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Bible Encyclopedias
Founding
1911 Encyclopedia Britannica
or (from Lat. fundere, to pour), the process of casting in metal, of making a reproduction of a given object by running molten metal into a mould taken in sand, loam or plaster from that object. To enable the founder to prepare a mould for the casting, he must receive a pattern similar to the casting required. Some few exceptions occur, to be noted presently, but the above statement is true of perhaps 98% of all castings produced. The construction of such patterns gives employment to a large number of highly skilled men, who can only acquire the necessary knowledge through an apprenticeship lasting from five to seven years. A knowledge of two trades at least is involved in the work of pattern construction - that of the craft itself and that of the moulder and founder. Patterns have to be constructed strongly. They are generally of wood, and they thus require skill in the use of woodworking tools and the making of timber joints, together with a knowledge of the behaviour of timber, &c. Some few patterns are made in iron, brass or white metal alloys. They have to be embedded in a matrix of sand by the founder, and being enclosed, they have to be withdrawn without inflicting any damage in the way of fracture in the sand. Since cast work involves shapes that are often very intricate, including projections and hollow spaces of all forms, it is obvious that the withdrawal of the patterns without entailing tearing up and fracture of the sand must involve many difficult problems that have to be as fully understood by the pattern-maker as by the moulder. It is from this point of view that the work of the patternmaker should be approached in the first place. No closed mould can possibly be made without one or more joints, for if a pattern is wholly enclosed in a matrix of sand it cannot be withdrawn except by making a parting in the sand, and it is not difficult to conceive that the parting in the pattern might advantageously be made to coincide, either exactly or approximately, with that of the mould. Nor must obstacles exist to the free withdrawal of patterns. They must therefore not be wider or larger in the lower than in the upper parts; actually they are made a trifle smaller or "tapered." Nor may they have any lateral extensions into the lower sand, unless these can be made to withdraw separately from the main portion of the pattern. Finally, there are many internal spaces which cannot be formed by a pattern directly in the sand, but provision for which must be made by some means extraneous to the pattern, as by cores.
A single example must illustrate the main principles which have just been stated. The object selected is a bracket which involves questions of joints, of cores, of pattern construction and of moulding. The casting, the pattern, and its mould are illustrated. Fig. I illustrates in plan the casting of a double bracket, the end elevation of which is seen in fig. 2; the pattern of which presents obvious difficulties in the way of withdrawal from a mould, supposing it were made just like its casting. But if it be made as in fig. 3, with the open spaces A, B, in fig. 2, occupied with core prints, and the pieces A, A in fig. 3 left loosely skewered on, everything will " deliver " freely. Moreover the pattern might be made solidly as shown in fig. 3, or else jointed and dowelled in the plane a-a, as in fig. 4, or along the upper faces of the prints b-b, fig. 3. The FIG. I. FIG. 2.
timber shadings in figs. 3 and 4 illustrate points in the most suitable arrangement of material. The prints are " boxed up." Fig.. shows a certain stage of the moulding, in which one half of the pattern has been " rammed " in sand, and turned over in the " bottom box," and the upper half is ready to be rammed in the " top box," with " runner pin " or " git stick " A, set in place. The lower loose piece has had its skewer removed during the ramming. Fig. 5 illustrates the mould completed and ready for pouring. The boxes have been parted, the pattern has been withdrawn, cores inserted in the impressions left by the prints, vents taken from the central body of cinders, the pouring basin made and the boxes cottered together.
Every single detail now briefly noted in connexion with this bracket is applied and modified in an almost infinite number of ways to suit the ever varying character of FIG. 3. foundry work. Yet this process does not touch some of the great subdivisions of moulding and casting. There is a large volume of large and heavy work for which complete patterns and core boxes are never made, because of the great expense that would be involved in the pattern construction. There are also some cases in which the methods adopted would not permit of the use of patterns, as in that group of work in which the sand or loam is " swept " to the form required for the moulds and cores by means of striking boards, loam boards, core boards or strickles. In these classes of moulding the loose green sands and core sands are not much used; instead, loam - a wet and plastic sand mixture - is employed, supported against bricks (loam moulds) or against core bars and plates, and hay ropes (loam cores). All heavy marine engine cylinders are thus made by sweeping, and all massive cores for engine cylinders and large pipes, besides much large circular and cylindrical work, as foundation cylinders, soap pans, lead pans, mortar pans, large propeller blades, &c. In these cases the edge of the striking board is a counterpart of the profile of the work swept up. Joints also have to be made in such moulds, not of course in order to provide for the removal of a pattern, but for the exposure FIG. 4.
of the separate parts in course of construction, and for closing them up, or putting them together in their due relations. These joints also are swept by the boards, generally cut to produce suitable " checks," or " registers " to ensure that they accurately fit together. Fig. 6, showing a portion of a swept-up mould, illustrates the general arrangement. A plate, A, carries a quantity of bricks, B, which are embedded in loam, and break joint. To a striking bar, C, supported in a step, a striking board or sweeping board, D, is bolted, and is swept round against plastic loam, which is afterwards dried. The check on the board at A corresponds with a similar check on the board which strikes the interior of the pan, and by which top and bottom portions of the mould are registered together. This is indicated in dotted outline. Its mould also is swept on bricks, and turned over into place, and the metal is poured into the space b, b, between the two moulds. There is also a large group of swept-up work which is not symmetrical about a centre of rotation. Then the movements of the sweeping boards are controlled by the edges of " core plates," or of " core irons " (fig. 7). Bend pipes, and the FIG. 5.
volute casings of centrifugal pumps and pipes, afford examples of this kind. In fig. 7, A is the core iron, held down by weights, and B the " strickle," sweeping up the half bend C, two such halves pasted together completing the core.
D C FIG. 6.
Core-making is a special department of foundry work, often involving as much detail as the construction and moulding of patterns. Two perfectly plain boxes are shown in figs. 8 and 9, in both of which provision exists for removing the box parts from the core after the latter has been rammed. Core boxes are jointed and tapered, and often have loose pieces within them, and also prints, into the impressions of which other cores are inserted.
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