pj-L
.
H.HAND
.
Making
Pattern
AND
Foundry Practice A PLAIN STATEMENT OF THE METHODS OF WOOD PATTERN MAKING, AS PRACTICED IN MODERN PATTERN SHOPS, WITH COMPLETE INSTRUCTIONS FOR SWEEP WORK AND NOTES ON FOUNDRY PRACTICE, TOGETHER WITH NUMEROUS DRAWINGS TAKEN FROM ACTUAL PATTERNS WHICH HAVE BEEN SELECTED AT RANDOM BY THE AUTHOR FROM A MODERN PATTERN ROOM WITH A VIEW TO ILLUSTRATE THE PROCESSES OF THE CRAFT AND THE INSTRUCTIONS CONTAINED IN THIS WORK.
NOTE — The
majority of the problems in this book
hwve been
solved^ the ivork performed directly under the super-vision of the author.
By
L.
H.
HAND, M.E 3(lllu0trateD
FREDERICK
J.
DRAKE &
PUBLISHERS 1905
CO. CHICAGO
B8ARY
of
OONQR£SS
Iwo Oopies
riiscMvoci
SEP. 5 ^Oopvrmnx
COPT
J9U5 cuiry
8.
COPYRIGHT,
1905
BY
FREDERICK
J.
DRAKE &
CO.
CHICAGO
6-^Wl
PREFACE
My
purpose in writing
parent from quite
sure, will
this
book
great usefulness,
its
be conceded by
be ap-
will
which, I
am
intelligent
and
thoughtful readers.
For many years I have been employed
in rail-
road and construction shops and have observed that the principles of pattern
than
understood
work.
I
any other branch
have frequently noticed,
shops especially, that the
"make a
pattern"
and were
smaller
is
is
railroad
in
better position
demand than
who
those
makers are regularly employed, but in the
systematically arranged;
shops
workman
wood
of
In large shops from one to a great
pattern
and work
less
workmen who could
commanded a
greater
in
could not.
many
making were
it
is
very important to
in the cabinet or carpenter
have a
shop who
competent to make a correct pattern and who
may be
called
upon
at
any time
to
perform
duty, thereby being instrumental in saving
money
this
much
for his employers.
For a term
of years I 3
was employed as gen-
PREFACE
4 eral
foreman of the wood working department
of a factory near one of the large cities
start,
on Lake
This factory, from a very modest
Michigan.
advanced rapidly
tance, until
its
wealth and impor-
in
employes were numbered by the
In the beginning the pattern shop
hundreds.
was only a branch
of,
or rather a bench in, the
cabinet shop.
For about three years the growth
of the pattern
shop kept pace with the growth
of the plant, until eventually
ment
of itself
it
became a depart-
and passed out from under
my
supervision.
During
my
term as foreman of the pattern
shop, I observed that sidered pattern
some
workmen who were con-
makers were
entirely ignorant of
of the simplest problems in pattern
ing, while others
the business.
were expert in every
detail of
I also discovered that there
great scarcity of literature
mak-
was a
upon the subject
of
pattern making, and such as was obtainable was
not generally read by the members of the trade.
Having become much
interested
problems with which I was
in
the various
confronted
from
time to time, I consulted frequently with the intelligent
I
and expert members
became thoroughly
of the craft, until
familiar with the business
PREFACE in all its details
and quite
workshop practice to
6
skillful in
become a master
the actual
Being ambitious
of the art.
of the science, I took great
pride in working out difficult problems at the
application
persistent
soon acquired a sub-
I
stantial reputation as a pattern
Not being engaged winter, I devoted
my
maker.
active
in
business
confer a lasting benefit
workmen
upon those
who
of the craft,
it
would
it
my
fellow
contains with
same care and earnestness which to
The
elaboration.
their
treated relate mainly to patterns
from time to time, to
my
under
man
of
study the expla-
will
nations and illustrations which
devoted
have
I
subjects
which came,
bench or which
fell
observation while I was general fore-
the
of
my
last
time to the prepa-
leisure
ration of this work, feeling assured that
the
and
and the bench, and by assiduous
lathe
wood working department
in
the
factory.
A
wide and varied experience in the employ
of railroads
vinced
maker
me is
and car shops that
even the professional pattern
ignorant of
problems, while to
workmen
generally, has con-
many
many
comparatively simple
careful
and
wood
close
the simplest rules are unknown.
As
PREFACE
6
evidence corroborating this statement, I will cite
an instance
maker whom
pattern
man
of the ignorance of a professional
up about
cut
I once
knew.
six dollars'
This work-
worth of lumber
and spent two days' time making a Later on
box. ations,
this core
large core
box needed some
alter-
and another pattern maker, who had
been employed subsequently, was called upon to
He
looked the box over and
seemed much amused.
Then he picked up
make some
the changes.
and four
large scraps
the desired length,
and
in
strips
of
wood
of
about thirty minutes
he made a skeleton box, at a cost of about thirty or
forty
cents,
which answered
all
purposes,
thereby demonstrating the fact that "knowledge is
power," and that the serving
of
a given time
a pattern shop does not always develop pro-
in
ficiency to
Should
its
highest plane of usefulness.
this
work be the means
of
improving
the condition or advancing the wages of any of
my
fellow laborers,
from them, and filed
away
I shall be pleased to hear
their
letters
as the tokens of
will
some fellowmen's
burdens which have been made a through
my
be carefully
little
lighter
efforts.
The Author.
PATTERN MAKING AND FOUNDRY PRACTICE PRELIMINARY REMARKS While the catalogues
of
publishing
houses,
dealing in scientific works, abound with hand-
books published
in the interest of the progressive
wood worker who about the while
desires
possibilities of
we may
find
to learn
wood
all
he can
construction,
and
books devoted to the use of
the steel square, building construction, superin-
tendence, different rules and methods for
esti-
mating and contracting, forms of specifications
and
contracts,
straight
hand
and
railing
rules
for
laying
out arches
in
circular walls, different systems of
and
stair
building,
rules
and
formulas for determining the strength of materials
and estimating the natural
strains to
which
such materials are subject, hopper bevels, hip
and
valley roof framing,
groined ceilings, rake
mouldings, roof and bridge trusses
and
their
PATTERN MAKING
8 joints
and
ticular
branch of the
it
seems that the par-
art of
wood working, which
strength, yet
pertains to the
making
of
wood
patterns for the
moulder's use in making cast metal forms of the various kinds, shapes and dimensions required
by the numerous and ever-increasing demands of
modern
little
on
literature
exists,
and that which does
extent
by the
craft, the
bulk of information on it
were, carried by
from foreman to apprentice.
tradition
of this fact,
it
subject
this
not read to any
is
technical points being, as
all
much
construction, has not been given
attention, as very
occurred to
me
and comprehensive work on
In view
that an exhaustive
this
subject, giving
the results of years of practical experience, eluci-
dated by clear and concise instructions and trated
by drawings, cannot
fail
to
illus-
supply an
urgent want in the ever-growing complexity of this masterful era of
This work trained
and
diflScult
will
is
mechanical progress.
destined not only to aid the well
skillful
artisan
by simplifying many
and seemingly impossible
tasks,
become an indispensable source
tional advantage to the inexperienced
but
it
of educa-
mechanic
and apprentice. There
is
absolutely nothing
known
as to the
AND FOUNDRY PRACTICE
9
from
origin of the process of casting metal forms
wood
man of
Among
patterns.
the reUcs of prehistoric
which,
bronze
by
must
material in sand or earth. probability,
all
we
made by
a pattern of wood or other
either
metal, in
vessels
inference,
inevitable
concede were cast in moulds
embedding
of
and
there are weapons, implements
The
very discovery
owes
its
some kind
the accidental fusing of
origin
of ore,
to
and
the form of the cavity in the earth in which
it
has cooled suggested to the mind of primitive
man
the wonderful process of moulding, which
has been
so great a factor in
development
the
of
human
the
marvelous Patient
race.
research has revealed incontrovertible
scientific
evidence that the art of moulding in earth of high antiquity,
tion that pattern
and
one
justifies the
deduc-
also as a craft,
though
this
making
is
no doubt struggling through long periods
of time
of
almost
in
a
of
state
equally
primitive
remote
necessity of
origin,
crudity,
as
is
the conception
a pattern to construct the mould
would most naturally follow the discovery fusion
of
and
of the
ores into the various forms given to
the cooled metal in earth or sand.
by the accidents
of its position
PATTERN MAKING
10
In the early history of pattern making the art
was not separated from ordinary wood working. It
was a branch
trade,
all
the purposes
but the demands
period;
that
of
of the millwright or wheelwright
and answered
and wants of
modern
manufacture are so multitudinous and exacting that the highest order of
has become an
skill
imperative necessity in every department of the
wood worker's
trade.
The wonderful improvement
in
machinery
during the past century has created a for forms in casting, so variety,
less
pattern ing
that
numerous
the vocation
maker has become a
scientific
demand
in their end-
of the
modern
specialized art requir-
knowledge highly developed, and
coupled with the ability to apply this knowledge practically to the requirements of
modern me-
chanical discovery and invention. It is
therefore of the utmost importance that
every mechanic life
who
selects for his
vocation in
that of the pattern maker, should thoroughly
master
all
the technical knowledge of the art,
not only for his that
still
own temporal
interests,
higher motive which actuates
workers in every department of
and who reap
as
their
all
but for zealous
human endeavor
reward, in addition to
:
A>D ForyBRY
tioiL,
practice:
ii
and tbtmq
that the patterr y--
and no* made,
wcMbf experier to the effioenc;
indnsinr in
tlie
Xambered young
man
:
&:
j
~i= a
:
wt^.
great cities an
brass foandry Talves,
z
checks,
from the time foveman of
poatkm
.
foi'
h'r
.
^
th-^
years.
a farmer, made
his
A:-
for a grain bir
the straw.
TL
but the introc
sc^ed the proh
b had
two la^ge Imic tion
larmed and
under ecu
jcMned the gecK
cansi^ a
V-^^
his inren-
:
_
:
binder, al!
his
PATTERN MAKING
12
These two
the machine.
labor on
however, of rapid success and utter extremes
resent the
failure, rep-
good and bad fortune
of
medium
rather than the average
instances,
which
of success
always attends assiduous application and persistent
The
endeavor in the aggregate. principal
aim
of the pattern
maker should
be to make himself so absolute a master of
work
that the solution of
may be
he
problems with which
confronted can be quickly obtained
and with the ern pattern
with
all
least possible
expense.
The mod-
maker should be thoroughly
the rules for draft shrinkage,
all
apply them
ready to
Under
at
a moment's
familiar
etc.,
the old regime, the millwright
hewed
made
patterns for boxing, gear wheels, etc.
He
up
the
then
the machinery, officiating practically as
millwright,
penter;
and
notice.
the timber, framed his building and
set
his
machinist, pattern
in fact, he
factotum;
and
yet,
was a
maker and
car-
veritable mechanical
although the millwright
is
credited with the ability to figure out the speed of gears, pulleys, etc.,
he
may be
and
to set
up machinery,
totally ignorant of the simplest rules
for shrinkage, draft, etc.
Hence the importance
of specialized labor in the vast
number
of de-
AND FOUNDRY PRACTICE
13
partments which have been created by the neces-
modern
the gigantic industrial world of
sities of
times, as
and money saved. of high pressure
and time
are obtained
better results
Living as
and quick
we do
results,
in this
age
incum-
it is
bent upon every worker to do his part with as expenditure of time, energy and
little
possible, or the procession will pass
he
money
as
him by and
be consigned to the rear in the ranks of
will
that great
army
of those
who
are unfit to con-
tinue the fierce struggle of existence under
mod-
ern industrial conditions.
The smith
old time
buggy maker, who was black-
and wheelwright, body maker, trimmer
and
painter,
like
the
was wont
to build
a few vehicles
famed "one hoss shay," but they were
so expensive that only a very few people, exceptionally fortunate could afford to
own them.
these days half a dozen smiths
make
different parts of the gear, while the
welds the
tires
could not in
all
as
In
many
man who
probability forge
the simplest part of the gear, and the curtain
maker may never
The
gear
shafts least
in
see
Indianapolis,
money
will
top
the
may be made
in
the
buy the
of
the buggy.
Grand Rapids,
the
body wherever the largest box,
and the
PATTERN MAKING
14
Then
parts assembled in Chicago.
product
the finished
put on the market at a price so
is
low that the barefooted boy in the country can take his grist to mill in a buggy. gies
have become so cheap
In
bug-
fact,
that, driving along
almost any country road, one will often pass a
up
buggy wreck
piled
side
These wrecked
ditch.
entirely is
worn
in a fence corner or in a
vehicles
out, but the price of a
so low that
it is
not
are
new buggy
cheaper to buy one than to
incur the expense of repairs upon the old one.
A
thorouo^h division of labor, while
mechanic
to
become, as
it
were,
it
forces a
a cog in the
wheel of some great machine, which grinds the
same round from day month,
to
day and month
also cheapens the product of every
chanic's labor, so that
now
to
me-
people of small means
are not denied the products of mill, loom and factory,
which half a
century ago
With the
obtainable by the very rich. increasing tern
more
demand
making
is
a trade to
were only
for cheaper production, pat-
destined to
become more and
be desired.
The
destruction of
the forests and the presence of the iron tain in Missouri are
where we
will
ever-
two fixed
moun-
facts, indicating
be forced in the near future to
AND FOUNDRY PRACTICE
15
seek our raw material which heretofore the great forests
timber,
the
iron
slowly and
is
but surely taking
ceptibly
men
heard old try
With the disappearance
have suppHed.
when
almost imper-
have
I
place.
its
of
bewail the condition of the coun-
the supply of
rail
timber becomes ex-
hausted, and yet what farmer would split the
now
rails
The wooden
ber?
way
he were given free of cost the tim-
if
for cast
fence post
rapidly
is
making
or a block of concrete with a
iron
rolled sheet iron standard.
The wooden
railroad
bridge has almost disappeared, and even country
now
road bridges are
Wooden
its
now
all
only exist because the
cost
first
is
yet cheaper than other
better material for construction. cross tie
when
of iron.
built
have not entirely disappeared, and wood
forests
in
buildings
nearly
is
The
and
railroad
yet a perplexing problem; nevertheless,
the timber for
exhausted,
its
necessity
manufacture
will
give
birth
is
entirely
to
some
ingenious device or substitute in iron, glass, concrete or paper,
wooden
cross
which
tie,
so far superior to so to
come
will
and it
will
supersede the present
will in all probability
prove
that those of a generation or
contemplate with amusement the
primitive methods employed
by
their fathers in
PATTERN MAKING
16
the construction of roadbed, just as
we
of this
generation look with jocose good nature upon the
oW wooden
plow of our ancestors.
