IMPROVEMENTS IN MACHINES FOR MAKING MOLDS FOR CASTINGS
Year: 1885

page_text: I, MATTHEW ROBERT MOORE, of Indianapolis, in the County of Marion, and
State of Indiana, one of the United States of America, Engineer, do hereby declare
the nature of this invention for "IMPROVEMENTS IN MACHINES FOR MAKING
MOLDS FOR CASTINGS," and in what manner the same is to be performed, to be
particularly described and ascertained in and by the following statement:
Machines have been recently introduced, and are much approved, which serve to
rapidly compress the properly mixed and dampened earth, technically denominated
sand, in the rigid frames, technically denominated flasks, employed in molding iron
and other metals. Such a machine, employing fluid as a means of transmission of
the pressure, is set forth in a Patent of the United States, dated July 22nd, 1884,
N° 302,349, reissued February 24th, 1885, N° 10,562, and British Letters Patent,
dated July 22d 1884, N° 10,436. I have devised an important improvement
applicable to nearly all machines of this class.
In compressing the sand upon a pattern of greatly varying thickness, my
previously described machine, by means of yielding pressure, was capable of
depressing the upper surface of the sand more at one point than at another, and
by that means was able to approximate to an even compression of the sand over
the entire pattern. My present invention goes farther.
I provide for applying a greater pressure on those parts of the mold where
the pattern is lowest, and where consequently the sand to be compressed is
deepest.
Another feature of my present invention, which is in some respects of still more
importance, is the provision for conveniently compressing the sand in two flasks,-
to wit: both the cope and the drag,--at the same time. I make the machine
duplex, having a quantity of sand in a drag, and in a part which I will call a
sand-box, below the pattern, and compressing it against the pattern from below by
forcing such sand upward while another quantity of sand in another flask, the
cope, and an attached sand-box or top piece above the pattern is compressed by
pressure from above, forcing such sand downward.
I will designate as air-bags the several diaphragms and spaces for fluids to act
on them, although other fluids than air may be used if preferred. I can use any
n

page_text: fluid or semi-fluid, or thin plastic material.
Preferably the strong pressure
induced on the upper face of the mass of sand is, in a machine constructed
according to my present invention, balanced by an equal pressure exerted by the
diaphragms which are forced upward from below, with the proper variations of
pressure on the different parts both below and above.
I provide means for automatically regulating the variable pressure on the
several different parts of the mold, both on the under side and on the upper side.
I regulate the pressure in each air-bag independently of the others. I thus give
any required amount of excess of pressure on one part over that on another part of
the flask.
I employ a device which I term a pattern-box, so connected as to be readily
swung into and out of position for work, capable by a single movement of moving
the parts of the pattern downward and upward into the flasks, and drawing them
by a reverse movement after the pressure has been applied and the sand compacted
by the other means.
For castings which do not require the pattern-box, I can use a match-plate. The
machine is capable of being adjusted to a considerable range of heights of the
flasks and of the pattern-boxes, or match-plates.
It will now be understood that both on the under side and upper side, instead of
employing one single diaphragm extending over the whole face of the sand,
I divide the area into any required number of separate sections. I will describe
them as four. Each is a separate and distinct diaphragm or air-bag.
Each is con-
nected with a common passage through a regulating device which may be adjusted
to shut off the further reception of air when different degrees of pressure are
attained in the respective air-bags. Thus, one may receive the air until the
pressure is twenty pounds per square inch, and then the supply will be shut off
while another receives the air until the pressure is fifty pounds per square inch.
I esteem it preferable, though not absolutely essential, to some degree of success,
that as before intimated the aggregate pressure on the under face, pressing up from
below against the mass of sand in the lower flask shall be just equal to the
aggregate pressure on the diaphragms which act on the sand in the flask on the
upper side of the pattern, with a slight excess of pressure on the lower side to com-
pensate for the weight of the material. The adjustment of the pressure in this
manner is to relieve the match-plate or other central portions of the apparatus
from strain. I can operate successfully with considerable differences in the aggregate
pressures.
