PATTERN

1. INTRODUCTION

PATTERN
1. INTRODUCTION
A pattern is a model or the replica of the
object (to be casted).
It is embedded in molding
Pattern can be said as a model or the replica
of the object to be cast except for the
various al1owances a pattern exactly
resembles the casting to be made.
It may also possess projections known as
core prints for producing extra recess in the
mold for placement of core to produce
hol1owness in casting.
It establishes the parting line and parting
surfaces in the mold.
The first step in casting is pattern making.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL

The pattern is a made of suitable material

and is used for making cavity called mold in
molding sand or other suitable mold
materials.
When this mold is filled with molten metal
and it is allowed to solidify, it forms a
reproduction of the, pattern which is known
as casting.
Proper construction of pattern and its
material may reduce overal1 cost of the
castings.

PATTERN MATERIAL
The common materials used for making
patterns are wood, metal, plastic, plaster,
and wax.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD

2.1 WOOD
Wood is the most popular and commonly used
material for pattern making.
It is cheap, easily available in abundance,
repairable and easily fabricated in various
forms using resin and glues.
It is very light and can produce highly smooth
surface.
After some use it warps and wears out quickly
as it is having less resistance to sand abrasion.
Wooden patterns are preferred only when the
numbers of castings to be produced are less.
Advantages of wooden patterns
1 Wood can be easily worked.
2 It is light in weight.
3 It is easily available.
4 It is very cheap.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS

5. It is easy to join.
6. It is easy to obtain good surface finish.
7. Wooden laminated patterns are strong.
8. It can be easily repaired.
Disadvantages

1. It is susceptible to moisture.
2. It tends to warp.
3. It wears out quickly due to sand
abrasion.
4. It is weaker than metallic patterns.

2.2 METALS
Metallic patterns are preferred when the
number of castings required is large
enough.
These patterns are not much affected by
moisture as wooden pattern.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS

The wear and tear of this pattern is very

less and hence posses longer life.
Metal is easier to shape the pattern with
good precision, surface finish and
intricacy in shapes.
It can withstand against corrosion and
handling for longer period.
The main disadvantages of metallic
patterns are higher cost, higher weight
and tendency of rusting.
The metals commonly used for pattern
making are cast iron, brass and bronzes
and aluminum alloys.
Advantages
1. It is cheap
2. It is easy to file and fit

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS

3. It is strong
4. It has good resistance against sand abrasion
5. Good surface finish
Disadvantages

1. It is heavy
2. It is brittle and hence it can be easily
broken
3. It may rust
2.3 PLASTICS
Patterns made of these materials are lighter,
stronger, moisture and wear resistant, non
sticky to molding sand, durable and they are
not affected by the moisture of the molding
sand.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX

This material belongs to gypsum family

which can be easily cast and worked with
wooden tools and preferable for producing
highly intricate casting.
2.5 WAX

Patterns made from wax are excellent for

investment casting process.
The materials used are blends of several
types of waxes, and other additives which
act as polymerizing agents, stabilizers,
etc.
The commonly used waxes are paraffin
wax, shellac wax, bees-wax, ceresin wax,
and micro-crystalline wax.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL

3. FACTORS EFFECTING SELECTION

OF PATTERN MATERIAL
The following factors must be taken into
consideration while selecting pattern
materials.
1. Number of castings to be produced. Metal
pattern are preferred when castings are
required large in number.
2. Type of mold material used.
3. Kind of molding process.
4. Method of molding (hand or machine).
5. Degree of dimensional accuracy and
surface finish required.
6. Minimum thickness required.
7. Shape, complexity and size of casting.
8. Cost of pattern and chances of repeat orders
of the pattern

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN

4. TYPES OF PATTERN
4.1. Single-piece or solid pattern
Solid pattern is made of single piece without
joints, partings lines or loose pieces. It is the
simplest form of the pattern.

