Producing sand moulds or cores with mechanical assistance
URN: SEMMPF206
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 moulds or cores from plated patterns (with and without cores) or 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 pattern or core box, the moulding or coremaking method employed and the metal to be cast. You will be expected to check the machine you use, prior to production, to ensure that it is in a safe and usable condition and you will be expected to shut down the machine to a safe condition on completion of the moulding or coremaking activities. Moulding or coremaking will take place using recognised techniques, in semi-mechanised foundries. You will be expected to produce the moulds or cores using sand mixtures such as greensand, chemically bonded gas activated sand, chemically bonded resin/catalyst activated sand or resin bonded heat activated sand. You will be expected to gas/cure your own moulds or cores, either manually or by using the gassing/heating system incorporated in the machine. You will also need to determine the length of time that resin bonded sand moulds or cores need to cure, prior to stripping. The patterns used will be plated and, either fitted to a moulding machine, or sited on a roller track. The moulding machine will be either the jolt squeeze, jolt/squeeze/rollover or blow/blow squeeze type. Mould stripping will, in general, be performed mechanically. Core boxes will be simple in shape and it is expected that the cores will be blown. Special sands will be used, where applicable, to suit core sections and the metal being cast. Moulds and cores will be removed from the machine in use and placed in areas specified for the product. Sub-standard mould or cores will be scrapped and placed in non-production storage areas for examination by others. The profiles will be curved and tapered. The moulds will be produced either in boxes, or boxless, as appropriate. Your responsibilities will require you to comply with organisational policy and procedures for the moulding or coremaking activities undertaken and to report any problems with the patterns or core boxes, sand and 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 moulds or 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 the semi-mechanised production of sand moulds or cores. You will have an understanding of the different types of sand in use and the additives and additions used in preparing the sand you are using to make the moulds or cores. You will understand the different types of pattern or core box and the associated equipment, materials and consumables, 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, patterns, core boxes and moulding equipment and finished moulds or cores. You will understand the safety precautions required when carrying out the sand moulding and 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. confirm that the equipment is set up correctly and is ready for use 4. control the machine in line with operational procedures 5. produce components to the required specification 6. carry out quality sampling checks at suitable intervals and check the final 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 the information 6. the different plated pattern types used in the moulding process 7. the methods used to locate mould boxes or frames onto pattern plates 8. the different types of coremaking processes 9. the main types of mould or core reinforcements (boxes, frames, cast bars or grids) 10. the different sand moulding/coremaking processes used (chemically bonded sand, gas activated, chemically bonded resin catalyst or resin bonded heat activated) 11. the additions and additives that are used when mixing sands and how these affect the moulding/coremaking process 12. the effects of using incorrect amounts of additions and additives to moulding sands 13. the application and use of release agents and mould coatings 14. why different types of sand mixes have limited or unlimited life for producing moulds 15. mould/core curing techniques (gas, resin catalyst or heat activated) 16. the core and mould stripping techniques and methods 17. how to identify mould or core defects (soft spots, broken/damaged mould/core surfaces or clagging/sticking) 18. the company quality control procedures for producing and inspecting moulds and cores 19. the importance of keeping the pattern or core box equipment clean and free from damage, good housekeeping of moulding tools and equipment maintaining a clean working area 20. the extent of your own authority and whom you should report to if you have problems that you cannot resolve when making the moulds or cores 21. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Produce sand moulds or 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 moulding specifications 4. follow the defined moulding or coremaking ensure that the moulds or cores produced meet the required specification for quality and accuracy 5. shut down the machine and leave the work area in a safe condition on completion of the moulding or coremaking activities 2. Use one of the following types of machine to produce the moulds or cores: 1. jolt/squeeze 2. mixer/vibratory table 3. blown 4. blow/blow squeeze 5. jolt/squeeze/rollover 6. squeeze 7. blown/vibratory 8. other (specify) 9. mixer/slinger 3. Confirm that the machine is set up for use, to include checking and ensuring all of the following: 1. safety locks, guards or screens are operational 2. sand discharge points are clean and operational 3. pattern plates or core boxes are free from damage and are correctly mounted and secured 4. consumables to be used are at the required levels 5. the gassing systems are connected and operational 6. emergency stop controls are operational 4. Produce moulds or cores from one of the following types of sand: 1. greensand (naturally or synthetically bonded) 2. chemically bonded resin catalyst activated 3. chemically bonded gas activated 4. resin bonded heat activated 5. other type of sand (specify) 5. Produce one of the following: 1. moulds from plated patterns, with mechanical assistance, to include at least one core 2. cores from split boxes, with mechanical assistance inserting, where appropriate, suitable reinforcements 6. Strip moulds or cores, using one of the following methods: 1. manually 2. manually, using vibratory action 3. automatically 7. Complete the organisational quality inspection checks, using one of the following methods: 1. visual 2. using jigs, gauges or templates 3. using automated techniques 8. Apply mould/core coatings/dressings, using one of the following methods: 1. spray 2. flood 3. brush 4. dry 9. Check sand moulds or 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. the required specification (shape, dimensional accuracy) 10. Sort the finished moulds or cores, into both of the following areas: 1. placing acceptable moulds or cores into designated areas 2. disposing of sub-standard moulds or cores into designated areas |
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
MPF2.06
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; sand; moulds; cores; greensand; chemically bonded