It is not essential to success that the inequalities in the pressures on the different
sections shall be exactly equal. Some forms of patterns may require a maximum
pressure on the under side opposite a less pressure on the upper side. The
pressures can be so adjusted when required.
The accompanying drawings form a part of this specification, and represent what
I consider the best means of carrying out the invention.
Fig. 1 is a side elevation, and
Fig. 2 is a section on the line y, y, in Fig. 1. These views show the novel parts
with so much of the ordinary parts as is necessary to show their relations thereto.
Fig. 3 is a vertical section of the central removable portion, which I will call the
pattern-box, on a larger scale. It is a section corresponding to Fig. 2.
Fig. 4 is a vertical section on the same scale as Fig. 3, and corresponding thereto.
It is in a plane at right angles to that in Fig. 3.
Fig. 5 is a perspective view of the upper platen and sand-box in a raised
position.
Figs. 6 and 7 show a portion of the mechanism when the machine is adjusted to
use a match plate. Fig. 6 is an elevation, and Fig. 7 is a vertical section on the
line x, x, in Fig. 6.
Similar letters of reference indicate corresponding parts in all the figures where
they occur.

page_text: E is a part of the stationary frame-work. J are screw-posts, stiffly supported
on the frame-work E, and adjustable up and down to accommodate flasks of different
heights. K is the hinge-bolt on which the upper platen and sand-box turn.
The main part of the top of the frame E I will term a table. In its middle
is a hole of the shape and dimensions of the inside of the flask to be used.
Surrounding the hole is a flange or coaming E¹, which projects downward, and
forms a lower sand-box of sufficient depth to contain the surplus sand which is to
be forced into the drag of the flask in the process of molding.
Below the framing E is attached what I term the lower platen G* lying face
upwards, and carrying on its upper side diaphragmns or air-bags, with provisions
for inflating them upwards, which may be similar to the corresponding parts on
the under face of the upper platen G. The latter is provided with a counter-
weight g, and with hooks F, which are adjustable with nuts F1, F²;
N✶ is a flexible hose of stout vulcanized India-rubber, or other suitable material,
bringing air under pressure from a capacious chamber (not shown), which receives
the fluid constantly or at intervals from a pump or other supplying means, not
represented.
The provisions for compressing the sand in the several parts of each flask, giving
a greater pressure on one part than on another, are the same on the lower platen
as on the upper, but in reversed positions. I will describe that on the upper
platen.
On the under face of the platen G are four distinct and independent diaphragms,
marked respectively G1, G2, G3, G4. Each is capable of being expanded downward
by the pressure of the air or other fluid received from a common source through a
corresponding number of pipes N¹, N³, N³, N. These pipes, shown clearly in Figs. 1
and 2, are provided each with an independent pressure-regulator, marked respectively
01, 02, 03, 0%, which is adjusted to regulate the air or other fluid flowing through
so as to give any required pressure less than that received through the common
flexible hose N* and induction pipe N, which latter connects through a stop-cock M
with the reservoir.
The regulating devices may be of the construction set forth in the Patent of the
United States to Nelson Curtis, dated August 23rd, 1881, No 246,088. Each is
capable of adjustment by means of its screw, marked respectively P1, P2, P³, or P4.
Setting the screw P¹ in the device 0¹ further inward will adjust that regulating
device to a higher pressure, and will admit the air to the corresponding diaphragm G₁,
until a corresponding higher pressure is attained, and the surface of the sand under
it is correspondingly more depressed, and the sand more compacted. Adjusting the
screw P¹ outward will have the opposite effect; the air or other fluid will be shut
off sooner, the surface of the sand will be less depressed under the corresponding
diaphragm, and the sand there will be less compacted.
