Method and system for manufacturing railcar couplers

Abstract

A casting mold with rigging for casting a railcar coupler, which includes a shank portion and a head portion, includes cope and drag portions that define an external shape for each of at least two couplers. The couplers are nested together and oriented in opposite directions to one another along respective longitudinal axes. A down sprue is centered between the first and second couplers and is configured to direct molten material to a gating system positioned between the at least two couples.

We claim: 
     
         1 . A casting and rigging apparatus for casting a railcar coupler that includes a shank portion and a head portion, the casting apparatus comprising:
 a mold that includes cope and drag portions that define an external shape for each of at least two couplers, wherein the couplers are nested together and oriented in opposite directions to one another along respective longitudinal axes; and   rigging formed in the cope and drag portions that includes:
 a down sprue centered between the first and second couplers configured to receive molten material; 
 a gating system positioned between the at least two couplers configured to direct the molten material. 
   
     
     
         2 . The casting and rigging apparatus according to  claim 1 , wherein the gating system comprises:
 a pair of runners with diameters of at least about 2 in that extend in opposite directions away from the down sprue; and   a pair of in-gates, each in-gate being connected to an end of a respective runner, wherein each in-gate directs molten material to one of the at least two couplers.   
     
     
         3 . The casting and rigging apparatus according to  claim 2 , wherein each in-gate is a fin in-gate with a cross-sectional width and height of about 0.83 in and 4.82 in, respectively. 
     
     
         4 . The casting and rigging apparatus according to  claim 3 , wherein each fin in-gate is formed entirely in the drag portion. 
     
     
         5 . The casting and rigging apparatus according to  claim 4 , further comprising a fin core configured to be inserted into an in-gate channel of the drag portion, wherein when inserted, the fin core and in-gate channel define an opening that matches the cross-sectional width and height of the fin in-gate. 
     
     
         6 . The casting and rigging apparatus according to  claim 4 , wherein each fin in-gate enters a respective coupler from a bottom side of the shank or a lower end of a side of the shank that is nearest the down sprue. 
     
     
         7 . The casting and rigging apparatus according to  claim 2 , wherein an angle formed between a respective runner and in-gate is about 60°. 
     
     
         8 . The casting and rigging apparatus according to  claim 2 , further comprising a pair of risers, each riser being positioned between a respective runner and in-gate. 
     
     
         9 . The casting and rigging apparatus according to  claim 2 , wherein a length of each runner is about 6 in. 
     
     
         10 . The casting and rigging apparatus according to  claim 2 , wherein the pair of in-gates are formed entirely in the drag portion. 
     
     
         11 . The casting and rigging apparatus according to  claim 2 , wherein the pair of in-gates enters a respective coupler from a bottom side of the shank or a lower end of a side of the shank that is nearest the down sprue. 
     
     
         12 . The casting and rigging apparatus according to  claim 1 , wherein the at least two couplers are SBE60 couplers with shank lengths of about 21½ in, and wherein when viewed in a direction perpendicular to a top surface of the mold, the at least two couplers and rigging fit within a bounding rectangle that has a square area of less than about 10 ft 2 . 
     
     
         13 . The casting and rigging apparatus according to  claim 12 , wherein a square area of an entire top surface of the mold is less than about 14 ft 2 . 
     
     
         14 . The casting and rigging apparatus according to  claim 1 , wherein the gating system comprises:
 a pair of runners with diameters of about at least about 2 in that extend in opposite directions away from the down sprue; and   first and second in-gates, each in-gate being connected to an end of a respective runner, wherein the first in-gate is configured to direct molten material to first shank sections of the at least two couplers at an angle of about 90° to longitudinal axes of the shank sections and the second in-gate is configured to direct molten material to second shank sections of the at least two couplers at an angle of about 90° to longitudinal axes of the shank sections.   
     
     
         15 . The casting and rigging apparatus according to  claim 14 , wherein a cross-section of each in-gate has a width and height of about 4.5 in and 3.5 in, respectively. 
     
     
         16 . The casting and rigging apparatus according to  claim 14 , wherein a cross-sectional area of each in-gate is greater than about 15 in 2 . 
     
     
         17 . The casting and rigging apparatus according to  claim 14 , wherein the at least two couplers are E69CE couplers with shank lengths of about 53¼ in, and wherein when viewed in a direction perpendicular to a top surface of the mold, the at least two couplers fit within a bounding rectangle that has a square area of less than about 18 ft 2 . 
     
