Title: No-Bake Core Making Work Instruction

Objective: The objective of this work instruction is to provide step-by-step guidance

for the process of no-bake core making. No-bake cores are used in foundries to
create cavities in metal castings. This instruction aims to ensure safe and efficient
core production.

Note: This work instruction assumes that the necessary equipment, materials, and
safety measures are already in place.

Equipment and Materials Required:

1. Core box
2. Core sand
3. Binder (resin)
4. Catalyst
5. Mixing equipment (such as a mixer or muller)
6. Core vents (optional)
7. Core stripping tool
8. Vent rods (optional)
9. Pneumatic hammer (optional)
10. Safety equipment (gloves, goggles, apron, etc.)

Procedure:

1. Prepare the Core Box: a. Inspect the core box for any damage or defects. Replace or
repair if necessary. b. Ensure the core box is clean and free from any residual sand or
debris. c. Apply a thin layer of parting compound or release agent to the interior
surfaces of the core box to aid in the easy removal of the core.
2. Prepare the Core Sand: a. Select the appropriate core sand mixture based on the
casting requirements and specifications. b. Mix the core sand in the muller or mixer,
following the manufacturer's instructions. c. Adjust the sand mixture to achieve the
desired consistency and compactability. Consult the foundry's guidelines for the
correct sand-to-resin ratio. d. Ensure the core sand is properly conditioned and free
from lumps or moisture.
3. Prepare the Binder: a. In a separate container, measure the correct amount of binder
(resin) according to the recommended ratio. b. Add the catalyst to the binder
following the manufacturer's instructions. c. Mix the binder and catalyst thoroughly
until a homogenous mixture is obtained.
4. Core Making: a. Place the prepared core box on a level and stable surface. b. Fill the
core box with the prepared core sand mixture, ensuring it is evenly distributed and
compacted. c. If using core vents, insert them into the appropriate locations in the
core box, ensuring they are securely positioned. d. Pour the prepared binder mixture
 evenly over the core sand. e. Use a core stripping tool to level and smooth the
surface of the core, removing any excess sand or binder. f. Allow the core to cure for
the specified time, considering the resin's curing properties. g. If required, use vent
rods or a pneumatic hammer to remove any trapped air pockets or improve the
core's permeability.
5. Core Removal: a. Once the core has fully cured, carefully open the core box and
remove the core. b. Inspect the core for any defects or damage. Discard any cores
that do not meet the quality standards. c. Trim any excess sand or rough edges using
appropriate tools.
6. Post-Processing: a. If necessary, store the cores in a designated area for further
processing or assembly. b. Clean the core box and other equipment used in the
process, removing any residual sand or binder. c. Properly dispose of any waste
materials, following the foundry's environmental guidelines.

Safety Precautions:

1. Always wear appropriate personal protective equipment (PPE) such as gloves,

goggles, and aprons when working with core sand, binder, and chemicals.
2. Follow the manufacturer's instructions for handling and storing binders, catalysts,
and other chemicals.
3. Ensure good ventilation in the work area to minimize exposure to fumes or dust.
4. Be cautious while handling sharp tools and equipment, and use them only for their
intended purposes.
5. Follow all safety guidelines and regulations established by the foundry.

Note: This work instruction provides a general guideline for no-bake core making. It
is essential to consult the specific procedures and guidelines established by your
foundry, as they may have variations or additional steps based on their requirements
and processes