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CORES
A core can be defined as a body of sand, generally prepared separately in a core box,
which is used to form a cavity of desired shape and size in a casting. However, there are
some exceptions to this definition. For example, a pattern can be used to form a core as a
part of the mould, this being known as a green sand core. Similarly, in permanent moulds
or dies the cores are formed by the metallic moulds themselves as an integral part of
theirs. Cores which are prepared separately in core boxes are called dry sand cores and
are held and located in the moulds in the seats formed by the core prints provided on the
patterns.

Fig- 1 (a)Core , (b) Chaplet, (c) Pattern

The main characteristics required in a good core are the following formed.
I. It must be sufficiently permeable to allow an easy escape to the gases
2. It should be highly refractory to withstand the intense heat of molten metal.
3. It should be enough hard and strong to bear its own weight and the force of molten
metal.
4. It should have high collapsibility i.e., it should be able to disintegrate quickly after the
solidification of the metal is complete.
5. It should not carry such constituents which will give rise to excessive gases on coming
in contact with the molten metal.
The main ingredients of core sand mixtures and their essential characteristics - have
already been discussed in the last chapter.
TYPES OF CORES
Various types of corns of different designs and sizes are employed in different ways in
foundry work. The cores are essentially of two types, based on the type of sand used.
1. Green sand cores: Green sand cores are those which are obtained by the pattern itself
during moulding. Though this is the most economical way of preparing core, the green
sand being low in strength cannot be used for fairly deep holes. Also, a large amount of
draft is to be provided so that the pattern can be withdrawn. This is used only for those
type of cavities which permit the withdrawl of pattern as in Fig -1 below
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Fig- 2 Green sand cores

2. Dry sand cores: Dry sand cores are those which are made by means of special core
sands in a separate core box, baked and then placed in the mould before pouring. Some-
of the types of cores used in various situations are presented in Fig 3—8.
Another general way of classifying them is to do so according to their shapes and
positions in the prepared moulds. The main types of these are described below:

1. Horizontal core. It is the most common and simple type of core. It is assembled in the
mould with its axis horizontal. Depending upon the shape of the cross-section of the hole
to be made in the casting, it may have any shape of its cross-section but the most
commonly used shape is cylindrical. This corn
is supported in the mould at its both ends. Unless it has a non-uniform cross- section, it is
held in the mould on the parting line such that its one half remains in the cope and the
remaining half in the drag (See Fig. 3).

Fig. 3. A Horizontal core. Fig. 4 A Vertical core.

2. Vertical core: It is quite similar to a horizontal core except that it is fitted in the mould
with its axis vertical, as shown in Fig. 4. It rests on the seat made at the bottom of the
mould by the core print and is further supported by being located in a similar seat made
in the cope. The top end of the core is provided with more taper in order to have a smooth
fitting of the cope on the core. A major portion of the core usually remains in the drag
part of the mould.
3. Balanced Core (Fig. 5): It is used to produce a blind hole along a horizontal axis in a
casting. As a matter of fact it is nothing but a horizontal core, with the exception that it is
supported only on one end, the other end remaining free in the mould cavity. It is, thus, a
sort of cantilever. Since it has to support the weight of the overhanging portion, the core
print provided on the pattern should be long enough so that sufficient length of the core
may be embedded in the sand to balance the weight of the overhung. However, if the
overhung is too much, such balancing will not be enough and the overhanging length of
the core will have to be supported by means of chaplets.
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Fig. 5. Balanced core.

4. Hanging or cover core: A core which hangs vertically in the mould and has no
support at its bottom is known as a hanging core. In such a case it is obvious that the
entire mould cavity will be contained in the drag only. A good many green sand cores
formed in the cope by the pattern are of hanging type. Even otherwise, dry sand cores can
also be suspended from copes by being suitably fastened to them by means of wires or
rods etc., extending from within the core body to the top of the cope. Unlike this, a
hanging core may be supported on a seat made on the parting surface in the drag, as
shown in Fig. 6. It is, then, known as a cover core.

Fig. 6. A Hanging or cover core.

5. Wire core. (Fig. 7): It is also known as a stop-off core, It is employed when a hole is
desired to be produced in the casting at such a position that its axis falls either above or
below the parting line. In such a core, its one side remains flush with the inner surface of
the mould and the core, thus, acts as a stop-off. The back surface of this core s provided
with enough taper for its easy location. Many other names, like tail core and saddle core,
etc., are also given to this type of core according to its shape and use.

Fig. 7. A stop-off core.

