Railcar sideframe casting method

Abstract

The present invention provides a method of casting a sideframe including the steps of dividing the sideframe into design zones, and providing a core module for forming internal surfaces of the sideframe casting in the design zones. The design zones include a right outer leg design zone, a left outer leg design zone, a right tension member design zone, a left tension member design zone, and a bolster opening design zone. The present invention also includes the step of varying at least one core module to correspond with varying sideframe casting geometry in at least one design zone. The core modules include a right outer leg core module, a left outer leg core module, a right tension member core module, a left tension member core module, a right column wall core module, a left column wall core module, and a bolster opening bottom core module. The core modules define internal surfaces of the sideframe casting in their respective design zones.

The invention is claimed as follows:  
     
         1 . A method of casting a sideframe comprising the steps of: 
 dividing the sideframe into design zones; and    providing a core module for forming internal surfaces of the sideframe casting in at least one of the design zones.    
     
     
         2 . The method of  claim 1  further comprising the step of varying at least one core module to correspond with varying sideframe casting geometry in at least one design zone.  
     
     
         3 . The method of  claim 1  wherein the step of providing a core module includes providing a core module in each design zone.  
     
     
         4 . The method of  claim 1  wherein the step of dividing the sideframe into design zones includes a right outer leg design zone.  
     
     
         5 . The method of  claim 1  wherein the step of dividing the sideframe into design zones includes a left outer leg design zone.  
     
     
         6 . The method of  claim 1  wherein the step of dividing the sideframe into design zones includes a right tension member design zone.  
     
     
         7 . The method of  claim 1  wherein the step of dividing the sideframe into design zones includes a left tension member design zone.  
     
     
         8 . The method of  claim 1  wherein the step of dividing the sideframe into design zones includes a bolster opening design zone.  
     
     
         9 . The method of  claim 1  wherein the step of providing a core module includes providing a core module corresponding to a right outer leg design zone.  
     
     
         10 . The method of  claim 1  wherein the step of providing a core module includes providing a core module corresponding to a left outer leg design zone.  
     
     
         11 . The method of  claim 1  wherein the step of providing a core module includes providing a core module corresponding to a right tension member design zone.  
     
     
         12 . The method of  claim 1  wherein the step of providing a core module includes providing a core module corresponding to a left tension member design zone.  
     
     
         13 . The method of  claim 1  wherein the step of providing a core module includes providing at least one core module corresponding to a bolster opening design zone.  
     
     
         14 . The method of  claim 2  wherein the step of varying at least one core module comprises varying the core module corresponding to a right outer leg design zone.  
     
     
         15 . The method of  claim 2  wherein the step of varying at least one core module comprises varying the core module corresponding to a left outer leg design zone.  
     
     
         16 . The method of  claim 2  wherein the step of varying at least one core module comprises varying the core module corresponding to a right tension member design zone.  
     
     
         17 . The method of  claim 2  wherein the step of varying at least one core module comprises varying the core module corresponding to a left tension member design zone.  
     
     
         18 . The method of  claim 2  wherein the step of varying at least one core module comprises varying at least one core module corresponding to a bolster opening design zone.  
     
     
         19 . The method of  claim 1  wherein the sideframe has a central longitudinal plane, and the core module forms internal surfaces of the sideframe casting in at least one design zone on both sides of the central longitudinal plane of the sideframe.  
     
     
         20 . The method of  claim 19  wherein the core module forms all of the internal surfaces of the sideframe casting in at least one design zone on both sides of the central longitudinal plane of the sideframe.  
     
     
         21 . The method of  claim 9  wherein the sideframe has a central longitudinal plane and a right pedestal section, the right pedestal section having a roof and a jaw, and the core module that corresponds to the right outer leg design zone forms internal surfaces of the right pedestal roof and the right pedestal jaw on both sides of the central longitudinal plane of the sideframe.  
     
     
         22 . The method of  claim 21  wherein the core module forms all of the internal surfaces of the right pedestal roof and the right pedestal jaw on both sides of the central longitudinal plane of the sideframe.  
     
