IMPROVEMENTS IN CASTING METALS, IN THE MANUFACTURE OF THE MOULDS THEREFOR, AND IN APPARATUS EMPLOYED THEREIN.
Year: 1881

page_text: LETTERS PATENT to John Clayton Mewburn, of 169, Fleet Street, in the City
of London, Patent Agent and Consulting Engineer, for an Invention of
"IMPROVEMENTS IN CASTING METALS, IN THE MANUFACTURE OF THE MOULDS
THEREFOR, AND IN APPARATUS EMPLOYED THEREIN. A communication from
abroad by Jules Demogeot, of Paris, France.
"
PROVISIONAL SPECIFICATION left by the said John Clayton Mewburn at
the Office of the Commissioners of Patents on the 26th March 1881.
"
JOHN CLAYTON MEWBURN, of 169, Fleet Street, in the City of London, Patent
Agent and Consulting Engineer. "IMPROVEMENTS IN CASTING METALS, IN THE
MANUFACTURE OF THE MOULDS THEREFOR, AND IN APPARATUS EMPLOYED
THEREIN. [A communication from abroad by Jules Demogeot, of Paris, France.]
Hitherto in the manufacture of ornamental castings or of plain castings of
special forms in iron, bronze, or other metal, it has been the practice to employ
metal flasks or mould boxes, into which the workman by hand tool has rammed
the sand which is required to take the impression of the pattern. The process to
which the present Invention chiefly relates differs essentially from the above
because the sand is rammed by a machine, and also because instead of having at
least two parts of the flask for each mould there is only a single flask for each
description of piece or casting.
I will explain the method to be followed for three different types of pieces or
castings.
First. Castings requiring only two flask parts in the ordinary method, such as
bedstead frames, balconies, or architectural roses. According to the present
Invention the flask for these castings is composed of two pieces connected at one
corner by a hinge and at another by a clamp or other fastening. The inside of the
flask is well smoothed or dressed. The bottom is of cast iron and likewise well
dressed, and is connected by means of screws to one half only of the flask. Above
the bottom is a cast iron or bronze plate having formed in it one of the faces of
the mould to be produced; this plate is well dressed on all its edges, and the
hollow of the pattern well polished. The height of the flask above this plate
should be double that of the sand moulds to be produced. The flask having been
dusted with charcoal in order to prevent adherence of the sand it is filled with
unrainmed sand; it is then placed in a press, the descending ram or plunger of
which carries in relief the other face of the mould; the part carrying the design
should enter the flask truly and freely, but have no play therein, it is of bronze or
cast iron and is attached to the ram or plunger by means of a screw. The pressure
ND...All

page_text: having been given the flask is removed and opened and the mould is then easily
removed therefrom, the plate not being fixed to the bottom. There is thus
obtained a sand mould presenting on one of its faces in relief one face of the
pattern. By piling several of these moulds one upon another a number of spaces
will be formed which can be filled with the molten metal. Each mould has a
groove formed down its side, and has also several smaller grooves, these grooves
being produced by projections on the flask. The large groove forms the gate or
runner, and the smaller grooves allow of the escape of the hot gases which are
disengaged from the sand during the casting. The moulds may be piled on a cast
iron table and held by vertical plates which are movable so as to be capable of
holding moulds of various dimensions.
Second. Castings requiring more than two flask parts. in the ordinary method,
such as door knockers, casement window espagnolettes, or statuettes.
For a casement espagnolette, for example, the bottom of the flask and the
plunger of the press will each carry in relief one half of the mould, but instead of
the face of the inounted handle, I make in the large moulds a trapezoidal opening.
In a small flask and with another press I make small moulds exactly filling these
trapezoidal openings, and having recessed therein the form of the face of the
handle. I then mount all these moulds as in the first case.