4.2. Two-piece or split pattern

When solid pattern is difficult for withdrawal
from the mold cavity, then solid pattern is
splite in two parts.
Split pattern is made in two pieces which are
joined at the parting line by means of dowel
pins.
The splitting at the parting line is done to
facilitate the withdrawal of the pattern.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN

4.3. Cope and drag pattern

In this case, cope and drag part of the
mould are prepared separately.
This is done when the complete mould is
too heavy to be handled by one operator.
The pattern is made up of two halves,
which are mounted on different plates.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN

4.4 THREE-PIECE OR MULTI-PIECE

PATTERN
Some patterns are of complicated kind in shape
and hence can not be made in one or two pieces
because of difficulty in withdrawing the pattern.
Therefore these patterns are made in either three
pieces or in multi-pieces. Multi molding flasks are
needed to make mold from these patterns.

4.5. Loose-piece Pattern

Loose piece pattern is used when pattern is
difficult for withdrawal from the mould.
Loose pieces are provided on the pattern and
they are the part of pattern.
The main pattern is removed first leaving the
loose piece portion of the pattern in the
mould. Finally the loose piece is withdrawal
separately leaving the intricate mould.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN

4.6. Match plate pattern

This pattern is made in two halves and is
on mounted on the opposite sides of a
wooden or metallic plate, known as match
plate.
The gates and runners are also attached to
the plate. This pattern is used in machine
molding.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4. 7. Follow board pattern

When the use of solid or split patterns
becomes difficult, a contour corresponding
to the exact shape of one half of the pattern
is made in a wooden board, which is called
a follow board and it acts as a molding
board for the first molding operation as
shown in Fig.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4.8. Gated pattern

In the mass production of casings, multi
cavity moulds are used.
Such moulds are formed by joining a
number of patterns and gates and providing
a common runner for the molten metal, as
shown in Fig.
These patterns are made of metals, and
metallic pieces to form gates and runners
are attached to the pattern.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN

4. 9. Sweep pattern
Sweep patterns are used for forming large
circular moulds of symmetric kind by
revolving a sweep attached to a spindle as
shown in Fig.
Actually a sweep is a template of wood or
metal and is attached to the spindle at one
edge and the other edge has a contour
depending upon the desired shape of the
mould. The pivot end is attached to a stake
of metal in the center of the mould.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN
5. PATTERN ALLOWANCE

5. PATTERN ALLOWANCE
Pattern may be made from wood or metal and
its color may not be same as that of the
casting.
The material of the pattern is not necessarily
same as that of the casting.
Pattern carries an additional allowance to
compensate for metal shrinkage.
It carries additional allowance for machining.
It carries the necessary draft to enable its easy
removal from the sand mass.
It carries distortions allowance also. Due to
distortion allowance, the shape of casting is
opposite to pattern.
Sharp changes are not provided on the
patterns. These are provided on the casting
with the help of machining.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN
5. PATTERN ALLOWANCE
5. 1. SHRINKAGE ALLOWANCE

The size of a pattern is never kept the same as

that of the desired casting

5. 1. Shrinkage Allowance
In practice it is found that all common cast
metals shrink a significant amount when they
are cooled from the molten state.
The total contraction in volume is divided into
the following parts:
Liquid contraction
Solidifying contraction.
solid contraction

The first two of the above are taken care of by

proper gating and risering. Only the last one,
i.e. the solid contraction is taken care by the
pattern makers by giving a positive shrinkage
allowance.
This contraction allowance is different for
different metals.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE
PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN
5. PATTERN ALLOWANCE
5. 1. SHRINKAGE ALLOWANCE
5.2. MACHINING ALLOWANCE

The contraction allowances for different

metals and alloys such as Cast Iron 10
mm/mt.. Brass 16 mm/mt., Aluminium
Alloys. 15 mm/mt., Steel 21 mm/mt., Lead 24
mm/mt.

5.2. Machining Allowance

It is a positive allowance given to compensate
for the amount of material that is lost in
machining or finishing the casting.
If this allowance is not given, the casting will
become undersize after machining.
The amount of this allowance depends on the
size of casting, methods of machining and the
degree of finish.
In general, however, the value varies from 3
mm. to 18 mm.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN
5. PATTERN ALLOWANCE
5. 1. SHRINKAGE ALLOWANCE
5.2. MACHINING ALLOWANCE
5. 3. DRAFT OR TAPER ALLOWANCE

