IMPROVEMENTS IN MOULD- ING OR SHAPING METALS AND OTHER MATERIALS.
Year: 1856

page_text: LETTERS PATENT to John Downie, of Glasgow, in the County of Lanark,
North Britain, Engineer, for the Invention of "IMPROVEMENTS IN MOULD-
ING OR SHAPING METALS AND OTHER MATERIALS.
Sealed the 5th August 1856, and dated the 7th March 1856.
PROVISIONAL SPECIFICATION left by the said John Downie at the Office
of the Commissioners of Patents, with his Petition, on the 7th March
1856.
I, JOHN DOWNIE, of Glasgow, in the County of Lanark, North Britain,
Engineer, do hereby declare the nature of the said Invention for "IMPROVE
MENTS IN MOULDING OR SHAPING METALS AND OTHER MATERIALS," to be as follows,
that is to say-
This Invention relates to a system or mode of moulding metals or other
materials, wherein the pattern has motion given to it during moulding, so as
to effect the finishing of the moulded surface by mechanical means, leaving
nothing to be done by hand on the withdrawal of the pattern, from the
mould.
This system is applicable in moulding a wide range of articles, but in
making such articles as cast-iron socket pipes, rain water conducting pipes,
camp ovens and covers, three-legged pots, kettles, coolers, sugar pans, boilers,

page_text: shot and shell, cannons, mortars, and articles generally of cylindrical or spherical
contour, the following routine of operations is adhered to:-The pattern for
producing the external surface of the mould (the internal parts being made
separately in core boxes or otherwise in the customary manner) is mounted hori-
zontally on a bearing apparatus, fitted with a mechanical contrivance, arranged
to elevate the pattern and pass it between two opposite edge surfaces contrived
exactly to embrace the pattern longitudinally along its diametrical line. These
edges may be described as being formed by a slot or hole in a horizontal plate
of iron or other material, the upper side of which is made true by turning,
planing, or other mechanical means, so as to present a perfect surface for the
parting" of the mould. The pattern is fitted with an eccentric piece or other
apparatus, by which it rests upon corresponding surface bearings in the framing
beneath the patteriis.
"
or
In proceeding to mould according to this system, the "flask" or sand box
for one half of the mould is placed upon the ramming plate, and the pattern is
turned round, so that the action of the eccentric portion thereof on the bear-
ings may gradually elevate it to its diametrical line. A central portion of the
eccentric is made concentric with the axis of the pattern, so that when it
reaches this part it causes to elevate it, and by causing the pattern partially
to rotate on the concentric portion the surface of the mould is "sleeked "
made smooth, and the further turning of the pattern then lowers it, leaving
the half mould in its finished condition. The "parting" of this half mould
(the flat longitudinal edges of the half mould), or the actual junction portions,
when the two halves are put together for casting, are formed true. by the
unaided effect of the true surface plate on, which the flask has been rammed
up, so that no cleaning up or hand work of any kind is required after the half
mould leaves the machine. Various plans are employed for raising the pattern
and causing it to rotate. In cases where the form of the patterú prevents
rotation, rectilinear or other motion may be adopted for obtaining the same
finishing result. The sand or other moulding material is or may be primarily
prepared with ingredients of such a nature as will render the ordinary coating
of charcoal blackening" unnecessary; or where such coating is required,
the pattern may be withdrawn from the mould for the purpose of allowing the
preparative coating to be applied, when the pattern may be returned' for the
finishing of the moulding action. The pattern may either be vertical, horizontal,
or otherwise, according to form or circumstances.
The Invention relates also to the arrangement and manufacture of moulding
flasks in such manner as to form exact counterparts of each other. In carrying
this out in practice, the bearing or contact surfaces of the flasks are cast on

