Pon tavedosd UDC 621.74.072 DEUTSCHE NORMEN Pattern Equiament for Foundries Production and Quality Giesserei-Modelleinrichtungon; Herstellung und Gite STANDARDS DEPT} Contents ” a 1 General 17 Auxiary matesials and secessoies 2. Quality categories 1 for pattern eadipment 10 21 Drawing dat, designation 18 Painting and eof coding 10 | 4 Shrinkage allowances 19 Inscription. + 10 8] 5: ttacniningstownncrs 110. Storing patern equipment 10 2] Patteindote 10 i Dimensions in mm 2] 1 General Table 1. Quality categories for pattrn equipment 2] Patterns and pattern equipment ere used for making >, 8] moulds tor snd casting purposes in hand moulding o Pate uatiy For gti 8] machine moulding shops. Such equipment comprises raterial categories see Table 3) pattems, core bones and templates os wel asthe neces 3] Sov toviary motionces such score dries, moulgana [Wood Ha H2HS | 2 | core gauss, battens ond the like. Below, these tems are [weit at 8] tetered to in brief as patiorn equipment. The bosis for MEY ! | 2) the prodvation of pottern equipment isthe unfinished | Pasiiematedals |KVK2 - §] anafor tinsher pare drawing of the casting for whic [Foamed matorai $52.83 the mould iso be prepared, Owing tothe various work ing methods used in foundries iti also appropriate that at the stage when pattern equipment is being designed, the casting manufacturer should agree with the customer fon a design which meets the moulding, casting and farting requirements 40 as to ensure economic produc tion of the castings. The essential points to be settled in such disqussions are the following: moulding method pattern quality category mould and core partinas shrinkage allowance pattern draft degree of accuracy of castings machining allowances ‘modifications to dimensions and/or shape desirable for reasons of foundry and moulding practice 2 Quality categories | On pes renal es SVisunsty proces ne to he mes ; oe “S\Ealanotons on pape 10 Features oursice the quality category chosen may be agreed between the parties The permissible dimensional deviations apply to newly smanufacturgd pattern equipment with the agieed sri age allowance taken into account 3. Drawing data, designation In drawings or in the order, the quality category of the pattern equipment isto be stated, ¢ Quality category DIN 1511 —H1 4 Shrinkage allowances Except where other shrinkage allowances have been agreed, the reference values in Table 6 apply. 5 Machining allowances DIN TST nal Provan,Page 2 DIN 1817 fs BOWS Table 2, Quality categories for wooden patterns category H2 43 Short runs and recur ting one-off eastings in hand moulding shops, Reference value for ‘number of times pattern can be used: favourable shape {or small patterns 50 for large patterns 15 Luntavourable shape {or small patterns 30 for large patterns 5 ‘One-off castings in hand moulding shops. Reference value for ‘number of times pat tern can be used: ‘small patterns 1 to 5 medium and large pat terns 1102 AW 100 glued Quality Features ita Hy Use. =| Batchwide'B Butction’ *] Sung runs in hand and inhand and machine | machine moulding moulding shaps when | shops when high stand very high standards | ards are required. Ref are requiced ference value for num Reference value for | ber of times pattern umber of times pat- | can be use: tern can be used: favourable pattern favourable pattern shape 500 shape 1000 not farge | unfavourable pattern patteras) shape 200 Unfavourabte pattern | large patterns 18 shape 600 (not large patterns) Material?) | Hardwood (maple, pear, | As for quality category cherry, walnut and etm) | H 1a, pine for larger or equivalent plywood | patterns sheets (maple, beech). [Aldor and pine or equiv alent manmade wood ‘materials Softwood (spruce, pine alder and lime, aso fir as filler Chipboards with tongue and in, Wood sorews Framing box jointed, Hardwood dowels glued Fastenings | External butt joints | As for quality category groove | Ha Plain butted, framing box jointed, 1/2 or 2/2 lapped as required Screwing and nailing Plain butted, framing lapped, important points screwed, otherwise railed Frame member crost-seetion: 120 mm x up to 140 mm x 25 t0 40 mm “Thickness of cor Frame | Reference values for | Reference values for and com: | component distances: | component distances: ponent | 200 to 250 mm 350 to 400 mm distances Frame member 45 mm 110 mm x 45 mm 50 mm | up to 130mm x 45 mm Thickness of outer skin: | Thickness of outer skin: 25 to 40 mm ebox | Thickness of core box walle: 30 t0 40mm | walls: 25 to 40 mm according to size. Core | according to size box heights exceeding 400 mm in framed con: struction or in laminated! Reference values for component distances approx. 