Improved Foundry Practice*

Quantity Production of Automobile Castings (By D. R. Wilson, Vice-President, Wilson Foundry & Machine Company)

(Continued from June Number)

To illustrate in greater detail some of the methods used for producing accurate cores we will follow through some of the points in the making of a six-cylinder job.

[FIG. 28.-Reaming Jacket Cores for 6-Cylinder Job

*Address to Convention, National Founders Association, November, 1922.

Fig. 28 shows a jacket barrel reaming jig. The counterbalanced reaming roller is run down into each barrel of the jacket until it meets the stops. In practice every other barre is reamed, the jig is then cleaned, and the alternate barrels reamed.

(The girl at the left is using a corrugated rubbing down plate to smooth the jacket core face. The girl in the center at the rear is gauging openings in the core with hardened steel gauges, while the two girls at the right are sanding cores with special jigs.)

Fig. 29 shows a number of fixtures which have been gathered together on one bench for illustration sake. At the left there is a corrugated plate used for smoothing the ends of the jacket cores, or for surfacing any other core requiring a smooth surface, the core being rubbed back and forth against the corrugated surface. The girl in the center at the rear is using a hardened steel plug to gauge openings in the jacket, while the girls at the right are sanding the top and bottom respectively of certain jacket cores. As already stated these sanding

blocks are used for removing the majority of the stock, and the final jointing is done with the hardened steel jointing broach or bar.

In Fig. 30 the girl at the right is jointing the edge of a core, while the girl at the right in the back row is sanding. The girl in the center at the back is fitting a core into an assembly jig or gauge block, while the one at the left is rubbing down a

Operations on Jacket Cores for 6-cylinder job.

(The girl at the left is smoothing core to fit gauge. The one in the center at the rear is gauging core by a special setting device. The one at the right in the rear is sanding the surface of a core and the one at the right in front is using a special square hardened steel surfacer to smooth the joints.)

portion of the core with a rubbing block to make it fit the gauge.

In Fig. 31 the girl at the right is assembling two units of a three-part jacket in a machined fixture, which is used for drying the core after assembly, the final assembly of the core being shown at the extreme right. The girl on the left is making the final assembly, taking the parts that have been

dried in the drying fixture, and placing them, together with the other cores and the intake cores.

We might go on showing a good many other views of core room operations, but believe that those given cover the principles involved.

We will now turn our attention to the molding and core setting of the six-cylinder job under consideration. Fig. 32

(The girl on the right is assembling two parts of the jacket core in a special jig used for drying the paste. The one at the left is assembling three parts of the jacket, which are later clamped in a machined fixture for drying. At the extreme right is shown the completed assembly.)

shows a general view of the floor, with the two Grimes jarramming roll-over molding machines used for producing copes and drags.

Fig. 33 shows the six core-setting jigs used on this job. These jigs being of considerable size are made of aluminum, so

as to reduce the work necessary in handling them, and as will be noted they are equipped with suitable steel handles where necessary. All locating pins are bushed with hardened steel, and where a jig is used for locating vertically, a spring-actuated plunger is placed in hardened bushings. When the jig is in position, if the core is properly set, this plunger should stand level with the top of the bushing. If it is lower it shows that

the core is too low, while if it projects it shows that the core is not set low enough in the mold.

Fig. 34 shows the drag with the lower jacket in place, and the lower jacket setting-jig in position. Fig. 35 shows the crank-case cores in position with the crank-case core-setting jig in place. This jig is used for setting the lower half of the crank-case cores.