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(ME-202)
Sheet Metal
Operations
Keywords:
Cores
Figure 11.4 (a) Core held in place in the mold cavity by chaplets, (b)
possible chaplet design, (c) casting with internal cavity.
Core Parts
Smooth surface.
Cores are generally made of sand & are even used in permanent molds.
BASED ON THE TYPE OF SAND USED:
1. Green sand core: these are obtained by the pattern itself during
molding.
This is used only for those type of cavities which permit the
withdrawal of the pattern.
Though this is the most economical way of preparing core, the
green sand being low in strength cannot be used for fairly deep
holes.
A large amount of draft is to be provided so that the pattern can
be withdrawn.
2. Dry sand cores: are those which are made by means of special
core sands in a separate core box, baked and then placed in the
mold before pouring.
Green Sand Core
Types of Cores
3. Horizontal core: the most common type.
Usually in a cylindrical form laid horizontally in the mold.
Ends of core rest in seats provided by the core prints on pattern.
Horizontal core may be made in one piece using a split core box, or in
two halves using a half core box.
4.Vertical core:
The core is placed along a vertical axis in the mould.
The ends of the core at top and the bottom fit into the seats provided
in the cope and drag halves of the mold.
Both horizontal and vertical cores are used more frequently than
other cores in the foundry work. For this reason they are called stock
cores and are kept ready in various diameters and lengths.
Balanced core
Types of Cores
6. Cover Core:
Cover core is used when the entire pattern is
rammed in the drag and the core is required to be
suspended from the top of the mold.
Unlike the balanced core, which extends horizontally
in the mold cavity, the cover core stretches
vertically downwards.
Cover core
Types Of Cores
7.Hanging Core:
If the core hangs from the cope and does not have
any support at the bottom in the drag, it is referred
to as a hanging core.
In this case, it may be necessary to fasten the core
with a wire or rod, which extends through the cope
to a fastening on the top side of the cope.
Hanging core
Types of Cores
8. Wing core" or stop-off:
Wing core may be used when a hole or recess is to be obtained
in the casting either above or below the parting line.
Wing core is necessitated when it is not possible to place the
pattern in the mold such that the recess can be cored
directly or with the other types of cores.
Since a part of the core placed in seat becomes a stop-off and
forms a surface of casting, it is also referred as stop-off core.
It is also known as tail core, chair core, and saddle core
according to its shape and position in the mold
Wing core
Types of Cores
9. Ram-Up Core:
Sometimes, the core is set with the pattern in the mold
before the mold is rammed. Such a core is called ram-up core
it is favored when the core detail is located in an
inaccessible position.
It may be used for both interior and exterior portions of a
casting.
Ram Up core
Types of Cores
10. Kiss Cores:
When the pattern is not provided with core prints and no
seat is available for resting the core, the core is held in
position between the cope and drag simply by the pressure
of the cope.
Kiss cores are useful when a number of holes are required
in the casting
Dimensional accuracy with regard to the relative location of
the holes is not important.
Kiss Core
Core Making
Cores for sand casting are manufactured by packing
specially prepared sand in Core boxes.
Core-making processes include sand preparation, core
shooting, coating/treatment and placement in mould.
The cavity in a core box is a negative replica of the
corresponding part feature.
The core box is made in two segments (with a parting) to
enable removal of the core.
Complex cores are prepared by assembling or gluing two or
more cores of simpler shapes.
The core-related activities consume significant resources.
Thus the number and volume of cores must be minimized
to the extent possible, to reduce tooling cost and
manufacturing time.
Core Boxes
Core boxes are used for making cores. A core box is a wooden
or metallic type of pattern and are made either single or in
two parts.
They may be classified according to the method of making the
core or shape of core.
The common types of core boxes are described below:
1. Half Core Box
Half core box is used when a symmetrical core is prepared in
two identical halves which are later on pasted or cemented
together to form a complete core.