page_text: chill plates, turned in the lathe, planed or otherwise, reduced to an accurately
regular surface. In flasks for "pot" and other moulding, this Invention
dispenses with the necessity of using "cheeks" for protecting the partings in
the mould. The principle is applicable to the moulding of various materials,
such as terra cotta, encaustic tiles, stucco, and other decorations for buildings,
statuary and ornamental fire clay work, drainage or sewer tubes in .clay or
other materials, and, in short, to all classes of moulding or shaping metals or
other materials where moulds are employed.
SPECIFICATION in pursuance of the conditions of the Letters Patent, filed by
the said John Downie in the Great Seal Patent Office on the 6th.
September 1856.
TO ALL TO WHOM THESE PRESENTS SHALL COME, I, JOHN
DOWNIE, of Glasgow, in the County of Lanark, North Britain, Engineer, send
greeting.
WHEREAS Her most Excellent Majesty Queen Victoria, by Her Letters
Patent, bearing date the Seventh day of March, in the year of our Lord One
thousand eight hundred and fifty-six, in the nineteenth year of Her reign,
did, for Ierself, Her heirs and successors, give and grant unto me, the said
John Downic, Her special license that I, the said John Downie, my exe-
cutors, administrators, and assigns, or such others as I, the said John
Downie, my executors, administrators, or assigns, should at any time agree
with, and no others, from time to time and at all times thereafter during
the term therein expressed, should and lawfully might make, use, exercise,
and vend, within the United Kingdom of Great Britain and Ireland, the
Channel Islands, and Isle of Man, an Invention for "IMPROVEMENTS IN
MOULDING OR SHAPING METALS AND OTHER MATERIALS," upon the condition
(amongst others) that I, the said John Downie, by an instrument in writing
under my hand and seal, should particularly describe and ascertain the nature
of the said Invention, and in what manner the same was to be performed,
and cause the same to be filed in the Great Seal Patent Office within six
calendar months next and immediately after the date of the said Letters
Patent.
NOW KNOW YE, that I, the said John Downie, do hereby declare the
nature of my said Invention, and in what manner the same is to be per-
formed, to be particularly described and ascertained in and by the following
statement in writing, reference being had to the accompanying Drawings, and
to the letters and figures marked thereon, that is to say :-

page_text: My said Invention relates to a system or mode of moulding metals or other
materials, wherein the pattern has motion given to it during moulding, so as
to effect the finishing of the moulded surface by mechanical means, leaving
nothing to be done by hand on the withdrawal of the pattern from the moulds.
This system is applicable in moulding a wide range of articles, but in making
such articles as cast-iron socket pipes, rain water conducting pipes, camp ovens
and covers, three-legged pots, kettles, coolers, sugar pans, boilers, shot and
shell, cannons, mortars, and articles generally of cylindrical or spherical con-
tour, the following routine of operations is adhered to:-The pattern for
producing the external surface of the mould (the internal parts being made
separately in core boxes or otherwise in the customary manner) is mounted
horizontally on a bearing apparatus, fitted with a mechanical contrivance,
arranged to elevate the pattern and pass it between two opposite edge surfaces,
contrived exactly to embrace the pattern longitudinally along its diametrical
line. These edges may be described as being formed by a slot or hole in a
horizontal plate of iron or other material, the upper side of which is made true
by turning, planing, or other mechanical means, so as to present a perfect
surface for the "parting" of the mould. The pattern is fitted with an eccen-
tric piece or other apparatus, by which it rests upon corresponding surface
bearings in the framing beneath the patterns.
In proceeding to mould according to this system, the "flask" or sand
box for one half of the mould is placed upon the ramming plate, and
the pattern is turned round, so that the action of the eccentric portion
thereof on the bearings may gradually elevate it to its diametrical line.
A central portion of the eccentric is made concentric with the axis of the
pattern, so that when it reaches this part it ceases to elevate it, and by
causing the pattern partially to rotate on the concentric portion, the surface
of the mould is "sleeked" or made smooth, and the further turning of the
pattern then lowers it, leaving the half mould in its finished condition.
The parting of this half mould (the flat longitudinal edges of the half
mould), or the actual junction portions, when the two halves are put together
for casting, are formed true by the unaided effect of the true surface plate
on which the flask has been rammed up, so that no cleaning up or hand
work of any kind is required after the half mould leaves the machine; various
plans are employed for raising the pattern and causing it to rotate. In cases
where the form of the pattern prevents rotation, rectilinear or other motion
may be adopted for obtaining the same result, that is to say, for sleeking or
finishing the mould and withdrawing the pattern; and in cases where, from the
shape of the pattern, the sleeking or finishing cannot be effected by moving

