Process flow of purple sand production
Raw material preparation, including dredging, refining and material selection. The hard soil excavated in the mine is mashed, screened and filtered, and the fine soil obtained is stored in the kiln, which is called "soil cultivation".
The main modeling method of purple sand ware is hand kneading. First pinch the body, then dig the foot, open the face, and finally add the handle, mouth, cover, etc. From the Ming Dynasty to the Kangxi period of the Qing Dynasty, a large number of molded products appeared in the Yongzheng and Qianlong periods of the Qing Dynasty by kneading. During Jiaqing and Daoguang years, Chen Mansheng once again advocated the ancient law and made it popular. Li Jingkang and Zhang Hong put it well: "As far as impression and manufacturing are concerned, the impression method is easy to refine and improve in industry, but the production method is difficult to refine, but the skill is the most important. Therefore, the method of impression is easy to imitate, and the fabricated law is not easy to grasp. Famous pots are well made, and sitting is reasonable. "
The early tools for making blanks were mainly bamboo knives. Later, tools made of wood, horn, stone, metal and other materials were gradually added, and ceramic wheels were used to pull and repair blanks. By the Qing dynasty, there were more than ten kinds of tools, such as vertebrae, cymbals, darts and hairpin, and there were many shapes such as reed, water, shell, kidney, moon and scorpion tail.
The finished blank should be carefully trimmed and decorated with some utensils. Decoration methods include: applique-piling up decorative patterns such as landscapes, flowers, figures, birds and animals; Painting-painting and writing on the blank with alumina, iron oxide or magnesium oxide as colorants; Carving-Carving calligraphy and painting on the blank. Purple sand is generally not glazed, but also decorated with a small amount of glaze. Glazed large pieces, glazed small pieces. Generally, it is glazed once and painted twice in monochrome.
After the green body is dried in the shade, it is put into a sagger and fired in a kiln. The traditional kiln for firing purple sand ware is the "Dragon Kiln", that is, the inclined kiln with low head and high tail. The dragon kiln is generally 40 meters long, and there is a section every other meter. Stove burning, fuel is firewood and firewood. There are 50 burning holes on both sides of the kiln back, and the fuel is supplied from here. On both sides of the kiln body, an entrance and exit are opened every four or five meters, from which blanks are loaded and containers are taken. Each kiln needs to be fired for 4042 hours at the kiln temperature of 1 100℃ to 1200℃; Stop after firing 1524 hours, and then open the kiln to take the device. Fired in the dragon kiln, the kiln worker is very hard. Now the purple sand factory has changed to a new type kiln burning heavy oil, which not only saves manpower, but also improves the firing quality.
After firing, the purple sand ware should be polished and waxed, which is a unique process of purple sand. Painted purple sand utensils need to be installed and burned twice.
There are also special decorations on the fired purple sand utensils. Shi Dabin's square pot is collected in the Palace Museum, and its surface is painted and carved, combining purple sand technology and Qi Diao technology. During Daoguang period of Qing dynasty, tin coating technology appeared, but it could not be continued because of the complicated process. There is also the process of polishing copper coating, which is more common at the edge of spout head and lid. Gold and silver thread inlay is a new decorative technology, which absorbs the carving technology of wood and lacquer. First, a pattern groove is carved on the clay blank, and then the gold and silver wires are embedded in the groove after firing, compacting and polishing.
The molding method of purple sand pottery has been used since Zheng De's time in Ming Dynasty. Through the exploration, improvement and scientific and technological progress of artists of past dynasties, its methods are diversified and its skills are becoming more and more perfect.
To sum up, there are several molding methods, such as manual, grouting, blank coating and blank printing.
Manual molding methods: including "beating cylinder" and "fixing cylinder", which is an ancient manual manufacturing process.
