Experiment 1: Study of the preparation of a wooden pattern.
Definition: Pattern may be defined as “a replica of the object to be cast, used to prepare the
cavity into which molten material will be poured during the casting process.” The making
of patterns is called pattern making.
Requirements of Pattern material:
Easily shaped, worked, machined, and joined
Resistant to wear and corrosion
Resistant to chemical action
Dimensionally stable
Easily available and economical
1. Wood:
Easy availability, low weight, and low cost
Can be easily shaped
More than 90% castings use wood patterns
Absorbs moisture. So, distortions and dimensional changes occur
Relatively lower life, hence suitable for small quantity production
2. Metal:
Used for large quantity production and for closer dimensional tolerances
Longer life
Aluminium is mostly used.
Other metals: cast iron, brass etc.
3. Plastic:
Low weight, easier formability, smooth surfaces, and durability
Do not absorb moisture. So, dimensionally stable
Corrosion resistance
4. Polystyrene:
Changes to gaseous state on heating
Disposable Patterns. Hence, suitable for single casting.
When molten metal is poured into cavity, polystyrene transforms to gaseous state.
Used mostly for small and complicated shaped castings.
Types of patterns
1. Single piece pattern:
Used for simple shaped & large castings.
Pattern and cavity produced by it are completely in the lower flask (i.e., drag)
Causes difficulty in making the mold.
2. Split pattern:
Split pattern models the part as two separate pieces that meet along the parting line of
the mould
Two parts are aligned by Dowel pin.
3. Loose Piece pattern
As per the name Pattern Contain One or more than one loose piece
Loose piece is used to make removal of pattern easy from mould box
Loose pieces are attached to main body with the help of dowel pins or wire
First main pattern is drawn and then carefully loose pieces
Moulding with this pattern is expensive and require more skill
4. Match-plate pattern:
Similar to a split pattern, except that each half of the pattern is attached to opposite
sides of a single plate.
Match plate confirms the parting line
Ensures proper alignment of the mould cavities in the cope and drag and the runner
system can be included on the match plate.
Used for larger production quantities.
IC Engines piston rings
4. Cope-Drag pattern:
It is similar to split pattern
Each half of the pattern is attached to a separate plate and the mould halves are made
independently.
Pattern is made in two halves and split along parting line
These two halves are known as cope and drag
There moulding done independently
After moulding they are assembled to form complete mould box
Often desirable for larger castings
5. Gated pattern:
In this pattern of gate and riser or runner are permanently attached to regular pattern
They are used to manufacture multiple casting in on time
Each pattern is connected with common runner.
Suitable for pouring small castings and for mass production
It saves labour and time
PATTERN ALLOWANCES
1. Shrinkage Allowance:
Shrinkage means contraction of metal on solidification
All metals shrink after solidification. (Except grey cast iron that expands on
solidification).
It is expressed in mm/m.
Shrinkage allowance Differs from material to material.
Positive type of allowance.
It may be:
Liquid Shrinkage
Solid Shrinkage
2. Draft / Taper Allowance:
Taper provided by the pattern maker on all vertical surfaces of the pattern so that it
can be removed from the sand without tearing away the sides of the sand mould.
Inner details of the pattern require higher draft than outer surfaces.
commonly applied draught allowance is 1°to 3°
due to draught allowance pattern can easily be removed from mold box
3. Machining / Finishing Allowance:
The finish and accuracy in sand casting is generally poor.
Extra material provided on the casting to enable their machining or finishing to the
required size, accuracy, and surface finish.
So, it is added in pattern dimensions.
allowance is provided only in machining area
Amount of machining allowance depends upon:
Method of moulding and casting used
Size and shape of casting
Casting orientation
Metal used in casting
Degree of accuracy and finish required
4. Distortion / Camber Allowance:
Due to their typical shapes (U, V, T, L shapes), castings get distorted during
solidification.
Distortion is observed in irregular castings so that it shrink in uneven manner
Distortions are caused by internal stresses which are generated on account of unequal
cooling of different sections of casting.
To avoid this distortion allowance is provided
It varies from 2 to 20 mm
5. Rapping / shake Allowance:
Before the withdrawal from the sand mould, the pattern is rapped all around the
vertical faces to enlarge the mould cavity slightly, which facilitate its removal.
When pattern is rapped, mould cavity is enlarged.
To account for this increase, pattern size is reduced.
This allowance is important in large-sized castings and precision castings.
Amount of rapping allowance depends upon:
Extent of rapping
Degree of compaction of sand
Size of mould
Sand type