page_text: the pattern, the rotatory or rectilinear movement may be adopted for merely
withdrawing the pattern from the mould. The sand or other moulding
material is or may be primarily prepared with ingredients of such a nature as
will render the ordinary coating of "charcoal blackening" unnecessary; or
where such coating is required, the pattern may be withdrawn from the
mould for the purpose of allowing the preparative coating to be applied,
when the pattern may be returned for the finishing of the moulding action.
The pattern.may either be vertical, horizontal, or otherwise, according to form
or circumstances.
The Invention relates also to the arrangement and manufacture of moulding
flasks in such a manner as to form exact counterparts of each other. In
carrying this out in practice, the bearing or contact surfaces of the flasks are
cast on chill plates, turned in the lathe, planed or otherwise reduced to an
accurately regular surface. In flasks for "pot" and other moulding, this
Invention dispenses with the necessity of using "checks" for protecting the
partings in the mould. The principle is applicable to the moulding of various
materials, such as terra cotta, encaustic tiles, stucco, and other decorations for
buildings, statuary and ornamental fire clay work, drainage or sewer tubes in
clay or other materials, and, in short, to all classes of moulding or shaping
metals or other materials where moulds are employed.
And in order that my said Invention may be properly understood, I have
hereunto appended and shall now proceed to describe two Sheets of expla-
natory Drawings, shewing the application of my improved system to the
moulding of various articles.
Figure 1, on Sheet 1 of the Drawings, is a longitudinal vertical section of a
machine for moulding three-legged pots. Figure 2 is a transverse vertical
section, and Figure 3 is a horizontal section of the machine. Figure 4 is a
partially sectioned elevation of the core box for forming the core for the pot;
and Figure 5 is a vertical section of the mould as complete and ready for
receiving the molten metal. The moulding apparatus consists of a casting A,
fitted with a horizontal plate or table B, upon which the sand to form the
mould is rammed in the flask or mould box C. The pattern D lies bori-
zontally in an aperture in the table B, which aperture it exactly fills when it is
raised to its highest position. This pattern D corresponds to the exterior of
the pot to be moulded, and is formed with a number of rings or collars
E. F, G, extending beyond its rim. The collar E is conical, and forms a
conical parting surface in the mould to secure the subsequent accurate adjust-
ment together of the core and external portions of the mould. The collars
F and G are turned accurately on the faces looking towards each other to fit-

page_text: a diaphragm H, the lower portion of which is formed upon the casting A,
whilst the upper portion is formed upon the casting I, constituting the hood
of the apparatus. The sides of the diaphragm H are turned or planed to fit
the collars F and G, and the aperture in the diaphragm through which the
pattern piece passes fits the neck J between the collars F, G, laterally, but is
elongated vertically to allow of the rising and falling of the pattern. The
collar G is in the form of a cam or eccentric, and rests upon a bearing piece
K, capable of accurate adjustment as to height by means of a wedge L below
it. On the front of the collar or cam G is keyed a spur wheel or toothed
rim M, which is in gear with a pinion N, carried on a spindle which has
bearings in the side of the apparatus, and passes out in front to receive a
hand wheel O, by means of which rotatory 'motion is imparted to the pattern
piece. It will be obvious that by turning the pattern piece it will rise and
fall accordingly as the projecting or the reverse part of the cam G comes upon
the bearing K. In Figures 1 and 2 the pattern piece is represented with
the projecting part of the cam downwards, and the pattern is consequently
elevated to its highest position. Patterns or pieces P are formed or placed
upon the plate B for the handles of the pot and for the pouring gate, and the
sand is rammed into the flask C upon the pattern, the legs, being moulded in
the usual way by means of loose pieces, which are subsequently picked out
of the mould. The projecting part of the cam G is made concentric with the
axis of the pattern for a short distance, and on the pattern being turned after
the sand is rammed in, it keeps in contact with the surface of the mould for
a short time whilst the turning action sleeks or smooths the surface of the
mould. On continuing to turn the pattern, the eccentric part of the cam G
comes upon the bearing piece K, and causes the pattern to be lowered from
the mould. When the lowest position is reached the pattern will be quite
free from the mould, and the flask or mould box C with this portion of the
mould may be removed without danger of injuring the sharpness of any part
thereof. The core for the pot is formed in the core box, shown in Figure 4.
The indented portions of the core are shaped by two semicircular pieces Q
fitted into the box R, and a conical box S placed on the top keeps them in
place, and serves to form the base and support for the core, which remains
in it when the entire mould is put together in a complete state, as shown in
Figure 5.
When the boxes R, S, are rammed full of sand the whole is
inverted and the box R is removed, this leaving the pieces Q free to be
removed laterally: Two half moulds T, formed separately by means of the
apparatus already described, and represented in Figures 1, 2, and 3, are placed
round and above the core U (Figure 5), which completes the mould ready for