The forming method of "barrel beating" is as follows: firstly, the cooked mud is cut into "mud shreds" with a certain width, thickness and length, then these mud shreds are beaten into mud strips and pieces that meet the requirements of the manufactured utensils, and the width, outlet, bottom and apron of the mud strips are marked with a lathe tool, then the apron is stuck in the center of the turntable, and the mud strips are surrounded along the apron to form a mud barrel.
"Inlaid cylinder" molding method: suitable for square ware products: firstly, cut the mud line into square mud blocks, break the square mud blocks into blocks, prepare a template according to the required size of the product, cut the mud blocks according to the template, coat the cut mud blocks with grease according to the requirements of the ware molding specification, and inlay and form. The key of manual molding lies in the proper specification of mud embryo forming skills and fine surface processing. Fine leveling and correction can make the shape structure more rigorous, the outline lines clear and decent, and the ribs and capsules clear, which can meet the requirements of making round, smooth and seamless beads. Modern molding method: grouting molding method: it is a widely used molding process in modern ceramic production. Using the water absorption of gypsum model, a hollow slurry blank can be obtained by injecting slurry into the mold and then removing the gypsum model.
Forming tool
The success of a purple sand handicraft has to go through dozens to dozens of complicated molding processes. To complete these processes, one depends on the artist's production skills and the other depends on various production tools, both of which are indispensable. The ancients said well: "If a worker wants to do a good job, he must sharpen his tools first." . The "implements" here also refer to making tools. Through the constant exploration, reform and innovation of artists of past dynasties, Zisha modeling tools have now formed a unique, economical and self-contained set of tools, made of hundreds of materials such as copper, iron, wood, bamboo, horn, leather and plastic.
There are many kinds of purple sand modeling tools, and they also pay attention to the beauty of modeling, provided that they are practical. Most of these tools are made by ourselves. Even some bought tools can only be used after being processed and trimmed. This requires the producer to have a systematic and comprehensive understanding of the whole molding process, to understand the different uses and specifications of various tools, and to consider the convenience of use and the comfort of touch. Therefore, the production of purple sand modeling tools is also very knowledgeable, which should not only consider the appearance of modeling, but also conform to the actual use function. The specification requirements of different tools are summarized as follows:
First of all, partners
Spoon is one of the main tools in molding, which is mainly used for making mud strips, making films, punching holes and putting mud pieces. The main materials of your partner are beech, sandalwood, jujube and so on. And the material should be dry.
Usually after use, your partner should wipe it with a wet cloth and put it in a dry place. Can't bask in the sun, nor can it be used to smash hard objects such as iron.
Second, the beat
Racket is mainly used for beating barrels, taking photos and patting the mouth. The best material is mahogany, the total length of the racket is 28CM, and the width of the racket body is 10cm. The thickness depends on the material. Jujube is 3 mm thick in front, 4 mm thick in the middle and 4 mm thick in the back. Cedar is thicker, mahogany can be thinner. The racket should not be immersed in water after use. It should be placed in a dry place to avoid one side being wet and prevent the racket from cracking.
Third, a sharp knife.
There are many kinds of sharp knives, such as iron sharp knives, bamboo sharp knives, straight sharp knives and curved sharp knives. Sharp knife is a common tool for cutting handles, buttons, turning feet and leather facets, and it is also a simple carving tool. Materials are general steel, copper, stainless steel, old bamboo and so on. Its shape is wide in the middle, sharp at one end and slightly round at the other. The lines on both sides should be symmetrical, thick in the middle and thin on both sides to form an arc. Sharp knives should be selected according to different uses, and there are different requirements for thickness and width.
Fourth, the knife
Knife is the most widely used tool in molding. In the production process, it is used for cutting, cutting, picking, holding, digging and scraping. From beginning to end. The most commonly used material for making knives is ordinary steel, and the blade should be ground frequently. The ratio of shank to blade is about 6: 1.