Third. Special castings, chains. For this manufacture, which is very expensive
with the ordinary method, the flask differs from the preceding. It is still composed
of an iron frame, but three of the sides are fixed, and the fourth is held to the others
by clamps. This side bears in relief one fourth of the large link of the chain to
be manufactured. The plunger of the press bears in relief at each side th of the
small link. Thus a sand mould is obtained which has recessed in one face one
fourth of the one link, and on a face perpendicular to the first two eighths of the
other link. Four of these moulds combined will give an entire link and two half
links, and by placing four others at the side of the first four, two entire links are
obtained united by another, and so on. All the links communicate with each
other by small channels or runners produced by projections on the press plunger;
they serve for the introduction of the molten metal. The gate or gates are formed
by hand at the place or places which the workman judges most suitable. A chain
of considerable length is thus made at one casting. But in the case of very long
chains they will be made in several lengths, which will be afterwards united by
placing the last link of each length in a set of four moulds.
The press employed may be arranged in many different ways; I will describe
one way to be worked by the attendant, but it is evident that steam or hydraulic
power may be employed to actuate the press which will automatically effect all the
operations for the manufacture of the moulds, that is to say, the attendant will have
to introduce the charcoal dust and the sand into the hoppers, and to remove the
moulds which are drawn by the machine. The machine which I will describe is
composed of a standard or upright with a projecting bracket to support the flask,
and a projecting guide for the rod of the press plunger. This plunger is fitted with
a counterweight for lifting it. A cam worked by a lever forces down the plunger
into the flask.
To avoid the great difficulty of working together a number of sand moulds of
large dimensions, such, for example, as those for balconies or railings I adopt the
following method:-Between two hinged flasks similar to those first herein
described I interpose a plate pattern presenting one face of the pattern on the top
and its other face on the bottom; that is to say, this plate represents an ordinary
pattern divided horizontally and then rejoined by placing between the halves a
plate more or less thick. The press to be used in this case has its upper plate or
head fixed, and the bed or lower plate movable, or they may both be movable; in
either case the pressing plates or plungers should enter the flasks so as to ram the
sand above and below the plate pattern. The pressure having been given the
flask is withdrawn from the press and is placed on a table having a projection
which penetrates the flask until it reaches the sand; I remove the upper flask,

page_text: then the plate pattern; I bring the upper flask upon the lower one; the contours of
the object to be reproduced then coincide on both moulds because the flasks are
connected by ordinary guides or steady pins. Other pins long enough to hold the
plate model when between the flasks are removed. There remain the two flasks,
the one above the other, thus forming a mould ready for casting. It is evident
that in order to prevent large moulds getting out of shape during the manipulations
cross bars may be placed in them, and to prevent the moulds slipping in the flasks
small bars are made to project into the interior of the flasks on the large sides,
which bars are removed when the flasks are ready to be opened.
In order to facilitate the manufacture I can, instead of pressing with plain
plates or plungers, ram the sand with plate patterns, whereby at each action of the
press I obtain a mould and two half moulds. Instead of drawing the moulds by
placing them on a table, I place the moulds on those previously obtained, as before
described.
Instead of employing a hinged flask fixed above the lower plate pattern, as
before explained, I can proceed as follows:-I take a box or frame without a
hinge into which the lower plate pattern can enter truly. The height of this box
is such that its upper surface is flush with the upper face of the plate pattern.
On the box I place a hinged flask whose height is equal to that of the mould to be
produced. On the flask I place a second box, not hinged, whose height depends
upon that of the flask, that is to say, upon the castings to be made and the degree
of cohesion to be given to the moulds. The lower box has guides, which prevent
all horizontal displacement of the flask with respect to the lower box. The flask
has similar guides for the upper box. The two boxes are planed or smoothed
inside. The result of the arrangement is that if the upper plate pattern be placed
in the upper box all the points of the contour would be exactly opposite those of
the other plate patter. I put sand in the flask and the upper box, and I ram it by
means of a press of any suitable construction, but it is well to provide it with a
disengaging apparatus, which when the lower face of the upper plate pattern is
O level with the upper surface of the flask causes the movement of the plate to
change its direction, so that it rises out of the upper box. The upper box has
therefore for object to measure the volume of unrammed sand, which ought to be
removed in order that a proper cohesion may be obtained and especially to guide.
the upper pattern plate. The ramming having been finished the upper box is
3 removed, then the flask is lifted with the mould; the pattern plate and the lower
box remain on the table. The above will be the practice for the greater part of
the pieces to be cast, but for very delicate pieces it is preferable to return the flask
and the lower box with the plate pattern and then to lift this plate above the
flask this prevents the very fine parts of the sand becoming detached; afterwards
) the flask with the mould is carried to the place where the casting is to be effected.
