US1586321A - Sectional core - Google Patents

Description

May 25; l1926. 1,586,321

` C. F, NEWPORT SEGTIONAL 10111:

1 Filed Dec. 28, 1922 Patented May 25, 1926. i i ff i y UNITED STATES PATENT: OFFICE.

CHARLES EUNEWPORT, OF CI-VIICAVGO, ILIiIIl'OIiS.` i i i I i i i 'i sEcrIoNAn conn. i i i i i Application filedl December 28, 19272. Serial No.

This invention. relates to Vimprovements in the process. Fig. n4 is fa transverse vertical sectional (ores and the process of making sectional'y view ofthecoinpleted sectional the same. core, partly broken away, and illustrates the One object of the invention is to provide final step of the process. Figs. 5 and 6 are 5 a core used in foundry practice, comprising views similar to Figs. 2 and 4 respectively, Q0 a plurality of sections, wherein the core secillustrating a modification of the invention. tions are tightly held together by simple, And Figs. 7 andS areviews showing a furclficient, and economical connecting means. ther modification of the invention, Fig. 7

Another object of the invention is to probeing a view similar'to Fig. 5, and Fig. 6

10 vide any exceedingly simple and effective showing a transverse sectionalview of the 65 process of' making sectional vcores and unitfinished article, and killustrating the final ing the sections thereof. step of the process.

Another and more specific object of the In said drawings, 10 indicates the upper invention is to provide a core of the type section and l1 .the lower section of a core A specified, rwherein the sections are `secured constructed in accordance with my inven- 70 together by integral joining members setion, and 12, `a core box or inold used in curely anchored in adjacent contacting porcarrying out the process. tions of the core sections, by forming in the The. core box 12 is interiorly recessed as contact-ing portions ofsaid sect-ions, pairs .indica-ted by 13 to conform in shape tothe of alined recesses, fiaring inwardly from the core section to be formed, and is provided 75 meeting faces thereof and securing the secwith spacedtapered pins 14 upwardly protions togetherby casting a joining member jecting'froin the bottom of the recess, with in each pair of said recesses, while the secthe smaller end of each `pin uppermost. As tions o f-the core are'in assembled relation, clearly shown in Fig. 2, the pins 14 are thereby forming integralV connecting memfixed to the bottom of the core box b y stems 80 bers provided with oppositely extending 15 seated in recesses 16. LThe pins 14; are of flaring portions imbedded in the respective such a height that the upper end thereof core sections. e will be in alinement with the plane of the A further object of the invention is to upper face 17 ofthe core box 13, and with provide a sectional core, wherein the secthe line of parting of the sectional core. 85 tions are secured together solely by av plu- In carrying out the process as illustrated,

rality of joining members,each of which is in Figs. 1 to el inclusive, the yprepared core provided with flaring anchorage portions Vsand is packed into the corebox 12, thereby extending into adjacent sections, and whereforming a core section 11 having olo`wn in the joiningmembers are formed by castwardly` flaring openings 18 therethrough. 90

ingy the same in alined recesses in said sec- The upper core'section-l() isy formed in a tions, the material composing the joining ysimilar manner, in an upper or cope core members being such that it .contracts upon box providedr with downwardly tapering cooling, whereby the sections `are tightly pins, whereby` thecore 10 is `provided with 40 drawn together into intimate face to face upwardly flaring openings 19 therethrough, 95

contact. i the relative location 0f ttlie'pins vbeing 'such ln the drawings forming `a part vof this that the openings18 and l19 will be in alinespecification, Fig. 1 is a perspective view of ment when the core sections 11 and 10jare a pair of core sections constructed in yacinassembled relation.- cordance with myinvention, said core sec- "The core sections 10 and 11y are thenr'e'` 100 ktions beingv shown separated and partly: `moved and thoroughly baked, in the usual broken away and partly in section, to more manner. After the'core sections have been. clearly illustrate the form and arrangement baked, the `largeends of the openings 1a of of the recesses. Fig.A 2 is a transverse verthe section 11 are plugged withy green sand tical sectional View of a core box and a core as indicated by 20 in Fig. 8. The core sec-k 105 i section, and illustrates one of the steps of tions are then assembled asshown'in Fig. 3, the process. lFig. 3 is a transverse vertical with the upper `face 21of the core section sectional view through a pair of assembled 11Y abutting the lower face 22 of the section core sections, each constructedas shown in 10'and the respective openings 18 and 19 Fig. 2, and illustrates a subsequent step ofv alined, with the smaller ends thereof ad- 7110 jacent each other and registering. Molten lead or other suitable cheap metal is next poured into the openingsthrough the upper enlarged ends of the openings 19 in the sect-ion 10, and allowed to set, thereby casting integral connecting members 21 of double tapered formation. As clearly shown in Figs. 3 and et, the connecting members 21 are thus formed with upper outwardly tiaring portions 22 securely anchored in the upwardly flaring openings 19 of the upper core section 10 and lower downwardly tiaring portions 23 securely anchored in the downwardly flaring openings 18 ot' the lower core section 11.

