IMPROVEMENTS IN APPARATUS FOR FORMING MOULDS FOR LIQUID METALS, AND IN CONNECTION WITH MOULD BOXES AND FLASKS
Year: 1880

page_text: LETTERS PATENT to John Thomson King, of Liverpool, in the County of
Lancaster, Patent Agent, for an Invention of "IMPROVEMENTS IN APPARATUS
FOR FORMING MOULDS FOR LIQUID METALS, AND IN CONNECTION WITH
MOULD BOXES AND FLASKS." A communication from abroad by Steven
Jarvies Adams, of Pittsburgh, Pennsylvania, United States of America,
Manufacturer.
PROVISIONAL SPECIFICATION left by the said John Thomson King at the
Office of the Commissioners of Patents on the 10th day of December 1880.
JOHN THOMSON KING, of Liverpool, in the County of Lancaster, Patent Agent.
IMPROVEMENTS IN APPARATUS FOR FORMING MOULDS FOR LIQUID METALS,
AND IN CONNECTION WITH MOULD BOXES AND FLASKS." [A communication from
abroad by Steven Jarvies Adams, of Pittsburgh, Pennsylvania, United States of
America, Manufacturer.]
The first part of the said Invention relates to apparatus for forming moulds for
making castings of iron, steel, or other metals, the object being to provide
apparatus whereby cylindrical moulds practically perfect in shape are more rapidly
formed than by any of the methods or apparatus heretofore employed.
Apparatus under the first part of the said Invention consists of a revolving
pattern provided with knives so disposed that it cuts its way into a solid body of
sand, and with sleekers or smoothers at the back of the said knives for polishing
the surface of the moulds formed. The said revolving patterns are in some cases
made hollow for the reception of the sand removed. When the revolving patterns
are arranged to enter the solid sand from above they are attached to the base of
perpendicular shafts, and the said shafts are mounted in a suitable frame in such
manner as to have both a rotary and a longitudinal motion therein. The rotary
motion is imparted to the shafts by suitable gearing. Springs are provided to raise
the shafts after the formation of the moulds; adjustable stops are used to limit
their longitudinal movement, and handles are employed to draw them down. The

page_text: patterns correspond in shape to the article to be cast. In front of each knife is
an opening leading into the interior of the pattern for the passage of the sand
into the hollow pattern, and the pattern is slightly reduced in front of and curves
off into the opening to enable the knives to cut away the sand. At the back of
each knife the pattern is slightly enlarged to form a sleeker or smoother, which
polishes over any irregularity left by the knives and imparts to the mould a smooth
and even surface.
Where the mould is perpendicular or nearly so a knife is fitted only to the
bottom of the pattern, and the said pattern is made slightly larger than the
knife below, so that it will compact and harden the sides of the mould by its
revolution. More than one knife may be used at the bottom of the mould.
The patterns are rotated at a speed of about two hundred revolutions per
minute, and are drawn down so as to enter and cut their way into the sand.
The sand may be packed in the mould boxes or flasks by jarring, ramming, or in
other suitable manner, but the most rapid way is to use a long mould box or
flask, as less time is consumed in feeding to the revolving cutters, and to pack the
sand by means of the apparatus described under the second part of the said
Invention.
When the pattern enters the sand from below it is mounted under the table on
which the mould boxes or flasks are placed, and arranged to be raised and lowered
through an opening in the table. In this case it is unnecessary to use a hollow
pattern, as the sand removed can fall through the opening.
When the pattern enters the sand at the side to form the mould the knives and
sleekers are on its edges, and the said pattern is rotated above the table and has no
longitudinal movement. Two half mould boxes or flasks filled with solid packed
sand are arranged to slide on the table in suitable guides, and they are brought up
against the revolving pattern and a half mould formed in each.
The second part of my Invention relates to apparatus used in filling moulds, and
such apparatus consists of a large heavy roller, which is passed back and forth over
the sand as the sand is filled into the mould boxes and flasks. In order to pack
the sand in the ends of the mould boxes or flasks a recess is formed across the face
of the roller in which the end boards of the mould boxes or flasks fit, the roller
being of such a size that one revolution is made in passing from one end of the
flask to the other. As no patterns are used in the flasks a much more solidly and
uniformly packed body of sand is obtained.
