Railcar bolster casting method

Abstract

A coring arrangement for casting a railcar bolster, including left and right half center cores having faces defining internal surfaces of each of the bolster top, bottom, and opposing side walls from the bolster central transverse plane to a point between the left and right friction shoe pocket inner and outer walls. The coring arrangement also includes left and right top half end cores having faces defining an internal surface of the bolster top wall, and of each opposing side wall from a point between the left and right friction shoe pocket inner and outer walls to the ends of the bolster. Left and right bottom half end cores have faces defining an internal surface of the bolster bottom wall, and of each opposing side wall from a point between the left and right friction shoe pocket inner and outer walls to the ends of the bolster.

The invention is claimed as follows:  
     
         1 . A coring arrangement for casting a railcar bolster, the coring arrangement located in a mold, the bolster having hollow sections, the bolster also having a top wall, a bottom wall, and a pair of opposing side walls connecting the top wall and bottom wall, the bolster further having a central transverse plane, the coring arrangement comprising: 
 a left half center core having faces defining an internal surface of each of the bolster top wall, bottom wall, and opposing side walls left of the central transverse plane;    a right half center core having faces defining an internal surface of each of the bolster top wall, bottom wall, and opposing side walls right of the central transverse plane;    a left top half end core having faces defining an internal surface of the bolster top wall, and an internal surface of each opposing side wall left of the central transverse plane;    a left bottom half end core having faces defining an internal surface of the bolster bottom wall, and an internal surface of each opposing side wall left of the central transverse plane;    a right top half end core having faces defining an internal surface of the bolster top wall, and an internal surface of each opposing side wall right of the central transverse plane; and    a right bottom end core having faces defining an internal surface of the bolster bottom wall, and an internal surface of each opposing side wall right of the central transverse plane.    
     
     
         2 . The coring arrangement of  claim 1  wherein the bolster includes a pair of left friction shoe pockets and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, and wherein the left half center core defines an internal surface of each of the bolster top wall, bottom wall, and opposing side walls from the bolster central transverse plane to a point between the pair of left friction shoe pocket inner and outer walls.  
     
     
         3 . The coring arrangement of  claim 1  wherein the bolster includes a pair of left friction shoe pockets and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, and wherein the right half center core defines an internal surface of each of the bolster top wall, bottom wall, and opposing side walls from the bolster central transverse plane to a point between the pair of right friction shoe pocket inner and outer walls.  
     
     
         4 . The coring arrangement of  claim 1  wherein the bolster has a left end and a right end, a pair of left friction shoe pockets and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, the left top half end core defining an internal surface of the bolster top wall and an internal surface of each of the opposing side walls from a point between the pair of left friction shoe pocket inner and outer walls to the left end of the bolster.  
     
     
         5 . The coring arrangement of  claim 1  wherein the bolster has a left end and a right end, a pair of left friction shoe pockets and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, the right top half end core defining an internal surface of the bolster top wall and an internal surface of each of the opposing side walls from a point between the pair of right friction shoe pocket inner and outer walls to the right end of the bolster.  
     
     
         6 . The coring arrangement of  claim 1  wherein the bolster has a left end and a right end, a pair of left friction shoe pockets and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, the left bottom half end core defining an internal surface of the bolster bottom wall and an internal surface of each of the opposing side walls from a point between the pair of left friction shoe pocket inner and outer walls to the left end of the bolster.  
     
     
         7 . The coring arrangement of  claim 1  wherein the bolster has a left end and a right end, a pair of left friction shoe pockets and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, the right bottom half end core defining an internal surface the bolster bottom wall and an internal surface of each of the opposing side walls from a point between the pair of right friction shoe pocket inner and outer walls to the right end of the bolster.  
     
