Manufacturing Technology (2022) Types of patterns:

Solid or single
Module 1: Significance of manufacturing processes piece pattern:
and relevance of foundry. Made in one piece.
Split pattern:
Manufacturing: Conversion of raw materials to Made in multiple
finished goods by using various machineries, pieces.
processes and human labour. Dowel pins are
Significance of manufacturing: used for keeping
the alignment
• Integral to the economy of a country.
between the two
• Backbone of both social and economic parts of the
development. pattern.
• Manufacturing has improved quality of life and Match plate
drives innovation. pattern: Generally
used with
Properties of engineering materials: moulding
• Strength: Ability to withstand applied load machines for mass
production of
• Hardness: Ability to resist scratching, abrasion,
small castings.
indentation, etc. The cope and drag
• Brittleness: Property of breaking without portions of the
appreciable deformation. pattern are
• Toughness: Ability to withstand shock loading mounted on
without fracture. opposite sides of a
wood or metal
• Malleability: Ability of a material to be flattened
plate conforming
into thin sheets. to the parting line
• Ductility: Ability of a material to be drawn out called match plate.
into thin wire.
• Stiffness (rigidity): Ability of a material to resist Loose piece
elastic deformation. pattern:
Projections or
• Resilience: Ability of a material to absorb energy
hanging parts of
elastically. the pattern make
• Plasticity: Ability of a material to undergo some the removal of the
permanent deformation when load is applied. pattern difficult.
• Elasticity: Ability of a material to regain its original To overcome these
shape and size after the removal of applied load. patterns are
produced as
• Fatigue:
assemblies of
o Failure of a material under cyclic loads. loose component
o Fatigue strength: Ability to withstand cyclic pieces.
loads.
Gated pattern:
Pattern: Model of the object to be cast. A group of
Functions of patterns: patterns attached
• To produce the cavity of required shape and size. with a common
• Good surface finish. gating system.
For mass
• Minimize defects.
production of
• Provides core prints. small castings.
• Minimize cost.
• Provide runner, gates and risers.
• Establishes parting line and surface.

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Prepared by: Manu K Joseph, Lecturer, St. Mary’s, Palakkad
Sweep pattern: Plasters:
A sweep pattern is • Made of gypsum cement or plaster of paris.
a template of • Advantages:
wood or metal,
o Easily cast into complex shapes
which has a
contour o Can be worked easily.
corresponding to o High compressive strength.
the shape and size o They are cheap.
of the casting. • Disadvantages:
o Only be used for small castings.
When rotated
o It expands during solidification.
about a central
spindle, it sweeps o There are different types of gypsum plaster
the shape of the available with different expansion rate and
casting into the A sweep pattern is preferred for setting time.
sand all around the producing large castings of Plastics:
circumference. circular sections and • Thermo-setting plastic widely used as pattern
symmetrical shapes. material now days.
• Advantages:
o Light in weight
Commonly used pattern material:
o Reasonable cost.
Wood: (Teak, mahogany, pine, etc.)
o Not affected by moisture.
• Most common material.
o Good durability
• Optimal for very large casting and small quantity
o Good formability.
production.
o Good compressive strength.
• Advantages:
• Disadvantages:
o Cheap and easy availability.
o They are fragile.
o Can be easily shaped.
o Not suitable for machine moulding (jolting) as it
o Light in weight
will not withstand shock loads.
o Design can be easily changed.
o Narrow section may need reinforcement.
• Disadvantages:
Wax: (bee wax, shellac, paraffin wax, etc.)
o Affected by moisture.
• Excellent choice for investment casting.
o Low resistance to abrasion.
• Advantages:
o Shorter life.
o Provide very good surface finish.
o Low strength
o Mould cavity will not be damaged while
Metal: (Aluminium and its alloys, steel, Cast iron,)
removing the pattern.
• Used for large scale production with closer
o Provide high accuracy for costs.
dimensional accuracy.
• Disadvantages:
• Metal patterns are cast from wooden patterns
o Equipment and process costs are high.
called master patterns.
o Requires high level of skill.
• Advantages:
o Do not absorb moisture. Pattern allowances:
o Durable. Shrinkage
o High strength (contraction)
o Precise. allowance:
o Gives smooth surface finish Allowance to be
added in the size of
• Disadvantages:
the pattern to
o Tendency to get corroded. compensate the
o High cost. contraction of the
o Heavy. metal during
o Hard to modify and repair. casting.