The third part of my Invention relates to the mould boxes and flasks used in
forming castings, and it bas special reference to securing together the two parts or
top and bottom of the mould box or flask so that the recesses or projections of the
one part shall occupy the proper positions in connection with the recesses or
projections of the other part. This has heretofore been accomplished by means of
guides on the sides or frames, but on account of the loosening of the guides, the
swelling of wood mould boxes or flasks, and other causes, a perfect adjustment of
the two parts was difficult to obtain. In the said improvement the relative
adjustment of the two parts does not depend on the guides affixed to the mould
boxes or flasks, and therefore is not subject to the difficulties encountered
therein.
The said Invention consists in forming in top of the sand in the bottom box
guide or seat for the reception of the top box, so that the relative positions of the
top and bottom boxes depends on the sand in the lower box and not on guides on
the sides or frames. The top and bottom boxes are made of any suitable material
and are of any desired shape. A plate formed or fitted with a projecting rib or
piece and carrying the pattern or patterns is placed beneath the lower box, and the
sand is filled into the said box in the usual or any desired manner. Upon removal
of the pattern plate a recess corresponding in shape to the projecting rib, and
preferably to that of the shape of the top box, will be found moulded in the
sand.

page_text: The top box is made smaller than the bottom box, and its base is the same size
and shape as the seat or recess formed in the sand of the said bottom box, so that
it will fit therein and be guided to its proper relative position. The mould in the
top box is formed by placing the cope on a reverse pattern plate having a recess
or guide to direct the said top box to its place, and moulding the reverse patterns
on the base of the cope in the usual manner.
Different shapes of guides or seats in or on the drag-sand for the reception of
the cope may be employed, and the apparatus described under the first part of
my Invention may be used to make the moulds in the said top and bottom
boxes.
The fourth part of the said Invention relates to tubular castings, and consists in
means for supporting the cores from the top box. To support the said cores on
the top box the core-rods extend from the body of the core sand through the
centre of the cores, and are provided at their ends with buttons or cups, on which
the cores rest, and the said core-rods are held in position by skeleton supports
attached to the inner sides of the top box; the said skeleton supports are formed
of thin metal blades and are so disposed that they do not prevent the packing of
the sand by jarring or ramming.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said John Thomson King in the Great Seal Patent Office on the
10th June 1881.
JOHN THOMSON KING, of Liverpool, in the County of Lancaster, Patent Agent.
"IMPROVEMENTS IN APPARATUS FOR FORMING MOULDS FOR LIQUID METALS,
AND IN CONNECTION WITH MOULD BOXES AND FLASKS." A communication from
abroad by Steven Jarvis Adams, of Pittsburgh, Pennsylvania, United States of
America, Manufacturer.
The first part of the said Invention relates to apparatus for forming moulds for
making castings of iron, steel, or other metals, the object being to provide apparatus
whereby cylindrical moulds practically perfect in shape are more rapidly formed
than by any of the methods or apparatus heretofore employed.
Apparatus under the first part of the said Invention consists of a revolving
pattern provided with knives so disposed that it cuts its way into a solid body
of sand, and with sleekers or smoothers at the back of the said knives for polishing
the surface of the moulds formed. The said revolving patterns are in some cases
made hollow for the reception of the sand removed. When the revolving patterns
are arranged to enter the solid sand from above, they are attached at the base of
perpendicular shafts, and the said shafts are mounted in a suitable frame in such
manner as to have both a rotary and a longitudinal motion therein. The rotary
motion is imparted to the shafts by suitable gearing. Springs are provided to raise
the shafts after the formation of the moulds; adjustable stops are used to limit
their longitudinal movement, and handles are employed to draw them down. The
patterns correspond in shape to the article to be cast. In front of each knife is an
opening leading into the interior of the pattern for the passage of the sand into the
hollow pattern, and the pattern is slightly reduced in front of and curves off into
the opening to enable the knives to cut away the sand. At the back of each knife
the pattern is slightly enlarged to form a sleeker or smoother, which polishes over
any irregularity left by the knives, and imparts to the mould a smooth and even
surface.
