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Патент USA US2127204

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Aug. 16, 1938.
5 Sheets-Sheet 1
Filed May 20, 1955
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DONALD J (594466221.
Patented Aug. 16, 1938
2,127,204 ‘
Donald J. Campbell, Spring Lake Township, Ot
tawa County, Mich., assignor to Campbell,
Wyant & Cannon Foundry Company, Muske
gon, Mich., a corporation of Michigan
Application May 20, 1935, Serial N0. 22,286
5 Claims. (Cl. 22—96)
This invention relates to metal founding, and the inner side and at spaced‘apart points ad
is more particularly concerned with a method of jacent the sides, pins 3 extend the full height of
producing molds for the casting of metal articles the ?ask, being provided with shoulders or collars
and which may be used for a great variety of 4 thereon between their ends which bear upon
articles, but which is particularly useful in con
integral shoulders 5 cast with and extending in- 5
nection with the casting of crank shafts for in
wardly from the sides of the ?ask.
ternal combustion engines. Other elongated ar
A pattern plate 6 is designed to be located at
ticles, such as cam shafts for internal combustion the lower side of the ?ask. The plate is reinforced
engines, or other elongated shafts of irregular and supported by ribs 1 at its lower side, termi
shape may be readily produced by use of the nating at their lower ends in horizontal ?anges 8 10
method for producing the molds therefor which forming supporting pads which in practice rest
I have devised, and which may be fully understood upon the platen of a molding machine. At the
from the following description, taken in connec
upper side of the pattern plate 6 the patterns 9,
tion with the accompanying drawings, in which, in this case two identical patterns, are located
Fig. 1 is a plan view of a ?ask with the pattern and permanently secured.
plate and a reinforcing mold grid or arbor assem
A reinforcing arbor for the mold is adapted to
bled ready for the reception of the molding sand. be located within the ?ask. It is in the form
Fig. 2 is a transverse vertical section through substantially of a rectangular open grid having
the ?ask, the pattern plate and arbor, and with parallel sides and intermediate parallel bars II],
20 the bottom plate applied and detachably con
with parallel ends and cross bars H (see Fig. 8) .20
nected thereto, as is done after the ?ask has been thus forming an open grid which may be inserted
?lled with sand.
downwardly into the ?ask as shown in Fig. 2.
Fig. 3 is a similar section of the bottom plate.
The undersides of the intermediate portions of
Figs. 4 and 5 are like sections of the reinforcing
25 ?ask arbor and of the ?ask, respectively.
Fig. 6 is a similar section of the pattern plate
shown located within and surrounded by the sub
platen of a molding machine.
Fig. 7 is a side elevation of the reinforcing arbor.
Fig. 8 is a plan View thereof.
Fig. 9 is a plan of a mold section after. the
same has been produced.
Fig. 10 is an elevation of a crank shaft, two
of which are produced in the mold shown.
Fig. 11 is a horizontal section through a com
plete mold for a crank shaft, the same consisting
of two mold sections placed together and secured
in ?xed relation to each other.
Fig. 12 is an elevation of the complete mold
40 shown in Fig. 11 associated with which at the
upper end thereof, and being shown in section, are
the gate member and pouring basin which are
superimposed above the upper end of the com
pleted mold.
Fig. 13 is a plan view of the pouring basin.
Fig. 14 is a central section therethrough, and
Fig. 15 is an underplan view of the gate mem
Like reference characters refer to like parts in
50 the different ?gures of the drawings.
As illustrated in the drawings, the ?ask I has
the grid bars l0 and H may be cut away as at
l2 so as to afford proper space for the reception 25
of the pattern. Pins l3 extend downwardly from
the grid at its corners also midway between its
sides and lugs l4, cast integral with the outer
sides H) of the grid, extend outwardly and are
divided so as to permit the passage of the pins 3, 30
the lugs resting upon the collars 4. The arbor
at its corners and ends has outwardly extending
wings I5 as shown to afford further reinforce
ment to the mold which is made within the ?ask,
the grid being located in the ?ask and retained 35
in the mold after the ?ask is removed.
A bottom or strike plate I6 is likewise used, it
being of a size to cover the upper end of the ?ask
(Fig. 1) and having reinforced and strengthening
ribs ll cast integral therewith, and also having 40
outwardly projecting clamp lugs I8 at its side
edges to cooperate with similar lugs I 8 on the
?ask over which a detachable clamp l9 may be
placed to secure the plate and ?ask together.
The bottom plate has many openings or perfora- 45
tions therethrough as shown.
