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June, 1919 which to mold and cast the interme- diate cylinder alone, and the fact that the foundry is turning out six com- plete sets of cylinder castings a week is ample evidence that the demands of rapid production have been met by devising improved methods in molding practice. The foundry operations are interest- ing. For many years it has. been the established practice to mold these large cylinders with the heads down but this foundry saves time by mold- ing them with the heads up. It used to require half a day to black one of these large molds but through the use of a spray nozzle, this time was cut to half an hour or less. Again, the dry- ing of these large molds with char- coal fires used to require days but the| utilization of waste space allowed an | entire cylinder mold to be dried in fic hotirs. To assemble the cores in the molds on this class of work often required many days while the complete build- ing up of the mold sections with all the cores for a large cylinder often consumed several weeks time. It this foundry the cores were bunched on a common arbor, larger cores were grouped and baked together and as- sembling crews put together an entire cylinder mold in less than a day. The high-pressure intermediate and low- pressure cylinder castings weigh re- spectively 21,200, 21,300 and 22,900 pounds. Adequate foundry equipment had much to do with the success attained in getting out these huge castings in record time. The flasks for the cylinder job were built at the found- ry to the superintendent's specifica- 'tions. Strength is assured through side flanging while the flask sec- tions are securely fastened together by bolts at the four corners. Each end of the flask has a loop cast for the accommodation of the crane-fall hook. The continuation of the sides THE -MARINE. REVIEW and the end flange connections are rounded to form a cradle for rolling over the flasks. The object of this is to lessen the jar when the flask is rolled over. All molds are rammed up on ma- chined plates which insures level surfaces. The plates are set on firm foundations. The flasks are matched by means of two 1-inch guide pins at opposite ends, the holes for which are drilled by means of templates to insure proper registry. How Molding is Expedited Each cylinder is molded in four units, a practice which insures con- venience in handling. These nits comprise the drag and barrel core, the lower cheek, the upper cheek and the cope. In: each. case the cope carries the mold for the cylinder head. Three full patterns are pro- vided for cylinder work. One crew is employed in ramming drags, two oth- ers on cheeks, one on copes and another on assembling. This division 275 of operations insures teamwork and has been productive of high efficiency. The drag and barrel cores are made together. The drag flask is first 'rammed full of sand.) Next a spindle is set at a central point from which loose pieces are located and bedded in to form the portion of the bottom of the cylinder which is car- ried in the drag. Then the core cylinder is rammed in a cylindrical hollow box. The sand mixture con- sists of one-half old and one-half new material with no compound. Each drag is baked over night in a gas- fired oven. The'next day the valve chamber core for the low-pressure cylinder is set in place, all bolt holes, etc., .are filled' and the. drag ' with the new core added is again baked. The drag for the high-pressure aud intermediate cylinder is ready for assembly after one night's baking. In this way, two complete sets of flasks for 'each cylinder are required. The high-pressure cylinder is a complicated piece to mold as the ' FIG. 4--PLANING THE ENDS OF A CONNECTING ROD ON A DRAWCUT SHAPER--THESE MEMBERS ARE HAMMERED FORGINGS, FINISHED ALL OVER