Where the mould is perpendicular or nearly so a knife is fitted only to the
bottom of the pattern, and the said pattern is made slightly larger than the knife
below so that it will compact and harden the sides of the mould by its revolution.
More than one knife may be used at the bottom of the mould.
The patterns are rotated at a speed of about two hundred revolutions per minute,
and are drawn down so as to enter and cut their way into the sand.
The sand may be packed in the mould boxes or flasks by jarring, ramming, or in
other suitable manner; but the most rapid way is to use a long mould box or flask,
as less time is consumed in feeding to the revolving cutters, and to pack the sand
by means of the apparatus described under the second part of the said Invention.
When the pattern enters the sand from below it is mounted under the table on
which the mould boxes or flasks are placed, and is arranged to be raised and
lowered through an opening in the table. In this case it is unnecessary to use
a hollow pattern as the sand removed can fall through the opening in the table.
When the pattern enters the sand at the side to form the mould the knives and
sleekers are on its edges, and the said pattern is rotated above the table, and has
no longitudinal movement. Two half mould boxes or flasks filled with solid
packed sand are arranged to slide on the table in suitable guides, and they are
brought up against the revolving pattern and a half mould formed in each.
The second part of my Invention relates to apparatus used in filling moulds; and
such apparatus consists of a large heavy roller which is passed back and forth over
the sand as the sand is filled into the mould boxes and flasks. In order to pack
the sand in the ends of the mould boxes or flasks, a recess is formed across the face

page_text: of the roller in which the end boards of the mould boxes or flasks fit, the roller
being of such a size that one revolution is made in passing from one end of the
flask to the other. As no patterns are used in the flasks a much more solidly and
uniformly packed body of sand is obtained.
The third part of my Invention relates to the mould boxes and flasks used in
forming castings, and it has special reference to securing together the two parts or
top and bottom of the mould box or flask, so that the recesses or projections of the
one part shall occupy the proper positions in connection with the recesses or pro-
jections of the other part. This has heretofore been accomplished by means of
guides on the sides or frames; but on account of the loosening of the guides, the
swelling of wood mould boxes or flasks, and other causes, a perfect adjustment
of the two parts was difficult to obtain. In the said improvement the relative
adjustment of the two parts does not depend on the guides affixed to the mould
boxes or flasks, and therefore is not subject to the difficulties encountered therein.
The said Invention consists in forming in top of the sand in the bottom box
a guide or seat for the reception of the top box, so that the relative positions of the
top and bottom boxes depends on the sand in the lower box and not on guides on
the sides or frames.
The top and bottom boxes are made of any suitable material, and are of any
desired shape. A plate formed or fitted with a projecting rib or piece and carrying
the pattern or patterns is placed beneath the lower box, and the sand is filled into
the said box in the usual or any desired manner. Upon removal of the pattern
plate a recess corresponding in shape to the projecting rib, and preferably to that
of the shape of the top box, will be found moulded in the sand.
The top box is made smaller than the bottom box and its base is the same size
and shape as the seat or recess formed in the sand of the said bottom box so that
it will fit therein and be guided to its proper relative position. The mould in the
top box is formed by placing the said top box on a reverse pattern plate having a
recess or guide to direct the said top box to its place, and moulding the reverse
patterns on the base of the cope in the usual manner.
Different shapes of guides or seats in or on the drag sand for the reception of
the cope may be employed, and the apparatus described under the first part of my
Invention may be used to make the moulds in the said top and bottom boxes.
The fourth part of the said Invention relates to tubular castings, and consists in
means for supporting the cores from the top box. To support the said cores on the
top box the core rods extend from the body of the core sand through the centre of
the cores, and are provided at their ends with buttons or cups on which the cores
rest, and the said core rods are held in position by skeleton supports attached to
the inner sides of the top box; the said skeleton supports are formed of thin
metal blades, and are so disposed that they do not prevent the packing of the sand
by jarring or ramming.
DESCRIPTION OF THE DRAWINGS.
Figure 1 is a side view of the apparatus employed in the said improved method
of forming moulds.
Figure 2 is a face view of the same.