400 mm Frame momber cross-section: 100 mm x 40 mm up to 120 mm x 45 mm ‘Thickness of outer skin: 20 to 35 mm ‘Thiekness of core box walls: 25 to 40 evn according to size Reference values for ‘component distances 450 mm Frame member cross-section: 100 min x 35 mm typ to 100 mm x 40 mm Thickness of outer skin 2010 30 mm ‘Thickness of core box ‘walls: 25 to 35 mm according to size to occur Parting | Parting surfaces surfaces | hollowed. Met and guides ing hetween with-yain and acroze-qrain to be voile at sides wood Wood | Preferably in lifting | As for quality category | Preferably in ifting | No special instructions gain direction, Atsideno | H1a direction: also cross: itection | change between with- wise when sides are train and across-grain steeply sloping. Chang, [As for quality category dowels | H1a Parting surfaces not hollowed; open in framed construction Metal and wood dowels ‘As for quality category H2 1) Wood for patterns shall be dey; the recommended moisture content is 10 to 14% by wtTable 2. (continued) DIN 1811. Page 3 Features Hie Quality category Mt 42 HS Fillets Worked in solid when ‘below this, plastic wood fr synthetic resin radius is 5 mm or above;| gory H 1a, but synthetic Same as quality cate rain also permissible In small patterns mastic fillets up to 15 mm radius. Subject to agree ‘ment in the case of ‘medium size and large patterns No filets fitted, black painted line as ident fication Loose pieces ‘Wearing edges Light metal, synthetic resin or wood with metal auides Metal not less than 3 mm thick Wood or synthetic | cesin with doverail uides On large patterns made (of pine with glued-on ‘hardwood strips ‘Made of wood with pins or serews and mark: ing in the farm of black paint fines No special instructions [As for quality category H2 Working edges of tem: plates faced with sheet met Lifting arrange ment For hand:moulded pat- terns, drawplates or ‘drawstraps sunk in and covered As for quality category Hia Drawplates or draw: straps sunk in Drawplates or drav straps on surface Core print construe: ton Core box construe: tion Paint finish With sand bars and fillets. Guides and sup: ports to be of adequate size. Positive protection ‘against rotation and Iispasitinning to be provided ‘Shake-out core box, framed core box with metal closure Injection core boxes rade of wood are to be protected against the injection pressure by metal external fittings, Allowance to be made of core print Dovetail fastening according to DIN 1527. ‘Wedge fastenings nade of steel. Screwed rods ‘with wing nuts, Stripper ‘eciges of metal, wearing points of metal or plastie material 3 coats jn the core box for dratt | T=NtY category H Ta 1s for quality category Ha ‘Same as quality category 111, but without metal protection to wearing points and stripping edges. Large core boxes made of pine, wearing points and stripping edges of hardwood, core bbox fastening as for [As for quality category Hla Without sand baes and fillets, but with ade: quately dimensioned bearing andl guiding surfaces also with posi mispositioning Core straps and framed core boxes, clowelled or screwed. Draft of core print left out of account As for quality category HD ‘As for quality category HE Conti inuation of Table 2 on page 4Page 4 DIN 1511 Table 2._ (Continued) Nominal dimension range?) Permissible dimensional deviations over upto 30 50 0| 120 1802 250 315 400|, 00 630 a0o| 4000 1260| 1600] 2 2000) 2500) 3150 3150] 000, Over 30 mm rounded values to 4 1/2114 | __ Over 30 mm rounded values to + 1/2 1T 15 2) Permissible dimensional devi manufacturer ions on nominal dimensions over 4000 mm are to be agreed between customer andTable 3, Quality categor {for metal patterns DIN 1511 Page S Features Mt ‘Quatity eategory m2 Use Mae LLong-run batchwise manufacture using ‘machine moulding and invalving high standards Copper/tin/zine alloy, copper/zine alloy, ‘aluminium alloys, east iron and steel Batchwive manufacture using machine moulding Same as quality category M1, but also including hard tead and pattern metal (83% Sn, 17% Sb} Surface quality Machined all over, apart from difficult, transitions Only parting and quiding surfaces machined, surface of pattern smoothed and scraped by hand Fillets Worked on As for quality category M1 Loose pieces Dovetail guides As for quality category Mt ‘Wearing edges With light