It is important that the several diaphragms shall be depressed to the required
varying extents without allowing the excess of pressure which obtains on one to
act laterally to a sufficient extent to encroach upon the other spaces. I attain this
by a peculiar construction of the parts over or behind each diaphragm. Each air-
bag is constructed in two or more horizontal layers, separated by flexible and
nearly or quite inextensible horizontal webs. I have shown but one such web D¹
in each air-bag, but the number may be increased, if preferred. Figure 2 shows
this construction clearly. The horizontal webs D¹ may be strong fabrics of hemp,
linen or cotton, saturated with India rubber, and vulcanized. They are capable of
enduring a tensile strain in all directions, due to the pressure of the air or other
fluid against the sides or bounding walls of the air-bags. The webs are perforated
so that the air can flow with sufficient freedom up and down, and exert its full
pressure on the diaphragm which forms its working face.
The lower platen G* is equipped in a precisely similar manner with the sectional
diaphragms or air-bags, and the air is admitted to the several sections through
similarly adjusted pressure-regulators. The air is admitted to and shut off from

page_text: loth the upper and lower series of air-bags by a single valve M, equipped with
convenient connections to the lever M³, as shown, for operating it from the front
side of the machine at will.
The valve M is a two-way valve. Turning it in one position allows the air to
be admitted from the hose Ñ* through the several regulating devices O, P, and to
act on the several diaphragms connected with each platen.
The lower platen G* is hinged to the framing E at K*, the back side (the right
hand side in Fig. 1,) while at the front it is supported by the yoke I, which is
attached to the framing by trunnions I. The trunnions are longer than their
bearings, leaving a space between the bearing and the body of the yoke. By
swinging the yoke forward, the front edge of the platen G* is released so that it
may be dropped for convenience of cleaning or adjustment when required, which
need not be except at long intervals.
When the mold is to be pressed, the hooks F are extended through slots in the
table, and grasp the trunnions 11 of the yoke I between their bearings and the
body of the yoke. Thus the strain of pressing is taken off the frame, and confined
to the platens and their attachments which are made strong enough to with-
stand it.
On the right hand back screw, J, adjustably supported by a nut J¹, is a ring or
loose collar L¹ by which the pattern-box L is sustained. This allows the pattern-
box to be placed in position for use in the flask, or to be swung out of the way,
and holds them always within convenient reach of the workman operating the
machine.
The pattern-box has the same horizontal dimensions as the flask with which it is
to be used, and such depth as may be required by the class of work to be done.
At the bottom edges of the pattern-box are lugs 7, perforated to fit the steady-
pins a*, of the drag, and at the top are corresponding steady-pins to fit the lugs
of the cope.
a
The pattern-box is open both at top and bottom, except for certain stripping
plates, which I sometimes term silhouette plates and movable pattern plates, both
to be described further on. The pattern-box contains a horizontal septum or
partition L, through its middle, dividing it into two equal parts. In the plane
of this partition lies a shaft 12, having two sets of arms or tumblers . These
tumblers work through holes provided for that purpose in the septum L³. The
ends of the shaft project through the sides of the pattern-box, and are squared to
receive a handle or wrench whereby the shaft may be partially turned.
The patterns are divided along the line where the parting of the mold will come,
and the parts R and S are fastened upon two pattern-plates R and S', which are
of such size as to move easily up and down within the pattern-box. In the edges
of each pattern-plate, opposite the ends of the tumbler-shaft, are recesses containing
wrist-pins 7, 8, whereby the pattern plates are connected to the proper tumblers 1³
by means of the links 1, 81. When in the position shown in full lines (Figs. 2, 3,
and 4), the tumblers 1, being prolonged and cam-shaped at their ends, apply cam-
wise against the pattern plates, and form distance-pieces between the two pattern
plates, holding them firmly apart in opposition to the pressure against the patterns
in pressing the mold. Two stripping plates L³, LA, form the top and bottom of the
pattern-box to which they are fastened, and through them the parts of the pattern
R, S, project. Each stripping plate is a plane plate with an aperture or apertures
matching closely to the shape of the pattern or patterns to be moved smoothly and
strongly through it.