It should not
be inferred that any arbitrary
of rules can be devised governing the
every description of pattern which the
may be
upon
called
approach
making
of
workman
The
to produce.
set
nearest
an unerring guide, covering the
to
widest range of the subject,
the classification
is
of certain forms of patterns with drawings illus-
trating each class, with concise
nations
and
lucid expla-
by which the well-informed and
mechanic can work out problems class they
may
This
appear.
is
intelligent
whatever
in
what the author
has done in this work, and in a manner to insure the certain accomplishment of his purpose, and yet the hope
is
v/ork, either
by
that any
nowhere excited throughout
this
direct statement or implication,
self -educational facilities
afforded
by the
study of this work will supply the deficiency of natural mechanical talent which must primarily
be possessed by any person who may hope to excel in
any department of mechanical
science.
In a factory which employed over one hun-
dred carpenters and
cabinetmakers,
think there were more
I
do not
than three or four
who
AND FOUNDRY PRACTICE
17
could or ever did turn anything on the
and whenever many
lathe,
tempted to result,
do
the
of
wood
others
at-
a complete failure was the
so
notwithstanding the most explicit verbal
instructions as to the holding of the tools practical
and the
demonstration by the instructor taking
and performing the operation
the tools himself for the students.
In the preparation of
aim
work
this
and present
to simplify
light so clear that the
all
my
has been
it
problems in a
principles at least will
be
thoroughly understood by any reader of ordinary
but the practical
intelligence;
application
of
the
principles
and
successful
expounded
depend wholly upon the innate
ability
ful execution of the operator.
Even with
will not
workman any
The work
and carenative
rough and careless
talent of the highest order,
work
will
promote success nor obtain for the creditable reputation. of a
pattern
maker
is
clean and
pleasant, but requires a very high grade of skill to properly execute, even
under the direction of
The
cutting tools should be
a
skillful
foreman.
the very best that the market affords, with edges
smooth and keen of the
at all times.
shop every new job
is
To
the foreman
"another problem
PATTERN MAKING
18
to
solve."
jobs
job
— no is
ered,
There
no precedent
beaten path to follow.
for
many
Often after a
completed a better way has been discov-
by which the job could have been done
greater advantage. of
is
to
There have been instances
capable pattern makers widely differing in
their views
of
how
certain patterns
should be
made; each one maintaining vehemently that
method was the only
right
and proper one.
his
FOUNDRY PRACTICE Before entering into the details of
making, of
let
making
manner
in
us
castings; for
it
if
are ignorant of the
by the use
would be impossible
to the best advantage. I
we
believe
that
a
to
of the
make
wood
I say this advisedly,
successful
casting.
mould
related of a certain
perfect,
has been
It
to
it
out of
authentically
buck from the
grew on the animal's head.
remember an instance
of a
a small foundry the
stove,
it
and make a
moulder that he could mould
the pronged horns of an antlered
natural pattern as
and
moulder can take
first-class
the sand, leaving the
pat-
the pattern
nearly any object for a pattern and get
I
way
which the moulder obtains the proper
cavity in the sand tern,
pattern
consider the customary
first
which was broken
fire
farmer
who brought
bowl of a heating
in seven pieces.
bowl was moulded from the
pieces,
A new
a feat of
moulding which suggests a strong argument the pattern
him
to
maker and which should convince
that a knowledge of foundry practice 19
is
a
PATTERN MAKING
20
most powerful auxiliary
him always
to
make
Castings are usually
his
enabling
trade,
made
two or more rough boxes, so con-
by
This
in use.
would show a jog
When more called a
is
casting
the
otherwise
is
is
the use of dowels or other devices,
as to retain their relative positions at
when
This
in a flask.
of
composed structed,
to
his patterns.
all
absolutely necessary, as
would be one-sided or
at the joint or parting.
than two boxes are used,
compound
flask.
The upper box
cope, and the lower box the drag. portions of a casting are usually
which naturally
retains
its
this flask
Usually only two
boxes are used, and this arrangement two-part flask.
times
is
is
The
left
called a
called
the
heaviest
in the drag,
shape, thereby mini-
mizing the risk of agitating the sand, whereas the cope has to
be
lifted
and moved around,
which has a great tendency to disturb the sand in
it
overcome or
To
and break and destroy the mould. this danger,
wooden
bars,
it is
customary to put rods
or both,
across
the
cope,
through the sand, v/herever they can be placed without interfering wath the pattern.
and rods hold the sand be
lifted to
in
Then
bars
shape so that they can
remove the pattern and replaced
to
AND FOUNDRY PRACTICE make
the finished mould.
do
to
so,
best to
is
it
wooden pattern
Where
make a
at the point
21
it is
possible
parting in the
where the sand
cope and drag divide on a straight Hne.
the
This done, that part of the pattern which be
in
left in
the drag
is
placed on a
is
board or
flat
The drag
bench, with the parting down.
to
is
placed in an inverted position on the same board
bench and "rammed up";
or
filled
and tamped
The drag
solidly with
that
to
is
say,
moulding sand.
then placed right side up on the
is
foundry floor and the upper part of the pattern is
put on.
A
parting
is
then
parting sand and the cope
and rammed up.
made
is
with fine dry
secured in place
made down
Holes are then
through the cope to the pattern, for the purpose of pouring the metal into the
allow the air to escape. apart and the
also to
flask is then taken
wooden pattern removed, leaving
two halves
the
The
mould and
of
the mould, which are then
placed in their proper positions, making a complete
and
finished mould.
board, which
is
a "follow board," special in
In ordinary work a
the size of the flask is
and
cases
when
the
parting
called
For some
used for parting.
work, a special follow board
is
is
used, as
would describe a
PATTERN MAKING
22
In other cases a follow board
curve. for
a single piece pattern,
for a car break, its
the
like
made
is
hand wheel
by bedding the pattern one-half
depth in plaster of Paris, thus bringing the
parting to the center of the pattern without any parting in the
wooden pattern and without the
use of the trowel.
All these things are
done
convenience to the moulder, so that he can
for
make
time in getting out his work.
The
first
a pattern
thing to be considered in looking at
how
is
it
will
best
draw out
of the
sand.
Every complicated form of casting pre-
sents
a partially new problem to the pattern
maker.
If
a piece will readily draw out of the
sand except one or more small projections, they can sometimes be
left
will allow the pattern
on a dovetail to
slide,
which
be drawn, leaving a
part in the sand to be removed later on; or
be a cavity,
it
must be cored
if it
out.
In preparing this work I have begun with the simplest forms and kinds of patterns, progressing
gradually through the more difficult features of the work, and for illustrations I have used principally patterns
which may be found
in the pattern loft of the
Car Works, near Chicago.
in duplicate
Hicks Locomotive and
These patterns have
AND FOUNDRY PRACTICE
23
been made by different pattern makers and have been selected with a view to properly ideas
and demonstrate such
illustrate
peculiarities of con-
structions as are treated in this work.
The
very simplest form of pattern
sented by the cast iron washer, Fig.
on one
pattern, being straight
below the parting and
When
the drag.
is
This
1.
side, lies entirely
consequently entirely in
is
a great
many
article of this class are required,
to
repre-
is
pieces
of
any
customary
it is
make what called
pat
"gated
which
tern," consists
number
of
,
^
rosi
section
patterns
made
strips
of
side,
lying
a
ca^t Washer*
a
fastened together with straight
= throvjih
level
alike
and
small strips let into the
with
on the
exactly
its
follow
Then
face.
board
leave
small little
grooves in the sand which allow the molten metal to pass easily
freely into
all
the moulds,
broken apart when the metal
manner
of
moulding
this
kind
of
which are
cools.
This
pattern
is
similar to that previously described, except that
the cope
is
simply placed on the drag and
with sand, as there
is
no part
of
filled
the pattern
PATTERN MAKING
24
projecting this
up
may be
into
A
it.
better understanding of
derived by a study of A-1, Fig 2,
wliich shows a cross-section through the drag,
the
the
pattern,
rammed
the entire box and
its
contents ready to be in-
and placed on the foundry
verted
follow board
'•'<'••
is
floor,
when
the
removed and the cope secured
in
"'Tl-'
Cto^H section
place and
and the sand
shows the cross-section of
Fig. 2
up.
board
follow
filled
up
£11
£
pattern rn
i hrotigh
Ihe^
^and
as previously described.
See
Fig. 3,
which shows a cross-section through the
mould
finished
metal.
and ready
The
next form to be considered
which, while being ^
to receive the
moulten
^
It is
all in
one piece,
deemed more expedient work in cross
illustrations in this
understanding of the subject that character of design.
is
of a class
is is
to m.ake
of such
most
a
of the
section, as a clearer
generally derived from
AND FOUNDRY PRACTICE
25
shape as to render the moulding of the casting
more convenient when cope.
If
it
is
entirely
up
in
the
executed otherwise, the sand in the
ssfiiiay
Cro53 secti on through finisheci
cope would difficult
make
tendency to drop
heavy and clumsy and very
it
to handle
inould
and the cope would have a
off
and ruin the mould/
In
be borne in mind that the manner of makmould depends entirely upon the nature of the work and the purpose for which it is to be used. Thus it will be found that all, or nearly all, stove castings are made in a manner exactly the reverse from that which is employed in the moulding of ordinary castings. The hollow or concave parts are usually made down in the drag, and the sand in the cope is strengthened by cross bars of wood fitted in such a manner as to come as near the metal as is practicable, and these bars are driven ^
It should
ing the
full of nails or made with other projections in order to prevent the sand falling out. By this means a smooth casting on the outer surface is obtained, as the metal, being heavier than the dross or other foreign substances,
PATTERN MAKING
26 this
case the pattern, which
is
assumed
to
be
hollow or of cup shape (see Fig. 4), should be placed the
on
follow
board with
cup
the
hollow
or
downward.
Tig
Over
^
<^ro55 5€ction through
cup
should
this
be
placed that part of the flask which cope, and
it
settles to the
smooth
is
should then be
bottom
of the
to be used for the
rammed up
in the
mould and shows a perfectly
surface, while the imperfections float to the top
In small shops where repair work maker is often taxed to devise means for making flasks perform work for which they were not intended, for the reason that in cases where only one piece of casting is required, the cost of making a special flask would be more than the value of the castIn factories such as stove works, etc., where a great ing. or inside of the sheet. is
done, the ingenuity of the flask
number of made for
similar pieces are required,
many
flasks are
particular pieces, such for instance as oven
In these cases the flasks are spedesigned with a view to performing the work with the least possible amount of labor by the moulder. There are a great many devices for holding the flasks in position, and some very ingenious patented hinges, clamps, etc. but most moulders use a square-jawed dog or clamp, doors, fire-backs, etc. cially
;
which
is
a fraction longer than the height of the flask
AND FOUNDRY TRACTICE
27
usual manner, after which the proper vents to receive
the
The cope
moulten metal
should
be
made/
should then be turned over, the follow
board removed and the drag placed
and rammed up.
Then
the flask
in position
(cope and
(cope and drag). This clamp is slipped on the flask and then crowded into a slightly diagonal position with a short bar or chisel, used as a pry, and which holds the For small work the flask is boxes firmly together. hinged together on one side with an iron hinge so designed as to be readily slipped apart. The vents or holes down through the cope for pour^
ing the metal, are called gates,
and are made by placing
tapered pins or wedges of proper size in the cope and touching the wood pattern. These, being withdrawn, leave the desired gates or ways for the molten metal to pass into the mould in the sand.
PATTERN MAKING
28
drag) should again be turned over, taken apart
and the wood pattern removed, leaving the
mould
ished
In
many
as
shown
instances
it
is
sand entirely by the use especially
fin-
in cross-section, Fig. 5.
customary to part the
of the moulder's trowel,
where the pattern
is
of
some simple
form, or where only a few pieces are required, as, for
example, the small connecting rod shown
in Fig. 6.
In
and smoothed
this case off,
a flask
after
with sand
which the pattern or
down
patterns are pushed
is filled
into the sand about
half of their depth, or to such a point as will
most readily permit
their
The moulder
way.
down and packs
it
then
Then
dry sand and the cope
and rammed up Fig. 7,
as
smoothes the
sand
thoroughly around the pat-
tern with his trowel. vv^ich
withdrawal from either
a parting is
is
made
placed in position
previously described.
See
which shows a cross-section through the
same pattern
in the sand.
Many
other forms of
AND FOUNDRY PRACTICE
29
manner where
castings
are parted
parting,
instead of being on a plane with the
in
parting in
the flask,
crooks and
offsets.
packed
this
curved or has sudden
is
In such cases the sand
is
drag to conform as nearly as pos-
in the
sible to the crooks in the parting. is
the
The
pattern
then placed in position and bedded firmly in
The moulder
the sand.
down
then packs and trowels
the sand around the pattern until a perfect
V/eTf' cartel
core
-|j |f
w:r:r7:^^^^r3^g-^l^:-
'A
'.'-v.-f-^^*;
SnUona l view
parting
is
around
of mould
foT Fig
6
Wio\¥mff
pattem
m
made, sometimes cutting deep
portions
manner an expert moulder at first glance look to
primarily
it is
cavities
which otherwise would
out the sand in drawing the pattern.
which
9and
will
get out forms
the duty of the pattern
may be
But
maker
construct his patterns as to reduce to a
which the moulder
In this
be impossible.
of intricacy all of these difficult
tear
so to
minimum
problems with
confronted.
As an
instance of the value of a correctly-made pattern
PATTERN MAKING
30 as
an
initial
illustrates
desideratum, see Fig. 7a, which
a small
top
extinguisher
fire
which, at a cursory glance, appears very cult,
but which in
This
the sand.
reality is readily is
and diffi-
drawn out
of
a cup-shaped brass casting
with round, projecting handles serving to screw
and unscrew
it.
A
cross-section of this
The heavy
sand in Fig. la.
in the
113.
^Toss
SfCtton
i
7
shown
is
lines
show
**
Tirong h fire e tlitigmsJter tcp
& ntoii'lci
the parting in the flask and the dotted lines
show
the parting in the sand. It is of
the greatest importance that a pattern
should have draft;
such a shape that the sand the out.
To
cessful
that it
moment
facilitate
withdrawal
work should be
is
to say,
it
must be
will begin to loosen
a
move
is
made
to
of
from
draw
it
a ready loosening and suc-
from the sand,
all
pattern
slightly out of square or slightly
AND FOUNDRY PRACTICE beveled;
i.e.,
it
should be a
Then
sand.
smaller at the
trifle
embedded
portions which are
31
the deepest in the
again, the moulder often raps
patterns very heavily to get them out. to say, a pointed iron,
wood
which
than
larger
so
shaped
of
the
the
Some
pattern.
that
sand, as
smartly struck
is
mould
in all directions, causing the
be
they
cannot
they
may be
is
driven into the
is
pattern for the purpose,
some
That
become
to
patterns
are
drawn
out
hollow and of
irregular form, or contain cavities or projecting
parts which would tear out or loosen the sand.
In
such cases
all
made
moulds a preparation
made
is
are
thoroughly
enough
certain
flour
sand with flour and
packed, and the forms or cores so balced
baked,
in
an
these
to stand handling
own weight by
of
are
Into these boxes or
of the proper shape.
molasses
to use
which boxes or moulds
prepare
to
cores,
becomes necessary
it
across
purposes
substituting
oven.