It will be evident that, as the cast lead or other metal connecting member 21 shrinks during cooling, a strong pull will be exerted thereby onl the sections 10 and 11, thus drawing and holding the sections tightly together and forming a tight seam therebetween.

To provide the core with a smooth eXterior finish, the spaces lett at the upper ends of the openings 19 above the connecting members 21 may be iilled with green sand as indicated at 211.

Although in the specific form or" cere as illustrated in Fig. 1, the sections are shown as provided with four openings, thereby providing for four connecting members, it will be evident that the number of connecting members and their relative positions in the core sections may be varied as desired, as circumstances require, to suit conditions and to produce the best results.

The improved sectional core A, as clearly shown in Fig. a, comprises the upper core section 10 and the lower core section 11 rigidly joined by double tapered cast connecting members 21, each provided with an upwardly flaring portion 22 seated in the upwardly tapering recesses of the upper core sections 10 and a downwardly flaring portion seated in the downwardly tapered recesses oi the lower core section 11, the connecting members 21 forming the sole means for holding the core sections together.

In the modilications shownin Figs. 5 and 6, a core section A1 is shown comprising an upper thin core section 110 and a lower relatively thick core section 111. As clearly shown in Fig. 111 are joined by double tapered cast connecting members 121 similar to the connecting member 21 of the preferredV form, having the tapered portions 122 and 123 thereof seated in correspondingly tapered recesses 119 and 118. The space lett at the upper end ot the opening 119 may be filled with green sand as indicated at 124 in amanner similar to that shown in connection with the preferred form in Fig. 4.

The core box 112 is interiorly recessed as indicated at 111 to conform in shape to the 6, the core sections 110 andV core to be formed. The upper side of the core box 112 lis provided with upwardly projecting guide pins 125 to engage with corresponding recesses in a template 126 to properly center the same. rlhe template 126 is in the form ot' al fiat plate adapted to rest on the upper surface 11T of the core box 112 and is provided with a plurality ot' downwardly tapering recesses 12T corresponding in number and position to the openings 118 to be formed in the core section 111. T ie material around the openings 127 is thickened as clearly shown in Fig. 5, to provide upwardly extending hemispherical bearing members 128 for the rods 129. rl`he rods 129 serve as tools tor forming the flaring openings 118 in the core section 111 and are provided with fixed collars 130 adapted to rest upon the bearing members 127, and so spaced from the lower end ot' therods 129 that the same will project the proper distance downwardly into the core 111 to form the proper depth ot openings 118.

In carrying out the modified form ol.- process as illustrated in Figs. 5 and (i, the prepared core sand is iirst packed into the core box member 112, the template 12o' is then placed on the upper tace 117 or the Core bOX 112 with the pins 125 engaging the gage recesses in said plate and the rocL 129 inserted through one of the openings 127 and pushed down into the green core sand and given a lateral swinging and rotary movement, thereby forming the Haring opening 118 in the core section 111. This operation is repeated by inserting the rod 129 through each of the remaining openings in the template and manipulating the same to form the desired number of openings 118 in the core section.

The upper core section 110 is formed in a manner similar to that described in connection with the formation ot' the core sections 10 .and 11, and provided with upwardly tiaring openings 122 therethrough; the relative location' of the openings 119 and 118 being such that the same will be in alinement when the core sections 110 and 111 are assembled. Y

Atteiremoval trom the respective core boxes, the core sections 110 and 111 are baked in the usual manner. The core sections are then assembled as shown in Fig. 6 with the upper tace ot the core section 111 abutting the lower tace of the core section 110 and the respective openings 118 and 119 alined with the small-er ends thereof adjacent each other and registering. Molten lead is next poured into the openings through the upper enlarged ends of the openings 119 and allowed to set, thereby casting integral connecting members 121 of double tapered formation, in all respects similar to the connecting members 21 shown in the preferred filled with green sand as indicated at 124.