Figure 3 is a side view, Figure 4 a perspective view, and Figure 5 a cross section
of the hollow revolving pattern.
Figure 6 shows the apparatus employed where the mould is formed from
below.
Figures 7 and 8 are views of the pattern employed where the mould is formed
from below.
Figures 9 and 10 show the apparatus and pattern employed where the mould is
formed from the side.
Figure 11 is a view of another form of revolving pattern in which the sleekers
are made adjustable so as to be thrown beyond the cutters and finish the mould,
all under the first part of the said Invention.

page_text: Figure 12 illustrates the method of packing the sand under the second part of
the said Invention.
Figure 13 is a longitudinal section of a bottom or drag of the said improved
moulds and flasks for castings, the moulds being formed therein and the patterns
ready to draw.
Figure 14 is a like view of the top or cope and its reverse pattern block before
the mould is formed therein.
Figure 15 is a cross section of the cope and drag in place forming the complete
mould.
Figure 16 is a perspective view of the drag with the moulds formed therein.
Figure 17 is a like view of the cope with the hanging cores.
Figure 18 is a cross section illustrating the third part of the said Invention
where the base of the cope moulds its own seat in the drag sand.
Like letters and numbers of reference indicate like parts wherever they occur.
The improved method of forming moulds under the first part of the said
Invention by revolving patterns or cutters is illustrated as applied in different
ways in the several Figures, the revolving patterns being shown as entering the
sand from above, as in Figures 1 and 2, from below, as in Figure 7, and at the
side, as in Figure 10.
In Figures 1 and 2 the revolving patterns are mounted above the flask and
adapted to be drawn down so as to penetrate the sand and form the mould
therein.
The apparatus is supported on a suitable standard or support A provided with
two or more horizontal arms or plates a, a², in which the perpendicular shafts B
carrying the rotating or revolving patterns C are mounted, the shafts passing
through bearings in or supported by the arms or plates a, a¹.
The revolving patterns are generally arranged in a nest, say, of six patterns, as
shown, each pattern being secured to the base of one of the shafts B extending up
through the plates a, a¹.
The patterns are made corresponding in shape to the article to be cast, the pattern
shown being suited for the formation of pipe ball moulds, and when entering the
sand from above are formed hollow, so that the sand can pass into the pattern as
it cuts its way into the body of the sand.
The pattern is provided with knives or cutters D at all points where it has to
cut or press into the sand in forming the mould, there being the entering knife d
at the base, and the knife d' above to form the core-print, the curved knife d² to
form the curve or taper at the base of the mould, and the knives or cutters d³
and d to form the cope-print at the top of the mould, the knife d³ serving to cut
out the cope depression, and the knife d to taper off the sides thereof.
In front of each knife is an opening e leading into the interior of the pattern,
the sand cut off by the knives passing through these openings into the hollow
pattern.
The surface of the pattern in front of the knives is slightly reduced, and curves
off into the openings e as at e' to enable the knives to cut away the sand.
At the back of the knives the pattern is made full size or slightly enlarged to
form a sleeker or smoother, as at f, which imparts to the mould a smooth and even
surface, polishing over any irregularity left by the knives.
When the pattern is perpendicular or nearly so, as at c, no knives are necessary,
and the pattern is made slightly larger in diameter than the upper end of the
knife d², so that it will press, compact, and harden that portion of the mould by its
revolution, insuring a perfectly cylindrical mould.
The pattern is provided with the brace c¹ extending across the hollow interior,
to which brace a rod c³ is rigidly attached, and extending up from the centre of the
pattern is secured or otherwise removably secured at the base of the shaft B.
The shafts B have a longitudinal as well as a rotary motion in their bearings to
permit the patterns to be drawn down into the sand, and their longitudinal
movement is limited by means of stops or sleeves b, b, attached thereto by set

page_text: screws, so that the movement of the shafts may be regulated to the length of the
pattern used therewith.
The shafts B are provided with spiral or other springs g, confined between the
upper horizontal plate a' and tops 63 of the shafts, by means of which the patterns
are held up clear of the course of the flask when not in use, and withdrawn after
forming a mould.