In making a mold section the pattern plate is
placed on the platen of a molding machine with
substantially parallel sides and parallel ends,
being slightly tapered outwardly from its bottom
the supporting pads or feet 8 resting thereon,
and with the plate surrounding by the sub- 50
platen of the molding machine, upon which sub
platen the ?ask is placed. The sub-platen of the
machine is shown in Figs. 2 and 6 and indicated
to its top as shown. At the upper side are shoul
55 ders or ?anges with wear resisting strips 2. At
chine. After the ?ask has been located in place 55
at Go. It is a permanent part of a molding ma
on the sub-platen and with the pattern plate
located within the sub~platen and resting upon
the platen of the molding machine, the open grid
passed therethrough. These bolts are provided
or arbor is put within the ?ask as shown in Fig. 2.
The flask is ?lled with sand, which covers the
ers 21 or thin metal plates or bands are located.
patterns 9 and completely surrounds all parts of
the reinforcing grid or arbor. The molding sand
is rammed or jolted to the desired density and
any that projects above the plane of the upper
edges of the ?ask is struck off, whereupon the
bottom plate It is placed on the ?ask over the
mold and clamped to the ?ask.
There are two ways in which the mold may be
removed from the ?ask.
One is to remove the
whole assembly, consisting of the bottom plate,
with heads 26 at one end between which and
the adjacent outer side of a mold section wash
The threaded ends of the bolts receive thumb
nuts 28 between the inner sides of which and the
adjacent outer side of the mold sections 29, simi
lar washers, plates or bands 2'! are placed. The
bolts pass through the spaces made in the lugs
[4 as shown in Fig. 2.
When the two baked sand mold sections have
been thus secured together they are placed in
a vertical position on a suitable supporting base
as shown in Fig. 12. Over the upper end of the
complete mold a gate member 29, of baked core 15
sand, is placed. The gate member has an open
the machine, turn the same over so that the ing 30 therethrough and on the underside there
bottom plate serves as a support and then draw of from said opening are gates 3! which branch
and curve away from each other and are con
the patterns from the mold, after which, by un
clamping the clamps at I9, the ?ask may be nected by cross gates 32 with openings‘33 made
withdrawn from the mold leaving the same with vertically through the gate member, one of which
comes directly above each upper feeder cavity
the reinforcing arbor therein and resting on the
2lb at the upper end of each of the crank shaft
bottom plate. Another and a preferred method
mold cavities.
is to draw the patterns downwardly by lower
Over the gate section 29 a pouring basin 34, 25
25 ing the platen of the molding machine after‘ also made of core sand, baked in the usual man
which the ?ask, the mold therein and the bot
ner, is located. The'pouring basin has a well
tom plate are turned over, the clamps l9 re
moved, and the ?ask drawn upwardly away from 35 into which the metal is poured and from which
it ?ows into a shallower portion 36 and over a
the mold.
skim gate 31 which is disposed'directly above the 30
?ask pattern, plate and reinforcing arbor, from
The mold is made of core sand with a suitable
binder therein. After the pattern and ?ask have
been removed therefrom it is baked in a bak
ing oven thus providing a mold which, in char
acteristics, is similar to baked sand cores which
35 are used in molding.
In the'manufacture of shafts, such as crank or
cam shafts, a part of the mold cavities are made
in one mold section such as section 20 (Fig. 9)
and another part of the mold cavities in a simi
lar mold section. The mold cavities 2i are pro
vided by the parts of the pattern on the pattern
plate 6 when joined together with the two baked
sand mold sections located side by side, as in
Fig. 11 provide a complete mold cavity for the
45 shaft. In practice, in order to obviate the effects
of shrinkage, as draws and pits which would oc
cur from shrinking particularly in elongated arti
cles, there may be provided parts 9a and 91) on
the pattern to make feeder cavities in the mold,
50 the ?rst being shown in Fig. 1 to feed addi
tional metal to heavy parts of a crank shaft where
shrinking is liable to occur, and the latter at
one end of mold to supply additional molten
metal to feed into the upper end of the molten
55 iron which is poured into the mold when the
two mold sections are placed together and lo
cated vertically, as the same are located for
pouring. The mold cavities 2| and the feeder
cavities Zia and H2) (Fig. 9) are connected to
gether so as to completely ?ll with molten iron
upon pouring.
The section 20 of the mold made (Fig. 9) when
the same has had the ?ask withdrawn there
from, has openings 22 transversely therethrough
65 made by the pins 3, collars 4 thereon and the
shoulders 5. It is also contemplated that there
shall be recesses and projections on the pattern
plate ‘so that the mold sections 20 made there
are provided with corresponding projections 24
70 and recesses 23, such that when the two mold
sections are placed together the projections 23
on the face of one mold section enter the re
cesses 24 on the other, thereby properly locating
the two mold sections. This will also properly
75 locate the openings 22 so that bolts- 25 may be
opening 39 in the gate member, whereby the
molten metal, after passing through the skim
gate, follows the gates 3| to the openings 32
and thence into the mold cavities. There is also
formed in the-pouring basin, directly above each 35
of~the openings 33, a vertical opening 38, the
upper end of which is closed by a baked core sand
plug 39.
