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.

Description

BACKGROUND OF THE INVENTION

[0001] Railcar sideframes are cast from steel. Sideframes are cast in a mold. The mold has a top or cope section and a bottom or drag section. The cope and drag sections of the mold are each contained in a flask. A pattern is placed over one end of each flask and sand is rammed over the pattern. The pattern is then removed leaving an impression of the casting's external surfaces in the cope and drag section mold sand.

[0002] Sideframe castings typically have hollow sections that reduce the sideframe's weight while maintaining strength. The sideframes' hollow sections are formed with cores. Cores define the hollow sections' internal surfaces, and may define some external surfaces of the casting.

[0003] Cores are typically made from sand. The sand contains a binding agent to maintain the core's integrity while handling the core during the casting process. Typical binders include phenolic resin, polyurethane, and sodium silicate. A popular core sand binder is Ashland Inc.'s Isocure® binder.

[0004] Cores are made in core boxes. The core box includes a drag section and a cope section. Cores can be produced manually or with automated core making equipment such as a core blower. To make a core with a core blower, the core box cope and drag sections are fastened together, and the core box placed on the core blower. Tooling is required to fit the particular core box to the core blower. This tooling typically includes a blow plate, a gassing manifold (or plate), a stool, and various core ejection systems. Different tooling is generally necessary to fit each different core box to the core blower.

[0005] The core blower produces cores by blowing sand into the core box. The core blower typically uses sand containing binders such as Isocure® that cure the core in the core box. The core blower injects curing gas into the core box to cure the core. The cope and drag sections of the core box are separated leaving the core.

[0006] Once made, the cores are placed in the bottom or drag mold. Cores are supported and located in the drag mold in a number of ways. Cores may be supported and located in the mold on core prints which extend from the core surface into cavities in the mold. Core prints are the usually the best way to support and locate cores in the mold. Where core prints are not possible, cores may also be supported on chaplets. Chaplets, however, are expensive and can cause stress risers in the casting. Cores may also be supported and located by other cores. When supporting and locating one core by another core, there is no reference to the mold surface for the supported core. This can result in loss of casting wall thickness dimensional control.

[0007] After the cores are placed in the drag mold, the cope mold is placed on top of the drag, and the cope and drag are fastened together. Molten metal is poured into the mold and allowed to cool, thus hardening the metal. The casting is then removed from the mold and the sand is shaken out. The casting is then typically heat treated, machined, and finished.

[0008] There are numerous freight railcar manufacturers. Each freight car customer typically requires a different sideframe casting design. Each sideframe casting design requires patterns, molds, cores, and core arrangements specific to that design. Thus, each sideframe casting design requires different mold cope and drag patterns to form the external surfaces of the casting, and different shaped cores to make the internal surfaces of the casting. Each different core shape requires a separate core box. Separate tooling to fit each core box to the core blower is also necessary.

[0009] Manufacturing different sideframe designs also requires frequent core box and tooling changes to core production lines. This results in significant downtime and increased costs in core and casting production costs. The railcar sideframe casting method of the present invention addresses these and other problems.

SUMMARY OF THE INVENTION

[0010] 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.

[0011] In another aspect, the present invention 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.

[0012] In a further aspect, the present invention provides the ability to support and locate core modules within a mold through use of core prints. The sideframe has a right and a left pedestal top opening, and the right and left outer leg core modules each have pedestal top core prints extending into the mold sand. The pedestal top core prints define the right pedestal top opening. The pedestal top core prints have a protrusion extending from them that extends into the mold sand.

[0013] The sideframe also has right and left pedestal end openings. The right and left outer leg core modules each have a pedestal end core print extending into the mold sand, the pedestal end core print defining the right and left pedestal end openings. The pedestal end core prints have a protrusion from the core prints into the mold sand.

[0014] The sideframe has a top wall. The right and left outer leg core modules each include a top wall core print extending from their outer surface through holes in the top wall of the sideframe and into the mold sand.

[0015] The right and left tension members have an outer wall, the outer walls have openings. The right and left tension member core modules each include a core print extending from their outer surfaces into the mold sand and forming at least part of the outer wall openings. The core prints have a protrusion extending from the core print into the mold sand. 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.

[0016] The right and left side windows of the sideframe each have a top perimeter and a bottom perimeter. The top perimeter has no outside corner radius. The right and left tension member core modules each have a core print extending from their outer surface that spans the entire top perimeter of their side windows.

