System and method for manufacturing bucket

Abstract

A method of manufacturing a bucket by casting includes determining a volumetric capacity of the bucket. A modular mold assembly is configured by selecting a cope box and a drag box from multiple cope boxes and drag boxes based on the volumetric capacity of the bucket. Further, a first core is selected from multiple first cores based on the volumetric capacity of the bucket. The cope box, the first core, a second core, and the drag box are assembled such that the cope box, the first core, the second core, and the drag box together define a bucket-shaped mold cavity. A volume of the mold cavity depends on the selection of the cope box, the first core, and the drag box. A molten material is poured in the mold cavity and the cast bucket is removed after solidification of the molten material from the modular mold assembly.

What is claimed is: 
     
         1 . A method of manufacturing a bucket by casting, the method comprising:
 determining a volumetric capacity of the bucket;   configuring a modular mold assembly to manufacture the bucket, wherein configuring the modular mold assembly includes:
 selecting a cope box from a plurality of cope boxes based on the volumetric capacity of the bucket; 
 selecting a drag box from a plurality of drag boxes based on the volumetric capacity of the bucket; 
 selecting a first core from a plurality of first cores based on the volumetric capacity of the bucket; and 
 assembling the cope box, the first core, a second core, and the drag box such that the cope box, the first core, the second core, and the drag box together define a bucket-shaped mold cavity, wherein a volume of the mold cavity depends on the selection of the cope box, the first core, and the drag box; 
   pouring a molten material in the mold cavity; and   removing the cast bucket after solidification of the molten material from the modular mold assembly.   
     
     
         2 . The method of  claim 1 , wherein the volumetric capacity of the bucket depends on the volume of the mold cavity. 
     
     
         3 . The method of  claim 1 , wherein the bucket includes a first side plate, a second side plate, a back plate, a support plate, a first hinge plate, and a second hinge plate. 
     
     
         4 . The method of  claim 3 , wherein the cope box and the drag box include projections complementary to shape of the first side plate and the second side plate respectively. 
     
     
         5 . The method of  claim 4 , wherein the cope box further includes a recess complementary to partial shape of the first hinge plate. 
     
     
         6 . The method of  claim 4 , wherein the drag box further includes a recess complementary to partial shape of the second hinge plate. 
     
     
         7 . A pattern assembly for preparing a modular mold assembly, the modular mold assembly adapted to produce buckets of varying volumetric capacity, the pattern assembly including:
 a box having a hollow shape, the box including a base and four side walls coupled to the base;   a first pattern coupled to the base of the box; and   a second pattern removably coupled to the first pattern, wherein the second pattern is selected from a plurality of second patterns based on a required volumetric capacity of the bucket.   
     
     
         8 . The pattern assembly of  claim 7 , wherein the plurality of second patterns have different widths. 
     
     
         9 . The pattern assembly of  claim 8 , wherein the volumetric capacity of the bucket varies with the width of the second pattern. 
     
     
         10 . The pattern assembly of  claim 7 , wherein the second pattern includes cylindrical ridges which fit in complementary grooves in the first pattern. 
     
     
         11 . The pattern assembly of  claim 7 , wherein the second pattern is coupled to the first pattern through a mechanical fastener. 
     
     
         12 . A modular mold assembly for manufacturing a bucket by casting, the modular mold assembly comprising:
 a cope box selected from a plurality of cope boxes based on a volumetric capacity of the bucket;   a drag box selected from a plurality of drag boxes based on the volumetric capacity of the bucket;   a first core selected from a plurality of first cores based on the volumetric capacity of the bucket; and   a second core;   wherein the cope box, the first core, the second core, and the drag box together define a bucket-shaped mold cavity, such that the volume of the mold cavity depends on the selection of the cope box, the first core, and the drag box.   
     
     
         13 . The modular mold assembly of  claim 12 , wherein the volumetric capacity of the bucket depends on the volume of the mold cavity. 
     
     
         14 . The modular mold assembly of  claim 12 , wherein the bucket includes a first side plate, a second side plate, a back plate, a support plate, a first hinge plate, and a second hinge plate. 
     
     
         15 . The modular mold assembly of  claim 14 , wherein the cope box and the drag box include projections complementary to shape of the first side plate and the second side plate respectively. 
     
     
         16 . The modular mold assembly of  claim 15 , wherein the cope box further includes projections complementary to partial shape of the first hinge plate. 
     
     
         17 . The modular mold assembly of  claim 15 , wherein the drag box further includes projections complementary to partial shape of the second hinge plate. 
     
     
         18 . The modular mold assembly of  claim 14 , wherein the second core includes projections complementary to shape of the back plate of the bucket, and partial shape of the first hinge plate and the second hinge plate. 
     
     
         19 . The modular mold assembly of  claim 12 , wherein the plurality of cope boxes are prepared by compacting sand in a pattern assembly. 
     
     
         20 . The modular mold assembly of  claim 12 , wherein the plurality of drag boxes are prepared by compacting sand in a pattern assembly.