Near the base of the shaft are arranged suitable handles i for drawing the nest
of revolving patterns down to form the moulds.
A rotary motion is imparted to the shafts B carrying the patterns, by means of
pulleys H supported on the horizontal frame h extending from the standard A, and
keyed in longitudinal slots in the shafts, so as to permit the shafts to slide through
them when the patterns are drawn down, as above described. The pulleys are
caused to rotate by belting extending from any suitable power connections.
I prefer to have the sand in which the moulds are formed packed in long flasks,
as less time is consumed in feeding to the patterns, and as the sand is packed solid,
flasks of about twenty feet in length can be employed to advantage.
The flasks can be rammed, jarred, or packed in any known manner, and as no
patterns are used in the flasks, a more solidly and uniformly packed body of sand
can be obtained.
The packed flask k is brought under the revolving patterns, either on a stationary
table or by means of the car or carriage k, the latter being preferred where long
flasks are used, as the flask can be moved along after one set of moulds are mado
until they are formed the entire length of the flask.
In making moulds by the improved method, by the mechanism above described,
where the patterns are drawn down from above to cut the moulds in solid sand, the
patterns are rotated at a speed of about two hundred revolutions per minute
through the pulleys H. The flask containing the solid body of packed sand is then
brought under the patterns, and the patterns drawn down by the handles i until
they come in contact with the sand. As the patterns are drawn down farther, the
core-print cutters d, d¹, penetrate or cut their way into the sand, which is forced
into the hollow pattern through the openings e, and as the pattern advances, the
curved cutter d² at the base of the mould-pattern enlarges the cavity formed by
the entering cutter, the tool thus forcing its way through the body of the sand
until the whole mould and its cope-print are formed. As the pattern advances
into the sand the sleekers back of the knives or cutters smooth over the sand,
and impart to the mould a smooth and almost polished surface by the rapid
revolution of the pattern. The mould is also further polished whenever the sides are
perpendicular, or nearly so, by the smooth surface of the pattern, as at c, and the
rapid revolution of the pattern insures a true cylindrical form to the mould.
The sand removed passes through the openings e into the hollow pattern, and is
removed therefrom during the process of cutting or after the pattern is raised from
the mould by an endless chain and buckets, an air blast, or other suitable means.
It is not necessary that hollow patterns should be used for raising the sand, as
separate apparatus, such as a worin, may be employed for that purpose.
As the pattern is revolving rapidly when withdrawn from the mould it will not
drag on the sides thereof, as is usual in old styles of moulding, and hence is
raised without injury to the mould, and for this reason the said improvements
are especially adapted for the formation of long, perpendicular, cylindrical moulds.
The longitudinal movement of the patterns is regulated by the stops b, b, and
the patterns are raised clear of the moulds by the springs g. After the formation
of one set of moulds in the flask it is moved along until fresh sand is brought under
the patterns, and the process continued by successive cuts until the flask is filled
with moulds, the one set of patterns serving to form all the moulds necessary, and
on account of the rapidity of the process accomplishing at least five times the
amount of work capable of being accomplished by any other process. The moulds
thus formed are of true cylindrical shape, perfect in surface, and correspond with
the pattern used, and are in no way marred by the withdrawal of the pattern.

page_text: Figure 6 illustrates the said Invention when the pattern enters the solid sand
from below. The pattern is mounted in substantially the same manner as shown
in Figures 1 and 2, and is arranged to be raised and lowered through a circular
opening m in the table M. It is raised by a spring and lowered by suitable lever
mechanism N, the handle n of which extends into a convenient position for its
operation by the workman and catches on the ratchet n¹.
The revolving pattern C is made of a flat plate, as fully shown in Figures 7 and 8,
and the sand removed falls through the opening m, and is carried by the trough or
inclined way m¹ into a suitable receptacle.
The knives or cutters D are formed along the edge of the flat pattern, and at the
back of these knives are formed the sleekers f for smoothing and polishing the
mould as above described.
The flask containing the body of packed sand is placed on the table M either face
downward or having suitable openings in the removable bottom board of the flask,
through which the cutters work in forming the moulds.