[0017] The right and left outer leg core modules include shelves corresponding with a weight bearing surface of their respective tension member core module. The bolster opening bottom core module includes a shelf corresponding to weight bearing surfaces on the right and left tension member core modules.

[0018] In another aspect of the present invention, the sideframe has a central longitudinal plane and a bolster opening. The bolster opening has a right side and a left side and a column wall on the right side and on the left side of the bolster opening. Right and left column wall core modules form the internal surfaces of the right and left column wall of the bolster opening. The right and left column wall cores are adapted to be inserted into a cavity in their respective tension member core module.

[0019] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the figures.

BRIEF DESCRIPTION OF THE FIGURES

[0020] FIG. 1 is a perspective view of a railcar sideframe and bolster.

[0021] FIG. 2 is a perspective view of a railcar sideframe.

[0022] FIG. 3 is a side plan view a railcar sideframe showing the design zones of an embodiment of the present invention.

[0023] FIG. 4 is a bottom view of a railcar sideframe.

[0024] FIG. 5 is a top perspective view of one end of a railcar sideframe.

[0025] FIG. 6 is a bottom perspective view of one end of a railcar sideframe.

[0026] FIG. 7 is a top perspective view of one end of a railcar sideframe showing a hole in its top wall in accord with one embodiment of the present invention.

[0027] FIG. 8 is a perspective view of core modules of an embodiment of the present invention.

[0028] FIG. 9 is a bottom perspective view of an outer leg core module of an embodiment of the present invention.

[0029] FIG. 10 is a top perspective view of an outer leg core module of an embodiment of the present invention.

[0030] FIG. 11 is one end perspective view of one side of a tension member core module of an embodiment of the present invention.

[0031] FIG. 12 is another end perspective view of one side a tension member core module of an embodiment of the present invention.

[0032] FIG. 13 is a perspective view of another side of a tension member core module of an embodiment of the present invention.

[0033] FIG. 14 is a perspective view of a portion of core modules of an embodiment of the present invention.

[0034] FIG. 15 is a bottom perspective view of a bolster opening bottom core of an embodiment of the present invention.

[0035] FIG. 16 is a top perspective view of a bolster opening bottom core of an embodiment of the present invention.

[0036] FIG. 17 is a section view of a prior art core print.

[0037] FIG. 18 is a section view of a core print of an embodiment of the present invention.

[0038] FIG. 19 is a perspective view of core modules of an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0039] FIG. 1 shows a typical railcar truck 10. There are two trucks 10 per railcar. The railcar truck 10 includes two wheelsets 12, a pair of sideframes 14, and a bolster 16. Each sideframe 14 accommodates the bearings 17 of the wheelsets 12. The sideframes 14 rest on the wheelsets 12. The bolster 16 extends between the sideframes 14. The bolster 16 is supported by the sideframes 14 on springs 18. The springs 18 may be supported directly on the sideframe 14, or on an intermediate assembly (not shown).

[0040] FIG. 2 shows a sideframe 14 made in accord with the method of the present invention. The sideframe 14 has a bolster opening 20 to accommodate the bolster 16 and springs 18. On either side of the bolster opening 20 are a right column wall 22 and a left column wall 24. The right and left column walls 22 and 24 have external wall surfaces 26 and 28.

[0041] The sideframe 14 also includes a right side window 30 and a left side window 32. The right side window 30 and left side window 32 each have a top perimeter 34 and bottom perimeter 35 extending around their entirety. Each side window 30 and 32 has an external surface 36 and 38.

[0042] The sideframe 14 further includes a right tension member 40 and a left tension member 42. The right and left tension members 40 and 42 have right and left openings 44 and 46 in their outer walls 48 and 50.

[0043] The sideframe 14 also includes a top compression member 52 extending substantially the length of the top 54 of the sideframe 14. At the left end 56 and right end 58 of the sideframe 14 are left pedestal section 60 and right pedestal section 62. Each of the pedestal sections 60 and 62 have pedestal jaws 64 and 66. The pedestal jaws 64 and 66 extend around the bearings 16 of the sideframes 14. The left and right pedestal sections 60 and 62 also include a left pedestal roof 68 and a right pedestal roof 70. The left and right pedestal roofs 68 and 70 rest on the bearings 16 of the wheelsets 12. The left and right pedestal jaws 64 and 66 have in their outer walls left and right pedestal end openings 72 and 74 (FIG. 6). The pedestal end openings 72 and 74 reduce the overall weight of the sideframe 14.