page_text: casting. The outer portions of the mould and the core are made to fit
accurately together, not only by the conical surface formed by the shoulder or
collar E (Figure 1), a surface corresponding to which is formed on the core,
but also by means of a check or step V formed, at the line of junction of the
mould boxes C and S.
Figure 6, on Sheet 1 of the Drawings, is a horizontal section of a mould-
making machine, of precisely the same construction as that represented in
Figures 1, 2, and 3, but represented as fitted with a pattern for a kettle.
The same parts in this Figure and in Figure 3 are indicated by the same
letters of reference, and the description already given will apply generally to
this modification. The spout of the kettle is moulded by means of half
pattern pieces W, fitted by means of pegs or otherwise upon the plate B.
The pattern spout for one half mould is placed at one side, whilst for the
other half mould it is placed at the other side, as shown by dotted lines in
the Figure, so that when the two half moulds are brought together upon the
core the two half spout portions will meet and form the complete spout.
The external mould and core for the kettle are shown in section in Figure 7
'ou Sheet 1 of the Drawings as fitted together in a complete state. The core
may be formed in a box similar to that represented in Figure 4 for the pot,
but it is shown as strengthened by means of a central spindle X with cross
pieces Y. The core Z for the spout is inserted in a socket formed in the side
of the main core U, and a wire which strengthens the spout core is entered.
into a hole in one of the cross pieces Y.
Figure 8, on Sheet 1 of the Drawings, is a plan, and Figure 9 is a trans-
verse vertical section, of my improved moulding apparatus as modified for
forming the outer moulds for cast-iron pipes. The apparatus consits of a
species of box frame A, the top side B of which is planed or brought to a
smooth plane surface. This top side or plate B is formed with apertures
exactly fitting the pipe patterns C diametrically. The flask D for the half
mould of the two pipes, for moulding which the apparatus is constructed, is
placed upon the plate B, and when the patterns C are in proper positions the
sand is rammed into this flask in the usual manner. The ends of the patterns
C pass through vertical slots in the sides of boxes E, fitted or formed upon
the frame A at each end. Inside these boxes E the patterns have upon
them eccentric pieces or cams F, which rest on bearing pieces G, capable
At one end the
of accurate adjustment vertically by means of wedges H.
patterns extend through apertures in the outer sides of the box E, and are
formed with holes, as at I, for the insertion of a lever, by means of which
they are turned. The action of this apparatus is precisely the same as that of

