Types of Pattern Allowances in Casting

A pattern is replica of casting but it has slightly large dimensions. This change in pattern in
casting due to various reasons is known as pattern allowances in casting.

For Example:

When the cast solidify, it shrink at some extent due to metal shrinkage property at the time of
cooling. So a pattern is made slightly larger to compensate it. This is an example of pattern
allowance. There are many other reasons for pattern allowances which will be discussed
below.

These are the types of pattern allowances: -

i) Shrinkage Allowances:

Shrinkage is defined as reduction is the dimension of the cast during the cooling or
solidification process. This is a general property of all materials. The magnitude of shrinkage
varies from material to material but every material shrinks.

Shrinkage is of three types:-

a) Liquid Shrinkage

b) Solidification Shrinkage.

c) Solid Shrinkage

ii) Draft Allowances:

When the pattern is removed from the mold, the parallel surface to the direction at which the
pattern is withdrawn gets damaged slightly and gets converted into slightly tapered surfaces.
For compensation of these changes, these parallel surfaces on pattern are made slightly
tapered (nearly 1 -2 degrees). This allow easy removal of pattern from the mold and does not
effect the casting by anyway. These changes in pattern surface to prevent it from damages are
called draft allowances.

The magnitude of taper depends upon:

iii) Machining allowances:

As we know that the product of a casting process gives very poor surface finish, hence the
surface of final product of casting will be rough. But we need a product which is polished and
have good surface finish.

So to obtain good surface finish, the final product of casting is machined with the processes
like turning or grinding to improve the surface finish.

This machining after the casting process causes a significant loss of material from the mold
part. To compensate this loss, machining or finishing allowances are given in the pattern of
casting. This allowance is added together with basic size of pattern. It ranges from lower than
2 mm to 15 mm based on size and material of the part.

The amount of allowance added to the pattern is based on,

a) Material used

b) Machining processes used

c) Requirement of accuracy.

d) Molding methods used.

When the pattern is to be removed from the sand of casting , the pattern will have to be
shaken slightly to remove it from the sand and this will cause a slight increase in dimension
of casting.
To compensate this increase in dimension of casting, the patterns are made slightly smaller
from casting. This change in dimension of pattern is known as shaking or rapping allowances.

v) Distortion or camber allowances:

When the metal is in cooling process, stress is developed in the solid metal due to uneven
metal thickness in the casting process. This stress may cause distortion or bending in the
casting.
To avoid this bending or distortion in casting, camber is provided in the opposite direction so
that when bending occurs due to uneven thickness of metal, casting becomes straight. This
change in pattern shape to compensate bending while casting is known as Bending
Allowances.