     
         23 . The method of  claim 10  wherein the sideframe has a central longitudinal plane and a left pedestal section, the left pedestal section having a roof and a jaw, and the core module that corresponds to the left outer leg design zone forms internal surfaces of the left pedestal roof and the left pedestal jaw on both sides of the central longitudinal plane of the sideframe.  
     
     
         24 . The method of  claim 23  wherein the core module forms all of the internal surfaces of the left pedestal roof and the left pedestal jaw on both sides of the central longitudinal plane of the sideframe.  
     
     
         25 . The method of  claim 11  wherein the sideframe has a central longitudinal plane, a right tension member, a right side window, and a top compression member, and the core module that corresponds to the right tension member design zone forms internal surfaces of the right tension member, the right side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe.  
     
     
         26 . The method of  claim 25  wherein the core module forms all of the internal surfaces of the right tension member, the right side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe.  
     
     
         27 . The method of  claim 12  wherein the sideframe has a central longitudinal plane, a left tension member, a left side window, and a top compression member, and the core module that corresponds to the left tension member design zone forms internal surfaces of the left tension member, the left side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe.  
     
     
         28 . The method of  claim 27  wherein the core module forms all of the internal surfaces of the left tension member, the left side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe.  
     
     
         29 . The method of  claim 13  wherein the sideframe has a central longitudinal plane, a bolster opening having a right side and a left side, and a column wall on the right side and on the left side of the bolster opening, and a core module that corresponds to the bolster opening design zone forms external surfaces of the column walls on both sides of the central longitudinal plane of the sideframe.  
     
     
         30 . The method of  claim 29  wherein the core module forms all of the external surfaces of the column walls on both sides of the central longitudinal place of the sideframe.  
     
     
         31 . The method of  claim 29  wherein the side frame has a top compression member, and the core module further forms internal surfaces of part of the top compression member on both sides of the central longitudinal plane of the sideframe.  
     
     
         32 . The method of  claim 31  wherein the core module forms all of the internal surfaces of part of the top compression member on both sides of the central longitudinal plane of the sideframe.  
     
     
         33 . The method of  claim 13  wherein the sideframe has a central longitudinal plane and a bolster opening having a bottom section, and a core module that corresponds to the bolster opening design zone forms internal surfaces of the bolster opening bottom section on both sides of the central longitudinal plane of the sideframe.  
     
     
         34 . The method of  claim 33  wherein the core module forms all of the internal surfaces of the bolster opening bottom section on both sides of the central longitudinal plane of the sideframe.  
     
     
         35 . The method of  claim 21  wherein the sideframe has a right pedestal top opening, and the right outer leg core module has a pedestal top core print extending into the mold sand, the pedestal top core print defining the right pedestal top opening.  
     
     
         36 . The method of  claim 35  further comprising a protrusion from the pedestal top core print that extends into the mold sand.  
     
     
         37 . The method of  claim 21  wherein the sideframe has a right pedestal end opening, and the right outer leg core module has a pedestal end core print extending into the mold sand, the pedestal end core print defining the right pedestal end opening.  
     
     
         38 . The method of  claim 37  further comprising a protrusion from the pedestal end core print that extends into the mold sand.  
     
     
         39 . The method of  claim 23  wherein the sideframe has a left pedestal top opening, and the left outer leg core module has a pedestal top core print extending into the mold sand, the pedestal top core print defining the left pedestal top opening.  
     
     
         40 . The method of  claim 39  further comprising a protrusion from the pedestal top core print that extends into the mold sand.  
     
     
         41 . The method of  claim 23  wherein the sideframe has a left pedestal end opening, and the left outer leg core module has a pedestal end core print extending into the mold sand, the pedestal end core print defining the left pedestal end opening.  
     
     
         42 . The method of  claim 41  further comprising a protrusion from the pedestal end core print that extends into the mold sand.  
     