5. 3. Draft or Taper Allowance

Taper allowance is also a positive allowance
and is given on all the vertical surfaces of
pattern so that its withdrawal becomes easier.
The normal amount of taper on the external
surfaces varies from 10 mm to 20 mm/mt.
On interior holes and recesses which are
smaller in size, the taper should be around 60
mm/mt.
These values are greatly affected by the size
of the pattern and the molding method.
In machine molding its, value varies from 10
mm to 50 mm/mt.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN
5. PATTERN ALLOWANCE
5. 1. SHRINKAGE ALLOWANCE
5.2. MACHINING ALLOWANCE
5. 3. DRAFT OR TAPER ALLOWANCE
5.4. RAPPING OR SHAKE ALLOWANCE

5.4. Rapping or Shake Allowance

Before withdrawing the pattern it is rapped
and thereby the size of the mould cavity
increases.
Actually by rapping, the external sections
move outwards increasing the size and
internal sections move inwards decreasing
the size.
This movement may be insignificant in the
case of small and medium size castings, but
it is significant in the case of large castings.
This allowance is kept negative and hence
the pattern is made slightly smaller in
dimensions 0.5-1.0 mm.

PATTERN
1.
2.

INTRODUCTION
PATTERN MATERIAL
2.1 WOOD
2.2 METALS
2.3 PLASTICS
2.4 PLASTER
2.5 WAX
3. FACTORS EFFECTING SELECTION OF
PATTERN MATERIAL
4. TYPES OF PATTERN
4.1 SINGLE-PIECE OR SOLID PATTERN
4.2 TWO-PIECE OR SPLIT PATTERN
4.3 COPE AND DRAG PATTERN
4.4 THREE-PIECE OR MULTI-PIECE PATTERN
4.5 . LOOSE-PIECE PATTERN
4.6. MATCH PLATE PATTERN
4. 7. FOLLOW BOARD PATTERN

4.8. GATED PATTERN

4. 9. SWEEP PATTERN
5. PATTERN ALLOWANCE
5. 1. SHRINKAGE ALLOWANCE
5.2. MACHINING ALLOWANCE
5. 3. DRAFT OR TAPER ALLOWANCE
5.4. RAPPING OR SHAKE ALLOWANCE
5.5. DISTORTION ALLOWANCE

5.5. Distortion Allowance

This allowance is applied to the castings
which have the tendency to distort during
cooling due to thermal stresses developed.
For example a casting in the form of U shape
will contract at the closed end on cooling,
while the open end will remain fixed in
position. Therefore, to avoid the distortion,
the legs of U pattern must converge slightly
so that the sides will remain parallel after
cooling.

MOULDING MATERIAL
1 INTRODUCTION

1 INTRODUCTION
A suitable and workable material possessing
high refractoriness in nature can be used for
mould making.
The mold making material can be metallic or
non-metallic.
For metallic category, the common materials
are cast iron, mild steel and alloy steels.
In the non-metallic group molding sands,
plaster of Paris, graphite, silicon carbide
and ceramics are included.
Out of all, the molding sand is the most
common utilized non-metallic molding
material because of refractoriness, chemical
and thermal stability at higher temperature,
high permeability and workability along
with good strength and it is also highly cheap
and easily available.

MOULDING MATERIAL
1 INTRODUCTION
1.2 CONSTITUENTS OF MOLDING
SAND

1.2 CONSTITUENTS OF MOLDING

SAND
The main constituents of molding sand involve
silica sand, binder, moisture content and
additives.

Silica sand
Silica sand in form of granular quarts is the
main constituent of molding sand having
enough refractoriness which can impart
strength, stability and Permeability to molding
and core sand.
But along with silica small amounts of iron
oxide, alumina, lime stone, magnesia, soda
and potash are present as impurities.
The silica sand can be specified according to
the size (small, medium and large silica sand
grain) and the shape (angular, sub-angular and
rounded).

MOULDING MATERIAL
1 INTRODUCTION
1.2 CONSTITUENTS OF MOLDING
SAND

Binder
In general, the binders can be either inorganic
or organic substance.
The inorganic group includes clay sodium
silicate and port land cement etc.
Binders included in the organic group are
dextrin, molasses, cereal binders, linseed oil
and resins like phenol formaldehyde.
Organic binders are mostly used for core
making.

Moisture
The amount of moisture content in the
molding sand varies generally between 2 to 8
percent.
This amount is added to the mixture of clay
and silica sand for developing bonds.