After
cores
become
and
will
being firm
support their
For
a considerable space. cores
linseed
are oil,
sometimes rosin,
made
etc.,
for
and molasses, and these are considered
superior, as they casting.
make a smoother and
stronger
PATTERN MAKING
32
In some instances the required cavity in the casting will be of such a form, or
manner, as to render
plicated in such a difficult to
box, and
more
mould
cores for
some
many
very
instances two or
made and glued of the parts
of
modern
tools in use in
matic
it
the desired core in a single
therefore in
cores are
may be com-
The
together.
improved pneu-
boiler shops
have
been made up of from twenty to thirty pieces
where the desired cavity was so complicated as to
be impossible of construction
box.
It is
in a single core
also frequently desirable to use cores
on work which could be drawn manner, and
this
and thin enough
is
when
in the ordinary
the casting
In
to spring easily.
is
hollow
all
cases
where cores are used, the pattern, instead of being the shape of the desired
have certain projections, termed "core
should prints," their
casting alone,
added
to
it.
impression in
These core
the
sand,
prints leave
thus forming a
cavity to hold the projecting ends of the core.
In such cases
maker
manner
it
is
necessary that the pattern
should construct his core boxes in such a as to produce a core of the exact shape
required by the cavity in the casting, together
with such projecting parts as
will exactly
fill
the
AND FOUNDRY PRACTICE cavities in the
pattern.
such as
sand
left
by the core
33
on the
prints
To illustrate this idea, a stake pocket, may be seen on the sides of a gondola
or coal car, has been selected, the pocket
flat
itself
being of the form shown in Fig.
will readily
draw out
of the
quently cast in this manner;
sand and
This
8. it is
fre-
but on account of
F/> e thinness
its
than
if
it
it is
more apt
to spring out of shape
were cast with a core, as shown in
Fig. 9.
Patterns are painted in such a
which portions are left
way
as to
show
and the core
prints are
white or painted of a light color.
Usually
colored shellac
is
iron,
used for the black portions and
uncolored for the core prints.
By
this
means
PATTERN MAKING
34
the moulder can
tell
at a glance the
how
moment he
make
takes
up
ing.
Recently, through the carelessness or ig-
the pattern just
to
the cast-
norance of a pattern maker, over two hundred
pounds at
of cast fittings in the Frisco R. R. shops
Cape Girardeau, Mo., were
cast solid instead of
hollow, because of the entire piece having been
painted black,
when
the core print should have
jF\y
been
same
In moulding patterns of the class
left light.
shown
9
in Figs. 9
and
10, the process is
as has already been described.
"a" "a", Fig.
when removed
10,
The drag
and rammed up; then
and the lugs "a" and "a" cured in
its
The
the lugs
made removable, and
the pattern. Fig. 9,
the follow board. position
are
much
is
laid flat
on
then placed in
is it
is
turned over
inserted, the cope se-
proper position, the parting
made
AND FOUNDRY PRACTICE and the cope rammed up,
The
flask
is
tern. Fig. 9, is
laid
J
35
as heretofore described.
then separated and the wood patis
removed and
in
its
place the core
making the complete mould,
as
shown
in Fig. 10.
Small patterns are often gated together, as previously mentioned, or a flask
is
leveled off
and
a quantity of tliem stuck around here and there,
///
£{gcftoytCT?
vt'gw
o£ mould for
/yy's
a
flf
^
^howin^ paiicrn
itt_
sang
while in other cases the pattern will be almost too large to be put in a flask at cases
it is
customary to dig a
all.
In such
pit in the floor of
the foundry to answer for the drag, and in the case of large castings, such as flywheels, engine beds,
etc.,
the pattern
itself
is
so
heavy that
it
can be handled only by the use of a power hoist or crane.
PATTERN SHOP PRACTICE It is
customary
pattern
in pattern shops to furnish the
maker with a mechanical drawing or blue
print of the part to be
made.
portant, in fact almost
an indispensable part
This
is
the work, and yet often this drawing
very im-
falls
of far
short as a reliable guide to the pattern maker; for wliile
it
may
indicate clearly
of casting desired,
may
it
enough the
style
contain no directions
or suggestions which will govern or assist the
pattern
maker
Although the
in the construction of the pattern. office
drawing
representation of the casting
maker's casting, etc.,
drawing
should
but also the
may be a itself,
the pattern
show not
cores,
core
perfect
only the
prints,
etc.,
and where practicable the pattern maker's
drawing should be dimensions
may be
full
size, in
order that the
taken directly from the draw-
Some shops may
ing with the dividers.
only
employ a rough sketch with figured dimensions,
and
this is
especially true of large repair shops,
the foremen of which will send a 37
man
fifty
or a
PATTERN MAKING
38
hundred miles down the road or cars which have
This
man
to repair engines
become temporarily
disabled.
a cracked or worn
will frequently find
out casting or a burned out set of grate bars, in
which event the number and date of the engine will
be noted and every
effort will
be made to
secure a correct description of the broken part in
may be
order that the blue prints of the engine consulted and the part located
however,
occurs,
that
the
damaged engine have been the pattern
maker
is
blue
mislaid
Having
failed
find
to
prints ;
instructed to
gate bar for the engine and have
engine immediately upon
its
It often
exactly.
it
of
a
consequently
make,
say, a
ready for the
arrival at the shop.
blue prints of the
the
engine, the foreman, as a last resource, carries to the pattern
shop a
from the notebook
of
memorandum sketch taken the mechanic who had been
sent to repair the engine,
drawing
and from
(see Fig. 00) the pattern
quired, at very short notice, to
which
will
give
character of
make a
drawing
re-
pattern old
will recognize
this
(Fig. 00).
therefore, that the pattern
crude is
Any
satisfactory results.
employe of a railroad shop
this
maker
It
is
apparent,
maker should under-
stand mechanical drawing, at least to an extent
AND FOUNDRY PRACTICE sufficient to
enable him to
make
39
working
full size
drawings of any piece of pattern work which he contemplates producing.
Drawing
is
plain surface
the art of representing objects on a
by the use
of lines
and shadows. illustrated
and
explained by the use of dotted lines, figures,
let-
Mechanical drawings are further
For certain purposes mechanical draw-
ters, etc.
ings are sometimes
pattern
shop uses
employed.
Two
made
in perspective;
perspective
effect
more views
or
of
is
but for never
any object
Fig. 00
treated should be given in a mechanical drawing.
The tical
art of
drawing
usefulness
is
in a very high state of prac-
now
respondence schools,
taught by several cor-
and
be
readily
Ordinary drawings for most patterns
may be
it
ma.y
acquired by any ambitious person.
made with
a lead pencil, a pair of dividers with
PATTERN MAKING
40
a pencil point, a pair of beam compasses or
trammel points and a pattern makers use their
no other
tools
A much
next job.
important job
and make
is
to
off to
make
Where paper
reference.
be ready for the
better way, however, for
filed
away
for future
drawino-s are to be used
ris
tt
be found very convenient to have a few
will
regular
drawing
The
instruments.
board should be of any convenient
made
an
the drawing on heavy
manila paper, which can be
drawing size
and
of well-seasoned, clear, soft pine, perfectly
straight
driven
and
square,
with
hardwood
snugly into dovetail gains
across the back of the board, as 11.
old
drawings on the surface of a smooth plank,
which only needs planing
it
Many
square.
steel
The T-square
lines, either
is
or
shown
cleats
grooves in
Fig.
used for drawing parallel
way, across the board, and
is
made
AND FOUNDRY PRACTICE of any hard, straight-grained wood. is
excellent for this purpose;
and maple T-square
also
being used.
made
is
41
Pear wood
mahogany, cherry
A
most excellent
for the trade with a trans-
parent celluloid edge.
A
proper T-square for
pattern shop use should have a blade at least
T^
y^r
three
feet
long,
S'X^y'X^^",
and
slightly
beveled toward the edges, with a head 2i''Xi" fastened securely at right angles to the blade.
The most approved form is
shown
wedge >--
of joint for a
A
at a 6, Fig. 13,
is
T-square
tapered dovetailed
glued to the blade of the square with
Dove, tail we^j9«-
-
1^
I
.
ri3
E
IS
the grain of the parts running at right angles to
each other.
made
A
corresponding notch or mortise
is
across the head of the square, which allows
the blade to be taken out of the head and trued
up.
The
of a few
joint
can be better secured by the use
round-head screws,
if
desired.
The
PATTERN MAKING
42 set squares or lines,
right
at
T-square;
draw
angles are used to
or to
angles
blade
the
to
draw such angles
parallel
as appear in
the corner of the set squares (see Fig. 14). first of
in
the
of
The
these set squares contains an angle of 45°
two corners and an angle
angle in the other.
This
is
of 90° or a right
used to lay out octa-
gons, or to bisect the right angle, producing a
Fi^ i
The second one
miter joint. 30°, 60°
and
90°.
contains angles of
This square
is
employed to
lay off the hexagon, or bisect the angles of the
hexagon
The 90°,
in order to obtain the
hexagon miter.
third one contains angles of 22^°, 67 J°
and
is
and
used to bisect the angles of the
octagon, obtaining the octagon miter (see a 6 Fig.
14).
Some few
extra
large
wooden
c.
set
AND FOUiNDRY PRACTICE
43
squares are yet in use for certain purposes; but for general use the
modern
celluloid or
amberoid
instruments are so far superior, on account of their transparency,
that the
wooden ones have
fallen into disuse.
A
set
of
may be
mathematical instruments
bought for from $2.00 to $25.00 or more, accord-
The
ing to the fancy of the purchaser.
Tin
/sr
cheap ones are not desirable, and instruments or tools
very
it
is
buying
in
always advisable
to
provide the very best that one's means will permit.
An
indifferent
mechanic can never do good
work with
inferior tools
use them
when he can
set
shown
in
and a good one possibly avoid
Fig. 15 has fairly
will
it.
not
The
good points and
PATTERN MAKING
44
answer very well
will
A
means.
set
for
of this
persons
kind
limited
of
for about
retails
$6.00 and will answer every purpose for the class of drawings required in the pattern shop.
In making up the working drawings for shop use
it is
preferable to trace the outlines faintly
with a sharp, hard lead pencil.
After this has
been done the drawing can be brought out with ink or a
soft,
When
black lead peacil.
ing has been plainly brought out,
men
the draw-
some
drafts-
give the cores or core prints a yellow tint
and darken the parts which are
to
be metal.
This not only improves the appearance of the drawing, but has additional advantages, especially is
to
if
some workman other than the draftsman
work from the drawing,
in
which event the
coloring of the drawing obviates the risk of any
misconception of what the finished pattern be,
thereby
result in
preventing what
awkward
mistakes.
is
to
might otherwise Mechanical draw-
ing, being a scientific subject in itself
and one
which for an elaborate elucidation would involve a voluminous ferred to in a
therefore
treatise,
book
can only be cursorily
of this nature,
and
be assumed that the reader
cieutly familiar with the
principles
re-
it
must
is
suffi-
and practice
A^D FOUNDRY PRACTICE of
45
mechanical drawing to readily understand the to the subject-matter of
instructions pertaining this
work.
The
pattern shop should always contain suffi-
cient space to provide for the free
and comfort-
volume
of production
able execution of
its
greatest
and should be arranged with a view to afford
ample room
for the
advantageous distribution and
location of machinery, benches, trestles, clamps,
The
tools, etc.
as
it is
light
should be as nearly perfect
and preferably derived
possible to obtain
through skylights which direct the rays vertically
upon the work, thereby escaping the shadows thrown upon
from the
it
by light which
side.
strikes
it
horizontally
should be so arranged
The room
that a proper temperature can be maintained in
winter to insure the successful gluing of work, as cold destroys the adhesive quality of glue and deti-imental to
work bench in order to
be
of
is
good work usually
made
keep the top
modern
in
equipped with
ways.
is
The
of three-inch plank,
true.
construction,
used either as a high or low
many
The
vise should
capable of being
vise,
and should be
an adjustable jaw for tapered
work, and so arranged as to hold the work firmly without bruising
it.
The shop
should be
PATTERN MAKING
46
equipped with a band saw or at
a
least
saw,
jig^
a pattern lathe and suitable clamps for gluing
up
worker
be found very
will
wood
In large shops a rip saw and
material.
The
useful.
highest
grade of glued work, such as piano and organ
bunks and
car
sleeping
cases,
generally,
made by
is
wood which has been heated work being done
Work
pose.
glued up in this manner
but unless
been made for to
become
to receive
this
chilled
it;
the
a room heated for the pur-
in
is
very
many
purposes than solid
special
arrangements have
strong and better for
timber;
furniture
fine
using hot glue applied to
work, ordinary glue
and
is
liable
There
lose its strength.
are several preparations of liquid glue v»4iich are
valuable substitutes
many
in
classes
of
work
where conditions are not favorable to the use hot glue. set,
These
of
liquid glues, being very slow to
allow plenty of time to work over a piece
where the assembling
and the
result
is
.of
the parts
is
far better than that
tedious,
which
is
obtained by clamping hot glue between two cold surfaces, the effect of
into
a
jelly,
with
which
little
is
to convert the glue
or no adhesive qualities.
The workman, however,
will
himself which kind of glue
is
have to decide for best suited to the
AND FOUNDRY PRACTICE specific
conditions
employed.
of
47
the shop in which he
is
In shops where the general conditions
for gluing are bad, liquid glue promises the best results,
when
are used to
nails,
screws or
add such strength
nature of the work
wood dowel
pins
to the parts as the
may demand.
TOOLS It
highly
is
impracticable
attempt
to
enumeration of any exhaustive
list
the
of tools for
pattern making, as the field covers such a wide
range of work that unless certain
it
were limited to some
branch of the trade,
would tax the
it
ingenuity of the most resourceful inventor to conceive of such a tool that the
wood worker might
not at some time meet with a situation requiring its
use.
To
the
workman engaged
entirely in
the making of stove castings, his carving tools are the most important of his kit; while
work were confined
to the
heavy machinery,
the
might never be
making
need
of
carving
The making
felt.
of
terns, while the principles involved are
tools
wood
in
all
work
of
any branch of the wood worker's
and embraces and windov/ the giant
the
covers the widest range of
castings
from the
size of
art
door keys
latches to the ponderous parts
engines
of
which supply the water to
great cities, turn the v/heels of tories
pat-
much
same
cases,
his
if
of patterns for
mammoth
and propel the iron-ribbed reindeers 49
fac-
of the
PATTERN MAKING
50 sea,
them plunging through the green
hurling
Most
surges of the sea.
pattern makers carry a
complete assortment of
very
including
tools,
their
gouges,
chisels,
and
etc.,
maker's
cabinet
lathe
tools
a
also
or set
turning of
long
called pattern maker's gouges,
straight gouges,
with a set of carving tools for some classes of
The
work.
special
for pattern
tools
making,
independent of those in general use, are shown
from
Fig. 16 to Fig. 22.
Fig. 16 represents the pattern maker's gouge,
which This
made
is
tool
is
paring out
in all
sizes
from J
to 2 inches.
used for making core boxes and for all
kinds of convex surfaces.
indispensable to the pattern maker.