Another flask exactly similar bas then another mould rammed in it; this second
flask is placed upon the first; they fit together without trouble by means of guides ;
then the first or lower flask is opened; a fresh mould is rammed in this flask,
which is then placed upon the second; this is then removed, and so on, until the
pile of moulds has reached a suitable height.
The plate patterns have projections at all the required points to form the holes
and runners complete, also air vents when necessary. When the pile is ready the
gates or holes at the top should be enlarged and the upper mould weighted and the
casting may then proceed.
For rapid manufacture 3 similar flasks are employed, so that while one man
places one upon the pile and removes the one below another man supplies the sand
and rams a mould in the third flask. The press should be arranged so that the
lower pattern plate rises while the upper one descends. The height of the lower
box is therefore equal to that of the upper box plus the thickness of the plate
¡ pattern.

page_text: SPECIFICATION in pursuance of the conditions of the Letters Patent filed
by the said John Clayton Mewburn in, the Great Seal Patent Office on the
21st September 1881.
JOHN CLAYTON MEWBURN, of 169, Fleet Street, in the City of London, Patent
Agent and Consulting Engineer. "IMPROVEMENTS IN CASTING METALS, IN THE
MANUFACTURE OF THE MOULDS THEREFOR, AND IN APPARATUS EMPLOYED
THEREIN." (A. communication from abroad by Jules Demogeot, of Paris, France.)
Hitherto in the manufacture of ornamental castings, or of plain castings of
special forms in iron, bronze, or other metal, it has been the practice to employ
metal flasks or mould boxes into which the workman, by a hand tool, has rammed
the sand which is required to take the impression of the pattern. The process to
which the present Invention chiefly relates differs essentially from the above,
because the sand is rammed by a machine, and also because, instead of having at
least two flask parts for each mould, there is only a single flask for each description
of piece or casting.
I will explain the method to be followed for 3 different types of pieces or
castings.
First. Castings requiring only two flask parts in the ordinary method, such as
bedstead frames, balconies, or architectural roses, &c. According to the present
Invention, the flask for these castings (see Figures 1 and 2 of the annexed
Drawings, which are respectively a section and plan), is composed of a frame a
made in two pieces connected at one corner by a binge o, and at another corner by
a clamp or other fastening b. The inside of the flask is well smoothed or dressed.
The bottom c is of cast iron, and likewise well dressed, and is connected by means
of screws v to one half only of the flask. Above the bottom is a cast iron or bronze
plate d, having formed in it one of the faces of the mould to be produced; this
plate is well dressed on all its edges, and the hollow of the pattern well polished.
The height of the flask above this plate should be double that of the sand moulds
to be produced. The flask (in the position shown in the Drawings) having been
dusted with charcoal, in order to prevent adherence of the sand, it is filled with
unrammed sand; it is then placed in a press, the descending ram or plunger p
(Figure 3) of which carries in relief the other face of the mould; the part e should
enter the flask truly and freely, but have no play therein; it is of bronze or cast
iron, and is attached to the ram or plunger by means of screws f. The pressure
having been given the flask is removed and opened, and the mould is then easily
removed therefrom, the plate not being fixed to the bottom. There is thus
obtained a sand mould presenting on one of its faces in relief one face of the
pattern, and on the other face the second face of the pattern. By piling several of
these moulds one upon another a number of spaces will be formed, which can be
filled with the molten metal. Each mould has a groove formed down its side at g, and
has also several similar smaller grooves h, these grooves being produced by projections
on the flask; the large groove forms the gate or runner, and the smaller grooves
allow of the escape of the hot gases which are disengaged from the sand during the
casting. Figures 4 and 5 represent in vertical section and plan respectively the
arrangement of the moulds m for the casting operation. They are piled on a cast
iron table i, and held by plates j which are movable, except that marked ³, so as to
be capable of holding moulds of various dimensions.