In themodification illustrated in Figs. 7 and 8, a sectional core A?, comprising upper and lower relatively thick core- sections 210 and 211 is shown. rlhe core sections 210 iii and 211 are joined by a double tapered cast connecting member 221, similar to the connecting member 21 of the preferred form, comprising the tapered portions 222 and k223 fixed in correspondingly tapered recesses 219 and 218 respectively of said core sections.

The lower core section 210 is in allrespects similar to the lower core section 110 and the process of forming the flaring openas that described in ings therein is the same therefore a'detailed connection with Fig. 5,

description thereof is not deemed necessary.

The tapered openings 219 of the upper core section 210 do not extend. yentirely through the same, but are all, approximately, of the saine size and depth as the openings 218, and means is therefore provided for permitting the molten metal to enter the saine. This means comprises ducts or gates 240 opening through the upper side of the core section and vcommunicating with the recesses 219. Y

The steps involved in forming the upper core section 210 with the recesses 219 and the Vgates 240, andthe means employed are clearly disclosed in Fig. 7, in which 212 indicates a core box. VThe core box 212 differs from the core boxl 112 previously described, in connection with the forni of the invention disclosed in Figs. 5 and 6, only, in that the same 'is provided with a plurality of upwardly tapering pins 241 secured f to the bottom of the core box by stems 242 fixed in the recesses 243. The pins l242 extendupwardly from the bottom of the core to a point corresponding' to the depth of the 7 amount actually recovered is approximately recesses 219, vas clearly shown'in Fig. In forming the core section 210, the prepared core sand is first packed into the core box 212 andY around the pins r'241. Then template 226, which is in all respects similar to the tem late`,126, described in connection with the orm of lthe invention shown iii Figs. 5 and 6, vis placed on top of the core box member 212, and held inproper position thereon by the centering pins 225. They openings 240 may then poured into the 227 in saidplate and the ref rod 229 projects into thev tion, the sections 210 and 211 are assembled as shown in pouredy through the gates 240 into the openings 'formed by the recesses218-219, thereby casting the integral connecting-members Fig. 8. Molten lead is then members, they are thoroughly baked in the Lusual manner, and after the baking opera- 221 of double tapered formation, and'joining the core sections. The upper end of the then be closed by plugging the saine with sand' as indicated at. 244.

It will be evident from the foregoing description taken in connection with lthe drawing that a great saving of material is yeffected by forming shallow recesses 118, 218

andc219 inthe thick core sections `111, 210 and '211 as shown in Figs. 5v to 8 inclusive, instead of forming recesses extending entirely through the sections.

After forming the cores as hereinbefore described, they are ready for the use in connection with the operation of forming the casting.l A mold'for the desired articleto be cast `is prepared and the core inserted therein, in ausual and well known manner. Molten lead or any other suitable metal, is mold and allowed to set. After the casting has cooled suiiiciently, the same is removed from the mold and the core broken up and extracted therefrom, either by a tumbling operation or in any other well known manner usual in foundry practise. `The operation of breaking up the core also serves to free the metal connecting members whichv serve to imite the core sections. After the metal connecting members have been thus freed, they are rcollected and remelted, thereby recovering the greater porl tion of the lead or other metal used in yjointhusl eecting a great saving in cost of material.

y to 80% of that originally used. f In disclosing different forms of the invention, the same has been illustrated in connection with cores of somewhat regular shape and composed of two sections, but it will be understood that cor-es of any shape and composed ofl any number of vsections may be joined in accordance with my invention.

Heretofore, the customary practice in making sectional cores has involved the making of the baked core sections, pasting the meeting faces of the sections with a tightening medium such as flour paste, .pressing the sections together, which causes a certain amount of the binding material to exude around the parting lin-e, wiping o the exuded excessbinding material, allowing ythe binding material to set or ,dry,jand, in a ico great many cases, wire is required to more securely hold the sections together. In this old or common practice, the labor timeelement is comparatively high and particularly so where large sectional cores are made, hav- .ing a big area to be covered with the binding medium. Furthermore, the cost of the binding material and the wire runs to large iigures in a foundry of large capacity and it is obvious that there can be no recovery of the binding medium or .the wire. lith my improved process, the labor time element is reduced to a minimum, it being evident that, in the process as illustrated in Figures l, 2, 3 and 4t, no extra time is required in making the openings and in the process illustrated inV Figures 5 and 6, a number of openings can be made in the core sections in a few minutes. rl`he plugging of the openings with green sand requires but a few seconds and the pouring of the metal can also be done very rapidly. In actual practice, I have found that the labor cost when employing my process is only a fraction of that involved in the usual or common practice. Furthermore, as hereinbefore pointed out, the greater part of the metal used in my process for the connecting means is recovered when the castings are tumbled so that the material cost is also very much less as compared with prior practice, and in the course of a year, in a large foundry, the saving amounts to considerable sums.