When the shaft is turned a quarter revolution, the tumblers ³, links r¹, 81, and
pattern plates R¹, S¹, are drawn inward, and assume the relation shown by dotted
lines in Fig. 4, thus withdrawing the patterns from the sand both above and
below.
Parts Lo, Lo, of the stripping plate which lie within the pattern, and are cut off
by the pattern, or which for any reason require to be supported when the pattern

page_text: is withdrawn, are held up by "stools" or stems 1, connecting them with the
septum L², through holes in the pattern-plates. The arms or web of the gear-
wheels shown as a pattern, and also the cylindrical masses of compacted green sand
corresponding to cores which form the bore of the hub, are supported by stools 15.
It will be readily seen how the patterns are projected and withdrawn by partially
turning the shaft 12.
Instead of making the stripping plates,-silhouette plates, always plane, they
can be variously curved or dished, taking care that they properly match together.
Parts of the pattern may in molding many forms be mounted on the stripping
plates, as in the example shown. The stripping plates thus to a limited extent
serve as match plates, while other parts of the pattern are carried on the pattern-
plates.
The mode of operating the machine is as follows:
The lower platen G* being in the position shown, and the upper one G, with
sand-box attached, thrown up to a vertical position, and the pattern-box swung
aside, the flask, serving as the drag, is placed on the table squarely over the lower
sand-box, and it and the lower sand-box formed by the lip El are filled with
screened molding sand let down from a hopper not shown, suspended over the
machine, or supplied in any other convenient way. The pattern-box L is then
swung around into the position for use, and engaged with the steady-pins of the
flask. Then the flask A for the cope is placed upon it, the upper sand-box H
unlatched and brought down upon it. Next the flask and upper sand-box are
evenly filled with screened sand from the same source as before, or from any other
source. The platen G is then brought down upon the flask, and the hooks F are
engaged firmly with the trunnions 11. Then after giving a quarter revolution to
the shaft to depress the lower pattern S through its silhouette plate L* to the
proper extent towards or into the sand of the lower part or drag A*, and to raise
the upper pattern R to the proper extent through its silhouette plate into the sand
of the upper part or cope A, a touch on the lever M¹ throws on the air-pressure,
and instantly rams both parts of the mold, the air-bags G¹, G³, expanding upward
from the lower platen G*, and compressing the sand in the drag A* at the same
time as the air-bags, similarly lettered G¹, G³, expand downward from the upper
platen G, and compress the sand in the cope A.
After the sand in a flask has been thus compressed, which may be effected in
a few seconds, the valve M is turned into the position to release the pressure,
allowing the air to escape from all the air-bags. The hooks F are then detached,
and the upper platen G is lifted by turning on the axis K. The patterns are now
withdrawn, as before described, by turning the shaft 12 a quarter revolution in the
proper direction. A piece of fine steel wire, having convenient handles attached, is
then drawn between the upper sand-box H, and the upper surface of the cope A,
the sand-box H is lifted, and its contents removed. Now the cope is lifted off.
Next the pattern-box is lifted, or other means are employed to clear the pins, and
the pattern-box is swung around out of the way. If there are parts of the mold
carried on the lower silhouette plate, the pattern-box must of course be lifted
carefully until such parts are drawn out of the sand.
The wire is next drawn between the lower sand-box E¹ and the drag A*, thus
cutting off evenly the sand not pressed into the mold from below, and the drag is
removed. After providing proper passages,-gate and sprue,-for the ingress of
the melted metal, if such have not been already provided, the cope and drag are
properly placed together on the casting floor.
If there are cores to be set, they may be introduced in the usual manner.
If snap-flasks are used, they are opened, leaving the mold, and brought back to
the machine. Three or more snap-flasks will be required to keep one machine
running. A mold can usually be made while one is being carried away.