Figure 9 illustrates the said Invention when the pattern enters the mould at
the side. The pattern extends through the opening m in the table M, and is
rotated in this position, it not being necessary for it to be raised and lowered through
the table.
Two half flasks K', K³, filled with solid packed sand are arranged to slide on the
table in suitable guides p on the sides thereof, and a stop or stops r check the
movement of the half flasks when they come to the centre of the pattern. The
two flasks are moved along the guides p against the revolving pattern, which cuts
the mould in the solid sand, one half being thus formed in each half flask, and the
half flasks are then removed and secured together in the usual way, thus forming
the complete mould.
The knives D are arranged on the sides of the pattern so as to cut into the sand
when the packed flasks are brought against it. The sand removed falls through the
opening m as above described.
The pattern can thus be adapted to form moulds for articles having rings or
enlargements, as the half flasks are fed sidewise to and withdrawn in the same
manner from the revolving pattern.
The knives and sleekers may be made adjustable on the different shaped patterns
to form different sizes of moulds, as shown at 8, Figure 8. This adjustment may be
accomplished by different means, not necessary to enumerate here. If desired the
cutters may be adjustable in the revolving patterns so as to be thrown out in front
of the sleekers, and when the mould is brought approximately to the proper shape
the cutters withdrawn, and the mould finished by the sleekers; or the sleekers may
be adjustable so as to be thrown beyond the cutters to finish the mould. A tool
of this construction is shown in Figure 11, in which the sleekers are adjustable and
are held below the cutters or pressers until the mould is formed, when the sleekers
are thrown out beyond the cutters and finish the mould. The patterns can be
made to correspond to the different articles to be cast, knives, pressers, or cutting
edges, and the necessary sleekers being placed wherever it is necessary for the
pattern to cut its way into the sand or the sleekers to polish the surface of the
mould, as illustrated in the different patterns shown, and by this means any
cylindrical mould can be formed in the solid sand whenever the sides of the mould
are perpendicular or tapering, as well as moulds having rings or enlargements
where half flasks are used. Sweeps or other mechanism for forming depressions or
curves at different points in the surface of the moulds may also be arranged to
operate in connection with the revolving patterns. By the movement of the flask
along the table or of the revolving pattern along the top of the flask elongated
moulds of the shape of the revolving patterns can also be formed.
When the apparatus is mounted in a moveable frame, the sand may be rolled or
otherwise packed on the casting floor, and the apparatus moved along to form the
mould in the sand so packed.
When long flasks are employed, they can be placed on cars and brought directly

page_text: under the cupola discharge, and the melted metal poured directly from the cupola
into the moulds, thus doing away with the heavy labor of carrying the metal.
The most rapid and efficient method of packing the long flasks is by rolling, as
shown in Figure 13. The flask K is placed on a suitable car or carriage k, and this
car brought under a heavy roller L. The roller is either mounted and rotated in
stationary housings, and the flask passed back and forth under it while the sand is
gradually fed thereto until it is packed full of sand, or the flask is held stationary,
and the roller passed back and forth over it as the sand is fed thereto.
Across the face of the roller L is formed the recess , which extends a sufficient
distance into the roller to allow the end boards of the flask to fit therein, forming
the corners or edges along the recess, which fit close into the corners of the flask
and pack the sand therein.
The roller L is made of such diameter that one revolution will be made as it
passes from one end of the flask to the other, the recess fitting over one end
board, and upon the rotation of the roller fitting over the opposite end board, as
shown in dotted lines. I am by this means enabled to pack the sand uniformly
and tightly, not only in the body of the flask, but in the ends thereof.
The third and fourth parts of the said Invention are illustrated by Figs. 13 to 18.
1 represents the botton or drag of the flask which is formed of wood or metal, and
is of any desired shape, being either round, square, or angular. The plate on
block 2 carrying the patterns 3 is provided with a raise or projection 4, beyond
which the patterns for forming the moulds extend, the patterns shown being for
the formation of pipe, mandrel, or balls, though any desired form of patterns may
be used. The projection 4 of the plate extends all around the patterns, as shown,
and corresponds in size and shape to the base of the cope, as that upon the formation
of the mould a recess or seat 5 corresponding to the shape of the top or cope base
will be formed in the sand 6 of the bottom or drag above the moulds. At the base
of each pattern 3 is formed an extension 7 for moulding the core-print in the
sand.
