Producing sand moulds or cores automatically
URN: SEMMPF207
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, using automatic methods, in accordance with approved procedures. Moulding or coremaking will take place using recognised techniques, in fully mechanised foundries. You will be expected to activate the operations at the start of your shift and to close down the operations when your shift finishes. Moulds or cores will be produced from either greensand, chemically bonded gas activated sand or chemically bonded resin/catalyst activated sand. You will be expected to check the systems that operate the production cycle. This will include safety checks, checking the correct location and security of pattern or core boxes and the supply of consumables (power, sand, gas (if used), track/conveyors, return belts) and any other special checks made (manually, visually or electronically). Patterns or core boxes will be fitted to a moulding or coremaking machine. The moulding machines will automatically perform the complete cycle of production. Mould or core stripping will, in general, be performed mechanically. Moulds and cores will be transferred or removed from the machine in use, in some cases by automatic means and placed in areas or on tracks or conveyors specified for the product. 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 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 also understand the cycle of operations used to produce the moulds or cores and the associated equipment, materials and consumables used, 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 when there are faults highlighted by the checking/production cycles and to take the necessary actions to solve, rectify or report the fault. You will understand the safety precautions required when carrying out the sand moulding and coremaking activities and when using fully mechanised moulding 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 safely and correctly 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 their 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 different sand moulding and coremaking processes used (chemically bonded sand, gas activated, chemically bonded resin catalyst) 10. the additions and additives that are used when mixing sands and how these affect the moulding and coremaking process 11. the effects, on the casting produced, of using incorrect amounts of additions and additives to moulding and coremaking sands 12. the application and use of release agents and mould coatings 13. why different types of sand mixes have limited or unlimited life for producing moulds 14. mould/core curing techniques (gas, resin catalyst or heat activated) 15. the various core and mould stripping techniques and methods 16. how to identify mould or core defects (soft spots, broken/damaged mould/core surfaces or clagging/sticking) 17. the organisational quality control procedures for producing and inspecting moulds/cores 18. the importance of keeping the pattern or core box equipment clean and free from damage, good housekeeping of moulding tools and equipment, and maintaining a clean working area 19. 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 20. 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 follow the defined moulding or coremaking procedures 4. ensure 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. automatic moulding machine 2. automatic coremaking machine 3. Confirm that the machine is set up, by 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. the machine sequence cycle is correct 7. emergency stop controls are operational 4. Produce moulds or cores automatically from one of the following types of sand: 1. greensand (naturally or synthetically bonded) 2. chemically bonded gas activated 3. chemically bonded resin catalyst activated 5. Produce one of the following: 1. moulds from plated patterns 2. cores from split boxes 6. Complete the organisational quality inspection checks, using one of the following methods: 1. visual 2. using jigs, gauges or templates 3. using automated techniques 7. Check sand moulds or cores meet all of the following quality and accuracy standards: 1. complete and free from obvious defects (cracks, soft spots, broken or damaged surfaces) 2. meet the required specification (shape, dimensional accuracy) 1. Sort the finished moulds or cores, into both of the following areas: 1. placing acceptable moulds/cores into designated areas 2. disposing of sub-standard moulds/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
MPF2.07
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; automatically; method