[0044] At the bottom 76 of the bolster opening 20 is a bolster opening bottom section 78. The bolster opening bottom section 78 may include a spring seat 80. The springs 18 rest on the spring seat 80 in a sideframe that has a spring seat 80. The bottom section 78 is beneath the spring seat 80.

[0045] The sideframe 14 also has top openings 82 and 84 in each of the left and right pedestal section sections 60 and 62 (FIG. 5). The top openings 82 and 84 reduce the weight of the sideframe 14.

[0046] The method of the present invention includes dividing the sideframe into design zones 81. FIG. 3 shows the design zones 81 of a preferred embodiment of the present invention. The design zones 81 include a left outer leg design zone 86, a left tension member design zone 88, a bolster opening design zone 90, a right tension member design zone 92, and a right outer leg design zone 94. The design zones 86 through 94 generally correspond to areas of the sideframe 14 where railcar customer-driven design changes are likely to occur.

[0047] The left outer leg design zone 86 preferably includes the left pedestal section 60, which includes the left pedestal jaw 64 and left pedestal roof 68. Similarly, the right outer leg design zone 94 preferably includes the right pedestal section 62, which includes the right pedestal jaw 66 and right pedestal roof 70.

[0048] The left tension member design zone 88 preferably includes the left tension member 42, the left side window 32, and a portion 96 of the top compression member 52. Similarly, the right tension member design zone 92 preferably includes the right tension member 40, the right side window 30, and a portion 98 of the top compression member 52.

[0049] The bolster opening design zone 90 includes the bottom section 78 beneath the bolster opening 20. A spring seat 102 may be located at the bottom 100 of the bolster opening 20. The spring seat 102 supports the bolster 16 on springs 18. The spring seat 102 has teeth 104 to accommodate the springs 18. The bolster opening design zone 90 also includes a left column wall 24 and a right column wall 22 on either side of the bolster opening 20. The top compression member 52 extends across the top 110 of the bolster opening 20. The left and right columns 24 and 22 preferably have bolt holes 112 to affix a wear plate (not shown) to the sideframe 14.

[0050] FIG. 4 shows a bottom view of the sideframe 14. The sideframe 14 has a central longitudinal plane 114 which divides the sideframe 14 into a top half 116 and a bottom half 118. A central transverse plane 120 divides the sideframe 14 into a left half 122 and a right half 124 (FIG. 14). FIG. 5 is a top perspective view of the left half 122 of the sideframe 14. FIG. 5 shows the left pedestal top opening 82 in the left pedestal section 60 on each side of the central longitudinal plane 114. FIG. 6 is a bottom perspective view of the left half 122 of the sideframe 14. FIG. 6 shows the left pedestal end opening 72 in the left pedestal jaw 64. FIG. 6 also shows the left outer wall opening 46 in the outer wall 50 of the left tension member 42.

[0051] The method of the present invention includes providing a core module for forming internal surfaces of the sideframe 14 corresponding to the design zones 81. FIG. 8 shows the core modules 123 that correspond to the design zones. The cores modules 123 preferably include a left outer leg core module 124, a left tension member core module 126, a bolster opening bottom core module 128, a right tension member core module 130, and a right outer leg core module 132. The core modules 123 also include a left column core module 134 and a right column core module 136. These core modules 123 define the internal surfaces of hollow sections of the sideframe 14.

[0052] The left outer leg core module 124 corresponding to the left outer leg design zone 86 is shown in FIGS. 9 and 10. FIG. 9 shows a bottom perspective view and FIG. 10 a top perspective view of the left outer leg core module 124. The right outer leg core module 132 is the mirror image of the left outer leg core module 124. The right outer leg core module 132 corresponds to the right outer leg design zone 94. The left outer leg core module 124 has a left pedestal roof portion 138 for forming the internal surfaces of the left pedestal roof 68, and a left jaw portion 140 for forming internal surfaces of the left pedestal jaw 64 of the sideframe 14. Preferably, the left pedestal roof portion 138 forms the entire internal surface of the pedestal roof 68, and the pedestal jaw portion 140 forms the entire internal surface of the pedestal jaw 64 on both sides of the central longitudinal plane 114 of the sideframe 14.