Second. Castings requiring more than two flask parts in the ordinary method,
such as doorknockers, casement window espagnolettes, or statuettes.
For a casement espagnolette, for example, the bottom of the flask and the
plunger of the press will each carry in relief one half of the pattern, but instead

page_text: of the face of the mounted handle, I make in the large moulds a trapezoidal opening,
as shown in Figures 6 and 7. In a small flask and with another press I make
small moulds exactly filling these trapezoidal openings, and having recessed therein
the form of the face of the handle. I then mount all these moulds as in the first
case, the same table answering the purpose. Figure 8 represents the arrangement
for this description of casting.
Third. Special castings, chains. For this manufacture, which is very expensive
with the ordinary method, the flask differs from the preceding. It is still composed
(see Figures 9 and 10) of an iron frame, but 3 of the sides are fixed, and the fourth
is held to the others by clamps or fastenings k. This side bears in relief at one
fourth of the large link of the chain to be manufactured. The plunger of the press
bears in relief at each side th of the small link. Thus sand moulds are obtained,
one of which is represented in elevation in Figure 11, and in bottom plan in
Figure 12. This mould has recessed in one face th of the one link, and on a face
perpendicular to the first two eighths of the other link. Four of these moulds
combined will give an entire link and two half links, and by placing 4 others at the
side of the first four, the two entire links are obtained united by another, and so
on, The arrangement for casting is shewn in Figures 13 and 14. The left hand
half of Figure 14 is a section through C, D, and the right hand half a section
through A, B. All the links communicate with each other at the points m by
small channels or runners produced by projections on the press plunger; they
serve for the introduction of the molten metal. The gate n (or gates if the chain
is long) is formed by hand at the place which the workman judges most suitable.
A chain of considerable length is thus made at one casting. But in the case of
very long chains, they will be made in several lengths, which will be afterwards
united by placing the last link of each length (Figure 15) in a set of 4 moulds.
The press employed may be arranged in many different ways. I will describe
one way to be worked by the attendant, but it is evident that steam or hydraulic
power may be employed to actuate the press which will automatically effect all the
operations for the manufacture of the moulds, that is to say, the attendant will
have to introduce the charcoal dust and the sand into the hoppers, and to remove
the moulds which are drawn by the machine. The machine which I will describe
is represented in Figure 16; it is composed of a standard or upright A with a
bracket a to support the flask, and a guide 6 for the rod B of the press follower C.
This plunger is fitted with a counterweight D for lifting it. A cam E worked
by a lever F forces down the plunger C into the flask by pressing upon the
roller G.
To avoid the great difficulty of working together a number of sand moulds of
large dimensions, such, for example, as those for balconies or railings, I adopt the
following method:-Between two hinged flasks H and K (Figures 17 and 18)
similar to those first herein described, I interpose a plate pattern C, presenting one
face of the pattern on the top and its other face on the bottom, that is to say, this
plate represents an ordinary pattern divided horizontally, and then rejoined by
placing between the halves a plate more or less thick. The press to be used in this
case has its upper plate or head fixed, and the bed or lower plate movable; or they
may both be movable. In either case the pressing plates or plungers should enter
the flasks so as to ram the sand above and below the plate pattern. The pressure
having been given the flask is withdrawn from the press and is placed on a table D
(Figure 19) having a projection I which penetrates the flask until it reaches the
sand; I remove the upper flask H, then the plate pattern; I bring the upper
flask Hupon the lower one K; the contours of the object to be reproduced then
coincide on both moulds because the flasks H and K are connected by ordinary
guides or steady pins. Other pins 9 (Figures 17 and 18) long enough to hold the
plate pattern when between the flasks are removed. There remain the two flasks,
the one above the other, thus forming a mould ready for casting. It is evident
that in order to prevent large moulds getting out of shape during the manipulations
cross bars, such as those shown at L, Figure 20, may be placed in them, and .to

page_text: prevent the moulds slipping in the flasks small bars 6 are made to project into the
interior of the flasks on the large sides, which bars are removed when the flasks
are ready to be opened.