When the molten metal is poured into the well
35 and passes therefrom through the gates to 40
the mold cavities, the air which is displaced by
the metal rises into the spaces 38 and slowly
passes through the bodies of the mold sections
and of the pouring basin, thereby controlling the
rate at which the molten iron may pass through 45
the skim gate 31, to the mold cavities. Without
the plugs 39 this rate of ?lling the mold cavities
would be too fast, but the air trapped in the
enclosed spaces 38 and passing therefrom with
relative slowness through the body of the pour
ing basin operates as a check and furnishes
a proper control to the rate of ?ow of the mol
ten metal into the mold cavities. It is, of course,
to be understood that the molds, like all other
molds, are suitably vented so that air and gases
can escape therefrom but not at the rate which
they would escape if the upper ends of the open
ings at 38 were open.
The crank shaft 4|] (Fig. 10) produced will
have thereon parts, indicated in dotted lines at
49a and 40b, which are cut away to provide the
finished casting. These parts, which are cut
away, will furnish, when in a molten state, addi
tional molten metal to the shaft to compensate 65
for shrinkage and to eliminate draws and pits.
Any draws, pitting or other imperfections will be
in the parts 40a and 40b which are cut away.
As the molten metal reaches the bottoms of the
mold cavities ?rst, and as the cavities are ?lled,
this metal at the lower end will begin to solidify
?rst and will have its shrinkage taken care of by
the molten metal above the solidi?ed portions
until the upper end of the mold cavities are
reached, whereupon the upper ends of the shaft 75.
portions will be fed from molten metal contained
within the cavities 9b.
With this method of producing molds the use
of a large number of ?asks is not required, as one
?ask is all that is required in making a large
number of molds; and duplication of ?asks and
patterns will be merely for multiplying produc
tion. In fact the only elements which must be
duplicated in large numbers are the reinforcing
10 open grills of arbors shown in Figs. 7 and 8. The
mold sections will be of a relatively hard consis
tency so that the passage of the molten metal
in the mold cavities will not act to break loose
parts of the mold. The reinforcing arbor in each
15 mold section helps to hold the sand against blow
outs from pressure which might otherwise occur.
In practical use of this method of producing
molds exceptionally satisfactory and consistent
results have been obtained. Large and economi
cal production is attained, and the shafts or other
articles cast are of a homogeneous character free
from weaknesses due to pitting, shrinking, blow
outs and the like.
The invention is de?ned in the appended
claims, and is to be limited in no respect other
than is required by the terms of said claims.
I claim:
1. In the art of molding, a ?ask open at its
upper and lower sides provided with inwardly
extending shoulder portions at its lower part and
at opposed sides thereof, pins mounted in said
shoulder portions and extending upwardly above
the same to substantially the plane of the upper
edge of the ?ask, and an open grille-like arbor
having sides and ends and cross members, said
arbor at opposite sides having outwardly project
ing lugs divided between their sides for the pas
sage of the pins therethrough, said arbor being
located in the ?ask with the lugs engaged with
said pins.
2. In the art of molding, a pattern plate with
a pattern at the upper side thereof adapted to
rest upon the platen of a molding machine with
said pattern plate located within the sub-platen
of a molding machine and with its upper sides in
substantially the same plane as the upper side of
the sub-platen, a ?ask open at its upper and lower
sides resting on said sub-platen, said ?ask at the
inner sides thereof being provided with vertically
extending pins, and an open grille-like arbor 10
carried and guided by and extending between the
pins and having its upper edges below the upper
edges of the ?ask, whereby sand may be placed
in the ?ask to ?ll the same and cover the pattern
and ?ll the open spaces in and cover said arbor, 15
as speci?ed.
3. In the art of molding, the combination of
an open grid-like arbor having sides and ends and
cross members, said sides having lugs extending
outwardly, integrally formed pins extending from 20
the corners of the arbor and reinforcing means
extending alongside of each of the corners to
reinforce the same.
4. A grid-like arbor as set forth in claim 3
in which additional pins are provided on oppo~ 25
site sides thereof between the corners and also
additional reinforcing members are provided
alongside of said pins.
5. In the art of molding, a ?ask open at its
upper and lower sides provided with inwardly 30
extending shoulder portions at its lower part and
at both ends thereof, a reinforcing arbor, pins
mounted on said shoulder portions and extending
upwardly, above the same, said arbor at oppo
site sides having outwardly projecting lugs cut 35
away to provide for the passage of the said pins
therethrough, said arbor being located in the
?ask with the lugs engaged with said pins.
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