Producing sand cores manually
URN: SEMMPF205
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
30 Mar 2020
Overview
| This standard identifies the competences you need to produce sand cores from solid turn out and split core boxes, using manual and semi-mechanised methods, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the type and size of the cores, the coremaking method employed and the metal to be cast. Coremaking will take place, using recognised techniques, in jobbing and semi-mechanised foundries. You will be expected to produce the cores using a range of sands, such as oil sand, chemically bonded gas activated sand, chemically bonded resin/catalyst activated sand or resin bonded heat activated sand. You will be expected to gas your own cores and determine the length of time that resin bonded sand cores need to cure prior to stripping. The coreboxes used will be simple in shape and it is expected that the cores produced will require the use of simple reinforcements and vents. You will be informed when the cores need to be produced in halves and you will need to complete the core joining operations, when this is applicable. Special sands will be used, where applicable, to suit core sections and the metal being cast. Repairs to the cores will be performed where necessary. You will make the decisions regarding core coating/dressing, if required and will mix/approve and apply the coatings/dressings to company standards. Your responsibilities will require you to comply with organisational policy and procedures for the coremaking activities undertaken and to report any problems with the core boxes, sand or equipment in use that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to instructions, with minimal supervision, taking personal responsibility for your actions and for the quality and accuracy of the cores that you produce. Your underpinning knowledge will be sufficient to provide a sound basis for your work and will enable you to adopt an informed approach to applying manual sand coremaking techniques. You will have an understanding of the different types of sand in use and the additives and additions used in preparing the sand you use to make the cores. You will also understand the different types of core box and coremaking accessories used and their application, in adequate depth to provide a sound background for carrying out the activities to the required specification. Your knowledge will be sufficient to enable you to identify sub-standard sand, core boxes, coremaking equipment and finished cores. You will understand the safety precautions required when carrying out the sand coremaking activities and when using the associated tools and equipment. You will be required to demonstrate safe working practices throughout. You will also understand your responsibilities for safety and the importance of taking the necessary safeguards to protect yourself and others in the workplace. |
Performance criteria
You must be able to:
| 1. work safely at all times, complying with health and safety legislation, regulations, directives and other relevant guidelines 2. follow the correct component drawing or any other related specifications for the component to be produced 3. obtain and prepare the appropriate tools, equipment and materials 4. carry out the moulding or laying-up activities using the correct methods and techniques 5. produce components to the required specification 6. check that all the required operations have been completed and components are to specification 7. deal promptly and effectively with problems within your control and report those that cannot be solved 8. ensure that work records are completed, stored securely and available to others, as per organisational requirements 9. leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements |
Knowledge and Understanding
You need to know and understand:
| 1. the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials) 2. the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you 3. the hazards associated with the activities, and how to minimise them and reduce risks 4. the personal protective equipment and clothing (PPE) to be worn during the activities 5. how to obtain the job instructions and how to interpret their information 6. the different core box types used in the core moulding process (solid turnout and split) 7. the different types of core box clamping devices 8. the different types of core reinforcement (wire, sprigs and bars) 9. the different sand coremaking processes used (oil sand, chemically bonded sand gas activated, chemically bonded resin catalyst and resin bonded heat activated) 10. the additions and additives that are used when mixing sands, and how these affect the coremaking process 11. why different types of sand mixes have limited or unlimited life for producing the cores 12. the application and use of release agents and core coatings or dressings 13. how to identify core defects (soft spots, broken/damaged core surfaces or clagging/sticking or distorted sections) 14. the company quality control procedures for producing and inspecting the cores (cleanliness, completeness, freedom from foreign bodies and defects) 15. the importance of keeping the core box equipment clean and free from damage, good housekeeping of coremaking tools and equipment and maintaining a clean working area 16. the extent of your own authority and whom you should report to if you have problems that you cannot resolve when making the cores 17. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Produce sand cores, carrying out all of the following activities: 1. confirm that all the required materials and equipment are available and are in a safe and usable condition 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. comply with job instructions and coremaking specifications use the correct tools and equipment for the coremaking activity 4. follow the defined coremaking procedures ensure that the cores produced meet the required specification for quality and accuracy 5. leave the work area in a safe condition on completion of the coremaking activities 2. Prepare the core boxes for use, to include both of the following: 1. visually inspecting the core box for damage 2. applying release agents to the core box (as applicable) 3. Produce full and half cores from both of the following types of core box: 1. solid turnout boxes 2. split boxes 4. Produce cores using two of the following techniques: 1. hand tucking and ramming 2. inserting reinforcements (wire or bars) 3. mechanical assistance with core consolidation 4. incorporating vents (pre-formed, manually applied) 5. Produce cores using one of the following sands: 1. oil sand 2. chemically bonded resin/catalyst 3. chemically bonded gas activated 4. resin bonded heat activated 6. Finish and repair cores using one of the following methods: 1. patching up/repairing oil sand cores 2. repairing rigid sand cores using adhesives 7. Apply core coatings/dressings using one of the following methods: 1. spray 2. flood 3. brush 4. dry 8. Check sand cores meet all of the following quality and accuracy standards: 1. complete and free from obvious defects (soft, spots, cracks, broken or damaged surfaces) 2. meet the required specification (shape, dimensional accuracy) 9. Sort the finished cores, placing them into the appropriate designated area for either: 1. acceptable cores 2. disposal of sub-standard cores |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
31 Mar 2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.05
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; manually; sand cores; chemically bonded sand; greensand; ester silicate