The top or cope 8 of the flask is made smaller at the base than the bottom or
drag, and is preferably made of metal, as that is not liable to shrink or swell, and
may be round, square, or of other desired shape, its base being of the same size and
shape as the projection 4 on the pattern plate 2, so that it will fit into the seat in
the bottom or drag sand formed by said projection. The mould in the top or
cope 8 is made by fitting the base of the said top or cope into a suitable recess or
guide 9 in the reverse pattern plate or block 10, the patterns on the reverse plate
corresponding in position to the patterns on the plate 2, so as to form a mould at
the base of the top or cope, which, when the said top or cope and bottom or drag
are placed together, as hereinafter described, will form a perfect mould. When a
circular top or cope is used, a feather guide on the side of the said top or cope may
be arranged to fit into a corresponding recess in the bottom or drag-sand, and thus
direct the parts into their proper relative positions. This is not necessary in
angular or oblong tops or copes. The pouring gates are formed either in the top
or cope or bottom or drag as desired at the same time when the moulds are made.
Where pipe balls, as illustrated in the Drawing or other long hollow castings are
to be formed, a nest of moulds may be formed in the bottom or drag, and their
corresponding cores on the base of the top or cope. These long hanging cores are
supported by core rods 12 which extend from the body of the top or cope sand 13
into the cores 14. The rods 12 may, if desired, be supported by and extend down
from a suitable skeleton support 15 attached to the under sides of the top or cope.
The most efficient support consists of thin metal blades extending across the inside
of the top or cope, their edges being in the direction of the packing of the sand, so
that it will not interfere with the formation of the mould by jarring or ramming.
A skeleton support loose in the top or cope may also be employed to advantage,
being made in the form of a star or comb, and having the core-rods 12 attached
thereto. At the end of each core-rod 12 is attached a button or cup 16 which

page_text: forms a support for the base of the sand core, and protects the end thereof in
handling. The core is thus braced from the cup 16 along the core-rods to the
skeleton support and cope frame, and I am enabled to use the mould without
baking the cores, as is usual where single cores are used.
The improved flask is used in the following manner :-The drag 1 is placed on
top of the pattern plate 2 carrying the raise 4 and patterns 3, and the mould is
formed either by jarring or in any other suitable way. The pattern plate is then
withdrawn, and above the moulds will be found the seat 5 for the reception of the
base of the top or cope, the seat and moulds being both formed in the sand of the
drag, and being in proper relative position to each other. The top or cope 8 is
then placed on the reverse pattern block 10, being to place thereon by the recess or
guides 9. Where long hollow castings are to be formed, as shown, the core-rods 12
extend into the core moulds 17 of the pattern block, the tops or cups 16 resting at
the base of the core moulds. The mould is now formed in the usual manner, and
when lifted from the pattern block the hanging cores 14 will extend out from the
top or cope, being supported thereon by the rods and cups.
Where no hanging
cores are attached to the top or cope, the core supports are dispensed with, the top
or cope mould being formed in substantially the same manner.
Both the top or cope and bottom or drag moulds having been formed, the top or
cope is placed on the bottom or drag, so that its base fits into and seats itself in the
seat or guide 5 in the sand 6 of the bottom or drag above the moulds. As the
relative positions of the top or cope and bottom or drag depend on the base of
the top or cope and its seat in the bottom or drag sand I dispense entirely with the
guides on the top or cope and the bottom or drag boxes, and therefore overcome all
the objections and difficulties arising from the use of these guides. The top or cope
is thus seated in its proper relative position with the bottom or drag, and a perfect
mould formed, and the only liability of throwing the parts out of line is in the dis-
placement of the guides or raises forming the seat in the bottom or drag sand. In
forming long hollow castings the bases of the cores fit into the core prints at the
base of the moulds, the cups 16 being below the moulds and not coming in contact
with the hot metal in casting.