metal construction, eg, sheet steel, not under 3 mm. No special instructions Core print construction With sand bars and fillets, As for quality category M1 Nominal dimension range 2) Permissible dimensional deviations $0.20 Ho. 400 £05 sor ny Over 30 mm rounded values to = W211 13 2) See page 4Page 6 DIN 1511 Table 4, Quality categories for plastics patterns Quality category Features Kt K2 Use Batchwise manufacture using machine ‘Small to medium runs using machine ‘moulding and involving high standarels moulding Material Plastics with extreme stability of shape | Plasties and resistance to abrasion Finish Worked from the solid; usually cast solid ‘or back-filed, oF asa shell with ribbing, preferably reinforced Some 2s K 1, but minus reinforcement Parting surfaces ‘Machined No special instructions Loose pieces Pattern component and dovetail guides of metal or wear resisting plastic material No special instructions Core print construction With sand bars and fillets As for quality category K 1 Nominal dimension range 2) over | upto, | 250 eee 30 50, 80 120 180 315, 400 _ | 500 | 630 800, 1000 1250 2000 2500 3150 Permissible mensional deviations Bh _| Over 30 mm rounded values to # 1/2 1T 13 Over 30 mm rounded values to + V2 IT 14_| 2) Sew page 4Table 5, Quality categories for patterns made with foamed material DIN 1811 Page 7 s1 Quality category 82 $3 For re-usable readily removable patterns For once-only use (expendable patterns) For onee-only use (expendable patterns) Rigid foamed plastic mate- | Rigid foamed plastic material e.g. polystyrene-based Fial, eg. polystyrenebased | according to DIN 7726 Part 1 with a density below according to DIN 7726 | 20 kg/m? according to DIN 53420 Part 1 with a donsity over 20 and up to 40 kg/m according to DIN 53.420 Smooth surface allowing | Preferably worked from Same as quality category convenient drawing (coat- | the solid, surface polished, | $2, but with less exacting ing). Suitable lifting devices | fillets worked on to be fitted requirements with regard to surface quality. Patterns can also be assembled by bonding together sheet of suitable thickness. Features Use Material Finieh Nominal dimension range?) Permissible dimensional deviations over upto 18 soa bos 18 50 tos toe 50 120 for : _ tha 420 250 +09 is 250 ‘400, 7) sie 400 630 bra | 422 | 630 1000 a6 tee 1000 1600 424 sn 1600 2500 _ __ tae _ tae i 2500 4000__| $40 rm 3} See page 4Page 8 DIN 1511 ‘Table 6. Reference values for shrinkage allowances Srnkae Casting metal, allowance aston wih tr aie DIN 1091 10 with moda graphite, nanneted oe ees pat 0 wih nova opie, nested os useiics ron DIN 1604 25 Cast steel iN r681 20 Cast austenitic manganese steel 2a ite maleate ron GTW 16 DIN 1622 Ute malabe ron GTS 05 Cost minim toys DIN rresem2 | 12 Cast magnesia alloys bin s729rm2 | 42 Cast copper In 17685 19 Cnr caning ays es bone) : loys es bores) om vee 15 Cannrlinfemccastig alloys ue 1 Copper ine ys fast rs 2 pps eu d DIN 1709 apoetain i, FA esting alloys paces tas) 20 Caprio (ie, easing ys feast inno roree)——OIN 1748 19 Fine rin casting allovs ow rsenz | 13 Pisin ewig alloys white met bin_1703, os Table. Pate daft for internal and extemal surface of pte 7 over 10 over 18 over 30 over 50 ] over 80 Heighe ‘up to 10 up to 18 up to 30 up to 50 up to 80 up to 180 van 3 2 15 1 075 os indayee coer 180 | ovr 250 ] ow 318 | ovr 400 | ovr 600 | ow 620 | om on Height upto 250 | upto 315 | up to 400 up to 500, up to 630, up to 800 | up to 1000 oar Ts [| 20 | 2s | 30 ees 55 Tower Ton ] ove 1280" | ove 1600 | over 2000 | or 2500 | ovr 9150 Height up to 1250 up to 1600, up to 2000, up to 2500, up to 3150, up to 4000, Pale ’ 3 n 135 ” 2 Table 8 Patten date for com pint vig [| wvo70 | om70 Dra in degree (°) 7 eyDIN 1511 Page 9 Table 9, Painting and eotour-coding of patterns surface an | cotton | Coniron | nite] Heow or cast | ithnodtr [oth tometar | matabie | rel portotsurtacear area ‘ropnte | 'gapnite | ton | cing Ground colour for surfaces ‘on the pattern and in the Seep ica blue Violet red grey yeltow ‘areen machined on the casting) Surfaces which Yettow6} | Yettow®) | Yellow) | Yellows | RedS) | Yellow®) ‘machined on the casting stripes stipes stripes srines stripes stipes Seats of loose pattern com ponents {loose pieces) on the pattern or in the core Outlined in black 1box, also for serews of loose pieces ‘Sites for chill plates and prints for inserted arbors red a oo ic) bod ad Cove print black Fillets 1, in special case, filets are not epptied, they shall