It is
17
Fig.
represents the turning gouge, about three sizes of
which are usually considered
practical purposes.
ing out
work
This
tool
in the lathe,
sufficient for all
is
and
used for roughfor turning
and
finishing the concave portions of the work.
Fig. 18 represents a paring tool, of
more than two tool it
is
sizes are
which not
usually needed.
used to finish the work in the lathe after
has been roughly formed by the gouge.
flat
chisel.
ovals,
This
etc.,
Fig. 19,
and
for
is
The
used for turning beads,
sizing
particular
work
as
6
AND FOUNDRY PRACTICE indicated
used
by the
much
in
In such cases
calipers.
the
51
same manner
it
is
as a scraper.
^ Ttg
1
'mahn
Th9 pattern
,^ugo
Tia It f'","f*
Tig /£ rhhel
The: flal
^ "The
pari t It q
'
The
itili
toot
itoseci cAist?
parting tool, Fig. 20,
is
deep grooves and for cutting lathe.
The diamond
point.
used for cutting off
Fig.
work 21,
in
the
and the
PATTERN MAKING
52
bull-nosed chisel. Fig. 22, are used for turning
both the outside and inside surfaces patterns, such as the piece
shown
of
hollow
in cross-section
in Fig. 23.
Figs. 15, 16
and 17 can be procured
at hard-
Ti^ 23
ware
stores generally.
large
supply houses,
specialties, or they
smith.
The or
rest
can be had from
from dealers
can be made by a
in
tool
first-class
In addition to the tools heretofore men-
tioned, the pattern
maker
will
sometimes find
it
AND FOUNDRY PRACTICE
53
convenient to have special tools of a peculiar design for some special work.
The shrinkage
rule
especially for pattern
make
is
a
measure designed
making, and
is
intended to
the proper allowance for the contraction
However,
of metal in cooling.
it is
not possible
to accurately figure the contraction or shrinkage of metal,
as a thick casting will shrink
Some shapes
than a thin one. others or
more
some
in
A
than in other parts.
more
shrink more than
same piece
parts of the
large cylinder,
if
cast
on
end, will shrink more at the bottom than at the top.
Castings are calculated to shrink from one-
tenth to one-eighth of an inch to the foot; but,
machine castings are
as nearly all
or planed tion
a
great cases
in
tern
the
an accurate
to
the
of
measure
where
heavily,
sand,
the
in
size,
amount
exact
moulder
order to
casting
will
the determina-
shrinkage
of
immaterial.
the
either turned
Then raps
it
show but
in
again,
the
withdraw
is
pat-
from
little
if
any shrinkage.
The
lathe
is
perhaps the most important of
the pattern maker's tools.
A
all
lathe suitable for
ordinary pattern work should have a swing of at least twelve inches over the
bed and
it
should be
PATTERN MAKING
54
so arranged as to allow a face plate for large size to be
swung
work
over the end of the
off
A
bed, as shown in cross-section in Fig. 23.
heavy cast iron tripod of
main steady when
sufficient
in use,
of
weight to re-
employed
is
to hold
the rest for this lathe.
The
of
art
wood turning has by
always been and as a trade to
is
itself,
tradition
present time classified
at the
properly appertaining to the
cabinet shop and planing mill; for the art,
applied to pattern making,
from that
differs so
of ordinary cabinet
work, that
when
materially
and planing
mill
cannot be considered in the same
it
category.
The wood on the lathe
turner, working
by gauges or marks
rest representing his
measurements,
depends almost entirely upon the accuracy of eye and
skill of
form and for
his
hand
to obtain the required
size of the piece;
such work
is
his
as the compensation
often determined
by a
fixed rate
per thousand pieces, the operator soon acquires
a peculiar sleight for getting out a great quantity of material in a given length of time, which,
if
displayed in regular rows, presents an appear-
ance sufficiently uniform to answer
all
poses for which the finished work
is
the pur-
intended,
AND FOUNDRY PRACTICE although
it
55
could not stand the test of rule and
calipers.
The
on the contrary, works
pattern maker,
from a drawing of some part of a machine or other device, showing the figured dimensions of all
Every
parts.
its
figure bears
relation to the finished
an important
work and each part
is
required to correspond with mathematical precision to
some other part already completed or
in process of completion
same
of the
The
city.
factory, or
loss of
mayhap
some
in
distant
only the sixteenth of an inch loss of the
Hence the paramount
piece.
maker should
that the
another department
any part may mean the
of material in
entire
in
exercise the
necessity
most scrupu-
lous care during the process of work, stopping
frequently as he proceeds to test his accuracy
with rule or calipers or both, for only painstaking vigilance
assure
will
to
even the most adroit
mechanic a perfect duplicate of
tail
the
part
in its minutest de-
represented
Manifestly, then, the art of the sists
in
turning
which bear to
to
in
the
drawing.
wood turner con-
out great quantities of pieces
one another
sufficient
resemblance
answer the purposes for which they are de-
signed,
whilst the science of lathe turning, for
PATTERN MAKING
56
pattern making,
and not
perfection,
wholly in the accuracy and
lies
volume
in the
work per-
of
formed.
In operating the pattern lathe to turn out hol-
low forms
it is
customary to fasten discs of wood
heavy
to the iron face plates of the lathe with
wooden
screws.
secured
to
The work
the
face of
wooden screws
passing
to
be turned
is
then
these discs with other
through
wooden
the
back of the piece to be turned.
discs into the
See Fig. 23.
When
on the face
plate, these
a pattern
wooden
is
to
be screwed
discs are
marked
with the point of the turning tool at the outside or inside of the piece,
and
can then be turned
it
over and fastened true to center.
To
formulate
any
set
of
apply to the production of or to the solution of every
making degree vision
which of
may
knowledge
rules
all
which
will
kinds of patterns
problem in pattern
arise
would
and a
gift
involve of
which cannot be expected to
a
prophetic fall
to the
lot of
any observer, however patient may have
been
his
research
or
broad
his
experience;
therefore, in the treatment of this work, I
have
availed myself only of such forms of patterns as
have been
successfully
made under my own
AND FOUNDRY PRACTICE supervision
and observation
;
using these forms as
object lessons to illustrate the subject to the student a practical tial
he
57
knowledge
and impart
of the essen-
principles of pattern making, in order that
may be
well prepared
—assuming, — grapple with of course,
the possession of natural talent
every
to
new and perplexing problem with which
the interminable intricacies of the craft front
him
in
any hour
of his career.
dentally I have introduced into this
problems submitted to with foundry work in
may And
inci-
work a few
me by workmen
all its details,
con-
famiHar
and whilst
I
have not seen these problems demonstrated by actual practice,
my
certainty as to the correctness
of their illustrations enables
me
to present
them
to the reader with the utmost confidence in their practical value.
MAKING THE PATTERN Many
patterns are of the simplest form
require only a single piece of stuff
>
and
turned or
carved into a proper shape, finished with shellac
and having proper
These
and shrinkage.
draft
simple patterns are usually given to the apprentice
boys to make;
for instance, the pattern of a
cast washer, such as
Assuming the
this
is
represented by Fig.
washer
to
be for a ij-inch rod,
diameter of the stock would be about 7
inches and the thickness If inches. this pattern, a
inches, one side is
1.
disc is
is
cut out of
made
true
and
To make
wood 7|XlJ straight
and
it
then secured in the center of the face plate.
The
pattern
points
is
then faced
off
with the diamond
and the center located with a pair
ders as the piece runs in the lathe. laid off for the center hole,
a
of divi-
Next a
line for the
the O. G. and a hne for the outside.
line is
edge of
Now
the
operator cuts straight into the face plate on the outside line
and with a very small gouge, turned
sideways, roughs out the O. G., taking care that it
does not jump back and tear up the work. 59
PATTERN MAKING
60
When
the operator
not sufficiently expert with
is
the gouge to turn the O. G.
shape with the bull-nosed is
cut out with a small,
When
plenty of draft.
must be sandpapered care that the hole
begins to set
it is
can be scraped to
chisel.
Next the hole
stiff, flat
chisel, leaving
the pattern to
is left
any desired color
of
it
is
is
turned
a polish, taking extra
smooth.
Next
applied,
and when
polished, while
still
shellac
Fig. 6 represents the piece
it
revolving,
with an old cloth and a few drops of linseed
to
it
oil.
sawed out as near
shape as possible and then carved or whittled
and
finished with sandpaper
and
shellac.
Passing on to another class of patterns, the stake pocket affords an apt illustration. piece Fig. 3.
It
has sometimes occurred that an old
stake pocket has been picked
smoothed
off
a
little,
up
for other pockets.
only resorted to
it
was necessary
on very short
with a core.
as follows:
First the
to get cars
The
notice.
usual custom and the proper method
is
up
for a pattern
This method, however, was
when
ready for service
in the yard,
the sand holes puttied
and the piece shellacked and used
this pattern
This
from a form as shown in
easily cast
is
is
to cast
The procedure
for this
working drawing
(see
AND FOUNDRY PRACTICE Fig. 24, a
and
h)
should be
the shrinkage rule.
made up
full
61 size
Next there should be
by
laid
out a pattern on a thin veneer of the cross sec-
CoT-e
TlQ 2f tion through the metal as size
it
appears in the
full-
working drawing, and the pattern cut out
with a sharp knife.
Then
this
pattern should
be plainly marked with a pencil on both ends of
PATTERN MAKING
62
a plank of
away
sufficient thickness
the surplus
all
and rounds, and
and
length, cutting
wood with ordinary hollows a moulding of the
this will leave
exact dimensions of a cross-section through the
Now
metal forming the pocket.
a block should
be made of the exact dimensions shown
working drawing and marked "Core" 24, a
and
be glued
6),
When
shown
entire
to
all
proper for
is
A
in Fig. 24.
be
should
corners
parts of the
this
mould meet
Next four holes should be bored
and match.
enough
the
dry,
smoothed up, making
c c c c, Fig.
(see Fig.
and the prepared moulding should
to this block as
square joint at the corner
work.
in the
24 fit
6,
making the tenons
snugly into the holes.
at
just large
Then
the
work should be smoothed and polished
making the
parts which are to be iron jet black,
and leaving the core Following
this
prints in the natural
a core box
is
to
be
wood.
made,
which should be exactly of the dimensions and shape inside as shown by the working drawing.
Such a box
is
shown
top and bottom.
in Fig. 25
and may be open
In order to make a core in
this
box, the core maker puts the box together before
him on
the table.
sand and smoothes
He it
then
fills it
off level
with prepared
with the top.
AND FOUNDRY PRACTICE
63
Core boxes are finished and polished on the inside only.
The for a
next example
pump
of
some
is
a casting which was
description.
made
a cylin-
It is
der which had a flange at one end and a pipe thread at the
other (see Fig. 26).
previous example, the
first
As
the
in
thing required
is
the
Joi
working drawing, which, as stated,
core
must show the
prints.
Fig.
27
shows a
through the casting and core;
drawing needed for pattern
has already been
casting, the core
this
making the
and the
cross-section
being the only pattern.
was made by gluing together
This
pieces of
material of ordinary size, as a solid block sufii-
PATTERN MAKING
64
was not obtainable, and
ciently large
matter of no material of
flange.
It
little
difficulty to secure
sufficient
was
It
was a
a piece of
diameter to turn up the
also desirable that the pattern
should be divided in the middle without ripping it
through after turning
it
up.
To
•
J'/y
this the stock
and a
a
in
were
tenons, d d,
>
37
was prepared as shown
cross-section first
made
accomplish
in
doweled
Fig.
29.
together
In Fig. 28,
The
pieces
and
short
across the ends of the piece
AND FOUNDRY PRACTICE and so fastened together
The
in
line
65
with the
gain for the flange piece, b
6,
joint.
was then
cut to the desired depth clear around the piece,
0:'i
3
Pi!
1 f i
hongiiudLincil sectioji ihroiicflt GfocTr for* .
and the flange
pieces fitted in.
The
Pzq SG
pieces,
a a,
were then taken apart and the flange pieces glued
PATTERN MAKING
66
apart
Then
when completed.
the parts were
put together again, grooves of proper then cut in the blocks c
were
size
to engage the short
c
tenons d d and the blocks glued on to the ends of the work, as
shown
When
in Fig. 28.
thor-
oughly dry, the ends of the prepared stock were centered, the stock then put into the lathe
the
pattern
ends,
as
turned
shown
in
which come apart
and
up, leaving the projecting Fig.
core
for
27,
prints,
convenience of
easily for the
the moulder.
This pattern only requires half a core box, a longitudinal section of which
the
27;
Two
cross-section
shown
is
describing
pieces are used to
make
a
in
Fig.
semicircle.
the core.
Many
moulders use ordinary flour paste to glue or
cement
All such patterns
their cores together.
should be painted in the parting just as shown in
the
working
drawing,
in
moulder may see at a glance to
be metal and which Fig. 30
order just
that
the
which part
is
core.^
shows a cast pipe
fitting
which was
'AH patterns should be painted so as to distinguish metal from core. Patterns for iron should be dark with light cores,
and
just the reverse for brass.
are finished in shellac, rubbed to a polish.
All patterns
AND FOUNDRY PRACTICE This
used for steam heating.
on account
selected
of
67
has been
fitting
peculiar shape, which
its
admits of making the entire pattern and part of the core box on the lathe.
shows the working drawing, the
Fig. 31
made
thing to be
make
to
first
proceeding
in all cases before
the
pattern,
reference
drawing be
it
seen
the
and
by
h
made
be
can
exactly the
same
process
7^7^ J30
described
as
making
for
Fig.
with
27,
required.
out
of
face in
that
straight
parts a
is
will
The
a disc of
plate
and
cro.ss-scction,
being
the
cut
exception
circular portion
proper size
turned as
across
a
to
shown
in
through
no flange
that c
is
secured true Fig.
the
turned to
the
semicircle
31 J, which, line
of
its
diameter and placed face to face, forms the
PATTERN MAKING
68
half circular portion of the pattern
c,
Fig. 31.
The
only difficulty to be met with in
making
this
pattern
is
miter
the
joint
found by the intersection of parallel
^,
which
lines of
is
equal
distance from each other on the straight side,
with similar circular lines struck from the center
^^
^<
^^^^^^^^;^^^^^;^^^^
.
Ti^ 31
of the circular portion of the work.
common
rule for mitering straight
mouldings.
Or
This
is
the
and curved
the joint can be coped together,
the circular part of the core box can be turned into the face of a plank of suitable size, which,
when
cut across the line of
the circular part
of
the
its
core
diameter, forms box.
The
re-
AND FOUNDRY PRACTICE mainder
69
have to be carved out with gouges
will
and the finished core box made as shown be observed that in
33.
It will
full
core box
is
pattern a
to say,
two half
boxes,
core
made left,
required, that
is
this
in Fig.
right
and
and dow-
eled together.
The
next
pattern
treated
that
is
double wheel,
of
a
flanged
-
for
use
on an overhead traveling crane.
Reference Fig. 34, a b,
7^^ 3/r
to
and
which shows an elevation and cross-section,
will afford
a clear idea of this wheel.