Apart from the above there are a few other types also, hut they are not so commonly
used. One such rarely used type is a ram up core, which is embedded in the mould. Such
a need arises when placement of core is not possible after ramming. Similarly, when such
a pattern is to be used which caries no core prints, the core is held between cope and drag
simply due to the pressure, put by the former. It is also called as kiss core.
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Chaplets
Chaplets are metallic supports often kept inside the mould cavity to support the cores.
These are of the same composition as that of the pouring metal so that the molten metal
would provide enough heat to completely melt them and thus fuse with it during
solidification. Some of the types of chaplets normally used are shown in Fig 8 with an
example of chaplet support in Fig 9

FIG 8 Types of chaplets

FIG 9 Core supported by chaplet

CORE MAKING
The complete core making cycle is accomplished in four stages as follows
I. Preparation of core sand: In small foundries the core sand mixtures are still prepared
through hand operations. But these operations do not facilitate a homogeneous and
efficient mixing. To achieve this, mechanical means are adopted. The common means
include the use of either roller mills or core sand misers. A Roller mill is nothing but a
large muller. In these, the combined action of mullers and ploughs enables a uniform and
thorough mixing of the sand. They are suitable for only those core sand mixtures which
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contain cereal binders. Against this core sand mixers are suitable for sands containing any
type of binder. Two varieties of core sand mixers are in common use. They are: (I) the
vertical revolving arm type and (ii) horizontal paddle type.
2. Core-making. For corn-making by hand, the sand prepared as above filled and
rammed in the core boxes. Odd shaped and large cores are reinforced by wires to prevent
deflection due to their own weight and make them strong
In all modern foundries, which are mechanized to a large extent, machines axe used for
core-making. The following types of machines are commonly used for this purpose
(a) Core blowing machines
Small and medium sized cores on mass scale can be made with considerable speed on
these machines. Their use for smaller quantities is not economical because of the high
cost of special type of core boxes and equipment used on them. They are commonly
available in two popular types the bench blowers and floor blowers. Bench blowers are
relatively low capacity machines as compared to the latter type. The floor blowers are
more sturdy, heavier and contain a higher degree of automation. The principle of
operation of both types is the same in that the sand is forced into the core boxes under
pressure of compressed air. A hopper carrying sand fills a sand reservoir which is brought
just above the core box placed on the machine table. The compressed air then forces this
sand into the core box at a pressure between 6.5 kg/cm 2 to 8.7 kg/cm2. Suitable vents are
provided in the core box to allow the escape of this air. The whole operation takes only a
few seconds, after which the core box is withdrawn and the core removed.
(b) Core ramming machines
These machines are similar to those used for ramming the sand moulds. Of all the
ramming machines, jolting and slinging machines are most commonly used in core-
making.
(c) Core drawing machines
These machines are mow commonly used when the core boxes have very deep cavities.
First of all the sand is rammed properly in the core box and the same is then placed on the
core plate mounted on the machine table. A vertical vibrating plate provides the rapping
action on the core box, after which the latter is pulled up leaving the core on the core
plate.
3. Core drying. After the cores have been prepared and suitably supported on plates or
dryers, they are sent to ovens to drive out the moisture content and provide them the
desired hardness. The ovens used for this purpose are called core drying ovens or core
baking ovens. Three types of ovens are commonly used for this purpose. They are:
(a) Batch type ovens. These ovens are employed in those foundries where cores are
required in batches. The prepared cores are placed in portable racks or drawers and sent
into the ovens, where they are baked. Gas, oil or coal may be used as fuel for the oven.
(b) Continuous type ovens. They are used for mass production work and are best suited
for small cores of approximately same size. The cores are loaded continuously at one end
on the continuous conveyor or chain, which moves slowly through the oven, and are
unloaded at the other end after baking. The speed of the conveyor controls, the baking
time of the cores.
(c) Dielectric bakers. These ovens, utilising dielectric heating, provide a much faster
baking operation and a better temperature control. For baking in these ovens, the cores
are mounted on specially made cement bonded asbestos plates.
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4. Finishing. After receiving them from ovens, the cores are properly finished by rubbing
or filing, etc., to bring them to correct dimensions, remove extra sand projections from
their surfaces and provide a good surface finish. Then only they become suitable for
being placed in the moulds.

CORE PRINTS
The core prints are provided so that the cores are securely and correctly positioned in the
mould cavity. The design of core prints is such as to take care of the weight of the core
before pouring and the upward metallostatic pressure of the molten metal after pouring.
The core prints should also ensure that the core is not shifted during the entry of the metal
into the mould cavity.
The main force acting on the core when metal is poured into the mould cavity, is due to
buoyancy. The buoyant force can be calculated as the difference in the weight of the
liquid metal to that of the core material of the same volume as that of the exposed core. It
can be written as

P=V (ρ — d)

where
P = buoyant force, N
V = volume of the core in the mould cavity, cm
ρ = weight density of the liquid metal, N/cm3
d = weight density of the core material = 1.65 X 10 N/cm
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Wing core. A wing core is used when a hole or recess is to be obtained in the casting
either above or below the parting line. In this case, the side of the core print is given
sufficient amount of taper so that the core can be placed readily in the mould. This core is
sometimes designated by other names such as drop core, tail core, choir core, and saddle
core, according to its shape and position in the mould.
Ram-up core. It is sometimes necessary to set a core with the pattern before the mould is
rammed up. Such a core is called mm-up core. This is used when the core-detail is
located in an inaccessible position in both interior and exterior portions of a casting.
Kiss core. When the pattern is not provided with a core print and consequently no seat is
available for the core, the core is held in position between the cope and drag simply by
the pressure of the cope. This core is referred to as a kiss core. They are
dimensional accuracy with regard required.
the drag it is called cover core. In this case, the core serves as a cover for the mould, and
also as a support for hanging the main body of the core.
suitable when a number of holes of less to the relative position of the holes are

