 
 
 Used for Copes 149 
 
 L 
 
 Le\'eling car 
 
 Deflection in 49 
 
 Design of 49 
 
 Use of 47 
 
 Libertv Engine 107 
 
 Loose Pieces 18, 23 
 
 M 
 
 Machinery Castings. . . .06, 67, ()S, 80 
 
 Maintenance of Machmes 120 
 
 Marine Castings. .. .63, 64, 65, 81 
 82, 83, 84 
 
 Match Plates 
 
 Alloys for 184 
 
 Construction of 176 
 
 Use of 145 
 
 Materials for Patterns 162 
 
 Metal Patterns and Plates 164 
 
 Method of 
 
 Drawing Pattern 49 
 
 Using Upset 13 
 
 Method of Making Moulds 
 
 On Floor 52 
 
 On Jolt Squeezer 20 
 
 On Plain Jolt 2, 3 
 
 On Roll Over Machines 4, 5 
 
 On Squeezer Alachines 7, 12 
 
 On Stripper Machines. . . .5, 8, 10 
 
 Moulds 
 
 Large .". 59 
 
 Medium 71 
 
 Small 93 
 
 Mounting Patterns 161 
 
 
 
 Oil Sand Match (See Hard Sand 
 Match) 
 
 Operation of Making Moulds on 
 
 Floor 52 
 
 Jolt Squeezer Machine 7, 20 
 
 Jolt Squeezer Stripper Mach. .5, 10 
 159 
 
 Jolt Stripper Machine 5, 8 
 
 Plain Jolt Machine 2, 3 
 
 Plain Squeezer Machine 7, 12 
 
 Roll Over Machine 4,5, 52 
 
 Operation of 
 
 Jolt Squeezer Machine 135 
 
 Pattern Drawing 48 
 
 Roll Over Machine 43-47 
 
 Squeezer Machine 135 
 
 Operations of Making Mould 52 
 
 Overhanging Projections 23 
 
224 
 
 Foundry Moulding Machines and Pattern Equipment 
 
 Output of 
 
 LarKC Roll Over Machine .")9 
 
 Patching Moulds ... .").j 
 
 Pattern Design IGl 
 
 Pattern Drawing 
 
 .\ccurac\' of Parts for 4'.) 
 
 Method 'of 49 
 
 On Roll Over Machines 48, .")1 
 
 Time saved by 48 
 
 Pattern Equipment 161 , 187 
 
 Pattern Materials lOi 
 
 Pattern Mounting 
 
 Cost of II 
 
 Skill required for !), 165 
 
 Pattern Plates, use of ')'2, llo 
 
 Patterns for 
 
 Flasks 19S 
 
 Plain Jolt Machines 114-131 
 
 Squeezer Machines 133-1."57. 173 
 
 Stripper Machines ISO 
 
 Patterns, Metal 164 
 
 Pins, Stripping of 151 
 
 Plain Jolt Machine. . . 114-131 
 
 Plain Squeezer 
 
 Operation of 137 
 
 Patterns for .137 
 
 Pop Valve 136 
 
 Portable Machines 94, 107 
 
 Production 
 
 On Plain Jolt Machines 115, 121 
 
 On Roll Over Machines . .61 et seq. 
 
 On Squeezer Machines 139 
 
 Q 
 
 Quality- of Castings . . 42 
 
 Quantity of Castings ... 116 
 
 R 
 
 Railway Castings 62 
 
 Ramming 
 
 See Hand Ramming 
 Also Jolt Ramming 
 
 Ram off 134 
 
 Ramming Requirements 33 
 
 Ramming. Uniformity of 33, 38 
 
 Ram-up Core, Uses of 25 
 
 Rapping of Pattern 19 
 
 Recess, jolting of 134 
 
 Remo\ing Mould from Machine . .50-51 
 
 Rigiditv of Patterns 163 
 
 Roll Over Jolt Machin-.-s 
 
 For Cores 69, 208 
 
 Functions of 41 
 
 Illustration of typical . . 40, 5S, 92 
 
 Large 59 
 
 Medium 71 
 
 Portable 94 
 
 Production on 72 
 
 Small 93 
 
 Use in Brass and Aluminum. . . . 107 
 
 Roll Over Operation 43 
 
 Construction 47, 48 
 
 Principles 43 
 
 Speed of 93 
 
 Time saved by 43 
 
 Rough Castings, cause of 31 
 
 Sand 
 
 Clearance 163 
 
 Moulding 29 
 
 Packing of 32 
 
 Spreading of 15, 16 
 
 Sand Straddlers 139 
 
 Savings in Shipbuilding Industry. . 
 
 83, 84 
 
 Shell Patterns 172 
 
 Shipbuilding Industry 83, 84 
 
 Slicking 55 
 
 Snap Flasks 201 
 
 Correct Proportions 141 
 
 Split Pattern Alachine 135 
 
 Sprue 137 
 
 Squeezer Machines 
 
 Design of 139 
 
 Development 133 
 
 Jolt Squeezer 133 
 
 Operations of 135 
 
 Patterns for 133, 173 
 
 Plain 133 
 
 Production on 139 
 
 Steel Flasks 199 
 
 Striking Off 17, 53 
 
 Stripping Plates 
 
 Gates on 151 
 
 Mounting of 150 
 
 Need for 1 50 
 
 Pins on 151 
 
 Swirl Gate 27 
 
 Symmetrical Patterns 72 
 
 T 
 
 Tabulations, Shipbuilding Indus- 
 try 83, 84 
 
 Tests on Moulding Sand 29 
 
 Theory of Jolt Ramming 31 
 
 Time saved bv Jolt Machine 33 
 
 Bv jolting.' 42 
 
 By "Rolling Over . 43 
 
Index 
 
 225 
 
 Top Strike Machine 117 
 
 Types of Machines 7 
 
 Typical 
 
 'Mould 1 
 
 Roil Over Alachines 40, oS, 70 
 
 Tunnel Segment Castings (50, 61 
 
 Tunnel Segment Cores 208 
 
 U 
 
 Universal Pattern Plate 168 
 
 Uniformity of Castings .">, 42, 156 
 
 Uniformity of Ramming 33, 38 
 
 Upset, use of 13 
 
 Use of Gaggers 13 
 
 Use of Gated Patterns 147 
 
 Use of Vibrator 137 
 
 Use of Vibrator Frame 145 
 
 Uses of ... 
 
 Inserted Cores 25 
 
 Ram-up Cores 25 
 
 \ 
 
 \'ariations in 
 
 Butting off 15 
 
 Size of Castings . 156 
 
 Weight of Castings 51, 156 
 
 \ ibration in machines 118 
 
 \ibrator 
 
 Diagram of 21 
 
 Use on Squeezers 137 
 
 \'ibrator Frames 
 
 Construction of 175 
 
 Use of . . .' 1 45 
 
 W 
 
 Weight of Castings 51 
 
 Wood Patterns 166 
 
 Wood Pattern Plates . . 166 
 
 Wood Flasks 189 
 
360 90 
 

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 BINDERY INC. 
 
 ^ AUG 90 
 
 N. MANCHESTER, 
 W INDIANA 46962