..In order to facilitate the manufacture I can, instead of pressing with plain plates
or plungers, ram the sand with plate patterns similar to those described in the
first process, whereby at each action of the press I obtain a mould and two half
moulds. Instead of drawing the moulds by placing them on a table I place the
moulds on those previously obtained as before described.
Instead of employing a binged flask fixed above the lower plate pattern, as before
explained, I can proceed as follows:-I take (see the section Figure 21, and plan
Figure 22) a box or frame M without a hinge into which the lower plate pattern C
can enter truly. The height of this box is such that its upper surface is flush with
the upper face of the plate pattern. On the box I place a hinged flask N whose
height is equal to that of the mould to be produced. On the flask I place a second
box O not hinged, whose height depends upon that of the flask N, that is to say,
upon the castings to be made and the degree of cohesion to be given to the moulds.
The box M has guides, as shown in the Figure, which prevent all horizontal
displacement of the flask with respect to the box M. The flask N has similar
guides for the box O. The two boxes are planed or smoothed inside. The result
of the arrangement is that if the upper plate pattern be placed in the box o all the
points of the contour would be exactly opposite those of the other plate pattern.
I put sand into the flask and the upper box, and I ram it by means of a press of
any suitable construction, but it is well to provide it with a disengaging apparatus,
which when the lower face of the upper plate pattern is level with the upper
surface of the flask N causes the movement of the plate to change its direction so
that it rises out of the box O. The box O has therefore for object to measure the
volume of unranımed sand which ought to be removed in order that a proper
cohesion may be obtained, and especially to guide the upper pattern plate. The
ramining having been finished the box O is removed, then the flask N is lifted
with the mould; the pattern plate and the box M remain on the table. The above
will be the practice for the greater part of the pieces to be cast, but for very delicate
pieces it is preferable to return the flask and the box M with the plate pattern C,
and then to lift this plate above the flask; this prevents the very fine parts of the
sand becoming detached; afterwards the flask with the mould is carried to the
place where the casting is to be effected; another flask exactly similar has then
another mould rammed in it; this second flask is placed upon the first; they fit
together without trouble by means of guides; then the first or lower flask is
opened; a fresh mould is rammed in this flask, which is theri placed upon the
second; this is then removed, and so on, until the pile of moulds has reached a
suitable height.
The plate patterns have projections at all the required points to form the holes
and runners complete, also air vents when necessary. When the pile is ready the
gates or holes at the top should be enlarged and the upper mould weighted, and
the casting may then proceed.
For rapid manufacture 3 similar flasks are employed, so that while one man
places one upon the pile and removes the one below, another man supplies the sand
and rams a mould in the third flask. The press should be arranged so that the
lower pattern plate rises while the upper one descends. The height of the lower
box is therefore equal to that of the upper box plus the thickness of the plate
pattern.
The following advantages are obtained by means of this Invention :-Great
rapidity of manufacture, because the chief operation, ramming the sand, is effected
mechanically; great equality of the castings obtained, because the patterns are not
agitated as with the hand process; considerable economy of hand labor, as one
workman can carry out the process; great economy due to the small quantity
of metal to be remelted, which is reduced to a minimum by the casting in a
pile.

page_text: The process is specially intended for the manufacture of ornamental castings in
iron, bronze, or zine; but it can be applied to other castings in iron, steel, or other
metal.
Having now described the nature of the said Invention, as communicated to me,
and in what manner the same is to be performed, I declare that I claim;-
First. The combined use in the manufacture of moulds for castings of flasks whose
parts are movable relatively to each other, of pattern plates, and of means for
ramming the sand mechanically, substantially as herein beforo described..
Second. The simultaneous moulding or formation of each of the faces of the
moulds, substantially as hereinbefore described.
Third. The manufacture of metal castings by means of a number of moulds piled
one upon another, substantially as hereinbefore described.
In witness whereof, I, the said John Clayton Mewburn, have hereunto set
my hand and seal, this Twentieth day of September, One thousand eight
hundred and eighty one.
J. C. MEWBURN. (L.S.)