There are so many ways that to
it
makes a
A
be considered
and B.
wheel
is
By
wheel
The
thing
nice illustration. is
how
to get
which problem we think
manner shown
to cast this
in the this
cored out;
is
it
first
out of the sand,
best solved in the
working drawing, Fig. 35,
method almost the but
it
is
entire
by no means an
PATTERN MAKING
70
and
intricate task
is
clearly illustrated in Fig. 36,
which contains a sectional view
of the finished
pattern.
To make
this
pattern, cut out the discs a a.
To
Fig. 36, of proper size for turning up.
T^a 7fC f
oj tvrrnTto
discs glue the
band
the core print
c.
to the lathe
co-re
"hote
for Tiq
h in sections,
and
30 one disc
Next attach the prepared
and turn up, as shown
tion, Fig. 36.
to
Turn up
these
discs
in cross-sec-
two core prints, d d,
and dowel the two halves together, making the finished pattern.
AND FOUNDRY PRACTICE Three core boxes are required
71
for this pattern:
a plain half core for the center hole through the wheel, which has already been explained;
box representing of the
all
Fig.
wheel,
the cavity between the spokes 38,
Qyte lidlf of cott lox
marked
cores
h
6,
a core
Fig.
represented by the six
for Tig 30
35,
B, and a circular
core box turned into the face of a plank (see Fig. 39, a
core d
A
and
shown
fe),
which
will
mould
half of the
in Fig. 35, B.
pattern for this wheel can be
made without
coring out the flanges, by contriving the pattern
PATTERN MAKING
72
to part near one side or at
any place which
will
permit the successful withdrawal of the half pattern.
For a wheel cast
part flask or a flask parting
after this pattern
made
of three boxes with
made between each box
(See a a, Fig. 37.)
TJj
two-part
flask
mended because ways
the pattern process.
of
its
without any core
greater cost
To make
be made as shown
it
not recom-
is
inferiority
well that
familiar with the
this pattern the
in
is
and
of doing the work,
maker should be
this
3^
whatever, and although this method
to other
a
employed.
is
It is possible to cast
o^
pattern in a
a three-
wheel should
Fig. o34, with spokes
and
AND FOUNDRY PRACTICE hub complete. sides of the
ple draft
The
73
center hole, the hub, both
rim and the spokes should have am-
and the lower flange should be
loose
left
so that the pattern will part at the line a
b,
Fig.
o34.
To mould
this
pattern, the cope
T75
in
an inverted position and
is
laid
down
3
filled
about half
full,
or within about two inches of the top, and the
sand smoothed down
The
solid.
pattern
is
turned with the spoke side up and pushed
hard into the sand. that the impression
made place
at
i.
The
It is is
and the parting
c-d
down
then taken out to see
perfect,
pattern
then
is
and a parting
then put back in
and
e-j is
made.
is
its
Th^
PATTERN MAKING
74
sand is
is
made
then
filled in to
Now the
at c-g n-j.
The
and rammed up. the vents made, in Fig. o34.
when
The
g-h and a second parting
flask
the line c d
is
is
put in place
then inverted and
the pattern will appear as
cope, which should part along
C o 73 e.
&hoY/inq
drag
hoW I^rtjSt
i e f, is
nrny
J.
>.'•'" •... '•
levtoiildecl
rn
a
now removed,
It/o part
as
pattern from the line a b upv/ards.
is
also the
The
should then be put together and turned
flask
over,
AND FOUNDRY PRACTICE
75
removing the drag, which should part along the is removed. line c g hf, after which the flange
The over,
flask
is
and turned
together again
now put
which completes the work, and
exactly right
If the pattern is
moulten metal.
to receive the
and the moulder
amiable, the casting can be
ready
it is
is
both expert and
made
in this
way,
Joi-n t
Tig ae but of
method
this
is
given more as an illustration
what can be done than as a sample
of
good
pattern shop practice.
Many
difhcult or otherwise impossible forms
can be cast by using a three-part
flask.
double-flanged gear wheel, Fig. 40, a and illustration of flask.
It
work
The
6, is
an
usually cast in a three-part
can also be moulded in a two-part
PATTERN MAKING
76 flask
by making a double parting
shown
Fig. 37.
in
Or
in the sand, as
be cored
the gear can
into the wheel.
The
next problem treated
is
that of an ordi-
nary brake wheel or hand wheel, such as
on freight illustrate
cars,
and which
wheel making in
will
serve
general
used
is
more
to
any
than
Tig 3© peculiarity in the construction of this particular piece.
In
this
pattern. Fig. 41,
quired but a plain wooden wheel. hole in the center, being tapered, core.
nothing
The makes
is
re-
square its
own
AND FOUNDRY PRACTICE When
a great number of wheels arc wanted
the pattern
is
bedded half
Tf'q
and the
its
depth in plaster of
o3 -y
CraiJ jMfjoTi throtigh.nxoulot
Paris
77
^l^^y/a^
pattern
plaster cast so obtained
a follow board.
-in tTtc sanB.
is
used for
This arrangement brings the
ri^
-»o
parting to the center of the pattern without the
use of the trowel.
PATTERN MAKING
78
To make
pattern
this
it is
best to lay out on a
shown
in
number
of
plain board the design or outline, as
dividing the rim into any
Fig. 41,
equal parts. parts.
One
In
case there are six equal
this
of these parts
is
a suitable pattern
from which to saw out the rim, allowing a
little
wood
extra
on both sides for
turning
up.
Hav-
ing
roughly
sawed
out
the parts of
rim,
the
the
fit
joints
together,
on
the drawing
Tis
^f
or
outline,
"
taking that
the
parts
of
the
rim
are
so
care fitted
together that they will describe in the rough as
nearly as possible a perfect circle. the second layer on to the
first,
Then
glue
breaking joints
with the sections, so as to form a rough ring, as
shown
in Fig.
42.
Next secure
this
prepared
ring to the face plate in proper position so that
AND FOUNDRY PRACTICE the tool will cut as nearly even sible
and turn up the
shown
wood
pattern
(See Fig. 43.)
shape. chisel,
metal
mark
position. its
will
it
be
in
in Fig. 43, using a thin
secure
to
the
Now, with
desired
the turning
the face plate lightly as a guide, in
order that the ring
be secured
around as pos-
ring so that
cross-section, as
or
all
79
may be
turned over and yet
to the face plate in
its
exact former
Another way to maintain the ring
proper position when turning
it
over
is
in
to tack
four httle blocks or brackets to the face plate so that they will just touch the
work
to
be turned
over on either the inside or outside of the
circle.
PATTERN MAKING
80
These blocks or brackets always bring the work to
Now
exact position in reversing.
its
in like
manner with the
and the
result will
proceed
reverse side of the piece
be a round
which
ring,
round
be in
will
also
cross-section.
Then the
get
out
hub
of
dimen-
proper
mortise a
sions,
square
tapered
hole in the center for the
brake
cut
staff,
six
gains in the
and
ends
and
both
cure
and rim
the
to
working drawing as a
parts together. sired
positions
form and
Provide fit
six
the
guide
hub
in their
plank, to
se-
using
put the
spokes of the de-
them neatly
All the parts should be snug
the
of
spokes,
proper relative
the
receive
to
-rig -^3
hub
the rim
in
and
into the gains. tight
enough
in
AND FOUNDRY PRACTICE their
a
81
adjustment to one another to require only
light
blow to drive them home.
up the spokes
Lastly finish
(See Fig. 44.)
as desired
and coat
with black shellac varnish.
The making the
most
of cog
important
or gear wheels features
of
the
is
one of pattern
maker's trade, and although a drawing or blue print
is
usually provided in repair shops, the old
cog wheel
A
itself
is
sometimes given as a guide.
brief review of the principles of gear
the technical terms employed relation to
it
will serve the
work and
by mechanics
purpose of
in
this vol-
ume, inasmuch as every pattern maker should
PATTERN MAKING
82
possess a reasonable knowledge of the principles
and
practical operation of the
mon
may be
use for which he
upon
machinery in com-
any time called
at
to produce patterns.
Gears are either straight or beveled.
Straight
gears are square on the face and transmit power
from one shaft to another one running to '
parallel
have
gears
an angle with
faces at
their '
Beveled
it.
1^
the line of the axis on which
A
they
and
revolve,
power from one other
running a
usually at
-su
The
itself.
.k--. JTrj
^r
line
at
right
pitch
gear wheel
is
transmit
shaft to an-
an
an
angle,
angle, line
of
to
a
imaginary
running around the wheel
through the cogs at a point
which of
is
the teeth.
the
number and
by the
governed
The
diameter would be
pitch
diameter of the wheel
line.
This pitch
where the wheels
line
is
at
tliis
friction
would touch
a gear wheel
wheels. is
the
imaginary
located at the point
each other
instead of being toothed or cogged, plain
size
The
circular
distance
if,
they were pitch
of
from center to
AND FOUNDRY PRACTICE and
center of the cogs on the pitch Hne,
by dividing the pitch
line into as
there are cogs in the wheel.
reference to gear wheels are
Cogs are always
line.
length, of
which
.4 lies
The
the pitch line.
many
it
venient
be assumed size, that
it
made from
.7 of
and
of a gear
.3
For
say 44.
spaces as
the pitch
outside of
any cog
of
is
(See Fig. 46.)
wheel of any con-
21 inches in diameter at
the pitch line, with any convenient teeth,
found
the circular pitch in
inside
thickness
is
is
All calculations in
always xVo of the circular pitch.
Let
83
all
practical
number
purposes
of
an
accurate measurement of the circumference of this
wheel would be accepted as G6 inches^ at the
pitch
Hne,
and
*The decimal
is
the pitch
65.9736.
66-^44=1.5
inches.
PATTERN MAKING
84
The
root of the tooth
pitch Hne
—being
—that
part inside of the
the circular pitch, would
.4 of
give 1.5''X.4=.6 of an inch inside of the pitch line as the
Now,
base of the tooth.
tomary to make
as
it is
cus-
a gear wheel plain and then glue
the cogs to the face of the rim,
follows that
it
the radius of the wheel would be the radius of
the pitch line, minus the root of the tooth, or of
an inch, making the wheel
.6
at the base of the
tooth 1.2 of an inch (.64-. 6= 1.2) less in diameter
than 21 inches, or 19.8 inches. length of a cog, being
Then
of the circular pitch,
.7
equals 1.5 X. 7= 1.05 inches, which of this particular tooth.
the total
is
the length
Its thickness
of the circular pitch gives
being .48
1.5X.48=.72 inches
as the thickness of the tooth on the pitch line.
Hence the
solution of the problem calls for a
wheel 19.8 inches
in
diameter,
to
the
outside
surface of which, at regular intervals, determined
by accurate measurement, there should be glued cogs or teeth which are 1.05 inches in length and .72 inches thick at the pitch line.
All wheels are
more or
less alike;
therefore
it
would be superfluous to treat the minor problems of wheel patterns in this work, as every
who
workman
understands the general principles involved
AND FOUNDRY PRACTICE will use his
own judgment and
85
discretion in such
cases, especially as the nature of the
work, the
size of the wheel, the strength of parts,
etc., will
always be the controlling factor in the construction.
Assuming that there has been constructed a wheel which has been turned to exactly 19.8 inches diameter by the shrinkage rule and the face
which has
of
face
sufficient
draft,
the
sur-
divided into 44 equal parts by scribing
is
square across the face of the work, with a pointed instrument or penknife, and marking the scribes
The
sides of the rim.
on the
teeth are gotten
out to approximately the proper shape and
Then
into a piece of thin
made
exactly the
The
size.
hardwood a hole
is
shape of the desired tooth.
teeth should then be carefully finished with
hand
tools
so that they will just pass through
this hole, allowing
a very
and marking the tooth
little
in
draft in each tooth
such manner as to
easily distinguish the allowance
work draft
is
made when
the
being glued together, in order that the
may
all
be the right way.
An
exact center
mark should be made on each end of the cog, matching exactly the marks on the rim of the wheel.
Next the cogs should be glued
to place,
PATTERN MAKING
86
using care that the center of each cog
exactly
is
with the dividing marks on the wheel.
Small
brads are used to hold the parts in place until the glue dries, and
when thoroughly dry
should be
dressed up with
small
of
fillet
the
sandpaper and a
beeswax run along both
the base of the tooth, pressing
it
sides of
in place with
irod rod
which has been warmed over a
lamp.
To
described,
shellac
finish,
is
work
spirit
before
as
varnish,
an
used.
Patterns of this class are usually parted
by the
moulder's trowel along the center of the spoke
and
at one edge of the rim.
Fig. 47 represents a pair of miter gear wheels
Beveled gear work
in mesh.
may be
either a
mitered gear wheel as shown (in which case the pitch line
is
at
an angle of 45° from the
shaft,
such
a gear transmitting power from one shaft to another at equal speed) or, in cases where a different ;
speed
is
required, one wheel will be larger than
the other (in which case
it,
the pitch line, will
be any angle which the nature
may
require).
beveled
The making
gear pattern,
while
of
not
of
a
the
case
miter or
necessarily
a
very difficult piece of work, requires persistent care and
skill.
The. pitch of a beveled gear
is
AND FOUNDRY PRACTICE an imaginary
line,
87
a a. Fig. 47, which Hne repre-
sents the surface of cones working as plain friction wheels.
of these
Any
variation in the relative sizes
two cones would also change the angle
TVg
of the pitch
from the axis
-f
V
of the wheels.
To
change the angle of the axis from a right angle
would
also determine the angle of the pitch line.
To more
fully illustrate the
Fig. 47, see Fig. 47^.
manner
Here a
h
of laying out
and a
c repre-
PATTERN MAKING
88
sent the axis on which the gear revolves
the pitch Hne. calculation,
Assuming, for convenience of
that the pitch diameter d-e
are 7 inches in length and the 22,
the
and a a
circumference at
the
and
d-f
number
of teeth
pitch
diameter
AND FOUNDRY PRACTICE
89
The
glued with accuracy and precision.
tion for both ends of the teeth should
by the
rules given for gear
cone and lay
up
it
work,
i.e.,
calcula-
be made
turn up the
into 22 equal spaces, square
off
for the centers of the teeth with the centering
tool (Fig. 48), glue the centers of the cogs to the
centers so established
and
in
finish
the usual
manner. Fig. 49,
showing an iron dome with projecting
ornament at the top and a handle at each here introduced as a sample of
done with hollow
cores.
Assume
form has been glued up as shown in Fig. 50.
Attach
turn out the inside
this
first,
form
side, is
what may be that a rough
in cross-section
to the lathe
otherwise
it
will
and
be im-
90
PATTERN MAKING Reverse the pattern
possible to turn that part.
and
finish the outside, as
shown by the shaded
portion in Fig. 50, and attach square core prints
for the handles
and
Make
finial.
suitable core
boxes for these prints, which core boxes should
Ti^} so be constructed so that the bottom of the box the center of the core.
In
this case the cores
is
go
together just the reverse of the ordinary way.