Five, instant car
The proper term of rectangular car should be gauge car, which is specially used to draw circular pieces and openings. The rectangular car is divided into four parts: handle, nail, standing person and pin. Rectangular handle is made of bamboo which is not easy to deform, standing person should be made of bamboo with thickness above 1.5cm, rectangular nail is made of iron, and pin is made of bamboo. The specifications of a general rectangular car are: the handle length is 20, 1.5, 0.5cm；; The total height of the standing person is 8.5cm, the width is 1.3cm, the eye length is 2.4-2.2, and the width is 0.55cm. Adjust the different uses of the rectangular car according to the height of the standing person and the nails of the rectangular car. Generally, people standing are 2mm taller than nails.
In addition, there are several special rectangular cars, mud-bent rectangular cars, equipped with two people standing on the handle; There are also double-track cars and tandem cars. Double-track vehicles are not equipped with nails, and tandem vehicles are equipped with bamboo nails.
Sixth, do it.
The stem is a tool for lighting various decorative lines. The stem is made of ox horn, iron, plastic and bamboo. Grind the stem according to different decorative lines, and determine the different angles of the stem according to everyone's gestures and habits. Making molding tools is the most difficult to master.
Seven, Ming needle
The bright needle is the trumpet, which is the tool to complete the surface of the work. When making bright needles, the head should be scraped flat and gradually tapered from top to bottom. Soak it in clear water when using it, and pick it up and dry it when not in use.
Eight, rectangular sediment skewer
These two tools are made of bamboo, and the rectangular bottom is also called the bottom. They are used to draw films under people standing on the rectangular car, with a round eye in the middle chapter. Is Dorobou used to show Dorobou and blockbusters? Made of bamboo pieces with a long pitch, it gradually narrows from the handle to the head. The back should be straight, the mouth should be aligned, one side should have a knife edge, and there is usually a bamboo joint at the handle.
Nine, only music, only grate, only complex
Music is just a tool used to smooth the joint of mouth, neck, bottom, foot and bucket. Materials include ox horn, bamboo and boxwood. According to different angles, the arc bottom is polished into the required shape. Grate is only used for shaping, and can be used to remove small gaps on the barrel. It is mainly made of simple pieces and boards. As long as the grate is made separately from the shoulder, abdomen and bottom, it is impossible to use only one grate for a pot shape. Composite is only used for composite mud, generally made of 2~3mm bamboo chips or open needles.
Ten, bamboo racket
There are several kinds of bamboo bats: large, medium, small and pointed. Large, medium and small strokes are used to pull out barrels of square goods, and small strokes are used to push barrel joints, sweep mud, push walls and scrape bottoms, and make handles. A pointed bamboo racket can be used to support a big face and make a mouth.
Eleven, digging knife, copper tube
Digging knife is used to dig a hole, and it is made of 2~3mm thick steel wire after burning red and adding handle. The copper tube is drilled with holes of various sizes. Roll lead or copper skin into a cylinder with a diameter of half, with a length of 10- 12cm, and add cutting edges at both ends.
Twelve, the only one
This is a tool with round eyes and mouth. At the same time, it is also used as a sculpture tool when making flowers and stumps. The advantages of bamboo are slippery and wear-resistant, easy to obtain materials and easy to cut. There are generally two kinds of undershirts, one is flat to cover your eyes, and the other is pointed (one is thick and the other is thin). Used for single hole and other holes.
Thirteen, pen broom
This is a traditional water lifting tool made of cloth. It can not be separated from the gun barrel, gun mouth, handle, button and so on. Its advantages are more water storage and convenient water lifting. Especially for rough products, when the blank is too dry, it can be directly dipped in water and brought to the blank.
In addition to the purple sand modeling tools mentioned above, there are many other tools, which will not be introduced here. Purple sand modeling tools are produced in practice and constantly improved, and are the crystallization of the wisdom of countless purple sand artists for thousands of years. It is inseparable from the traditional purple sand craft, which is not only related to the convenience of the artist's operation, but also directly related to the quality of the work.
Therefore, exquisite production skills must be assisted by perfect production tools, which is probably another unique feature of purple sand technology!