     
         43 . The method of  claim 21  wherein the sideframe has a top wall, and the right outer leg core module further comprises a top wall core print extending from its outer surface through a hole in the top wall of the sideframe and into the mold sand.  
     
     
         44 . The method of  claim 23  wherein the sideframe has a top wall, and the left outer leg core module further comprises a top wall core print extending from its outer surface through a hole in the top wall of the sideframe and into the mold sand.  
     
     
         45 . The method of  claim 25  wherein the right tension member has an outer wall, the outer wall having an opening, and wherein the right tension member core module includes a core print extending from its outer surface into the mold sand and forming at least part of the outer wall opening.  
     
     
         46 . The method of  claim 45  further comprising a protrusion extending from the core print into the mold sand.  
     
     
         47 . The method of  claim 27  wherein the left tension member has an outer wall, the outer wall having an opening, and wherein the left tension member core module includes a core print extending from its outer surface into the mold sand and forming at least part of the outer wall opening.  
     
     
         48 . The method of  claim 47  further comprising a protrusion extending from the core print into the mold sand.  
     
     
         49 . The method of  claim 25  wherein right side window has a top perimeter and a bottom perimeter, the right side window top perimeter having no outside corner radius.  
     
     
         50 . The method of  claim 49  wherein the right tension member core module has a core print extending from its outer surface spanning the entire top perimeter of the right side window.  
     
     
         51 . The method of  claim 27  wherein left side window has a top perimeter and a bottom perimeter, the left side window top perimeter having no outside corner radius.  
     
     
         52 . The method of  claim 49  wherein the left tension member core module has a core print extending from its outer surface into the mold sand, and spans the entire top perimeter of the left side window.  
     
     
         53 . The method of  claim 33  wherein the bolster opening bottom core module has a core print extending from its outer surface into the mold sand.  
     
     
         54 . The method of  claim 53  wherein the core print has a protrusion extending from it into the mold sand.  
     
     
         55 . The method of  claim 25  wherein the sideframe has a central longitudinal plane and a bolster opening, the bolster opening having a right side and a left side, a column wall on the right side and on the left side of the bolster opening, the method further including a right column wall core module forming the internal surface of the right column wall of the bolster opening on both sides of the central longitudinal plane of the sideframe, the right column wall core adapted to be inserted into a cavity in the right tension member core module.  
     
     
         56 . The method of  claim 25  wherein the sideframe has a central longitudinal plane and a bolster opening, the bolster opening having a right side and a left side, a column wall on the right side and on the left side of the bolster opening, the method further including a left column wall core module forming the internal surface of the left column wall of the bolster opening on both sides of the central longitudinal plane of the sideframe, the left column wall core adapted to be inserted into a cavity in the left tension member core module.  
     
     
         57 . The method of  claim 3  wherein the core modules include a right outer leg core module, a left outer leg core module, a right tension member core module, a left tension member core module, a right column wall core module, a left column wall core module, and a bolster opening bottom core module.  
     
     
         58 . The method of  claim 57  wherein the core modules further include a bolster opening core module.  
     
     
         59 . The method of  claim 57  wherein the core modules further comprise a spring seat core module.  
     
     
         60 . The method of  claim 21  wherein the sideframe also has a right tension member, a right side window, and a top compression member, and wherein the method further includes the step of providing a core module corresponding to a right tension member design zone, the core module that corresponds to the right tension member design zone forming internal surfaces of the right tension member, the right side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe, the right outer leg core module further comprising a shelf corresponding with a weight bearing surface of the right tension member core module.  
     
     
         61 . The method of the  claim 60  wherein the right out leg core module shelf extends the entire width of the right outer leg core module.  
     
     
         62 . The method of  claim 60  wherein the right tension member core module weight bearing surface extends the entire width of the right tension member core module.  
     
     
         63 . The method of  claim 60  wherein the sideframe has a central transverse plane, and the right outer leg core module shelf and right tension member core module weight bearing surface form a joint, the joint being parallel to the central transverse plane of the sideframe.  
     