AND FOUNDRY PRACTICE Next turn out the handles and
them apart and
sired form, rip
bottom
into the
A
moulded
core
finial of
the de-
fasten the halves
of the core boxes as in Fig. 52. in
one of these boxes
an impression of half of face,
91
this
will
have
turned piece in the
and when the two halves are pasted together
i 1
Cron
section ihraiiqjk
a proper cavity
flask ahaWiiig metaH Gc cores
is left
to
mould the desired form,
which can then be put into the sand
left
which
by the core
it
will
it
will
In
this
be necessary to make special pro-
visions for supporting the
wise
on the pattern, and
then appear as in Fig. 51.
will
pattern
prints
cavities in the
sand in the cope, other-
have a tendency to
fall
off
in
han-
PATTERN MAKING
92
Iron kettles with flaring legs and round
dling.
ears are cast in this manner. leg straight on one side so
and the ear
is
made
Others have the will
it
two
in
draw
pieces,
loose
from the pattern and remain
until
the pattern
remember which
is
withdrawn.
is
in the
It
is
sand
well
to
that any projecting part of a casting
of such a shape that
drawn out
readily,
which are
of the sand,
may
Tig
it
can of
be
itself
often be left loose
S-SL
Cto^^ oectian ihroujh core lcK£^forTi^ 9t
when on account
of
some angle
from being drawn with case
it
drawn,
it is
prevented
the pattern, in which
remains in the sand until the pattern after
which
it is
is
easily taken out.
There are many patterns which from some peculiar formation are special follow
board
is
much
easier to
made
mould
for them,
if
a
and on
account of a delicate form of construction are
much
easier to
make by
first
making a follow
board of the desired shape and then building
AND FOUNDRY PRACTICE
93
the pattern up piece by piece upon this form; for instance, the curved grates in stoves, the cast
basket racks in passenger cars, true
cially is
this
castings,
where
it
of
small,
etc., etc.
would be tedious, not
impossible, for the moulder to
make a
By
ing in the sand with the trowel.
a follow board, which exactly
Espe-
curved open work
fits
to say
nice part-
the use of
the plain side
TJ^ 53
of the casting, the parting
is
made without any
of
a pattern of this
trouble.
As an example
kind the
aisle
selected.
This pattern was arranged in such a
manner
end for a car seat has
as to be divided in the middle, so that
the upper portion
and used 53, a
been
is
for the wall
and
6.)
cast separate
end of the
from the
seat.
leg
(See Fig.
PATTERN MAKING
94
The
first
step in this case
the follow board
(Fig. 54),
7V^
end was on a
laid
out
straight-edge
size,
and
fnijitterrt
to the curved surface.
to
make up
on which the
aisle
S-f
full
TJQ 37rO'v\'9 yrnisTn^
was
taking dimensions
carrying
them
over
erg-
-in place
on faJfoW
JocrcL
In cases where the
fin-
ished pattern had to project below the face of
AND FOUNDRY PRACTICE follow board, as
this
a-a
and
55
the
y
the core prints
the sockets for the seat rails 6 6 in Fig.
wood was mortised out After this
depth. piece
shown by
95
by
the pattern
piece, fitted to the
to the
desired
was gotten out
board
in its proper
place and secured with small sprigs
until
the
glue joints hardened, care being taken not to
In
glue the pattern proper to the follow board. this
case
was necessary
it
to
allow the arm,
which carried the back cushion from side to side in reversing the seat, to pass h
by Fig.
55
y
thus making
it
behind the socket necessary to core
out a slot between the socket for the seat
and the
end,
aisle
by the cores a
rail
which was done as shown
a, Fig. 55.
These are samples
of
balanced cores, which will be explained further on.
This pattern has a joint at that
it
may be
ccc.
Fig. 53, so
cast without the leg being
fast against the wall of the car.
made
CASTING WITH PART PATTERNS, SWEEPS, OPEN SAND WORK, ETC. Castings are sometimes
made without
regular
patterns, or with only a portion of the pattern.
Some edges,
castings are
curves,
with sweeps.
down
to us
etc.
made by
the use of straight-
Many of
these methods have
from periods
of
wide and
come
remote antiquity.
Recently in the foundry of the moulders were
made
Other castings are
making a
at slab of iron 2 feet
5 feet long, with a
rim around the
under edge and V-shaped cross bars or
ribs
on
the under side at intervals of about 6 inches each
way.
(See Fig. 56, a b.)
There was no pattern instead there were straight plank, this off
v^^ith
mould, the
for this
some 1X2 inch
at all; but
strips
a V-shaped edge.
floor of the
and a
To make
foundry was leveled
with the straight-edge, the
into the
work
grooves rubbed
sand with the V-shaped edge of the
board and the
1X2
inch strip laid
down
the line of the outside of the casting. these the sand
was packed 97
level
to
form
Against
with their tops
98
PATTERN MAKING
and smoothed
off.
The cope was made
with a
straight edge.
A
very simple and useful "kink" was employed
recently in the case of a large piece of machinery
which was damaged
in shipping.
It
had a large
circular gear about 8 feet across without spokes
or hub which was broken in two or three pieces.
This was an
old, out-of-dale
machine and
it
was
AND FOUNDRY PRACTICE
To make
the
up
this partial pattern,
foundry floor with a straight-edge.
level off the
The
mould from
99
center stake
is
then driven and
left
standing
above the floor the thickness of the casting.
The
partial pattern
is
next put on the center pin
and rammed up, leaving both ends open.
After
^IS 57
lifted
and moved, taking
this
it is
last
cog on the pattern exactly
in the sand.
Ram
pattern as before. plete circle
is
fits
(jare
that the
the impression
up again and move the Continue this until the com-
this
made, which
of the complete gear.
will
be an impression
Since seeing this I have
PATTERN MAKING
100
used the same plan for making
mud
rings for
boilers with perfect success, thereby saving
This method
valuable time and material.
recommended single casting
making
of
in general practice; is
an
all
much is
not
but where a
that will ever be needed, the
entire
pattern can and in
some
cases should be avoided.
Another problem in
making a
cost of
number
of a similar nature
large pulley or flywheel
making the pattern of v»diecls required.
is
is
found
where the
not justified
by the
To make the mould
for such a pulley, first construct the
form
of the
radius desired for the rim of the wheel (see Fig.
AND FOUNDRY PRACTICE 58),
and
in
case of a belt wheel,
make
101
the rim
of the shape desired to hold the belt centrally
the face of the pulley.
two arms so
Now
fixed as to cause
secure this form to it
Tig
Core tor
on
to swing
around
S9
for.
a center stake at the proper radius.
f\g €/
Make up
a
core box of exactly the shape of one-sixth of the
wheel inside of the rim; that outside of
tlie
is,
the radius of the
core box should be the thickness
PATTERN MAKING
102
Get
of the rim less than the radius of the form.
out the rib, a-a. Fig. 59, and glue
Turn up a hub parts
one-half
and glue two
the core box, as in
its
in place.
it
length, cut
of the pieces into the c,
it
in six
apex of
Fig. 59, leaving a slot or
mortise for withdrawing the spoke.
Make
one
spoke and secure the joint with a dowel pin at 6, Fig. 59.
1
This
will
be better understood by a
AND FOUNDRY TRACTICE center stake
down
iron center pin
Bank
and
level.
Then put form
set the
103 in a small
(Fig. 58)
on
it.
the sand solidly against the outside of the
-
c
O
&7tcWrJrff
y7io7/Jd
w/M
pattern, level with the top,
coyrtf in palace
moving the form and
continuing the operation until a complete circular pit is
formed of the depth
move
the form
much
of the hole
of the pattern.
and the center
Re-
stake, leaving as
made by removing
the stake as
PATTERN MAKING
104
is
required for a core print for the center hole.
Place the six prepared cores in position, taking care
that
the
proper thickness
the
of
maintained clear around the wheel. center core in position, pushing
it
is level with the face of the wheel.
mould
is
shown
in Fig. 61.
rim
is
Place the
down
The
until
it
finished
SWEEP WORK Sweep work
made
or swept
up moulds are moulds
a pattern, and can only
entirely without
be used for circular forms which, for reasons
economy or otherwise,
of
it
may be deemed
ex-
pedient to have cast without the expense of a
The sweeps
pattern.
are
nothing more than
plain plank cut to the desired form
and arranged
around a stake driven into the
to revolve
The sand
the foundry.
is
packed
floor of
in front of the
sweep and the sweep moved around, thus scraping the surplus sand is
pack the sand ahead
as to push or
move around
various ways of
ordinary is
until the desired
way
to
the center stake.
is
to
of
them
as
There are
making and using sweeps.
The
sweep a pattern, where the form
such as to admit of doing
63,
form
Sweeps are beveled on the edge so
obtained.
they
away
make a sweep
outside of the casting
so, as
shown
in Fig.
form
of the
of the exact
and another one that
is
exactly the thickness of the casting, but deeper.
On
the second sweep the form and thickness of
the metal
is
painted black. 105
(See Fig. 64, a.)
PATTERN MAKING
106 It will
be seen that
this
pair of sweeps are so
arranged as to form a rabbet in the sand, which insures the cope being centrally located.
To make
a mould for Fig. 63 with this
sweeps, the floor of the foundry off
is
first
set of
leveled
and a stake driven down, leaving enough
Try G3 above ground
sweep
is
stake
and a
to operate the sweep.
The
first
then put on, the sand packed about the hill is
formed representing the out-
AND FOUNDRY PRACTICE side of the casting.
made and
rammed
When
cope
the
complete, a parting
placed
The second sweep
for the first
now
is
the sweep
is
casting lift
In
is
of
diflficult
operation
such a form that
is
foundry
a hole
floor, as
form of the inside
The
cope
is
is
is
impossible to (See Fig. 62.)
swept into the drag
the case
of the casting.
The second sweep
— or
—having
may be
the
(See Fig. 64.)
then placed in position,
and removed.
complete.
one where the
it is
the cope from the outside. this instance
a
removed, the cope
placed in position and the mould
more
until
produced of the inside of the
is
Now
A much
substituted
and the sweeping continued
perfect form casting.
is
and
position
in
Gates are then made and the cope
up.
removed.
107
is
rammed up then placed
on the stake and the sweeping continued
until
a
PATTERN MAKING
108 perfect
form
obtained.
of
the
outside of
(See Fig. 65.)
The
the casting
is
stake and sweeps
being removed and the cope placed in position, the case
mould is
is
complete.
The
in handling the cope,
difficulty in this
which special
for
^ -patr^oftmimttry
awe^Tja
arrangements should be made for supporting the sand. It is possible, for certain special
both cope and drag; but
it is
work, to sweep
seldom done.
There are various reasons
for
using
sweep
AND FOUNDRY PRACTICE work, the
first
and most common
from a consideration pattern
is
large
C/-rcy
and
of
which
is
economy, as where a
costly
se^c-tfoii
of
109
and only one or more
tltToiisT*
:5^noh€ "hot c^oor
PATTERN MAKING
no pieces
are
required,
it
is
often
better
to
use
sweeps, as they save the cost of making a pat-
The
tern.
cost of
moulding from sweeps, how-
'•^•^;v.b;.:'^::-;M1:
ever,
is
more than from a
pattern,
and
in very
heavy work the saving of the extra cost would
pay
for the pattern.
pattern
which
will
It is
not
possible to sweep a
draw
in
the
ordinary
manner, also circular castings having projections of various kinds
may be swept by
having wood
AND FOUNDRY PRACTICE patterns of the projecting parts.
an instance
this is cited
made
111
To
of a casting
illustrate
which was
at the Frisco R. R. shops last winter at
Girardeau,
Mo.
the front of an engine, usually termed "the
box door."
was required
It
this door, together
make,
to
smoke
to cast hinges
on
with some other minor projec-
tions not necessary to illustrate.
done was
Cape
This casting was the door on
The
first
thing
on a
piece of heavy manila paper,
a regular working drawing in
cross-section
the
of
re-
—=
Tigs'/*
quired
Then
064.)
the
center
sweeps
the of
sweep
No.
Fig.
perpendicular
and
line
a
drawn.
b
for
The
by pricking through
out
The upper 1
was
sweep
the
can be laid
the drawing. of
(See
casting.
line gives
the
the shape
lower one
sweep
PATTERN MAKING
112
No.
2.
the
for
A
Fig.
(See
face view of
purpose
this
casting
the
locating
of
Next wood patterns
063.)
given
is
hinges,
etc.
of
the
7Vy ©s hinges were made,
be
drilled
after
leaving
the
casting
Then
into a suitable drag
floor
a
stake
was
driven
pivot holes to
the
was
completed.
box or the foundry such
to
point
a
No.
as to allow
turn
to
with
Ti_3
^B
at the part-
ing
in
packed and the sweeps moved perfectly
true
and
w^ay
outer
end
the
or floor.
parting with dry sand was
freely
the
was
until the
form
complete.
made
and the wood patterns were
box
Then
sand
the
was
1
in
Next
a
the usual
set in position.
AND FOUNDRY PRACTICE
113
care being taken that they were exactly in position,
where they could be secured by packing a
little
sand around them.
Now
the cope
was put
on and rammed up, great care being taken not to
move
and
cope
the
Next
the hinges.
mained
hinge
which
patterns,
re-
cope,
the
in
were removed.
Now
center
was
the
down
driven ing
stake
^^
7:)^
^^^^
exactly the thickness of the cast-
by measurement, and
sweep No. 2 was
put on, which cut away exactly the
shape
of
the
required
A.
casting.
size
and
Then
the
core
'bala.rtfed.
and the sweep were removed, the cope
stake
replaced and the mould was finished.
To
lay out
make a casting.
and
any sweep,
full-sized
Then
see just
how
it
is
only necessary to
working drawing of the desired look carefully at this drawing it
ought to
lie
in the
mould.
PATTERN MAKING
114
Then
The upper
turn the drawing that side up.
Hne of the drawing
sweep No.
Hne
is
No.
1 laid
out on
painted black.
is
sweep No.
1
and the lower
2,
which also has the
it
and the shape
line of
of the metal
customary to add an
It is also
shown
angle to both sweeps, as
at c in Fig. 65.
This acts as a guide for gauging the thickness of the metal and insures proper locating of the cope.
frequently a matter of great convenience
It is
to be able to
sweep up quickly a large
core, such
as for the cylinder of a locomotive or other hol-
low work where straight core
is
nothing more
than
This can
required.
a plain, easily
be
done by the use of two half-circles of plank of the desired radius, secured in position with three
wood, as shown
strips of
packed in
this
Or
edge.
it
frame and swept
may be
round core
straight,
ing offsets, etc.
which
is
in Fig. 6Q.
of the
The
core
is
with a straight-
off
required to sweep up a
of different diameters, hav-
To do
this,
shape and
get out a plank
size of
a longitudinal
section through the center of the core, as at 6 in Fig. 67a, allowing for the thickness of the half circles /
and
if
/.
Fasten the half
possible secure
circles / /
in place,
them from warping with
good heavy angle irons
let
in
flush
with the
AND FOUNDRY PRACTICE wood, as sweep, this
at
c
c,
a. Fig. 67a,
Fig.
plank or bottom board.
by the two arms
c c to the
which
will
be
Fig. 67a
and
Fig. G7b,
of
Now
67a.
which exactly
easily
115
a
get out
fits
the side of
Hang
the sweep
center pins d d;
all
understood by referring to
The sweep
a should be
beveled on both sides towards the center on the
working edge, so that
it
T^ould for fhited ceRumn
it
will press the
ma^t
entirely ef core^
passes back and forth over
half core
on
this
device
it
is
sand in as
it.