page_text: the apparatus represented in Figures 1, 2, and 3, and already described herein,
except that the patterns are turned by means of a simple lever (such as the
rammer used in ramming in the sand) inserted at I, instead of by a pinion
and spur wheel arrangement. Thus, when the projecting or higher part of
the cam F is turned down, as shown at the right hand side of Figure 9, the
pattern C is raised up to its highest position, and projects through the plate B
to the extent of exactly half its circumference. With the patterns in this
position the flask D is rammed up, and the patterns are subsequently turned
to the position shown at the left-hand side of Figure 9, when they become"
quite detached from the mould, which can be removed without risk of damage.
The projecting parts of the cams F are made concentric with the axes of the
patterns for a certain distance, so as to keep the pattern in contact with
the mould surface for a short time when the patterns are being turned, so
that the turning action sleeks or smooths the surface of the mould before
withdrawing the patterns therefrom. Two flasks being rammed upon the
patterns in this way, and being put together with suitable cores, a complete
mould is formed for two lengths of piping.
Figure 10, on Sheet 2 of the Drawings hereunto attached, is a longitudinal
vertical section of my improved moulding apparatus as applied to the moulding
of a cannon of large size; Figure 1,1 on the same Sheet is a transverse vertical
section; and Figure 12 is a plan of the apparatus as arranged for moulding a
pair of smaller cannons. The arrangements shown in these Figures 10, 11,
and 12 are precisely the same as those already herein described with reference
to Figures 8 and 9 on Sheet 1 of the Drawings, and the same letters of
reference in the several Figures indicate corresponding parts in each. The s
trunnions of the cannons are moulded by means of loose pattern pieces J, held
in position by means of a loose pin entered into a hole in the pattern C.
When the flask is rammed, the pin is withdrawn so as to allow the pattern to
turn, and the trunnion pattern is is afterwards picked out of the mould.
Figure 13, on Sheet 2 of the Drawings, is a partially sectioned elevation, and s
Figure 14 is a vertical section, of a modification of my improved moulding
apparatus as adapted for moulding spherical shot or shell, the apparatus repre-
sented in the two Figures being for moulding the two halves of the shot or
shell. In the arrangement represented in these Figures the sleeking or
Smoothing action is dispensed with, and a simple rectilinear motion is given to
the pattern to withdraw it from the mould. The apparatus consists of a conical
casting A, formed with a horizontal plate B, which in this instance takes the
shape of a circular rin, with a central circular aperture for the pattern C. The
rim B is turned perfectly true and square to the vertical axis of the pattern to

page_text: form the parting surface in each flask D. The junction edges of these flasks
are turned to fit each other accurately, one being made to overlap the other to
insure the concentric adjustment together of the two flasks, whilst the plate B
of each moulding apparatus is shaped to fit the particular flask for which it is
constructed. The pattern C is supported in each case upon a vertical spindle E
jointed to a lever F below, the handle of which lever projects through a slot in
the side of the casting A, whilst the lever turns on a centre or fulcrum at the
opposite side. Two diametrical bars G placed across each other are attached
to the under side of the pattern, and are shaped with an edge directed upwards.
These edges determine the height to which the pattern is lifted through the
plate B by coming in contact with the under side of that plate, and are capable
of accurate fitting, which is necessary to insure the true spherical shape of the
shot or shell. When the moulder proceeds to ram up a flask he lifts the
pattern into place by means of the handle F, a weighted catch lever H coming
under this lever and holding it in position. When the flask is rammed up the
lever F is released by shifting the catch H, and the pattern is immediately
lowered from the mould, and the half mould may then be removed from the
apparatus without danger of injuring the sharpness of its parting edges.
A rotatory movement may be given to the pattern if desired for the purpose of
"sleeking" or smoothing the surface of the mould, either by attaching a lever
to its under side to turn it on its vertical axis, or a rim of teeth may be fixed
upon it below the plate B, a pinion in gear with these teeth serving to impart
the motion.
a
In Figures 15 to 18, on Sheet 2 of the Drawings, is represented a machine
for moulding railway chairs, showing the application to another form of pattern
of the rectilinear movement for withdrawing the pattern from the mould. The
apparatus is represented as arranged for moulding pair of chairs, the flask for
the tops of the chairs being shown in position. Figure 15. is a longitudinal
vertical section through one of the chair patterns; Figure 16 is a transverse
vertical section through the rail seats or jaws of the two chairs; Figure 17 is a
horizontal section taken just below the moulding plate; and Figure 18 is an
end elevation of the machine. The machine consists of the box casting A,
fitted with the horizontal table or plate B, planed truly to form a parting
surface for the mould, and formed with apertures corresponding in shape to the
outline of the soles of the chair pattern C. Each chair pattern C is fixed on
the top of a vertical spindle D, which slides in guide eyes in a bracket E,
bolted to cross bars F, attached underneath to the sides of the casting A. The
spindle D is in each case connected by a link G to one arm of a forked or
double lever II, which turns on centres or fulcra at one end of the casting A,