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Prepared by: Manu K Joseph, Lecturer, St. Mary’s, Palakkad
 Properties of moulding sand:
Solid shrinkage is • Porosity (Permeability):
compensated by o Property of moulding sand which allows the
giving the shrinkage
passage of gases and steam through the sand
allowance.
(Expressed in mould.
mm/m) • Refractoriness:
Draft (taper) o Ability of moulding sand to withstand high
allowance: temperatures.
Intentional taper • Adhesiveness:
given to all vertical o It is the property of moulding sand due to which
surfaces for easy
it sticks to the surface of the moulding boxes.
removal of the
pattern from the • Cohesiveness:
sand, without o It is ability of sand particles to stick together.
damaging the • Collapsibility:
mould. o It is the property of moulding sand due to which
it automatically gets collapse after solidification
Machining
of the casting allowing free contraction of metal
(finishing) allowance
Extra material added • Plasticity Or Flowability:
to certain parts of o It is the property of moulding sand due to which
the casting to enable it flows during ramming to all portions of the
finishing to required moulding flask and packs around the pattern to
size, accuracy and acquire desired shape.
surface finish
Types of sand used in mould:
Distortion (camber) Green sand:
allowance: • It is a mixture of silica sand with 5 to 20 % clay
Given to those
and 5 to 8 % water.
sections of casting
which tend to bend Dry sand:
or distort during • Green sand when baked is called dry sand.
casting. Loam Sand:
• It is a mixture of 50% sand and 50% clay
Rapping (shake) Facing sand:
allowance:
• Specially prepared moulding sand with high
When the pattern is strength and refractoriness which covers the
to be removed from pattern.
the sand mold, the Backing sand or flour sand:
pattern will have to • Old repeatedly used moulding sand used for
be shaken slightly backing up the facing sand.
for easy removal, Parting Sand
and this will cause
an enlargement of • It is sprinkled on the pattern and pattern surface
the mould cavity. of the mould so that the sand masses of cope
and drag separates without clinging and do not
To compensate this, stick to the pattern.
the patterns are Core sand (Oil sand)
made slightly • It used for the preparation of cores
smaller and this
negative allowance • It is prepared by mixing silica sand and core oil
is known as shaking composed of linseed oil, resin and other binding
or rapping materials.
allowance.
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Prepared by: Manu K Joseph, Lecturer, St. Mary’s, Palakkad
Composition/Ingredients of moulding sand: • Sweep moulding is best suited for large size
Silica sand: Major constituent of moulding sand (80 to moulds which are symmetrical in shape and
82 %). particularly of circular sections
• Impart refractoriness, chemical resistivity, and • The casting produced involves less time and
permeability reduced expenses in making a full pattern.
Clay:
• Imparts the necessary tensile strength Gating system:
o As the quantity of the clay is increased, the • The term gating system refers to all passageways
permeability of the mould is reduced. through which the molten metal passes to enter
Water: It is responsible for moulding action of clays. the mold cavity.
Binders: Holds the sand grains together. • A good gating design should ensure proper
• Impart strength, resistance to erosion and distribution of molten metal without excessive
breakage. temperature loss, turbulence, gas entrapping and
o Organic binders: Linseed oil, Dextrin, Resin, etc. slags.
o Inorganic binders: Fire clay, Bentonite, Illite,
Kaolinite, etc.
Additives: Materials added other than binders to
develop certain desirable properties.
• Sea coal improves surface finish.
• Wood flour increases flowability.
• Graphite increases mouldability.
• Silica flour increases hot strength.

Moulding process:
Bench moulding
• It is carried out in benches of convenient height.
• It is used for making small molds.
Floor moulding
• Moulding work is carried out on foundry floor.
• It is used for making medium and large-sized
castings.
• The gating system is composed of:
• Mould has its drag portion in the floor and cope
o Pouring cups or pouring basins: The Pouring
portion may be rammed in a flask and inverted on
basin is the funnel-shaped inlet, located on top
the drag.
of the system, where metal is poured from the
Pit moulding
ladles into the mould.
• Very big castings which cannot be made in flasks o Sprue (downsprue or downgate): Sprue is a
are moulded in pits dug on the floor. vertical passageway from pouring basin to
• The mold has its drag part in the pit and a runner.
separate cope is rammed and used above the (pit) ▪ Liquid metal going down the vertical sprue
drag. loses pressure but increases speed due to the
• The sides of the (pit) drag are lined with brick and effect of gravity.
the bottom is covered with moulding sand. ▪ The sprue cross section can be circular, square
• The cope (a separate flask) is rammed over the pit or rectangular (preferably circular).
(drag) with pattern in position. ▪ The foot of the sprue is rotated at a right angle
Sweep moulding: to the runner to prevent free fall of liquid
• The moulding done by using a sweep pattern is metal, known as the sprue well or choke or
called sweep moulding. sprue base.
• A sweep that can be rotated around an axis is
used for producing a surface of revolution.
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Prepared by: Manu K Joseph, Lecturer, St. Mary’s, Palakkad
• Runner (Cross gate): Runner is a horizontal
channel connecting the sprue well to the
gates.
• Gates (Ingates): It leads the liquid metal that flows
from the runner into the mould cavity.

Riser (Feeder head)

• Riser is a source of extra metal which flows from
riser to mould cavity to compensate for liquid
shrinkage and solidification shrinkage which takes
place in the casting when it is solidifying.
• Without a riser heavier parts of the casting will
have shrinkage defects, either on the surface or
internally.
• Risers are of two types; open riser and blind riser.
o Open riser is exposed to atmosphere where as
blind riser is closed at its top.
• A riser should be provided close to heaviest
portion of casting preferably on top.

Functions of Risers
• Provide extra metal to compensate for the
volumetric shrinkage.
• Allow mould gases to escape.
• Promotes directional solidification.
• Applies sufficient feeding pressure so that mould
is completely filled.

Fettling is the operation of cleaning and finishing of

castings
It includes:
• (a) removal of cores and surface cleaning of
casting(by using hand tools like hammers, files,
wire brush and machines for hydro blasting, sand
blasting and shot blasting)
• (b) removal of gates, risers, runners, fins and
other unwanted projection from castings(shearing
machine, hand saws, band saws, grinding
machines, oxy-acetylene cutting torch etc. are
used for this purpose)

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Prepared by: Manu K Joseph, Lecturer, St. Mary’s, Palakkad