MOULDING MATERIAL
1 INTRODUCTION
1.2 CONSTITUENTS OF MOLDING SAND

This is the amount of water required to fill

the pores between the particles of clay
without separating them.
This amount of water is held rigidly by the
clay and is mainly responsible for
developing the strength in the sand.
The effect of clay and water decreases
permeability with increasing clay and
moisture content.
For increasing the molding sand
characteristics some other additional
materials besides basic constituents are
added which are known as additives. Like
coal dust, corn flour, dextrin, sea coal,
pitch, wood flour and silica flour.

MOULDING MATERIAL
1 INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand

3. TYPES OF MOLDING SAND

Molding sands may be of two types namely
natural or synthetic.
Natural molding sands contain sufficient binder.
Whereas synthetic molding sands are prepared
artificially using basic sand molding constituents
(silica sand in 88-92%, binder 6-12%, water or
moisture content 3-6%) and other additives in
proper proportion by weight with perfect mixing
and mulling in suitable equipments.
Molding sands can also be classified according
to their use into number of varieties which are
described below.

3.1 Green sand

Green sand is also known as tempered or natural
sand which is a just prepared mixture of silica
sand with 18 to 30 percent clay, having moisture
content from 6 to 8%.

MOULDING MATERIAL
1 INTRODUCTION
2 CONSTITUENTS OF MOLDING SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand

The clay and water furnish the bond for

green sand.
It is fine, soft, light, and porous.
Green sand is damp, when squeezed in the
hand and it retains the shape and the
impression to give to it under pressure.
Molds prepared by this sand are not
requiring backing and hence are known as
green sand molds.
This sand is easily available and it
possesses low cost.
It is commonly employed for production of
ferrous and non-ferrous castings.

3.2 Dry sand

Green sand that has been dried or baked in
suitable oven after the making mold and
cores, is called dry sand.

MOULDING MATERIAL
1 INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand

It possesses more strength, rigidity and

thermal stability.
It is mainly suitable for larger castings.
Mold prepared in this sand are known as
dry sand molds.

3.3 Loam sand

Loam is mixture of sand and clay with
water to a thin plastic paste.
Loam sand possesses high clay as much as
30-50% and 18% water.
Patterns are not used for loam molding and
shape is given to mold by sweeps.
This is particularly employed for loam
molding used for large grey iron castings.

3.4 Facing sand

Facing sand is just prepared and forms the
face of the mould.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand

It is directly next to the surface of the pattern

and it comes into contact molten metal when the
mould is poured.
The layer of facing sand in a mold usually
ranges from 22-28 mm. From 10 to 15% of the
whole amount of molding sand is the facing
sand.

3.5 Backing sand

Backing sand or floor sand is used to back up the
facing sand and is used to fill the whole volume
of the molding flask.
The backing sand is sometimes called black
sand because that old, repeatedly used molding
sand is black in color due to addition of coal dust
and burning on coming in contact with the
molten metal.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF MOLDING SAND
3. TYPES OF MOLDING SAND

3.1 Green sand

3.2 Dry sand
3.3 Loam sand
3.4 Facing sand

3.5 Backing sand

3.6 system sand

3.6 system sand

In mechanized foundries where machine

molding is employed. A so-called system sand
is used to fill the whole molding flask.
In mechanical sand preparation and handling
units, no facing sand is used.
The used sand is cleaned and re-activated by
the addition of water and special additives.
This is known as system sand.
Since the whole mold is made of this system
sand, the properties such as strength,
permeability and refractoriness of the molding
sand must be higher than those of backing
sand.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF MOLDING SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand

3.7 parting sand

Parting sand without binder and moisture is
used to keep the green sand not to stick to the
pattern and also to allow the sand on the
parting surface the cope and drag to separate
without clinging.
This is clean clay-free silica sand which
serves the same purpose as parting dust.

3.8 Core sand

Core sand is used for making cores and it is
sometimes also known as oil sand.
This is highly rich silica sand mixed with oil
binders such as core oil which composed of
linseed oil, resin, light mineral oil and other
bind materials.
Pitch or flours and water may also be used in
large cores for the sake of economy.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF MOLDING SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand
4. PROPERTIES OF MOULDING SAND

4. PROPERTIES OF MOULDING SAND

1. Refractoriness
Refractoriness is defined as the ability of
molding sand to withstand high temperatures
without breaking down or fusing thus
facilitating to get sound casting.
Molding sand with poor refractoriness may
burn on to the casting surface and no smooth
casting surface can be obtained.
The degree of refractoriness depends on the
SiO2 i.e. quartz content, and the shape and
grain size of the particle.