be indicated by a black dashed line with a note of the radius Sink heads or feeders, work: ing allowances made for ‘easone of foundry tech: ‘nique and samples marked eee Black stripes and the appropriate inscription Cut-offs of reinforcements ‘and stopped-off parts of pattern bout with black stripes Position of core on parting surface of pattern Black or marked black In the graund colour of the pattern Strickles and screed templates Cofourless varnish arey yellow sreen ae ec 3) Surfaces to be left unmachined, but required to have a particularly clean appearance are to be identified on the pattern by the symbol ~ 4) This heading covers castings in alloys of copper, nickel, lead and zine 5} This heading covers castings in aluminium alloys to DIN 1725 Part 2 and magnesium alloys to DIN 1729 Part 2 65} Where small and medium-sized areas are involved, the whole surface should be coloured in and not striped,Page 10 DIN 1511 6 Pattern draft Before the production of pattern equipment starts, the necessary amount of pattern draft corresponding to the three variations shown below (tee Figure) should be speci Nails according to DIN 1151 and DIN 1152. ‘Screws for metal fastenings according to DIN 963, DIN 84, DIN 85, DIN 87, DIN 88, DIN 91 Solders according to DIN 1707, DIN 8512, DIN 8513 Part 1 to Part 3 fied in the drawing or in the form of written information, ; ul 7.2 Filler compounds for drawing fillets (radii to DIN 250) and for making gaod on patterns 7.3. Plastis sections for fillets (radii to DIN 250), parts ‘of the gating system and the like Pattern draft — (cemoval of material) 1 Pattern draft + addition of material) We Pattern draft 9 3 = inside 7.4 Dowels for patterns to DIN 1525, pattern characters 0 DIN 1826, core box fastenings to DIN 1827. 8 Painting and colour-coding Painting to protect the patterns and the necessary colour. coding are to be carried out in accordance with Table 9 Pattern draft + Inscription ‘The characters, letter symbols and figures needed! on the castings for identification purposes are to be applied to ‘the pattern or In the core box, unless agreed to the con- trary at the time of ordering, on a surface which will remain unmachined on the casting a outside Values of pattorn draft are given in Tables 7 and B. Other values should be agread at the time of ordering. On sur eens aaa eee benecn ctelE a ‘The pattern itself, each loose part betonging to it anc! each. core box forming a part of it are to be identified with the pattern number 7 Auxiliary materials and accessories for pattern equipment 7.1. Fastening and bonding agents Glues according to DIN 16 820 and DIN 4076 Part 3 Screws for wood fastenings according to DIN 97, DIN 571, DIN 603, DIN 605, DIN 7997 10. Storing pattern equipment Proper storing must be ensured, since this ~ plus the length of storage — largely determines the reusability Of pattern equipment, Explanations The direct dependence of casting quality on pattern quality makes DIN 1611 en import ant Standard for the industry concerned, and DIN 1511 can only live up to expectations by reflecting the state of the technique at all times. With the advent of the newer mate Used in pattern-marking practice, the 1957 edition of this Standard had become ‘due for revision, ‘The quality category classification of pattern equipment now also covers patterns made of east resin and foamed materials. In the interests af more rapid access to the inform. ation contained, the features characterizing pattern construction have been presented in tabulated form, ‘The question regarding the wear limit of pattern equipment during its use is of general interest through the interaction betweon the dimensional accuracy of the castings and the quality of the pattern, and therefore needs to he dealt with at least under the topic of “casting” even if not directly coupled with the pattern equinment. The Normenaus- schuss Giessereiwvesen (Standards Committee Foundry Pras siunestions and experienen concesnest with this subst ice) will at all times welcome The permissible dimensional deviations of pattern exipment to DIN 1511 only apply to the ‘as supplied’ condition, The request that symbols be roduced for dimensioning the thtee types of pattern draft could not be given effect. Since all three drafts may occur on the same drawing, the question of the introduction of symbols has been passed on to the Normenausschuss Zeichnungswesen (Standards Committee Drawing Practice) which is the competent bbody for this purpose in the DIN,