Assembling, core setting and closing sand/ceramic moulds

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This standard identifies the competences you need to assemble, locate and secure cores in sand/ceramic moulds and to prepare the moulds for casting. Manual and mechanised methods will be used, in accordance with approved procedures. You will be required to select the appropriate equipment to use, based on the type, size and number of the moulds to be assembled and the size, shape and number of cores to be secured within the moulds. The moulds you will assemble, core set and close, will have been produced as one-offs, by batch or by a continuous moulding process. You will be required to check the condition of the moulds and the cores you receive and to reject any considered to be sub-standard, in accordance with the company control procedures. You will be expected to clean the mould drags and copes and where appropriate, to apply a suitable mould dressing. You will need to insert the cores into the moulds and secure them, using prints and other approved methods such as studs or chaplets. Before the moulds are closed, you will be expected to carry out final checks to ensure that the quality of the mould and cores meets company standards. Mould closing and where appropriate, sealing will take place using approved location devices and sealing materials. Moulds will be secured or passed to the clamping area prior to being cast. Your responsibilities will require you to comply with organisational policy and procedures for the assembly, core setting and closing of the sand/ceramic moulds and to report any problems with the moulds, cores, materials 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 work that you carry out. 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 assembly, core setting and control of metal thickness and to the closing and securing of the various types of moulds. You will have an understanding of the different types of materials used to make the moulds and the associated machinery that is used to handle the different size of moulds. You will understand the different methods of locating the cores in the moulds and the mould location devices applicable to the various moulding processes (such as boxed and boxless). You will understand the safety precautions required when carrying out the mould assembling and closing 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.

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1. work safely at all times, complying with health and safety legislation,  regulations, directives and other relevant guidelines 2. follow the relevant instructions, assembly drawings and any other specifications for the component to be produced 3. ensure that the specified components are available and that they are in a usable condition 4. assemble the components in their correct positions using appropriate methods and techniques 5. secure the components using the specified connectors and securing devices 6. check the completed assembly to ensure that all operations have been completed and the finished assembly meets the 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

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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 procedure to be followed in the event of equipment or machine malfunction 7. why it is necessary to check the moulds and cores prior to commencing core setting and mould closing operations 8. the defects that can occur in the moulds and cores (cracked surfaces, exposed reinforcements, friable surfaces, broken or weak mould and core sections, incomplete mould or cores, damaged or broken core prints and core locations, mould location devices missing or distorted, uncoated moulds or cores) 9. the actions needed when moulds or cores are found to be sub-standard 10. the different types of sand that are used to produce the moulds and cores 11. the differences between box and boxless moulds and how this affects the preparation process 12. the reasons why core prints are needed and why cores must be located and secured correctly 13. the effects on casting quality and accuracy of incorrectly located and secured cores 14. why different methods are used to secure cores in moulds produced from different sands 15. why different techniques of mould locating are used 16. the reasons for sealing the mould joints prior to closing the mould 17.  the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and  maintaining a clean working area 18. the extent of your own authority and whom you should report to if you have problems that you cannot solve 19. how to access, use and maintain information to comply with organisational requirements and legislation

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1. Assemble, set and close moulds, carrying out the following  activities:

   1. confirm that all the required materials and equipment are available and 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 mould assembly  specifications
   4. use the correct tools and equipment for the mould, core  setting and closing activities
   5. follow the defined assembly and preparation procedures ensure that the completed mould assembly meets the    required specification for quality and accuracy
   6. leave the work area in a safe condition on completion of the moulding activities

2. Assemble and prepare one of the following types of mould:

   1. boxed                 
   2. boxless

3. Apply mould coatings, as appropriate, using one of the following methods:

   1. brush                  
   2. spray              
   3. flood

4. Insert at least two cores per mould, using two of the following methods:

   1. horizontal locations             
   2. vertical locations             
   3. horizontal and vertical locations

5. Secure the cores in the moulds, using two of the following methods:

   1. print locations                          
   2. adhesives                                
   3. metallic devices

6. Prepare the mould for closing, to include all of the following:

   1. cleaning and removing foreign bodies and surplus sand from the mould cavity
   2. carrying out visual checks on moulds for completeness (including all cores and freedom from cracks)
   3. checking that runner/riser/feeder systems are clean, connected and complete
   4. applying mould sealant, where appropriate

7. Complete the closing of the moulds, to include all of the following:

   1. locating the moulds using pins, rebates, diaboloes or cores, as appropriate
   2. closing moulds manually or by mechanical means securing the moulds using clamps/clips and/or weights

8. Sort the finished moulds, placing them into the appropriate designated area for either: 

   1. acceptable moulds
   2. disposal of sub-standard moulds

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2

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31 Mar 2023

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Current

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Original

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Semta

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MPF2.11

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Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives

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8115

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Engineering; manufacturing; processing; assembling; setting; core; sand; ceramic; moulds

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