Process flow of purple sand production
Raw material preparation, including dredging, refining and material selection. The hard and massive soil excavated in the mine is mashed, sieved and filtered, and the fine soil obtained is stored in the kiln, which is called "soil cultivation".
The main modeling method of purple sand ware is hand kneading. First pinch the body, then dig the foot, open the face, and finally add the handle, mouth, cover, etc. From the Ming Dynasty to the Kangxi period of the Qing Dynasty, a large number of molded products appeared in the Yongzheng and Qianlong periods of the Qing Dynasty by kneading. During Jiaqing and Daoguang years, Chen Mansheng once again advocated the ancient law and made it popular. Li Jingkang and Zhang Hong put it well: "As far as impression and manufacturing are concerned, the impression method is easy to refine and improve in industry, but the production method is difficult to refine, but the skill is the most important. Therefore, the method of impression is easy to imitate, and the fabricated law is not easy to grasp. Famous pots are well made, and sitting is reasonable. "
The early tools for making blanks were mainly bamboo knives. Later, tools made of wood, horn, stone, metal and other materials were gradually added, and ceramic wheels were used to pull and repair blanks. By the Qing dynasty, there were more than ten kinds of tools, such as vertebrae, cymbals, darts and hairpin, and there were many shapes such as reed, water, shell, kidney, moon and scorpion tail.
The finished blank should be carefully trimmed and decorated with some utensils. Decoration methods include: applique-piling up decorative patterns such as landscapes, flowers, figures, birds and animals; Painting-painting and writing on the blank with alumina, iron oxide or magnesium oxide as colorants; Carving-Carving calligraphy and painting on the blank. Purple sand is generally not glazed, but also decorated with a small amount of glaze. Glazed large pieces, glazed small pieces. Generally, it is glazed once and painted twice in monochrome.
After the green body is dried in the shade, it is put into a sagger and fired in a kiln. The traditional kiln for firing purple sand ware is the "Dragon Kiln", that is, the inclined kiln with low head and high tail. The dragon kiln is generally 40 meters long, and there is a section every other meter. Stove burning, fuel is firewood and firewood. There are 50 burning holes on both sides of the kiln back, and the fuel is supplied from here. On both sides of the kiln body, an entrance and exit are opened every four or five meters, from which blanks are loaded and containers are taken. Each kiln needs to be fired for 4042 hours at the kiln temperature of 1 100℃ to 1200℃; Stop after firing 1524 hours, and then open the kiln to take the device. Fired in the dragon kiln, the kiln worker is very hard. Now the purple sand factory has changed to a new type kiln burning heavy oil, which not only saves manpower, but also improves the firing quality.
After firing, the purple sand ware should be polished and waxed, which is a unique process of purple sand. Painted purple sand utensils need to be installed and burned twice.
There are also special decorations on the fired purple sand utensils. Shi Dabin's square pot is collected in the Palace Museum, and its surface is painted and carved, combining purple sand technology and Qi Diao technology. During Daoguang period of Qing dynasty, tin coating technology appeared, but it could not be continued because of the complicated process. There is also the process of polishing copper coating, which is more common at the edge of spout head and lid. Gold and silver thread inlay is a new decorative technology, which absorbs the carving technology of wood and lacquer. First, a pattern groove is carved on the clay blank, and then the gold and silver wires are embedded in the groove after firing, compacting and polishing.
The molding method of purple sand pottery has been used since Zheng De's time in Ming Dynasty. Through the exploration, improvement and scientific and technological progress of artists of past dynasties, its methods are diversified and its skills are becoming more and more perfect.
To sum up, there are several molding methods, such as manual, grouting, blank coating and blank printing.
Manual molding methods: including "beating cylinder" and "fixing cylinder", which is an ancient manual manufacturing process.