     
         8 . The coring arrangement of  claim 1  wherein the bolster includes a left spring set surface, a right spring set surface, a pair of left friction shoe pockets, and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner walls, outer walls, and a pair of friction wedges, the coring arrangement further comprising a left friction wedge core having faces defining external surfaces of the inner walls, outer walls, and a pair of friction wedges of the pair of left friction shoe pockets and the left spring set surface, and a right friction wedge core having faces defining external surfaces of the inner walls, outer walls, and pair of friction wedges of the pair of right friction shoe pockets and the right spring set surface.  
     
     
         9 . The coring arrangement of  claim 8  wherein the left friction wedge core and right friction wedge core each have a pair of lugs extending from the spring set surface defining face, and wherein the left half center core rests upon the left friction wedge core lugs, and the right half center core rests upon the right friction wedge core lugs.  
     
     
         10 . The coring arrangement of  claim 1  wherein the left top half end core and right top half end core each have pair of core prints extending from their top wall defining face into the mold.  
     
     
         11 . The coring arrangement of  claim 1  wherein the left bottom half end core and right bottom half end core each have an upper surface, and the left top half end core and right top half end core each have a bottom surface, and the left bottom half end core and right bottom half end core each have a plurality of lugs extending from their upper surface into corresponding openings in the left top half end core and right top half end core bottom surfaces.  
     
     
         12 . The coring arrangement of  claim 11  wherein each of the plurality of lugs has a top face, and the corresponding openings in the left top half end core and right top half end core bottom surfaces have upper faces, and the top faces of the plurality of lugs are spaced from the upper faces of the left top half end core and right top half end core openings.  
     
     
         13 . The coring arrangement of  claim 1  wherein the left bottom half end core and right bottom half end core each have a shelf, and wherein the left half center core and right half center core each have a weight bearing surface, the left bottom half end core shelf resting upon the left half center core weight bearing surface, and the right bottom half end core shelf resting upon the right half center core weight bearing surface.  
     
     
         14 . The coring arrangement of  claim 1  wherein the left half center core and right half center core each have a pair of core prints extending from their bottom wall defining face into the mold.  
     
     
         15 . The coring arrangement of  claim 1  wherein the bolster has a center bowl, the center bowl including ledges, the bolster also having a left brake beam opening left of the central transverse plane in each of the opposing side walls, and a left side window in each of the opposing side walls left of the central transverse plane, and wherein the left half center core defines the left brake beam openings and left side windows.  
     
     
         16 . The coring arrangement of  claim 15  wherein the bolster has a main pattern parting line, and a left brake beam core print protruding from each of the left half center core side wall defining faces to form the left brake beam openings, the left brake beam core prints extending between the left brake beam openings and the main pattern parting line.  
     
     
         17 . The coring arrangement of  claim 16  wherein each left brake beam core print protrudes into the mold and forms a portion of one center bowl ledge.  
     
     
         18 . The coring arrangement of  claim 17  wherein each of the bolster opposing side walls has a top and a bottom and a width, and the width of the bolster side wall at the bottom of each side wall is equal to or less than the width of the bolster side wall at any point between the bottom and the top of the side wall.  
     
     
         19 . The coring arrangement of  claim 1  wherein the bolster has a center bowl, the center bowl including ledges, the bolster also having a right brake beam opening right of the central transverse plane in each of the opposing side walls, and a right side window in each of the opposing side walls right of the central transverse plane, and wherein the right half center core defines the right brake beam openings and right side windows.  
     
     
         20 . The coring arrangement of  claim 19  wherein the bolster has a main pattern parting line, and a right brake beam core print protruding from each of the right half center core side wall defining faces to form the right brake beam openings, the right brake beam core prints extending between the right brake beam openings and the main pattern parting line.  
     
     
         21 . The coring arrangement of  claim 20  wherein each right brake beam core print protrudes into the mold and forms a portion of one center bowl ledge.  
     
     
         22 . The coring arrangement of  claim 21  wherein each of the bolster opposing side walls has a top and a bottom and a width, the width of the bolster side wall at the bottom of each side wall is equal to or less than the width of the bolster side wall at any point between the bottom and top of the side wall.  
     
