WORKSHEET REPORT

DJF21012 – FOUNDRY WORKSHOP

PATTERN PROCESS
GROUP MEMBERS :
NAME: REG .
NO.
BIL NAME MATRIX NO
1 NOOR SAKINAH BT KAMAL 16DTP20F1006
MARKS:
A B C D E F

LECTURER NAME :
BIL NAME
1 PUAN MARZIANA BINTI HASHIM
2 PUAN ZAFARIDA BINTI KADIR
CLASS : DTP2A
SUBMISSION DATE : 31 AUGUST 2021
1.0 Objective

o Observe and understand the pattern.

o Recognize the basic unit which generates the pattern.
o Be able to know a description of what students will be able to do at the end of the
learning activity.

2.0 Introduction

In casting, a pattern is a replica of the object to be cast, used to prepare the cavity into which
molten material will be poured during the casting process. Patterns used in sand casting may
be made of wood, metal, plastics or other materials. Patterns are made to exacting standards
of construction, so that they can last for a reasonable length of time, according to the quality
grade of the pattern being built, and so that they will repeatably provide a dimensionally
acceptable casting. Typically, materials used for pattern making are wood, metal or plastics.
Wax and Plaster of Paris are also used, but only for specialized applications. Sugar pine is the
most commonly used material for patterns, primarily because it is soft, light, and easy to
work. Honduras Mahogany was used for more production parts because it is harder and
would last longer than pine. Once properly cured it is about as stable as any wood available,
not subject to warping or curling. Once the pattern is built the foundry does not want it
changing shape. True Honduras Mahogany is harder to find now because of the decimation of
the rain forests, so now there is a variety of woods marketed as Mahogany. Fiberglass and
plastic patterns have gained popularity in recent years because they are water proof and very
durable. Metal patterns are long lasting and do not succumb to moisture, but they are heavier,
more expensive and difficult to repair once damaged. Wax patterns are used in a casting
process called investment casting. A combination of paraffin wax, bees wax and carnauba
wax is used for this purpose. Plaster of paris is usually used in making master dies and molds,
as it gains hardness quickly, with a lot of flexibility when in the setting stage.
3.0 Pattern Design
4.0 Tools / Equipments
 Tool / Equipments Figure
1. Wood

o The main material for

making the work.

2. Steel rule
o Steel rules come in rigid and
flexible versions. While their
primary purpose is accurate
measurement, they can also
be used as guides for laying
out lines, and if rigid enough,
for cutting. The thinner, more
flexible rules can also be
used to measure rounded or
cambered work.
3. Caliper
o Measuring the distance
between two opposite sides
of an object

4. Trisquare
o used for marking and
measuring a square piece of
wood.
5. Shrinkage rule

o To measure the material used

such as wood.

6. Compass
o To measure distance between
two points that are too great
to be reached with dividers.

7. Vice

o For holding a workpiece

8. G – Clamp

o Used to hold a wood or metal

work piece.
5.0 Safety Precautions

The following rules should be observed when working in a workshop:

a. Give full attention when listening to a description of the rules and steps in the

workshop.

b. Wear protective clothing when necessary such as gloves, goggles and aprons.

c. Do not change any of the warning notice has been placed on or next the machine by

technician or staff.

d. Know the main switch and an easy place to get first aid.

e. Do not play in the workshop.

f. Not too close to the machine is in operation or moving.

g. Do not try to fix a machine without telling lecturers or workshop assistants.

h. Do not wear jewelry such as rings, chains, rings and other jewelry in the course practice.

i. Must wear neat and appropriate to the work when you are in the workshop.

j. Give proper care to the machinery or equipment in the workshop.

k. Shall be returned to its original place after using equipment.

l. When finished using a machine, the machine should be cleaned as before.

m. Must know where emergency switch and first aid kit is

n. Ensure cleanliness the workshop on a satisfactory level.

o. Make sure the tables and chairs arranged neatly by the specified workshop layout.

p. Have a sense of responsibility to self, partner and equipment in the workshop.

q. Immediately report to the lecturer or assistant the workshop in the event of any

Damage or accidents in the workshop.

6.0 Procedures

Procedures Figure
1. Study the pattern layout carefully
and establish.

2. Measure marks on wood using a

pencil and ruler.

3. Location of parting surface

4. Cut the wood to the size.

5. Number of parts in which the pattern

will be made. Show a pattern which
will be made and in how many
pieces. (2 pieces).

6. Using the various had tools and

pattern making machines, fabricate
the different parts of the pattern.

7. Join the different parts by the glue

and nails.
8. Inspect the pattern as regard the
alignment of different portions of the
pattern and its dimensional accuracy.

9. Fill fillets in order to remove sharp

corners by putty filler.

10. For smoothing and finishing

purposes, sand the pattern and give
shellac coating.
7.0 Discussion

Explain below materials used to making pattern

i. Wood

 It can be easily shaped and it possess low weight as compared to

metal pattern. Wood is optimal for very large casting and small
quantity production.

ii. Polystyrene

 saves from separate workforce for different things. There is no need for parting line
to extracy the pattern from the mold cavity of expanded foam molding system.

At your explanation, give your concentrate on the following:

i. Application

ii. Advantages

iii. Limitations

i. Application The materials that are often used to make

patterns are metal, wood and plastic. These are
special materials used to make patterns. In
addition, patterns can also be made using
plaster and wax, but only for specific objects.
ii. Advantages This can expand students' knowledge of the
pattern. In addition, this project can open up
opportunities to use modern technology today.
iii. Limitations In this case, the limitation is,
picture results for the boundaries after the
study pattern.General Methodological
Limitations.Problems with sampling and
selection.The sample size is insufficient for
statistical measurement.
8.0 Conclusion and Recommendation

The bottom line is that I was able to learn a lot from this pattern project. In casting, a pattern
is a replica of an object to be thrown, used to prepare a cavity into which liquid material will
be poured during the casting process. thorough in measurement.Students can also learn to
produce a project perfectly with the help of a lecturer. Also, to produce a perfect and
beautiful project, I must always be patient. This is because, there are various steps that need
to be taken to complete this project. For example I need to measure the wood carefully to get
the right measurement, I also need to cut the wood with be careful so that the wood is not
broken and so on.Finally, I feel grateful to be able to complete this project on time even
though now there is a covid problem.
9.0 References

S.K.Yadav.(2006).Workshop Practice, 1st. Ed. Discovery Publishing House.

Serope Kalpakjian and Steven Schmid ( July 27, 2007). Manufacturing Processes for
Engineering Materials (5th Edition). Prentice Hall.

Charles A. Harper. (August 11, 2006). Handbook of Plastic Processes.Wiley- Interscience; 1

edition.

Dell Allen and Robert Todd. (Jan. 1, 1994). Manufacturing Processes Reference Guide.
Industrial Press, Inc.

Robert A. Malloy (1994). Plastic Part Design for Injection Moulding: an Introduction, Hanser
Gardner Publications, Inc, Cincinati