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Pattern Making in Sand Casting

Casting and Joining Processes
ME 251

Akash V. Vyas
Assistant Professor
(Mechanical Department- CSPIT)

Pattern & It’s Materials

Pattern is the replica of the part to be cast.

• Light in weight
• Shaped & Joined easily
• Strong, hard & durable
• Resistant to wear & abrasion
• Dimensionally stable, unaffected Factors considered
by temperature & humidity ➢ Quantity of casting
➢ Size & shape complexity
• Low cost ➢ Moulding method
➢ Nature of moulding Process
• Chemically inert ➢ Surface finish required.

Wood, metal, plastic, plaster, wax

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Types of Patterns
• One Piece Pattern
• Split-Two Piece Pattern
• Match Plate Pattern
• Cope and Drag Pattern
• Cope and Drag Pattern
• Gated Pattern
• Sweep Pattern
• Loose Piece Pattern
• Segmental Pattern
• Follow Board Pattern
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One Piece/Solid Pattern

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Split-Two Piece Pattern

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Split-Three Piece Pattern

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Match Plate Pattern

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Cope and Drag Pattern

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Gated Pattern

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Sweep Pattern

➢ Axi-symmetrical casting such as

bells, Kettles.
➢ Wooden sweep pattern rotates
around axis to produce 3-
dimensional cavity.
➢ Avoids unnecessary cost for
making full 3-dimensional pattern.

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Loose Piece Pattern

➢ Used when casting has

projections or undercuts.
➢ Create hindrance in
withdrawal of pattern.
➢ Loose pieces help to
facilitate pattern withdrawal.

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Follow Board Pattern

Segmental Pattern

Rings, gears, wheels, rims, pulleys..

For thin and fragile patterns to

support during ramming

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Exercise

(e) (f)
(g)

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Pattern Allowances
Pattern is always larger in size as compared to
final actual dimension of casting, because it
carries certain allowances due to,

Metallurgical reasons
Shrinkage

Mechanical reasons
Machining
Draft
Distortion
Shake/Rapping

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Volumetric Metal contraction (Shrinkage)

▪ Liquid metal contraction

Liquid
- Fall in liquid level

Liquid + Solid
▪ Solidification shrinkage (Semi solid)
- Requires feeding of metal
(Riser/Feeder)

▪ Solid metal contraction Solid

- Shrinkage allowance on pattern

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Shrinkage Allowance
Metal Linear shrinkage
(millimeter/meter)
Depends upon
Steel 20.8
➢ Cast metal/Alloy
➢ Pouring temperature White C.I. 20.8
➢ Casting size Gray C.I. 6.95-10.4
➢ Moulding material/method
Malleable C.I. 10.4
Aluminium 17
Magnesium 17
Zinc 24
Brass 15.3

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Machining/Finish Allowance
➢ To remove oxides & scales
➢ To remove surface roughness & Other imperfections
➢ Required to achieve exact casting dimension

Factors considered for machining allowances

➢ Nature of metal
Ferrous Non Ferrous

➢ Type of machining operation

Grinding Turning

➢ Casting type
Sand casting Die casting/Investment casting

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Draft/Taper Allowance
➢ It is given perpendicular to parting line (to all vertical surface).
➢ For ease of removal of pattern without damaging mould cavity.
➢ Allowance is given more on internal surface as compared to external surface.

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Distortion/Camber Allowance
Distortion can be eliminated by providing allowance and constructing pattern
initially distorted i.e. outsize in the opposite direction so that casting after
cooling neutralizes the initial distortion given on the pattern and acquires
correct shape.

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Shake/Rapping Allowance
➢ Rapping is done to loose sand particles and enlarge cavity
to loosen pattern.
➢ Negative allowance. (Due to increased casting size)
➢ Applied to dimensions that are parallel to parting line.
➢ Allowance is given as per foundry personnel experience.

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Design Consideration for pattern

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Difference Between Pattern & Casting

• Major difference is of Dimensions.
(Pattern is slightly larger in size due to shrinkage, machining &
draft allowances)
• A pattern may be in two or three pieces where as casting is
in one piece.
• A pattern may not have all holes & slots which a casting will
have.
• A pattern and casting also differs as regards the material out
of which they are made.

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Exercise
1. Determine the dimensions of wooden pattern to produce Aluminum
casting as shown in Fig. considering shrinkage allowance only. Shrinkage
allowance for Aluminum is 17 millimeter/meter.
(All dimensions are in millimeter)

2. Find out the new horizontal dimension as shown in Fig. if draft allowance is 1 degree.
?

100

40
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Exercise
3. A job shown in Figure 2 is to be made from steel by casting process. The
mold for this job is made from wooden pattern. Determine the dimensions
of the wooden pattern assuming machining allowance of 3 mm on each
side, shaking allowance of 1 mm on length and width, shrinkage allowance
of 3%.
(All dimensions are in millimeter)

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Reference
• O.P.Khanna, “Foundry Technology”, Dhanpat Rai Publications

• Rao P. N., “Manufacturing Technology – Foundry, Forming & Welding”,

Vol. 2, 4th Edition, Mc Graw Hill Education (India)

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