In Figure 18 is shown another means of forming the moulds, in which the base
of the top or cope forms its own seat in the sand of the bottom or drag. The top
or cope 8 is reversed and placed over the match block 19, which extends up through
it and holds the pattern at the base of the said top or cope. The top or cope is
preferably provided with lugs 20 on its sides, and the bottom or drag 1 is inverted
and placed on top of the cope resting on these lugs. The mould in the bottom or
drag is then formed, the base of the top or cope forming the seat 5 in the sand of
the bottom or drag. The top or cope and bottom or drag are then turned over,
the match block 19 removed, and the mould in the cope formed in the usual manner,
after which the top or cope is lifted off, the pattern removed, and the mould
completed by placing the top or cope on the bottom or drag, it being guided to its
place by the seat formed in the bottom or drag sand. When the mould is formed
in this manner the necessity for corresponding accuracy between the projection on
the pattern plate and base of the top or cope is overcome, as the base of the said
top or cope forms its own seat.
"In forming large hollow castings the top or cope may be formed circular, and only
one core attached thereto. The mould may also be formed in the sand of the
bottom or drag by means of a revolving cutting or presser and sleeking tool or
pattern, as described in the previous part of the Specification, and the seat for the
top or cope at the same time pressed into the sand by a projection above the
patterns. Different shapes of guides or seats in the bottom or drag sand for
the reception of the top or cope, such as a depression at each corner, or a raised
seat fitting into a corresponding depression in the top or cope sand, may also be
employed.
Having now described the nature of the said Invention, and particularized the

page_text: same in such manner that others will be enabled to carry the same improvements
into effect, I claim,―
Under the first part:-First. Apparatus for forming moulds for castings in a
solid body of sand, operating substantially as setforth.
Second. A revolving pattern provided with one or more knives or cutters, and
a sleeker at the back of each cutter operating substantially as and for the purposes
setforth.
Third. A revolving pattern provided with an entering cutter to penetrate and
form a cavity in a solid body of sand, and one or more cutters above the entering
cutter to enlarge the cavity so formed, substantially as described.
Fourth. A revolving pattern provided with one or more knives or cutters D,
and a smooth polishing surface, as at c, substantially as and for the purposes
setforth.
Fifth. The combination of a long flask packed with sand and a revolving pattern
mounted in a suitable frame, and adapted by successive cuts to form a series of
moulds in the said flask, substantially as and for the purposes setforth.
Sixth. A hollow revolving pattern for forming moulds in sand provided with
one or more knives or cutters for removing the sand, and corresponding openings
for the passage of the sand into the hollow pattern, substantially as described.
Seventh. A hollow revolving pattern for forming moulds in sand provided with
one or more cutters D, corresponding openings e for the passage of the sand into
the pattern, and sleekers f at the back of the cutters, substantially as and for the
purposes setforth.
Eighth. A revolving pattern provided with adjustable knives or pressers,
substantially as and for the purposes setforth.
Under the second part:-The heavy roller L for packing sand in flasks provided
with the recess extending across its face, substantially as and for the purposes
も
setforth.
Under the third part:-First. Forming in the sand of the bottom box or drag
above the mould a seat or guide for the reception of the top box or cope, and seating
the base of the said top box or cope in or around said guide, substantially as and
for the purposes setforth.
Second. The combination of the bottom box or drag 1, having the seat 5 formed
in the sand thereof above the mould, and the top box or cope 8, the base whereof
is adapted to fit into or around the seat formed in the sand of the drag, substantially
as and for the purposes setforth.
Under the fourth parth :-First. The top box or cope 8 in combination with the
skeleton support 15, carrying the core supporting rods 12, substantially as and
for the purposes setforth.
Second. The top box or cope 8 in combination with the skeleton support 15 the
core supporting rods 12, and the buttons or cups 16 attached to the ends of the
rods 12, substantially as and for the purposes setforth.
Third. The core supporting rod 12 in combination with the button or cup 16
attached to the end of the rod, and adapted to support the core around the rod,
substantially as and for the purposes setforth.
In witness whereof, I, the said John Thomson King, have hereunto set my
hand and seal, this Fourth day of June, in the year of our Lord One
thousand eight hundred and eighty one.
0 W. B. JOHNSON,
4, Clayton Square,
Liverpool.
Witness.
J. T. KING. (LS.)