     
         23 . The coring arrangement of  claim 15  wherein the bolster has a main parting line, and a left side window core print protrudes from each of the left half center core side wall defining faces to form the left side windows, the left side window core prints extending between the left side windows and the main pattern parting line.  
     
     
         24 . The coring arrangement of  claim 23  wherein each of the bolster opposing side walls has a top and a bottom and a width, the width of the bolster side wall at the bottom of each side wall is equal to or less than the width of the bolster side wall at any point between the bottom and top of the side wall.  
     
     
         25 . The coring arrangement of  claim 15  wherein the bolster has a main parting line, and a right side window core print protrudes from each of the right half center core side wall defining faces to form the right side windows, the right side window core prints extending between the right side windows and the main pattern parting line.  
     
     
         26 . The coring arrangement of  claim 25  wherein each of the bolster opposing side walls has a top and a bottom and a width, the width of the bolster side wall at the bottom of each side wall is equal to or less than the width of the bolster side wall at any point between the bottom and top of the side wall.  
     
     
         27 . A coring arrangement for casting a railcar bolster, the coring arrangement located in a mold, the bolster having hollow sections and a left end and right end, the bolster also having a top wall, a bottom wall, and a pair of opposing side walls connecting the top wall and bottom wall, the bolster further having a central transverse plane, a pair of left friction shoe pockets, and a pair of right friction shoe pockets, the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner and outer walls, the coring arrangement comprising: 
 a left half center core having faces defining an internal surface of each of the bolster top wall, bottom wall, and opposing side walls from the bolster central transverse plane to a point between the pair of left friction shoe pocket inner and outer walls;    a right half center core having faces defining an internal surface of each of the bolster top wall, bottom wall, and opposing side walls from the bolster central transverse plane to a point between the pair of right friction shoe pocket inner and outer walls;    a left top half end core having faces defining an internal surface of the bolster top wall, and an internal surface of each opposing side wall from a point between the left friction shoe pocket inner and outer walls to the left end of the bolster;    a left bottom half end core having faces defining an internal surface of the bolster bottom wall, and an internal surface of each opposing side wall from a point between the left friction shoe pocket inner and outer walls to the left end of the bolster;    a right top half end core having faces defining an internal surface of the bolster top wall, and an internal surface of each opposing side wall from a point between the right friction shoe pocket inner and outer walls to the right end of the bolster; and    a right bottom end core having faces defining an internal surface of the bolster bottom wall, and an internal surface of each opposing side wall from a point between the right friction shoe pocket inner and outer walls to the right end of the bolster.    
     
     
         28 . A railcar bolster, the bolster having a central transverse plane and a central longitudinal plane, the bolster comprising: 
 a top wall;    a bottom wall;    a pair of opposing side walls connecting the top wall and bottom wall; and    the bolster bottom wall having at least four bottom wall openings, two bottom wall openings on either side of the bolster central transverse plane and central longitudinal plane.    
     
     
         29 . The railcar bolster of  claim 28  wherein each bottom wall opening accommodates a bottom wall opening core print extending through the opening.  
     
     
         30 . A railcar bolster having a left end and a right end, the bolster comprising: 
 a top wall;    a bottom wall;    a pair of opposing side walls connecting the top wall and bottom wall;    a central transverse plane;    a pair of left friction shoe pockets;    a pair of right friction shoe pockets;    the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner walls and outer walls;    a pair of left top end openings in the bolster top wall between the bolster left end and the inner walls of the pair of left friction shoe pockets;    a pair of right top end openings in the bolster top wall between the bolster right end and the inner walls of the pair of right friction shoe pockets;    each top end opening accommodating a top end opening core print extending therethrough.    
     