The forming method of "barrel beating" is as follows: firstly, the cooked mud is cut into "mud shreds" with a certain width, thickness and length, then these mud shreds are beaten into mud strips and pieces that meet the requirements of the manufactured utensils, and the width, outlet, bottom and apron of the mud strips are marked with a lathe tool, and then the apron is stuck in the center of the turntable, and the mud strips are along the periphery of the apron to form a mud barrel.
"Inlaid cylinder" molding method: suitable for square ware products: firstly, cut the mud line into square mud blocks, break the square mud blocks into blocks, prepare a template according to the required size of the product, cut the mud blocks according to the template, coat the cut mud blocks with grease according to the requirements of the ware molding specification, and inlay and form. The key of manual molding lies in the proper specification of mud embryo forming skills and fine surface processing. Fine leveling and correction can make the shape structure more rigorous, the outline lines clear and decent, and the ribs and capsules clear, which can meet the requirements of making round, smooth and seamless beads. Modern molding method: grouting molding method: it is a widely used molding process in modern ceramic production. Using the water absorption of gypsum model, a hollow slurry blank can be obtained by injecting slurry into the mold and then removing the gypsum model.
Forming tool
The success of a purple sand handicraft has to go through dozens to dozens of complicated molding processes. To complete these processes, one depends on the artist's production skills and the other depends on various production tools, both of which are indispensable. The ancients said well: "If a worker wants to do a good job, he must sharpen his tools first." . The "implements" here also refer to making tools. Through the constant exploration, reform and innovation of artists of past dynasties, Zisha modeling tools have now formed a unique, economical and self-contained set of tools, made of hundreds of materials such as copper, iron, wood, bamboo, horn, leather and plastic.
There are many kinds of purple sand modeling tools, and they also pay attention to the beauty of modeling, provided that they are practical. Most of these tools are made by ourselves. Even some bought tools can only be used after being processed and trimmed. This requires the producer to have a systematic and comprehensive understanding of the whole molding process, to understand the different uses and specifications of various tools, and to consider the convenience of use and the comfort of touch. Therefore, the production of purple sand modeling tools is also very knowledgeable, which should not only consider the appearance of modeling, but also conform to the actual use function. The specification requirements of different tools are summarized as follows:
First of all, partners
Spoon is one of the main tools in molding, which is mainly used for making mud strips, making films, punching holes and putting mud pieces. The main materials of your partner are beech, sandalwood, jujube and so on. And the material should be dry.
Usually after use, your partner should wipe it with a wet cloth and put it in a dry place. Can't bask in the sun, nor can it be used to smash hard objects such as iron.
Second, the beat
Racket is mainly used for beating barrels, taking photos and patting the mouth. The best material is mahogany, the total length of the racket is 28CM, and the width of the racket body is 10cm. The thickness depends on the material. Jujube is 3 mm thick in front, 4 mm thick in the middle and 4 mm thick in the back. Cedar is thicker, mahogany can be thinner. The racket should not be immersed in water after use. It should be placed in a dry place to avoid one side being wet and prevent the racket from cracking.
Third, a sharp knife.
There are many kinds of sharp knives, such as iron sharp knives, bamboo sharp knives, straight sharp knives and curved sharp knives. Sharp knife is a common tool for cutting handles, buttons, turning feet and leather facets, and it is also a simple carving tool. Materials are general steel, copper, stainless steel, old bamboo and so on. Its shape is wide in the middle, sharp at one end and slightly round at the other. The lines on both sides should be symmetrical, thick in the middle and thin on both sides to form an arc. Sharp knives should be selected according to different uses, and there are different requirements for thickness and width.
Fourth, the knife
Knife is the most widely used tool in molding. In the production process, it is used for cutting, cutting, picking, holding, digging and scraping. From beginning to end. The most commonly used material for making knives is ordinary steel, and the blade should be ground frequently. The ratio of shank to blade is about 6: 1.