When the castings to be produced are of such shape as to render practicable the
use of a match plate, the arrangement shown in Figs. 6 and 7 is used, the example
being the pattern for four bends of pipe.

page_text: Before putting another drag on the machine, the compacted sand left in the lower
sand-box is broken up with the hands, or otherwise reduced to the required plastic
condition, and the operation described is repeated as often as desired.
Each air-bag is held in place by means of a clamping plate D³, and two bolts D³
(see Fig. 2).
This arrangement renders the removal and repairing or renewing of the air-bags
very easy.
The pressure is shown by the gage W, and limited by the safety-valve V.
Pattern plates and stripping plates,-silhouette plates, for many different
patterns may be fitted to and used with the same pattern-box L.
Modifications may be made in the forms and proportions within wide limits.
The number of separate air-bags or diaphragms G¹, G³, may be increased
indefinitely.
Parts of the invention may be used without the whole. I can dispense with the
horizontal partitions or webs D¹, allowing the lateral expansion of the air-bags
when subjected to the greatest pressure of air to be restrained by other means, or
allowing them to serve without any other restraint than such as the ordinary form
of rectangular or even spheroidal air-bags would impose.
I can in some cases use with advantage two or more tumbler-shafts 1, with
corresponding connections to the pattern-plates. When more than one tumbler-
shaft is used, they should be geared together so as to be operated by one hand.
Having now particularly described and ascertained the nature of my said
invention, and in what manner the same is to be performed, I declare that what
I claim is
1. The combination with a platen of two or more flexible diaphragms containing
a fluid, adapted to expand and yield independently, and to serve with a flask and
pattern, as herein specified.
2. In a machine for making molds for castings, the combination with a platen of
two or more flexible diaphragms adapted to yield independently, connections for
leading a fluid to each, and means, as the reducers O, for independently adjusting
the pressure in each, all substantially as herein specified.
3. The construction of the series of air-bags G1, G2, each with means, as the
open-work webs D³, for restraining the lateral expansion so as to allow the several
bags to lie adjacent and cover the whole surface of the platen, and be filled with
fluid at different pressures, without crowding each other, all substantially as herein
specified.
4. In a machine for making molds for castings, one or more flexible pressers G¹, G²,
with provisions for subjecting the same to a fluid pressure arranged to press the
sand in one direction, in combination with suitable means for pressing the sand in
the opposite direction, and with provisions for introducing flasks and patterns in
the space between, as herein specified.
5. In a machine for making molds for castings, one or more flexible pressers G¹G²,
carried on the balanced movable platen G, with means for applying fluid pressure
to act in one direction, in combination with one or more flexible pressers G¹ G³,
with means for applying fluid pressure to act in a direction opposite to the first-
named, and with provisions for introducing flasks and patterns in the space
between, as herein specified.
6. In an apparatus for making molds for castings, the silhouette-plate L³, a
pattern-box L, and provisions for moving it, in combination with the stool or
stools 1, arranged to support a portion or portions, as herein specified.
7. In a machine for making molds for castings, the pattern-box described having
the two silhouette-plates L³, L, and two movable patterns or sets of patterns R, S,
in combination with each other, and with connections as r³, 81, and operating
means, as 12, for forcing them outward and withdrawing them, as herein specified.
8. In an apparatus for making molds for castings, the pattern-box L, silhouette-
plate L³, and pattern R, in combination with links, and with the shaft 1³, having

page_text: projections 13, arranged to serve both as cams to support the pattern, and as levers
to operate the links, all substantially as herein specified.
9. In an apparatus for making molds for castings, a pattern-box L, turning on a
center J, supported on the framing, in combination with the two flasks A, A*, and
with one or more diaphragms or air-bags, arranged to be distended from below,
and with one or more diaphragms or air-bags carried on a platen G turning on a
hinge K, arranged to be distended from above, and with suitable connections for
supplying air or other fluid under pressure to both series of diaphragms, all
combined and arranged for joint operation, substantially as herein specified.
Dated this 6th day of October 1885.