page_text: and the handle I of which passes out through a slot in the other end of that
casting. Outside the casting A is a weighted lever catch J, which comes under
the lever handle I, when this is lifted, and retains it in its elevated position
until knocked away. When the chair patterns are raised to their elevated
position, the exact point being determined by knifé edges K, which come into
contact with the under side of the plate B, as much of them projects above the
plate Bas corresponds to what is to be moulded in the flask L. On the
patterns being so elevated, the sand is rammed into the flask, and then the
patterns are withdrawn or allowed to descend by their own weight by releasing
the lever I, and become detached from the mould, which can then be removed
without danger of. injuring the sharpness of any of its parts. Holes corre-
sponding to the spike holes are formed 'completely through the patterns, and
rods attached to the cross bars. F below rise up to a level with the plate B, so
as to sustain the cores 'of the spike holes, and to prevent their being brought
away by the pattern's, acting also as additional guides for the patterns:. The
overhanging or undercut portions: M may be provided for in various ways;
thus, for example, they may be moulded by means of loose pieces, which the
patterns leave in the mould to be afterwards picked out, or the whole space of
the jaw or rail scat may be filled up in the pattern, and be formed by means of
a sand or iron core subsequently inserted into the mould. The reverse flask for
the bottom of the chair is moulded in any of the ordinary ways,.and is placed
upon the flask E, after inverting this from the position in which it is repre-
sented in the Drawings, and so completes the mould. The arrangement of
moulding apparatus represented in Figures 13 to 18 is applicable to the
moulding of a variety of articles, such as camp ovens and covers, frying pans;
gas meter cases, and scale weights. By adopting the berein-before described
arrangements. for forming moulds, the castings are turned out much cleaner
and freer from blemishes than the ordinary systems are followed, so that
considerable labour and expence is saved in dressing or trimming the castings,
and the work is performed with.greatly, increased rapitity.
'
Having now described and particularly ascertained the nature of my said
Invention; and the manner in which the same is or may be used or carried
into effect, I may observe, in conclusion, that I do not confine or restrict
myself to the precise details or arrangement which I have had occasion
to describe or refer to, as many variations may be made therefrom without
deviating..from the principles or main features of my Invention; but what
I consider novel and original, and therefore claim as the Invention secured to
me by the herein-before in part recited Letters Patent, is,―
...First,, the system or mode of moulding articles of circular section wherein a

page_text: rotatory motion is imparted to the pattern, and, by means of an eccentric or
partly eccentric and partly concentric bearing formed or fitted upon the pattern
on the same axis, "sleeks," smooths, or finishes the mould surface and withdraws
the pattern, or only withdraws the patters, as herein-before described.
Second, the system or mode of forming moulds for casting shot; shell, railway
chairs, camp ovens and covers, frying pans, gas meter cases, and scale weights,
wherein the pattern is projected through a fixed "parting" plate for the flask
to be rammed up upon it, and is withdrawn to separate it from the mould surface
prior to the removal of the rammed flask from the parting plate, as herein-
before described more particularly in reference to Figures 13 to 18 on Sheet 2
of the Drawings hereunto attached.
In witness whereof, I, the said John Downie, have hereunto set my
hand and seal, this Fifth day of September, Oue thousand eight hundred
and fifty-six.
JOHN DOWNIE. (L.S.)
JOHN DOWNIE. (L.S.)