[0053] Extending from the outer surface of the left outer leg core module 124 is a pedestal top opening core print 142. The pedestal top opening core print 142 forms the pedestal top opening 82. Also extending from the outer surface of the left outer leg core module 124 is a pedestal end opening core print 144. The pedestal end opening core print 144 forms the pedestal end opening 72 of the sideframe 14. The pedestal top opening core print 142 and pedestal end opening core print 144 extend into the mold sand of the drag mold to support and locate the left outer leg core module 124 in the mold.

[0054] In a preferred embodiment, the pedestal top opening core print 142 has a protrusion 146 extending from its underside that further serves to locate the core in the drag mold and prevent core movement. The protrusion 146 is preferably located at the outer edge 148 of the pedestal top opening core print 142, and is preferably triangular in shape. The pedestal end opening core print 144 also preferably has a protrusion 150 on its underside. The protrusion 150 is preferably rectangular and is located at the outer edge 154 of the pedestal end opening core print 144.

[0055] The left outer leg core module 124 also has a shelf 156 located at its inner edge 158. The shelf 156 mates with the left tension member core module 126 to support the weight of the left outer leg core module 124 as described below. The shelf 156 preferably extends across the entire width of the inner edge 158 of the left outer leg core module 124.

[0056] FIG. 10 shows a top perspective view of the left outer leg core module 124. FIG. 7 shows a top perspective view of the sideframe 14. A top wall 160 of the sideframe 14 has an opening 162. A top wall core print 164 extends from the outer surface of the left outer leg core module 124 through the opening 162 in the top wall 160 of the sideframe 14 (FIG. 10.) The top wall core print 164 with the pedestal top opening core print 142 and end opening core print 144 and protrusions 146 and 150 primarily locate the left outer leg core module 124 in the mold.

[0057] FIGS. 11 and 12 show top perspective views of the left tension member core module 126 corresponding to the left tension member design zone 88. The right tension member core module 130 corresponds to the right tension member design zone 92, and is the mirror image of the left tension member core module 126. The left tension member core module 126 preferably has a left side window portion 166 for forming the left side window 32 of the sideframe 14. The left tension member core module also preferably has a left tension member portion 168 for forming internal surfaces of the left tension member 42, and a top compression portion 170 for forming internal surfaces of the top compression member 52 of the sideframe 14. Preferably, the left tension member core module 126 forms the entire internal surfaces of the left tension member 42 and top compression portion 170 on both sides of the central longitudinal plane 114 of the sideframe 14. The left tension member core module 126 has a cavity 172 to accommodate the left column core module 134 that defines the internal surface of the left column wall 24.

[0058] The left tension member core module 126 has a weight bearing surface 174 at its outer end 176. The weight bearing surface 174 mates with the shelf 156 of the left outer leg core module 124 to support its weight. Preferably, the weight bearing surface 174 extends across the entire width of the outer end 176 of the left tension member core module 126. Where the left outer leg core module 124 and left tension member core module 126 meet forms a joint 177. A similar joint 179 is formed where the right outer leg core module 132 and right tension member core module 130 meet.

[0059] The left tension member core module 126 has at its inner end 178 another weight bearing surface 180. The weight bearing surface 180 mates with the bolster opening bottom core module 128 as described below. Extending from the outer surface of the left tension member portion 168 is a core print 182. The core print 182 extends into the mold sand. The core print 182 also forms a portion of the opening 46 in the outer wall 50 of the tension member 42.

[0060] FIG. 13 shows a bottom perspective view of the left tension member core module 126. Extending from the core print 182 is a protrusion 184. The protrusion 184 is preferably located along the outer edge 186 of the core print 182 nearest the bolster opening bottom core module 128.

[0061] The left tension member core module 126 also has a side window core print 188 that extends into the mold sand of the drag mold. The core print 188 extends from the underside of left side window portion 166. The top perimeter 34 of the left side window 32 of the side frame 14 preferably has no outside corner radius as shown in FIG. 18.

[0062] As shown in FIG. 17, prior art sideframes had outside corner radii 190 at the perimeter of their side window 192. The core print 194 had to stop at the radius tangent point 193, and could not extend into the mold sand. As those skilled in the art will appreciate, if the core print attempted to form the outside radius, where the core print hole perimeters are parallel to the corebox parting line, a ledge is created when forming the core module in the core box. This will prevent the core module from being removed from the corebox. Thus, in prior art designs, the core print stopped at the beginning of the outer hole radii. This prior art core does not locate the core module with respect to the mold.