Five, instant car
The proper term of rectangular car should be gauge car, which is specially used to draw circular pieces and openings. The rectangular car is divided into four parts: handle, nail, standing person and pin. Rectangular handle is made of bamboo which is not easy to deform, standing person should be made of bamboo with thickness above 1.5cm, rectangular nail is made of iron, and pin is made of bamboo. The specifications of a general rectangular car are: the handle length is 20, 1.5, 0.5cm；; The total height of the standing person is 8.5cm, the width is 1.3cm, the eye length is 2.4-2.2, and the width is 0.55cm. Adjust the different uses of the rectangular car according to the height of the standing person and the nails of the rectangular car. Generally, people standing are 2mm taller than nails.
In addition, there are several special rectangular cars, mud-bent rectangular cars, equipped with two people standing on the handle; There are also double-track cars and tandem cars. Double-track vehicles are not equipped with nails, and tandem vehicles are equipped with bamboo nails.
Sixth, do it.
The stem is a tool for lighting various decorative lines. The stem is made of ox horn, iron, plastic and bamboo. Grind the stem according to different decorative lines, and determine the different angles of the stem according to everyone's gestures and habits. Making molding tools is the most difficult to master.
Seven, Ming needle
The bright needle is the trumpet, which is the tool to complete the surface of the work. When making bright needles, the head should be scraped flat and gradually tapered from top to bottom. Soak it in clear water when using it, and pick it up and dry it when not in use.
Eight, rectangular sediment skewer
These two tools are made of bamboo, and the rectangular bottom is also called the bottom. They are used to draw films under people standing on the rectangular car, with a round eye in the middle chapter. Is Dorobou used to hang Dorobou and blockbusters? Made of bamboo pieces with a long pitch, it gradually narrows from the handle to the head. The back should be straight, the mouth should be aligned, one side should have a knife edge, and there is usually a bamboo joint at the handle.
Nine, only music, only grate, only complex
Music is just a tool used to smooth the joint of mouth, neck, bottom, foot and bucket. Materials include ox horn, bamboo and boxwood. According to different angles, the arc bottom is polished into the required shape. Grate is only used for shaping, and can be used to remove small gaps on the barrel. It is mainly made of simple pieces and boards. As long as the grate is made separately from the shoulder, abdomen and bottom, it is impossible to use only one grate for a pot shape. Composite is only used for composite mud, generally made of 2~3mm bamboo chips or open needles.
Ten, bamboo racket
There are several kinds of bamboo bats: large, medium, small and pointed. Large, medium and small strokes are used to pull out barrels of square goods, and small strokes are used to push barrel joints, sweep mud, push walls and scrape bottoms, and make handles. A pointed bamboo racket can be used to support a big face and make a mouth.
Eleven, digging knife, copper tube
Digging knife is used to dig a hole, and it is made of 2~3mm thick steel wire after burning red and adding handle. The copper tube is drilled with holes of various sizes. Roll lead or copper skin into a cylinder with a diameter of half, with a length of 10- 12cm, and add cutting edges at both ends.
Twelve, the only one
This is a tool with round eyes and mouth. At the same time, it can be used to make flowers and stumps can also be used as sculpture tools. The advantages of bamboo are slippery and wear-resistant, easy to obtain materials and easy to cut. There are generally two kinds of undershirts, one is flat to cover your eyes, and the other is pointed (one is thick and the other is thin). Used for single hole and other holes.
Thirteen, pen broom
This is a traditional water lifting tool made of cloth. It can not be separated from the gun barrel, gun mouth, handle, button and so on. Its advantages are more water storage and convenient water lifting. Especially for rough products, when the blank is too dry, it can be directly dipped in water and brought to the blank.
In addition to the purple sand modeling tools mentioned above, there are many other tools, which will not be introduced here. Purple sand modeling tools are produced in practice and constantly improved, and are the crystallization of the wisdom of countless purple sand artists for thousands of years. It is inseparable from the traditional purple sand craft, which is not only related to the convenience of the artist's operation, but also directly related to the quality of the work.
Therefore, exquisite production skills must be assisted by perfect production tools, which is probably another unique feature of purple sand technology!