To make
a
only necessary to
pack the sand on the bottom board and pass the sweep a backwards and forwards over in
sand until the desired form Fig. 68
is
which bolt angles
to
is
it,
filling
obtained.
designed to illustrate the manner in
moulded
at
right
each other through a casting.
By
holes,
etc.,
are
PATTERN MAKING
116
drawing,
the
to
referring
observed that the holes 6 they can be drawn out
own
their
Fig.
68,
6, if slightly
it
be
will
tapered so
the sand, will leave
of
while the hole a, Fig. 68, will
core;
not draw out of the sand with any core yet de-
For
scribed.
such work a peculiar core and
ai]
For
core box, called a stop core, are used.
purpose a peculiarly shaped core print pattern,
the
shown
as
becomes necessary
mould a core Fig.
70,
is
as
in
make a
to
shown
shown a
Fig.
put on
is
69.
this
It
then
core box which will
at a in Fig. 70.
At
6,
through the
cross -section
casting, with the core in place.
In
many
cases
it
is
necessary to use cores
which, from some peculiarity of the design, will
have no support at one end and have a tendency to fall
down, or
at least sag
casting thin on one
and core to
lie
print are
made
to
make
called balance cores.
In other cases cores
own
weight.
the
long enough for the core
in the core print without tipping
These are
their
enough
In such cases the core
side.
may be
When
down.
(See Fig. 71.)
so long as to sag of
this is liable to occur,
small iron pieces called "bridges" are put under
them.
These fuse with the heat
and become part
of the casting.
of
the metal
In some
in-
AND FOUNDRY PRACTICE
necessary to nail the core in place to
stances
it is
keep
from
it
117
floating.
In cases of very complicated designs
make
times more convenient to
it is
the actual
some-
mould
for the casting entirely of cores, in v/hich event
the pattern would bear
little
resemblance to the
but would, instead, have the form of the
casting,
cavity in the sand which
would be required
to
hold in position the cores, forming the actual
As an instance
mould.
of this, observe Fig. 72,
such a
through
which shows a cross-section
In
mould, made for casting a fluted column. this
This
hexagon. of the is
the
instance
many
is
pattern
would
be
plain
a
only referred to as being one
possibilities of pattern
making and
not cited as being ordinary shop practice.
Having covered pretty thoroughly the common every-day problems which come to an ordinary pattern shop, a pattern
when
properly made,
is is
now
which,
illustrated
a simple matter;
yet
before the reasonable solution of this problem was
found, large
a
had
it
sum
triple
of
cost the firm doing the
money.
work a
The problem was
to cast
locomotive chime whistle, having three
separate compartments of different lengths in the bell,
and three chambers
for
steam in iho base.
PATTERN MAKING
118
This
pattern
was
first
made,
rather
or
at-
tempted, and some three or four whistles were cast
from
it.
It
was so compHcated a piece
work
of
an ordi-
that
nary moulder could put
not
and from
it;
quence to be
it
together
it
get
a
mould
in
conse-
had always
taken to
the
foundry by the pat-
The
maker.
tern
made
foundry
a
labor charge of $5.00
on
work,
this
in
addition to the weight of the brass, for
and
Having
cast.
each
whistle
every
de-
some im-
cided that
provement could be
made it
was sent
shop and remodeled and some
ments were made.
However,
in this pattern,
it
very unsatisfactory piece of work.
slight
to
the
improve-
yet remained a It
was given
AND FOUNDRY PRACTICE W. Sherwood, now
to C.
119
who
of Racine, Wis.,
produced the pattern as here shown, which has proven very satisfactory in its operation.
A
clear idea of this
casting
by
may be
reference
73, 74
and
shows
a
Figs.
Fig. 73
75.
cross-section
through the whistle
derived
to
bell of the
and the base,
Cross 3rcHo-n of
iell
both of which are hol-
low and
in three
The
compartments.
partment extends the
first
com-
the
bell;
length of
full
the next
shorter,
is
extending Fig.
third
73,
to
c,
and
the
shorter,
still
extending Fig.
7>y rsCro9 s 3cetzoit
of
the
Arae
is
ing of full size,
nearly
complete
In
73.
ceeding
work
to
6,
pro-
with
a
of this kind, first
requisite
a working draw-
and one which should be as in
every
detail
as
it
is
PATTERN MAKING
120
the
bell,
Fig.
Now make Fig. 78,
Next make the pattern
make.
possible to
two
76,
the core
and the
Fig.
base,
box as shown
slides, c-c. Fig. 78,
for 77.
at a-b in
being
made
for
Thr-ft rry
the
openings
at
the
upper
end.
One
slide
reaches almost across the opening and joins with the partition slide d^ Fig. 79. off
The
other
cuts
even with the inside of the core box and
only designed for closing up the slot
is
when not
AND FOUNDRY PRACTICE Next make the
needed.
partition slides d. Fig.
79, one for the middle partition c
the short partition
which are the dupHcates
more
slides e
slides
d d, except that they cut
e,
up the
slot
when not
out the
e.
Fig.
work
it
in halves, cut-
gain
little
can
g. Fig. 79,
down
clear
bottom
the inside
so that the
79,
sweep g
of the
Next make a
in use.
center pin d. Fig. 78, and rip ting
off at
for
two
These also are only used to
of the core box.
stop
and one
Now make
Fig. 79.
b,
121
the
of
to the of
bell
the whistle in sweeping
out the half partition Fig.
and
made
be
in
left,
reverse. is
These centers
79.
should
At
holes
over
a small iron rod to prevent
Fig.
hh-hh.
it
parts
the
that 78,
is
may be
79,
are
core
the
made
may
so
box. that
driven up into the core
from breaking apart.
box
Httle
Fig. 80
is
a
for the base of the
The box may be made
by allowing a
box
core
a half plug which
reversing
in
Fig.
cross-section of the core whistle.
ris Tj
right
order /,
changed
The
c c,
only two
in
draft at
e.
Fig.
80.
PATTERN MAKING
122
The
top b
is
turned up, as shown, and the par-
titions
d d d glued to
make
the vent holes
steam out into the
it.
The
cores
c c c, Fig. 75,
c~c.
Fig. 80,
which
let
the
bell of the whistle. (_^ 5*lerp
There tive
is
a variety of cast parts used in locomo-
and car work, such
as
draw
bars, truck
AND FOUNDRY PRACTICE pedestals, oil boxes, etc.
apparently very
These
castings, while
common and rough
for
considerable
skill
in the
123
to look at, call
mak-
ing of the pattern.
As a sample, an ordinary
oil
box a/
has been selected. (See
This fully
by
Fig. will
81.)
be more
r^ &o
understood studying
the
two sectional
and
castings. Figs. 82
oil ion f
drawing this
is
shown
pattern,
first
83.
A
/r-eig7tt
in Figs. 84
views
of
the
complete working
Cai»
and
85.
To make
prepare the working drawing
on heavy paper and prick out the outlines com-
PATTERN MAKING
124
and transfer them
plete
With
this
to a plank of proper size.
plank as a pattern, cut enough mate-
f>tat€D
JiOTtij itudtual
rial to
the
build
core,
section throtigh oil hot
up a block
making
of the entire thickness of
the
parting
the
in
Next get
center.
two
out
side
pieces of sufficient thick-
ness to complete the pat(See a
tern.
Now ter
glue
and
7y Cro33
g^
6,
Fig.85.)
dowel the two cen-
up
the
this will
roughly
and
together
pieces
remainder
form a block
resembling
the
section through oil box
carve this
,=^=
into
=
^==
the
paring tools, gouges,
desired
required etc.,
pattern.
Then
form with
and when
the
finished
AND FOUNDRY PRACTICE paint the inside as in Fig. 86. a, Fig. 86,
and the hinge
£5
The
125
core print
for the lid 6, Fig. 86,
MS
3ecftonal Worhhg ayaW^nff rfHlt cm-K ^
Wrii\i9 This
should be added to the original block. hinge
may
through
it
also
have the
slot for the
in the ordinary
way; that
lid is,
cored
by put-
Parfirt^
Vforkinj
drawing
Xoohin^
HoWrt
ting the necessary core print on the outside of
the
hinge piece, but
this
cannot be illustrated
PATTERN MAKING
126
plete core box, as
shown by the working drawing.
Half of such a core box Little strips
Fig.
Next make a com-
view of the pattern.
in this
of
wood
a.
is
Fig.
ria
A
may be
required by
rather neat piece of
a double-flanged elbow for a steam pipe,
shown
small
6,
paHeitt
the nature of the work.
as
87, or blocks
fie
slides, projections, etc., that
is
in Fig. 87.
can be tacked into the core for any
87,
ffd7f of f-rnisiheS
work
shown
in Fig. 88.
pipe,
Assuming
say 4-inch,
piece of lathe work.
it
this to
be for a
becomes a simple
Having made a proper
AND FOUNDRY PRACTICE working drawing
(Fig. 89) for
of the parts to be
made, prepare a piece
of suitable dimensions ring,
which
cross-section,
as
shown
determining the size
from which
should be
a perfect
in Fig. 90.
pieces
(see Fig. 91) in
of material
to turn out a
semicircle in
This ring
then cut into quarters, two of wliich principal part of the pattern.
127
make
is
the
Next turn up two
two parts each.
These,
PATTERN MAKING
128
when doweled mentioned,
make
quarter
the
to
circles
already
the desired pattern, as
shown
^^9 88
^
doxible flcnt^€J3i
in Fig. 92,
as
shown
and
it
in Fig. 92.
pattern,
yaxjae
elioW
should be painted in the joint,
*rh€ Worlii-n^
this
sfeam
take
To make
a core box for
SiraWiii^ for pijae
a
piece of
stuff
^boW of
proper
dimensions and into the face turn a semicircular
AND FOUNDRY PRACTICE Cut
groove of the radius desired.
129
plank in
this
quarters, using one of the parts for the curved
portion of the box, which
on
strips in
are cut,
and with additional
clearly illustrated
Fig.
93.
box
is
As the alike
finished
by gluing
strips for closing the
This
ends of the box. is
is
which proper semicircular notches
in
core
both
at
ends, the core will reverse
and glue together;
therefore a single all
that
If,
however,
differ
made.
IS
box
is
one
end
from the other,
Now
==• •=
necessary. of
a
the full
elbow
should
box should be
assuming that instead
of 4 inches
130
PATTERN MAKING
TVy
€for€
"hox fot*
_£f
Tt^ 93 ^izeS
STixalJ
elhaW
AND FOUNDRY PRACTICE elbow
this
is
4
in
feet
131
then
diameter,
we
have an entirely different proposition to consider,
and instead
have a problem
of a piece of lathe
in construction
work we
which should be
solved in the following manner: Get out the two circular flanges, a a. Fig. 94,
in
which should each be
two halves and
doweled
together.
Next, get out the pieces
and a
b
let
and
them
c,
into
gain,
suitable
j/alf
pattern for l^rge
sTiaWi'rit^
which
is
cross Sectioft
«»'
fjiov/ fiati^e
cut into
the straight side of these flanges.
(See Fig. 95.)
Now
get
ribs
body
of
out the
the
semicircular
pattern,
and the
ribs
for
the
and ends
PATTERN MAKING
132
the
for
core
Corc 'dok foT
as
shown
proper
Secure these
prints.
wood screws and
glue to the
1ar^
elboW
Fig.
in
allowance
of the lagging.
94,
Dvu'ed jine^
taking
made
is
Then
with large
pieces
and
sftt^
c,
Ttbi
that
care
the
for
b
a
thickness
get out suitable lagging,
the form of which
can
be
from
sectional
drawing,
Tig 0r CroM
section
throiigTi
core Trox
Now
obtained
the
cross-
working Fig.
cut this
95.
lag-
ging to such lengths as the
nature
secure
it
long
in
finish
of
place nails,
the
work may
require,
with glue and driving
all
nail
screws
and or
heads far
AND FOUNDRY PRACTICE enough below the surface
Then go
carefully
l.
l l
i'Tl
to allow truing up.
work with sharp
over the
Tlo-n of 5keJefon core
133
for Jar^c
loit
—
/
.l i
,n,.i|
eJbovsf
i
'Hvi,>,
'
WA
'^:mm^^i^^~ Elrvctttori
of
Stlte'let o-n
His
core boy for '
tools,
planes,
elhoW
"^^
CVoss 3CC < T o 7t Tlvro iijgh core
paring
fo-rtj/e
,
etc.,
coreiox
until
8r_
swefjg-
no
bumps
appear when rubbing the hand endways along
PATTERN MAKING
134
Lastly, put a leather
the pattern. fillet^
l^-
in
d and finish with shellac
at
making elbow
a core box for this
of
very
is
making except
The
ordinary manner.
the
similar
the
pattern
that
the
design
Figs.
in
itself,
le-
is
being
operation
the
rersed;
shewn
the
to
of
and
9G
97.
This core can be sw^pt in a
box
skeleton
similar
the
to
skeleton core boxes already de-
from the
scribed, excepting that
curved form
core
the
of
it
is
necessary to so design the core
box
work instead a device
101
to
around
and
be
end of the
Such
it.
shown
clearly
is
Figs. 98, 99
Fig.
of
may
sweep
the
that
moved from end
in
100.
an ordi-
represents
nary fluted cast-iron fence post, fot
which has hollow projections receiving
*
Leather
is
now
the
ends
generally used for
plied in various sizes
by the
trade.
of
fillets
the
and
is
for
top sup-
AND FOUNDRY PRACTICE and bottom
rail
of
135
the fence, which
is
itself
hollow.
Such a pattern would not draw the
ordinary
simple enough
and
103.
divided in
but the work becomes
manner;
when parted
The
if
as
shown
in Figs. 102
projections for receiving the ends
j9a Hinq
of the rail are left loose
drawn out and
from the pattern and are
of the sand after the pattern
these, being hollow, leave their
is lifted,
own
core in
the sand.
A
suitable core
box
for Fig. 101
may be made
PATTERN MAKING
136 of the
form shown
grooves, moulds,
if
any
shown on
the
in Fig. 104, especially
are to be
etc.,
core to correspond with the form of the outside If a plain
of the post.
required, a core
square core
made, open at top and bottom, which a
that
is all
is
box of the desired form may be is
laid
upon
surface filled with prepared sand, flour, etc.,
flat
and struck
off
with a straight-edge, as described
box as shown
for the core
mould such a core would
Fig. 25.
in
lie
In
this
with the corner up-
ward.
Having endeavored
work only
in a
by the
many
to treat the subjects of this
manner both
lucid
and exhaustive, not
directions simply stated, but also
by
illustrations, I feel confident that the care-
ful perusal
and study
great
to
aid
mechanic
in
his
the
of this
volume
intelligent
and
battle for success in
particular field of usefulness.