2. Permeability
It is also termed as porosity of the molding
sand in order to allow the escape of any air,
gases or moisture present or generated in the
mould when the molten metal is poured into it.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF
MOLDING SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand
4. PROPERTIES OF MOULDING
SAND

All these gaseous generated during pouring

and solidification process must escape
otherwise the casting becomes defective.
Permeability is a function of grain size,
grain shape, and moisture and clay contents
in the molding sand.
The extent of ramming of the sand directly
affects the permeability of the mould.
Permeability of mold can be further
increased by venting using vent rods

3. Cohesiveness
It is property of molding sand by virtue
which the sand grain particles interact and
attract each other within the molding sand.

MOULDING MATERIAL 4.Flow ability or plasticity

INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand
4. PROPERTIES OF MOULDING SAND

It is the ability of the sand to get compacted

and behave like a fluid.
It will flow uniformly to all portions of
pattern when rammed and distribute the
ramming pressure evenly all around in all
directions.
Flowability increases with decrease in green
strength, and, decrease in grain size.

5. Adhesiveness
It is property of molding sand to get stick or
adhere with foreign material such sticking of
molding sand with inner wall of molding box

6. Collapsibility
After the molten metal in the mould gets
solidified, the sand mould must be collapsible
so that free contraction of the metal occurs

MOULDING MATERIAL 7. Miscellaneous properties

INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand
4. PROPERTIES OF MOULDING SAND
5. GATING SYSTEM IN MOLD

In addition to above requirements, the molding

sand should not stick to the casting and should
not chemically react with the metal.
Molding sand should be cheap and easily
available.
It should be reusable for economic reasons. Its
coefficients of expansion should be
sufficiently low.

5. GATING SYSTEM IN MOLD

1. Pouring basin
It is the conical hollow element or tapered
hollow vertical portion of the gating system
which helps to feed the molten metal initially
through the path of gating system to mold
cavity.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand
4. PROPERTIES OF MOULDING SAND
5. GATING SYSTEM IN MOLD

MOULDING MATERIAL

It reduces turbulence and vertexing at the sprue

INTRODUCTION
2 CONSTITUENTS OF MOLDING entrance
SAND
2. Sprue
3. TYPES OF MOLDING SAND
3.1 Green sand
It is a vertical passage made generally in the
3.2 Dry sand
cope using tapered sprue pin.
3.3 Loam sand
It is connected at bottom of pouring basin.
3.4 Facing sand
3.5 Backing sand
It is tapered with its bigger end at to receive the
3.6 system sand
molten metal the smaller end is connected to the
3.7 parting sand
runner.
3.8 Core sand
4. PROPERTIES OF MOULDING SAND It helps to feed molten metal without turbulence
5. GATING SYSTEM IN MOLD
to the runner which in turn reaches the mold

cavity through gate.

3. Gate
It is a small passage or channel being cut by
gate cutter which connect runner with the
mould cavity and through which molten metal
flows to fill the mould cavity.

MOULDING MATERIAL
INTRODUCTION
2 CONSTITUENTS OF MOLDING
SAND
3. TYPES OF MOLDING SAND
3.1 Green sand
3.2 Dry sand
3.3 Loam sand
3.4 Facing sand
3.5 Backing sand
3.6 system sand
3.7 parting sand
3.8 Core sand
4. PROPERTIES OF MOULDING SAND
5. GATING SYSTEM IN MOLD

4. Runner
It is a channel which connects the sprue to
the gate for avoiding turbulence and gas
entrapment.

5. Riser
It is a passage in molding sand made in the
cope portion of the mold.
Molten metal rises in it after filling the
mould cavity completely.
The molten metal in the riser compensates
the shrinkage during solidification of the
casting thus avoiding the shrinkage defect
in the casting.
It also permits the escape of air and mould
gases.

PROBABLE CAUSES AND SUGGESTED REMEDIES OF VARIOUS CASTING DEFECTS

MOULDING MATERIAL