I have herein shown and described what I now consider the preferred manner of carrying out the invention, but the same isL merely illustrative and I contemplate all changes and modifications that come within the scope of the claims appended hereto.

I claim:

l. In a process of forming cores composed of a plurality of sections, the following steps: forming a plurality of core sections, each having a plurality of tapering openings therethrough, the openings being arranged to register with the smaller ends thereof communicating when said sections are` assembled; baking said core sections; closing the larger ends of the openings of one of said sections; assembling saidsections with corresponding openings thereof in registration and with the last named section lowermost; and joining the core sections by casting metal in said alined openings.

2. In a process of making cores, providing a pair of complementary core sections having inwardly flaring recesses in the faces thereof corresponding to the line of parting; assembling said core sections with the recesses thereof registered; and filling said registered recesses with molten metal, thereby joining said sections by integral metal connecting members.

3. In a process of making cores, molding a plurality of core sections; forming in.

wardly flaring recesses in one face of each of said sections; assembling the core sections with said faces in contact and the respective recesses of said core sections in alinement; filling said alined recesses with molten metal; and permitting said metal to solidify, thereby forming integral connecting members and drawing said core sections tightly together.

4t. In a process of making cores composed of a plurality of sections, providing a plurality of core sections having faces adapted to abut when the core sections are in assembled relation; forming recesses in said faces for receiving joining elements, said recesses being inwardly enlarged; assembling said core sections with the respective recesses of said sections in alinement; and uniting said sections by forming joining elements in said alined recesses.

5. In a process of making cores composed of a plurality of sections adapted to be assembled in face to face contact; molding a plurality of core sections having flat faces provided with means extending inwardly therefrom for receiving the enlarged portions of connecting members; assembling said sections with the flat faces thereof in contact and the respective receiving means of said sections in registration; and uniting said vsections by casting inV said alined receiving means connecting members having oppositely extending enlarged portions.

6. In a process of making corescomposed of a plurality of sections adapted to be assembled in face to face contact, forming a. plurality' of sections, 'each having a plurality of tapered openings extending therethrough, vby molding each section in a core box member interiorly shaped to correspond with the section to be formed, and provided with upwardly tapering pins projecting from the bottom thereof; baking said sections; assembling the sections with corresponding openings thereof in alinement and the smaller ends of said openings communicating; filling said alin'ed openings with molten metal; and permitting said metal to solidify, thereby forming integral connecting members having oppositely extending enlarged ends anchored in the respective sections and drawing the same together.

'7. The hereinafter described process of making sectional cores for castings which includes the following steps: providing a pair of baked core-sections adapted to be placed in face to face contact, said sections, on their meeting faces, having registering recesses, each undercut with respect to the meeting faces of its respective section; filling said recesses with metal in a molten condition when the recesses are registered; then allowing the metal to cool and contract.

8. In the process of making cores, providing a plurality of core sections; forming inwardly extending recesses in one face of.

each of said sectionsyassembling the core sections with said faces in Contact nnd'the respective recesses of said core sections in alinement; pouring molten metal in said alined recesses; and permitting said metal to solidify, thereby `forming integral connecting members and drawing said core sections tightly together.V

9. In nprocess, the following steps: :torming n plurality of core sections.; each having n plurality of recesses therein, said recesses being arranged to register with their open ends communicating when said section-s are assembled; baking said core sections; assembling saidvsections with corresponding recesses thereof in registration; joining the core sections by casting .metal in said zilined recesses; preparing a. mold for forming n castn ing and inserting the sectional core in said kmold; pouring molten metal into themold;

removing the casting from the mold; and recovering` the metal forming the joining members by breaking up the core and removing the same from the casting. n

In witness that claim the foregoing I have hereunto subscribed my name this 16th day of December 1922.

CHARLES if. mwron'r.V

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