TYPES OF CORES
The cores are essentially of two types, based on the type of sand used.
Green sand cores are those which are obtained by the pattern itself during moulding.
Though this is the most economical way of preparing core, the green sand being low in
strength cannot be used for fairly deep holes. Also, a large amount of draft is to be
provided so that the pattern can be withdrawn. This is used only for those type of cavities
which permit the withdrawl of pattern as in Fig below

Dry sand cores are those which are made by means of special core sands in a separate
core box, baked and then placed in the mould before pouring. Some-of the types of cores
used in various situations are presented in Fig 9—4.
In designing the core boxes, care should be taken to consider the strength of the core.
Before the baking process, core is generally weak and should be well supported. If the
core is simple and strong in itself, no special precaution is required. But for slender and
complicated cores it may be necessary to place the core in the core box during the baking
process. In such a situation the core box should be small. An example of a core box is
shown in Fig 9—5.
If a core is symmetrical, then it can be made into two equal parts and then assembled
together by adhesives or fastened by wires. The glues that are used are mixtures of talc,
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dextrin, flour, molasses and water, Care should be taken while applying the glue not to
close the core vent holes made earlier for the gases to escape. When very large cores are
to be joined, it may be necessary to use nuts and bolts. The bolt holes are generally
covered with a core plug. If the core is to be mounted in a particular orientation, then
some specific provision should be made in -the core prints so that the core can be placed
in the mould in only one position, as in Fig 9—6.
CORE PRINTS
The core prints are provided so that the cores are securely and correctly positioned in the
mould cavity. The design of core prints is such as to take care of the weight of the core
before pouring and the upward metallostatic pressure of the molten metal after pouring.
The core prints should also ensure that the core is not shifted during the entry of the metal
into the mould cavity.
The main force acting on the core when metal is poured into the mould cavity, is due to
buoyancy. The buoyant force can be calculated as the difference in the weight of the
liquid metal to that of the core material of the same volume as that of the exposed core. It
can be written as

P=V (ρ — d)

where
P = buoyant force, N
V = volume of the core in the mould cavity, cm
ρ = weight density of the liquid metal, N/cm3
d = weight density of the core material = 1.65 X 10 N/cm
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Fig- Dry Sand Core Types

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Chaplets
Chaplets are metallic supports often kept inside the mould cavity to support the cores.
These are of the same composition as that of the pouring metal so that the molten metal
would provide enough heat to completely melt them and thus fuse with it during
solidification. Some of the types of chaplets normally used 19.1] are shown in Fig 9—li
with an example of chaplet support in Fig

FIG 9—11 Types of chaplets

FIG 9—12 Core supported by chaplet

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Cores need to held in place

•One hazard during pouring is that the buoyancy of the molten metal will displace the
core
•According to Archimedes principle, the force tending to lift the core is equal to the
weight of the displaced liquid less the weight of the core itself

Weights are determined as the volume of the core multiplied by the respective densities
of core material (sand) and the melt

CORES AND COREMAKING

Cores are separate shapes of sand that are generally required to from the hollow interior
of the casting or a hole through the casting. Sometimes cores are also used to shape those
pans of the casting that are not otherwise practical or physically obtainable by the mould
produced directly from the pattern. The core is left in the mould in casting and is
removed after the casting.

CORE REQUIREMENTS
Cores are subject to severe conditions since after pouring the mould they are surrounded
on all sides by molten metal. Consequently, they must possess some special
characteristics which are as follows
1. Cores must be strong enough to retain its shape without deforming, to withstand
handling and to resist erosion and deformation by metal during filling of the mould.
2. Cores must be permeable to allow the core gases to escape easily.
3. Cores should be highly refractory in nature to withstand high temperature of the
molten metal.
4. Cores must be sufficiently low in residual gas-forming materials to prevent excess gas
from entering the metal.
5. Cores must be stable with a minimum of contraction and Expansion to make a true
form of the casting.
6. Cores should be sufficiently collapsible, i.e., they should disintegrate and collapse after
the metal solidifies, to minimise strains on the casting and to facilitate removal of the
core from casting during shakeout.

CORE SANDS

The ingredients of core sands are sand and binder. Core sands are usually silica but
zircon, olivine, carbon and chamotte sands are used. Sand that than 5 per cent clay cannot
be used for cores. Excessive clay reduces not only permeability but also collapsibility.

The type of sand to be used depends on the size of the core and also on the pouring
temperature of the metal. The important facts to be considered are the size, shape, and
distribution of sand grains, the clay content, and the mineralogical composition of clay
particles. The smaller of the sand used in cores, the smoother will be the surface of in
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contact with these cores. Furthermore, sand with ns is more satisfactory for cores than
with angular grains for es of permeability.