Knocking out and de-coring metallic castings
URN: SEMMPF220
Business Sectors (Suites): Materials Processing and Finishing Suite 2
Developed by: Enginuity
Approved on:
2020
Overview
| This standard identifies the competences you need to knock out and de-core castings produced from sand moulds, ceramic moulds or investment shells and includes the use of manual, mechanised and chemical methods, in accordance with approved procedures. You will be required to select the appropriate equipment and chemicals to use, based on the type, size and number of the moulds/shells to be knocked out and de-cored. The moulds/shells you deal with will have been produced as one- offs, batches or by a continuous casting process. Ferrous and non-ferrous castings are covered in this standard. Sand moulds will be knocked out in specified areas and the castings containing cores will be moved for de-coring, to ensure that the used core sand can be segregated from the moulding sand. Investment moulds and shells will be knocked out and the waste material collected for specialised removal. Cores from ceramic moulds or shells will, where appropriate, be removed by vibratory methods or chemical leaching. Moulding equipment, such as boxes, clamps, will be returned to the mould production area. Any coremaking ancillaries will be collected, and recycled or scrapped. You will operate any machinery that is used to transport, knock out and de-core the castings and also any machinery used to remove the castings to other areas for further processing. Where chemicals are used to remove cores from castings you will ensure that the solutions used are to the required specification. You will place obvious and suspect scrap castings in specified areas to await confirmation. Your responsibilities will require you to comply with organisational policy and procedures for the knocking out and de-coring of sand or ceramic moulds and investment shells. You will report any problems with the equipment and material in use that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work to verbal or written instructions and to take responsibility for the safe and correct handling of the rough castings. 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 knocking out and de-coring of the various types of moulds/shells. You will understand the different types of materials used to make the moulds/shells and the process of casting removal from the various types. You will have knowledge of the associated machinery that is used to handle the different types and size of cast mould/shells and you will understand why different methods and chemicals are used in the knocking out and de-coring process. You will understand the safety precautions required when carrying out the knocking out and de-coring activities and when using the associated tools, equipment and/or chemicals. 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 relevant work instructions and specifications to knock out and de-core metallic castings 3. check that the knocking out and de-coring tools and equipment are available and in a safe and usable condition 4. ensure that chemical solutions used to remove cores from castings are to the required specification 5. carry out the knocking out and de-coring activities in accordance with operating procedures and the casting specification requirements 6. check that removed castings are complete and free from obvious defects 7. segregate castings according to company procedures 8. deal promptly and effectively with problems within your control and report those that cannot be solved 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 emergency procedures to be followed in the event of a malfunction of any of the equipment that you use 7. why sub-standard castings should be removed from the production line during knock out and de-coring activities 8. the different types of materials used to produce moulds 9. the difference between sand moulds and ceramic moulds/shells 10. the different methods and machines used to transport moulds and/or shells to the knock out and de-coring areas 11. the different methods and machines that can be used to knock out and de-core moulds and shells 12. the reasons why some cores are removed from castings using chemicals 13. the reasons why mould, core equipment and ancillaries are returned to the production areas 14. the effect on casting quality of incorrectly knocking out and de-coring castings 15. the casting defects which can be directly related to the use of incorrect methods for the removal of runners/risers/feeders from castings during the knocking out 16. the reasons why runners/risers/feeders need to be identified 17. why some moulding materials can be returned for recycling and others must be disposed of 18. why some core materials need to be disposed of using specialist methods 19. the importance of keeping the equipment clean and free from damage, good housekeeping of tools and equipment and maintaining a clean working area, and to carry out shut-down procedures 20. the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve 21. how to access, use and maintain information to comply with organisational requirements and legislation |
Scope/range
Scope Performance
| 1. Knock out and de-core metallic castings, carrying out all of the following activities: 1. obtain all necessary documents and job instructions for the operations 2. adhere to health and safety regulations, systems and procedures to realise a safe system of work 3. ensure that the work area is clear of obvious hazards 4. check that lifting and handling equipment required is available and in good order 5. check that the necessary tools and equipment are available and in a safe and usable condition (blasting equipment or vibratory tables) 6. check that chemical leaching tanks are in good order and that chemicals are to the required specification 7. ensure that dust extraction equipment is functioning correctly 2. Knock out and de-core castings produced from one of the following: 1. ferrous alloys 2. non-ferrous alloys 3. Knock out moulds produced by one of the following casting processes: 1. green sand (naturally or synthetically bonded) 2. chemically bonded gas activated sand 3. chemically bonded resin activated sand 4. resin bonded heat activated sand 5. ceramic materials 6. investment casting shells 4. Remove castings from moulds, and carry out all of the following: 1. knocking castings out of the moulds 2. de-coring 3. removing castings from the moulding material 4. removing runner/riser/feeder systems 5. Remove and de-core castings, using one of the following methods: 1. manually 2. by blasting (including air, water, sand) 3. using vibratory tables/grids 4. by chemical leaching 5. using punch-out mechanism 6. Complete the knock out and de-coring activities, to include all of the following: 1. segregate and dispose of core sands and moulding sands 2. return mould and core-making equipment and ancillaries to the production area (where appropriate) 3. segregate and identify, where appropriate, runners/risers/feeders 7. Complete the visual inspection and segregation of castings, for all of the following categories 1. acceptable castings 2. scrap castings 3. castings requiring further inspection by supervision 8. Complete all of the following operations at shut-down: 1. close down any machinery or equipment used during knock out and de-coring operations 2. check that all systems are failsafe 3. complete the operational log 4. hand over to supervision ** ** |
Scope Knowledge
Values
Behaviours
Skills
Glossary
Links To Other NOS
External Links
Version Number
2
Indicative Review Date
2023
Validity
Current
Status
Original
Originating Organisation
Semta
Original URN
MPF2.20
Relevant Occupations
Engineering and Manufacturing Technologies, Manufacturing Technologies, Process Operatives, Process, Plant and Machine Operatives
SOC Code
8115
Keywords
Engineering; manufacturing; processing; knocking out; de-coring; casting; metallic; sand moulds; ceramic moulds