[0063] The top perimeter 34 without the outside corner radius of the present invention shown in FIG. 18 permits core print 188 to extend into the mold sand. Because there is no outside corner radius, no ledge will be formed when making the core module, thus permitting it to be removed from the core box. Moreover, the core print 188 together with the core print 182 and protrusion 184 extending into the mold sand primarily locates the left tension member core module in the drag mold sand.

[0064] FIG. 8 shows the left column wall core module 134 inserted into the cavity 172 of the left tension member core module 126. The left column wall core module 134 forms the interior wall of the left column wall 24. The right column wall core module 136 is similarly inserted into a cavity in the right tension member core module 130.

[0065] FIGS. 15 and 16 show the bolster opening bottom core module 128 in the bolster opening design zone 90. The bolster opening bottom core module 128 forms internal surfaces of the bolster opening bottom section 78. Preferably, the bolster opening bottom core module 128 forms the entire interior surface of the bolster opening bottom section 78 on both sides of the central longitudinal plane 114 of the sideframe 14. The bolster opening bottom core module 128 preferably has left and right core prints 196 and 198. The left and right core prints 196 and 198 extend into the mold sand to locate the bolster opening bottom core module 128 in the mold. The left core print 196 combines with the core print 182 of the left tension member core module 128, and forms a portion of the opening 46 in the outer wall 50 of the tension member 42. The right core print 198 does the same with the right tension member core module 130.

[0066] As shown in FIG. 16, the left and right ends 200 and 202 of the bolster opening bottom core module 128 have shelves 204 and 206. The left shelf 204 mates with the weight bearing surface 180 of the left tension member core module 126. Similarly, the right shelf 206 mates with a weight bearing surface of the right tension core module 130 such that the weight of the bolster opening bottom core module 126 is partially supported by the left and right tension member core modules 126 and 130. Where the bolster opening bottom core module 128 and left tension member core module 126 meet, a joint 195 is formed. Where the bolster opening bottom core module 128 and right tension member 130 meet a similar joint 197 is formed.

[0067] The left and right core prints 196 and 198 of the bolster opening bottom core module 128 preferably have protrusions 208 and 210 extending from their undersides at their outer edges 212 and 214. Protrusions 208 and 210 are preferably rectangular, and together with the left and right core prints 196 and 198, primarily locate the bolster opening bottom core module 128 in the mold.

[0068] The bolster opening design zone 90 may also include a bolster opening core module 216 and a spring seat core module 218 (FIG. 19). The bolster opening core module 216 preferably defines a portion of the top compression member 52 in the bolster opening design zone 90, and the external surfaces of the left and right column walls 24 and 22. The spring seat core module 218 defines internal surfaces of the spring seat 102.

[0069] FIG. 14 shows a central transverse plane 120 of the sideframe 14. The central transverse plane 120 divides the sideframe 14 into left and right halves 122 and 124. As shown in FIG. 14, the joints 177, 179, 195, and 197 are preferably parallel to the central transverse plane 120 of the sideframe 14.

[0070] Corebox tooling costs are a significant portion of producing sideframe castings. To minimize production costs, core production machines and coreboxes must be used to their full potential. This must be done while maintaining design flexibility. In the freight car market, each customer has a particular set of sideframe casting design requirements. To economically meet customer design requirements, core production tooling should be designed so portions are interchangeable. This minimizes customer driven tooling change costs. It also reduces the complexity of design changes, the number of corebox changes on the core production line, and the corresponding tooling changes.

[0071] The core modules 123 of an embodiment of the present invention provides great flexibility in the manufacture of sideframes 14. For instance, suppose a customer orders a sideframe 14, but desires a change made only to the sideframe in the left and right outer leg design zones 86 and 94, but keeps the rest of the design intact. Only the left and right outer leg core modules 124 and 132 need to be changed. The remaining core modules need not be changed. Corebox and tooling changes are only required for the core module that is changed.

[0072] Moreover, modular coreboxes can be used such that design changes occurring in a core module require only portions of the corebox to be changed. This way the same basic tooling can be used without having to build an entirely new corebox to accommodate the change.

[0073] It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

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.