Properties of Moulding Sand

1. Porosity or Permeability:
It is the ability of sand by which it allows the gases to pass through it easily.
Some gases get dissolved in molten metal and when this molten metal starts to solidify, these
dissolved gases come out of the molten metal and try to escape out of the moulding sand. If
the sand is not enough porous than these gases will not be able to go out of the mould and
gets trapped into the casting and produces holes and pores in metal casting. Also if the molten
metal comes in contact with the moist sand, steam or water vapor is produced. This steam or
vapors also results in the formation of holes in the casting if they do not able to escape out of
the mould. So it is advised to use sufficiently porous moulding sand to eliminate the porosity
defect in metal casting.
2. Flowability
The ability of moulding sand to behave like a fluid when it is rammed is called flowability.
Due to this property, the sand can easily occupy the space in molding box and take up its
shape. This allows the sand to compress to a compact density and let it pack around the
pattern. The sand should be of high flowability, so that it can be easily compacted for uniform
density and to obtain a good impression of the pattern in the mould. The flowability of the
sand can be increases as we increases the clay and water content in the sand.
3. Collapsibility
The ability of the moulding sand to collapse after solidification of the molten metal is
called collapsibility.
After the solidification of molten metal, the sand should get collapse for free contraction of
the metal. If free contraction of the metal will happen than if eliminates naturally the tearing
or cracking of the contracting metal.
4. Adhesiveness.
The ability of the sand particles to get stick with another body is called adhesiveness.
The sand should have sufficient adhesiveness so that it can easily get cling to the sides of the
moulding boxes and does not fall out to the box when it is removed.
5. Cohesiveness or Strength
The ability of the sand particles to stick with each other is called cohesiveness.
The strength of the sand depends upon how cohesive the sand particles are. The sand should
have sufficient strength so that it can easily capable to retain its shape during conveying,
turning or closing and pouring. If it is not of appropriate strength than it will not be able to
hold its shape and the mould may damage during pouring of molten metal. Low strength sand
leads to pouring casting defects in metals. To avoid pouring defects, the sand should be of
sufficient strength to produce mold of desired shape and also retain this shaped even when
the molten metal is poured in the moulding cavity.
The sand strength can be of two types
(i) Green strength: The strength of sand possessed by it in its green or moist state is called
green strength. The mould with adequate green strength retains its shape and do not collapse
even when the pattern is removed from the moulding box.
(ii) Dry strength: The strength possessed by the sand in its dry or baked state is called dry
strength. Enough dry strength allows the sand to withstand erosive forces due to molten metal
and helps to retain its shape.
6. Refractoriness
The ability of the moulding sand to withstand the high temperature of the molten metal
without fusing into it is called refractoriness.
The moulding sand must have enough refractoriness property to produce excellent quality of
casting free from defects. The sand with lack of refractoriness melts and gets fuse in the
casting and spoils the quality of the cast metal. The refractoriness is the measure of sinter
point of the sand not its melting point.
sand test and it’s different types for casting process
Sand test used to determine foundry sand properties for casting method. In this sand reject for
two reason such as sand defects due to sand property and metallurgical defects. In this defects
arise from sand testing and making the additives. The green sand is made from silica sand,
pitch powder and binder. It can be standard to maintain small amount of rejection.
The following sand test method performed to molding.
 Moisture content of sand test
 Clay content test
 Refractoriness sand test
 Strength test
 Permeability test
 Flowability test
 Mould hardness test
Moisture Content of sand test:
Moisture content Sand test
In this moisture content test method to determine amount of moisture by dry a mold sand
weight amount of 20 to 50 grams of mold sand and with constant temperature upto 100⁰c
above one hour. Then cooled with room temperature and reweight the mold sand.
The moisture content will be evaporated in the sand molding. Due to loss of moisture, the
weight of molding sand loose together , gives the some amount of moisture expressed as
percentage of original sand.
The moisture content tester as shown in figure. It tester contain the pan with infrared bulb. In
this pan above placed weight sand and infrared heating bulb is switched on & determine the
time require, the mold sand is weighted together.
Clay Content Test:
The clay content test is determined an amount of clay in test process. In this test to take 20
micron clay particles per 0.0008 inch diameter, dried sample such as molding sand with 50
gm, which is put in distilled water  with 1% of NaOH solution. In this mixture is stirred for
five minutes to allow settle. Then the dirty water is remove together, and process is repeated
until to get the clear water. In this process washes away. All clay in it the mold sand is dry
and weighted the Clay content.
Grain Fineness sand test:
The grain fineness test method is to find the size of the silica sand particles. It fine grain sand
associate with good surface finish & strength of mold will high and lower permeability.
It carried out on dry silica sand weight of 50 gms and free from the clay. When the top sieves
of mechanical shaker, the sand is placed with 6, 12, 20, 30, 40, 50, 60, 70, 140, 200 and 270
per mounted on table. In this sieve having meshed together. It sieve series placed with top to
bottom in order of fineness. The free silica is shaked together in this shaker within 15 minutes
or above after that weight of Sand retained for each sieve is obtains and also retained sand for
each sieve multiplied by 2 and give % of weight retained.
Refractoriness sand test:
In this test of mold sand is evaluated by heat the standard sand specimen with high
temperature based on sand type. It this specimen (heated specimen) are to allow cooled to
room temperature and it examined along with a microscope for surface characteristic or
scratching with steel needle. The specimen of sand placed into furnace, then it temperature
raise 100⁰c to 1300⁰c. And wait 3 minutes and taken from oven for examination use of
microscope for evaluate surface characteristic.