It
was
will
be a
ambitious life in this
my
inten-
AND FOUNDRY PRACTICE tion to
have added a chapter, or at
pages, to
kinds of
work, upon
this
wood
of patterns;
of
least
a few
the subject of the
usually employed in the
making
but as the subject has already been
so ably treated
number
137
by a
writer in the July, 1904,
"Carpentry and Building," I have
here reproduced the article in
full.
:
WOOD FOR MAKING PATTERNS "In a recent discussion of the different of
wood adapted
making
to the
varieties
of patterns,
M.
Golden, Professor of Applied Mechanics at
J.
Purdue University, Lafayette,
some very important points
among
class
we take space
ested,
to be considered
and as the subject
the pattern maker,
which a large
Ind., brought out
our readers
by
one in
is is
inter-
to present the following
extracts
"A
wood
suitable
formed
of strength.
out of the
use
have a
easily,
The list
making must be
for pattern
cheap, of such a nature that
it
fine grain
can be shaped or
and a
fair
degree
requisite of cheapness throws
—except
—some woods, such
for special or restricted
as cherry
and mahogany,
from which excellent patterns may be made. study of the microscopic structure of the will
show why
certain classes are not
be suitable for pattern making.
much
in cost and the ease with which they
Oak, however,
is
139
not at
wood
and cannot
For instance,
take oak and pine, which are very
shaped.
A
alike
may be
all suitable for
PATTERN MAKING
140
though weaker,
patterns, while pine,
be preferred, and
Some knowledge
woods.
growth of the two
Upon
this.
to
other
help us to understand
will
we
find that the pine
smooth and even, while the
is
oak has a very great variation is
much all
the structure and
of
examination
has a texture that
is
used more than
is
in the
wood which
formed in the spring of the year, and that
The
which
is
formed in the summer.
growth
is
open and has many holes that follow
the direction of the grain, while the is
spring
summer wood
In addition, in the oak we
dense and hard.
find the hard, shell-like plates that
form the
silver
grain comparatively large and numerous; while in
pine these plates are hardly distinguishable
at all.
" it
One
requisite of a
must be
filled
good pattern wood
of such a nature that the grain can be
to protect the pattern
of moisture in the
that the
wood
from the action
moulding sand.
of the
oak
It is evident
will serve this
but poorly, and that pine would be
two
that
with shellac varnish or some corresponding
medium,
"
is
The wood
of the
oak
is
This
is
much
better.
made up practically of
different kinds of elements ;
the vessel.
purpose
shaped
one kind
like
is
called
a tube, which
AND FOUNDRY PRACTICE often does extend the whole length
may and tree
trunk.
much
like
the is
141
The
of
structure
vessel
this
garden
a wire-wound
that of
of
hose, except that the ridges are on the inside of
stiffen
These ridges serve
the tube.
the walls of
and strengthen the tube.
The
vessel
is
to for
carrying sap from the roots to the branches and
This kind of element forms larger open-
leaves.
ings,
and the
vessels
have grouped around them
elements of the second kind. paratively short in length
The ends
the walls.
and
overlap
members
and much stronger
of these shorter
the
shorter
together;
of fibers
them are together ''
There
is still
serve
vessels.
The
vessels
that surround and
stiffen
is
another kind of tissue in the oak
found
in pith,
This
and
plates that connect the outer
it
is
of
them
is
One
h:?.rdens
flat
parts,
of these
wood
a bundle.
the tree grows older the
medullary ray
same
of the
occurs in
called the medullary ray and the
between two
"As
is
and inner
growing from the heart outward. plates
as
called a bundle.
that forms the. silver grain.
kind that
a
and
fibres
called
mechanical support to the
and groups
in
members
dovetail
are
These are com-
tissue
very much, and as
in it
the
does
PATTERN MAKING
142
not change
form during seasoning,
its
siderable influence in causing the
it
has con-
wood
to warp.
This greater tendency to warp on the part of the
oak
is
another point against
matter
food
carried
there
up is
it
is
for the pattern
it
During the growth
purposes.
of the tree the
taken up by the roots and
to the leaves through the vessels,
brought
is
and
in contact with the air that
it
takes in through openings in the surface of the
The
leaves.
matter for the
sap
The
tree.
changed into food
then
is
principal portion of the
food matter comes from the
air,
and
back with the sap from the leaves
is
to the outer
part of the branches and trunk, where in building
new wood and
carried
it is
other tissue.
used
The
medullary rays help to carry food matter to the inner growing parts of the tree.
" Pine
wood differs from oak in
that
one kind of element instead of two. the vessels and fibers there
is
it
has only
In place of
a kind of element
called tracheide that serves the purpose of both.
The
walls of this tracheide have small openings
through them from one to another so that the sap
may be
carried
and back again
when
from the roots
to the
growing
the flow of sap
is
tissue.
to the leaves
In spring,
greatest, the elements
AND FOUNDRY PRACTICE that are formed
summer
the
by the growing part
and have thin
are very large
143
walls, while during
the walls are thicker and stronger
and the elements correspondingly smaller.
summer wood and more for
growth
much
is
The
consequently harder
and thus better adapted
The
making.
difference
the
in
in pine at different seasons of the year
less
this,
is
than in oak, and so, of course, the
wood, as a whole,
When
oak
of the
fine in grain
pattern
oak
of the
and the
much more even
is
fact that there
is
in grain.
only one
kind of element in pine, are taken into consideration,
it is
pattern
"
evident that the pine
is
better suited for
work than the oak.
When
the pattern
maker comes
two woods he finds the oak having annual rings in which there tissue
that
is
very hard
summer wood, and
clearly
are, side
by
marked
side,
wood
and dense from the
tissue that
open from the spring
to use these
is
growth,
very light and so
that
it
is
practically impossible to get a surface that will resist
the action of
moisture in the mouldino-
sand, or even a surface
sufficiently
smooth
to
leave a good impression in the mould.
" Then,
too,
the oak pattern would have a
constant tendency to warp because of moisture
PATTERN MAKING
144
taken in from the open vessels of the spring
wood.
"The
pine,
on the contrary, has not much
difference in the tissue that goes to
spring
and summer annual
make up
its
these rings
rings,
being distinguishable more on account of a slight
change in color in some parts than on account of
The
the size of the elements. parts of the pine are thin
that the
wood
is
and
easily shaped,
elements in light
all
enough so
and yet the
ele-
ments are small enough to make protection
of
them by varnish an easy matter, on account
of
the fact that they are easily
These pecul-
filled.
iarities of structure adapt the pine especially to
the needs of the pattern maker,
its
principal draw-
back being because of the lightness of
and the ease with which In conclusion we
maker
is
it is
will
its
bruised."
remark, that a pattern
supposed to be a paragon of order, a
thorough mechanic and a gentleman. are of the best quality
and
His tools
in perfect order for
turning out the finest quality of work. tool
is
all
them.
Every
always in place and he knovv^s just where
to lay his
are
tissue
hands on the desired one.
His patterns
numbered and an accurate record kept
He
is
of
supposed to know what patterns
AND FOUNDRY PRACTICE
when they went and how
are at the foundry,
many
pieces
of
145
are required.
casting
He
is
expected to "keep tab" on patterns that leave the
shop, and
in
such patterns
case
are
not
returned at the appointed time, he should look
them
after
pleasant. softest
and
at
worth
desires
is
Hence a job
striving
to follow a
after life
clean
is
the best of
driest pine for ordinary
for fine work.
well
shop
His
once.
His material
its
and
kind; the
and mahogany
of pattern
making
is
by any person who
devoted
pursuits.
THE END
to
mechanical
— TABLE OF CONTENTS Foundry Practice.
— Cup-shaped casting— Con— Fire extinguisher cap— Stake
Cast iron washer necting rod
pocket casting.
Page
19-S
Pattern Shop Practice.
— —
Mechanical drawing Drafting tools Gluing up work. tion of machinery
i
— LocaPage. 37-48
Tools. loathe tools, rule
—
and gouges Shrinkage 49-58 Page lathe.
chisels
— Pattern maker's
Making the Pattern.
— —
Stake pocket pattern and core box
Flanged and core box Cast pipe Double flanged wheel fitting and core box pattern and core box Double flanged gear Brake wheel pattern Making a gear pattern Laying out gear teeth— Miter gear pattern Iron dome pattern and core box Car seat 59-96 pattern. Page cylinder pattern
— — —
—
—
—
Casting with Part Patterns, Etc. Ribbed plate Cast gear Large pulley or 97-104 flywheel. Page
—
—
Sweep Work.
—
Sweep for bowl or dome Sweep for smoke box door Sweep for locomotive cylinder 105-117 Mould for fluted column. Page
—
Complicated Patterns. Locomotive chime whistle Car journal box Double flanged elbow Skeleton core for
—
— Fluted
large elbow
— —
cast
iron
fence
post.
118-138
Page
Wood for Pattern Making.
Oak— Pine.
139-145
Page 147
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FOR STEAM ENGINEERS By HENRY C. HORSTMANN and VICTOR K. TOUSLEY, Authors of "Modern Wiring Diagrams and Descriptions for Electrical Workers." This excellent treatise is written by engineers for engineers, and is a clear and comprehensive treatise on the principles, construction and operation of Dynamos, Motors, Lamps, Storage Batteries, Indicators and Measuring Instruments, as well as full explanations of the principles governing the generation of alternating curi-ents and a description of alternating current instruments and machinery. There are perhaps hut few engineers who have not in the course of their labors come in contact with the electrical apparatus such as pertains to light and power distribution and generation. At the present rate of increase in the use of Electricity it is but a question of time when every steam installation will have in connecton with it an electrical generator, even in such buildings where light and power are supplied by some central station. It is essential that the man in charge of Engines, Boilers, Elevators, etc., be familiar v/ith electrical matters, and it cannot well be other than an advantage to him and his employers. It is with a view to assisting engineers and others to obtain such knowledge as will enable them to intelligently manage such electrical apparatus as will ordinarily come under their control that this book has been written. The authors have had the co-operation of the best authorities, each in his chosen field, and the information given is just such as a steam engineer should know, To further this information, and to more carefully explain the text, nearly 100 illustrations are used, which, with perhaps' a very few exceptions, have been especially made for this book. There are many tables covering all sorts of electrical matters, so that immediate reference can be made without resorting to figuring. It covers the subject thoroughly, but so simply that any one can understand it fully. Any one making a pretense to electrical engineering needs this book. Nothing keeps a man down like the lack of training nothing lifts him up as quickly or as surely as a thorough, practicalKnowledge of the work he has to do. This book was v^Titten for the man without an opportunity. No matter what he is, or what work he has to do, it gives him just such information and training as are required to attain success. It teaches just what the steam engineer should know in his engine room about electricity. 12mo, Cloth, 100 Illustrations. SizeSi^xTs^. PRICE NET A« Cft Sold by bookseller s gene rally, or sent, all charges paid, upon yi iO ;
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Fred T. Hodgson's
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STEEL SQUAR A TREATSBE OF THE PRAGTiOAl By FRED, New and
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Of
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the Square is used for laying out Mortises. Tenons, Shoulders, Inclined
Work, Angle Corners and
similai
work. The work also contains a large number of diagrams, showing how the Square may be used in finding Bevels, Angles Stair Treads and bevel cuts for Hip, Valley, Jack and other Rafters, besides methods for laying out Stair Strings, Stair Carriages and Timber Structures generally. Also contains 25 beauxiful halftone illustrations of the perspective and floor plana of 25 medium priced houses. The work abounds with hundreds of fine illustrations and explana* tory diagrams which will prove a perfect mine of instruction for the mechanic, young or old. Two large volumes, 560 pages, nearly 500 illustrations, printed on a superior quality of paper from new large type. Price, 2 Vols., cSoth binding i $2.00 Price, 2 Vols., haSf-Seather binding 3.06 Slngla Voiuises, Part 1, cloth l.OC •• •* Partl,haif>8eather 1.50 •• « PartSl.cIoth I.0
SEND FOR
COil/iPLETE
FREDERICK
ILLUSTRATED CATALOGUE FREE
J.
DRAKE
(SL
CO.
PUBLISHERS OF SELF-EDUCATIONAL BOOKS 211 E.
MADISON STREET
^
^
CHICAGO
Modern Carpentry
PRACTICAL MANUAL
A
WD WORKERS GENERALLY
fOR CARPENTERS AND
Hodgson, Architect, Editor of the National Builder, PracticaS Carpentry, Steel Square and Its Uses, etc., etc.
ANEW,
complete
containing
guide,
hundreds of
methods for performing work in carpentry, general wood-work. Like all of Mr. Hodgson's written in a simple,
bewilder
does
not
with
long
abstract
everyday
theories.
The
works,
it
is
and
style,
workmg-man
the
mathematical
quick
joining and
formulas
or
illustrations,
of
which there are many, are explanatory, so that any one who can read plain English will be able to understand them easily
and
without
to
follow
the work in
hand
difficulty.
The book
contains methods of laying
roofs, rafters, stairs, floors, hoppers,
bevels, joining mouldings, mitering, coping, plain hand-railing, circular work, splayed work, and many other things the carpenter wants to know to help Ml I SpffliiwimM him in his every day vocation. It is the most complete and very latest work published, being thorough^ One which no carpenter can afford io l^ractical and reliable. '!!
he without. j
9f
The work is printed from new, large type plates on a superior quali^ cream wove paper, durably bound in English cloth.
$^00
PfiOC
FREDERICK 211-213 E.
J.
DRAKE &
Madison
5t.,
Chicago.
CO,
^
F^i'tn Engines ami How im Run Tiiem ^IK?#gS BySTEPHESSS&a, MAGGARD A CQOY, Expept EesijIfSfi^s's
Fully Illustrated wlth:about
woodcuts.
7P beautiful A complete instructor
for the operator or amateur.
Uy^'oy^^^iX/:::^^^^ XZI^^^^^%(Mt 1
The book first gives a simple description of every part of a boiler and traction or simple stationary engine, with definitions of all the technical terms commonly used. This is followed by over 80 test questions covering every point that precedes. Then come simple and plain directions to the young engineer as to how to set up and operate his engine and boiler, followed by questions and ansv/ers as to what should be done in every conceivable diffi-
culty that may arise, covering such subjects as scale in the boiler, economical firing, sparks, pressure, low water and danger of explosions, lining and gearing the engine, setting the valves, oiling, working injector
and pump, lacing and putting on belts, etc. There are two Farm Engine Economy, giving the theory of the steam engine, especially in its practical applications to securing economy of operation. Chapter XII, describes "Different Types of Engines, " including stationary, cor»pound, Corliss and high speed engines, and all the leading makes of traction engines with an illustration of each. Also chapter on gasoline engines and how to run them,. and another on how to run a chapters on
The book closes with a variety of useful practical suggestions and tables, and 175 questions and answers often given in examinations for engineer's license. Beautifully illustrated with plans, etc. threshing ma*kine. recipes
and
12MO CLOTH. PRICE
$1.00.
Sent prepaid to any address upon receipt of price.
FREDERICK
J.
DRAKE ^
CO,,
PUBLISHERS
SEP
fi
J905