     
         31 . A railcar bolster having a left end and a right end, the bolster comprising: 
 a top wall;    a bottom wall;    a pair of opposing side walls connecting the top wall and bottom wall;    a central transverse plane;    a pair of left friction shoe pockets;    a pair of right friction shoe pockets;    the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner walls and outer walls;    a pair of left bottom end openings in the bolster bottom wall between the outer walls of the pair of left friction shoe pockets and the bolster central transverse plane;    a pair of right bottom end openings in the bolster bottom wall between the outer walls of the pair of right friction shoe pockets and the bolster central transverse plane; and    each bottom end opening accommodating a bottom end opening core print extending therethrough.    
     
     
         32 . A railcar bolster having a left end and a right end, the bolster comprising: 
 a top wall;    a bottom wall;    a pair of opposing side walls connecting the top wall and bottom wall;    a central transverse plane;    a pair of left friction shoe pockets;    a pair of right friction shoe pockets;    the pair of left friction shoe pockets and pair of right friction shoe pockets each having inner walls and outer walls;    the bolster bottom wall having at least four bottom wall openings, two bottom wall openings on either side of the bolster central transverse plane and central longitudinal plane;    each bottom wall opening accommodates a bottom wall opening core print extending through the opening;    a pair of left top end openings in the bolster top wall between the bolster left end and the inner walls of the pair of left friction shoe pockets;    a pair of right top end openings in the bolster top wall between the bolster right end and the inner walls of the pair of right friction shoe pockets;    each top end opening accommodating a top end opening core print extending therethrough;    a pair of left bottom end openings in the bolster bottom wall between the outer walls of the pair of left friction shoe pockets and the bolster central transverse plane;    a pair of right bottom end openings in the bolster bottom wall between the outer walls of the pair of right friction shoe pockets and the bolster central transverse plane; and    each bottom end opening accommodating a bottom end opening core print extending therethrough.    
     
     
         33 . A method of casting a railcar bolster comprising the steps of: 
 inserting cores into a mold to define internal surfaces of the bolster, the cores being made in coreboxes, the cores including a left half center core, a right half center core, a left top half end core, a right top half end core, a left bottom half end core, a right bottom half end core, a left friction wedge core, and a right friction wedge core;    the left half center core and right half center core being identical;    the left top half end core and right top half end core being identical;    the left bottom half end core and right bottom half end core being identical;    the left friction wedge core and right friction wedge core being identical; and    wherein all of the cores are made in two coreboxes.    
     
     
         34 . The method of  claim 33  wherein the left half center core and one of the left friction wedge core or right friction wedge cores are made in one corebox.  
     
     
         35 . The method of  claim 33  wherein the right half center core and one of the left friction wedge core or right friction wedge cores are made in one corebox.  
     
     
         36 . The method of  claim 33  wherein the left top half end core and left bottom half end core are made in one corebox.  
     
     
         37 . The method of  claim 33  wherein the right top half end core and right bottom half end core are made in one corebox.  
     
     
         38 . A method of casting a railcar bolster comprising the steps of: 
 inserting cores into a mold to define internal surfaces of the bolster, the cores being made in coreboxes, the cores including a left half center core, a right half center core, a left top half end core, a right top half end core, a left bottom half end core, a right bottom half end core, a pair of left friction shoe pocket cores, and a pair of right friction shoe pocket cores;    the left half center core and right half center core being identical;    the left top half end core and right top half end core being identical;    the left bottom half end core and right bottom half end core being identical;    the pair of left friction shoe pocket cores and pair of right friction shoe pocket cores being identical; and    wherein all of the cores are made in two coreboxes.    
     
     
         39 . The method of  claim 38  wherein the left half center core and one of the pairs of left friction shoe pocket cores or pairs of right friction shoe pocket cores are made in one corebox.  
     
     
         40 . The method of  claim 38  wherein the right half center core and one of the pairs of left friction shoe pocket cores or pairs of right friction shoe pocket cores are made in one corebox.  
     
     
         41 . The method of  claim 38  wherein the left top half end core and left bottom half end core are made in one corebox.  
     
     
         42 . The method of  claim 38  wherein the right top half end core and right bottom half end core are made in one corebox.