     
         18 . The casting and rigging apparatus according to  claim 17 , wherein a square area of an entire top surface of the mold is less than about 25 ft 2 . 
     
     
         19 . The casting and rigging apparatus according to  claim 14 , wherein a distance between the first and second shank sections is between less than about 21 in. 
     
     
         20 . The casting and rigging apparatus according to  claim 1 , further comprising a pair of risers, each riser configured to feed a tail end of a shank. 
     
     
         21 . The casting and rigging apparatus according to  claim 20 , wherein each riser is positioned above the tail end of the shank. 
     
     
         22 . The casting and rigging apparatus according to  claim 20 , wherein each riser is offset from a side of the tail end of the shank and is configured to feed the end of the shank through a channel, wherein the longitudinal axis of the channel forms an angle E of about 7° with a back end of the shank. 
     
     
         23 . The casting and rigging apparatus according to  claim 1 , wherein the cope and drag portions are formed from an air-set molding material. 
     
     
         24 . The casting and rigging apparatus according to  claim 1 , wherein at least a portion of the gating system is positioned below the shank. 
     
     
         25 . A method for casting a railcar coupler that includes a shank portion and a head portion, the casting method comprising:
 providing cope and drag portions that define cavities for at least two couplers, wherein the couplers are nested together and oriented in opposite directions to one another along respective longitudinal axes; and   providing a down sprue centered between the first and second cavities configured to receive molten material;   positioning a gating system between the at least two cavities configured to direct the molten material.   
     
     
         26 . The casting method according to  claim 25 , wherein the gating system comprises:
 a pair of runners with diameters of at least about 2 in that extend in opposite directions away from the down sprue; and   a pair of in-gates, each in-gate being connected to an end of a respective runner, wherein each in-gate directs molten material to one of the at least two cavities.   
     
     
         27 . The casting method according to  claim 25 , wherein each in-gate is a fin in-gate with a cross-sectional width and height of about 0.83 in and 4.82 in, respectively. 
     
     
         28 . The casting method according to  claim 27 , forming each fin in-gate entirely in the drag portion. 
     
     
         29 . The casting method according to  claim 28 , wherein each fin in-gate enters a respective cavity from a bottom side of the shank or a lower end of a side of the shank that is nearest the down sprue. 
     
     
         30 . The casting method according to  claim 28 , wherein at least a portion of the gating system is positioned below the shank. 
     
     
         31 . The casting method according to  claim 26 , wherein an angle formed between a respective runner and in-gate is about 60°. 
     
     
         32 . The casting method according to  claim 26 , further comprising providing a pair of risers, each rise being positioned between a respective runner and fin in-gate. 
     
     
         33 . The casting method according to  claim 26 , wherein a length of each runner is about 6 in. 
     
     
         34 . The casting method according to  claim 26 , forming wherein the pair of in-gates entirely in the drag portion. 
     
     
         35 . The casting method according to  claim 25 , wherein the at least two couplers are SBE60 couplers with shank lengths of about 21½ in, and wherein when viewed in a direction perpendicular to a top surface of the mold, the at least two couplers fit within a bounding rectangle that has a square area of less than about 10 ft 2 . 
     
     
         36 . The casting method according to  claim 25 , wherein the gating system comprises:
 a pair of runners with diameters of about at least about 2 in that extend in opposite directions away from the down sprue; and   first and second in-gates, each in-gate being connected to an end of a respective runner, wherein the first and second in-gates are configured to direct molten material to first and second shank sections of the at least two couplers at an angle of about 90° to longitudinal axes of the shank sections.   
     
     
         37 . The casting method according to  claim 36 , wherein a cross-section of each in-gate has a width and height of about 4.5 in and 3.5 in, respectively. 
     
     
         38 . The casting and rigging apparatus according to  claim 36 , wherein a cross-sectional area of each in-gate is greater than about 15 in 2 . 
     
     
         39 . The casting method according to  claim 36 , wherein the at least two couplers are E69CE couplers with shank lengths of about 53¼ in, and wherein when viewed in a direction perpendicular to a top surface of the mold, the at least two couplers fit within a bounding rectangle that has a square area of less than about 18 ft 2 . 
     
     
         40 . The casting method according to  claim 36 , wherein a distance between the first and second sections is less than about 21 in.