     
         64 . The method of  claim 23  wherein the sideframe also has a left tension member, a left side window, and a top compression member, and wherein the method further includes the step of providing a core module corresponding to a left tension member design zone, the core module that corresponds to the left tension member design zone forming internal surfaces of the left tension member, the left side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe, the left outer leg core module further comprising a shelf corresponding with a weight bearing surface of the left tension member core module.  
     
     
         65 . The method of  claim 64  wherein the left outer leg core module shelf extends the entire width of the left outer leg core module.  
     
     
         66 . The method of  claim 64  wherein the left tension member core module weight bearing surface extends the entire width of the left tension member core module.  
     
     
         67 . The method of  claim 64  wherein the sideframe has a central transverse plane, and the left outer leg core module shelf and left tension member core module weight bearing surface form a joint, the joint being parallel to the central transverse plane of the sideframe.  
     
     
         68 . The method of  claim 33  wherein the sideframe also has a right tension member, a right side window, and a top compression member, and wherein the method further includes the step of providing a core module corresponding to a right tension member design zone, the core module that corresponds to the right tension member design zone forming internal surfaces of the right tension member, the right side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe, the bolster opening bottom core module further comprising a shelf corresponding to a weight bearing surface on the right tension member core module.  
     
     
         69 . The method of  claim 68  wherein the bolster opening bottom core module shelf extends the entire width of the bolster opening bottom core module.  
     
     
         70 . The method of  claim 68  wherein the weight bearing surface extends the entire width of the right tension member core module.  
     
     
         71 . The method of  claim 68  wherein the sideframe has a central transverse plane, and the bolster opening bottom core module shelf and right tension member core module weight bearing surface form a joint, the joint being parallel to the central transverse plane of the sideframe.  
     
     
         72 . The method of  claim 33  wherein the sideframe also has a left tension member, a left side window, and a top compression member, and wherein the method further includes the step of providing a core module corresponding to a left tension member design zone, the core module that corresponds to the left tension member design zone forming internal surfaces of the left tension member, the left side window and part of the top compression member on both sides of the central longitudinal plane of the sideframe, the bolster opening bottom core module further comprising a shelf corresponding to a weight bearing surface on the left tension member core module.  
     
     
         73 . The method of  claim 72  wherein the bolster opening bottom core module shelf extends the entire width of the bolster opening bottom core module.  
     
     
         74 . The method of  claim 72  wherein the weight bearing surface extends the entire width of the left tension member core module.  
     
     
         75 . The method of  claim 72  wherein the sideframe has a central transverse plane, and the bolster opening bottom core module shelf and left tension member core module weight bearing surface form a joint, the joint being parallel to the central transverse plane of the sideframe.  
     
     
         76 . The method of  claim 68  wherein the right tension member has an outer wall, the outer wall having an opening, and wherein the bolster opening bottom core module includes a core print extending from its outer surface into the mold sand and forming at least part of the outer wall opening.  
     
     
         77 . The method of  claim 76  further comprising a protrusion extending from the core print into the mold sand.  
     
     
         78 . The method of  claim 72  wherein the left tension member has an outer wall, the outer wall having an opening, and wherein the bolster opening bottom core module includes a core print extending from its outer surface into the mold sand and forming at least part of the outer wall opening.  
     
     
         79 . The method of  claim 78  further comprising a protrusion extending from the core print into the mold sand.  
     
     
         80 . The method of  claim 1  wherein the design zones include a right outer leg design zone, a left outer leg design zone, a right tension member design zone, a left tension member design zone, and a bolster opening design zone.  
     
     
         81 . A coring arrangement for a railcar sideframe, the coring arrangement comprising core modules, the core modules including a right outer leg core module, a left outer leg core module, a right tension member core module, a left tension member core module, and a bolster opening bottom core module.  
     
     
         82 . The coring arrangement of  claim 81  further comprising a right column wall core module and a left column wall core module.  
     
     
         83 . The coring arrangement of  claim 81  further comprising a bolster opening core module.  
     
     
         84 . The coring arrangement of  claim 81  further comprising a spring seat core module.