FOUNDRY

PATTERN MAKING

Introduction

- Pattern is the principle tool used during the casting.

- Can be defined as model of anything so constructed that it may be used for

forming an impression called ‘ MOULD’ in damp sand or other suitable
materials.

- The process of making pattern is known as pattern making.

- Patternmaking is a skilled trade that is related to the trades of tool and die
making and mould making, but also often incorporates elements of fine
woodworking.

- Patterns are made of different materials like wood, plastic, or metal

depending on the type of casting and size of casting.

- Foundry engineering deals with process of making casting in mould

prepared.
 Fig. 1.1 Different types of pattern
DEF: PATTERN

- Pattern is a model or replica of the object to be manufactured around which

moulding sand is

Packed to get a mould of desired shape and size.

- Pattern is a model of the object that is to be cast and is used for making
mould cavity.

PATTERN MATERIAL

- Each material has its own advantages, limitations, and field of application.
- Mahogany is the most commonly used material for patterns, primarily because it
is soft, light, and easy to work.
- Metal patterns are more long lasting, and do not succumb to moisture, but
they are heavier and difficult to repair once damaged.

- Selection of pattern material depends on following factors

a) Type of production casting and the type of moulding process.

b) Possibility of design change.

c) Number of casting to be produced.

d) Service requirement e.g. Quantity, quality, minimum thickness desired

degree of accuracy.

- Qualities required for pattern material

a) Easily worked and shaped.

b) Light in weight.
c) Dimensionally stable in all situation.
d) Repairable and reused.
e) Able to take good surface finish.
f) Strong hard & durable.

- Material used for making pattern are

a) Wood & wood products

b) Metal & alloys
c) Plasters
d) Plastics & rubbers
e) Waxes.
  WOOD

- Wood is the most common material for pattern as it satisfies many of the
requirements.
- It is easy to work and readily available.
- Wood can be cut and fabricated into numerous forms by gluing, bending, and
carving.
- It is readily affected by moisture: it changes its shape when the moisture
dries out of it.
- It wears out quickly as a result of sand abrasion, and, if not stored properly, it
may warp badly.

- Wood used for pattern making should be free properly dried before it s used.
It should be straight- grained, free from knots, and free from excessive
sapwood.

- The most common wood used for pattern is teak wood.

Advantages

(i) It is cheap and available in abundance.

(ii) It can be easily shaped into different forms and intricate designs.
(iii) Its manipulation is easy because of lightness in weight.
(iv) Good surface finish can be easily obtained by only planning and sanding.
(v) It can be preserved for a fairly long time by applying proper preservatives
like shellac varnish.

Disadvantages

(i) It wears out quickly due to its low resistance to sand abrasion. As such, a
wooden pattern cannot stand a long constant use.
(ii) It is very susceptible to moisture, which may lead to its warping or splitting.
This needs its careful storing in a dry place and the application of preservatives.
(iii) Its life, owing to the above reasons, is short as compared to other pattern
materials. This confines its use to such cases only when a small number of
castings are required
 Fig. 1.2 wood pattern

 METAL

- Metal is used when a large number of casting are desired from a pattern or
when Conditions are too severe for wooden pattern.
- Metal pattern do not change their shape when subjected to moist conditions.
- It is freedom from warping in storage.
- Metal patterns are very useful in machine moulding because of their
accuracy, durability and strength.
- Metal pattern is itself cast from a wooden pattern called MASTER PATTERN.
- When metal patterns are to be cast from master pattern double shrinkage
must be allowed.
- The common metals used for pattern making are: Cast iron, Brass, Aluminum,
White metal.

Advantages

1) More durable and accurate in size than wooden patterns

2) Have a smooth surface
3) Do not deform in storage
4) Are resistant to wear, abrasion, corrosion and swelling
5) Can withstand rough handling

Disadvantages

1) Expensive as compared to wood

2) Not easily repaired
3) Heavier than wooden patterns
4) Ferrous patterns can get rusted

 PLASTIC

- They do not absorb moisture, and are strong & dimensionally stable.
- Resistant to wear, have very smooth & light in weight.
- Has a very low solid shrinkage.
- When a plastic pattern is required, a wooden pattern which forms the mould
into which the plastic resin is poured.
- These moulds may be made of variety of material including wood, rubber,
plastics Metal or plaster of Paris.
- Two types of plastic materials are used in pattern shapes
1) Thermoplastic 2) Thermosetting

Advantages

1) Facilitates the production process.

2) Makes it more economical in cost and labor.
3) Plastic patterns are highly resistant to corrosion, lighter and stronger than wood
patterns.
4) Molding sand sticks less to plastics than to wood.
5) No moisture absorption.
6) Smooth surface of patterns.
7) Plastic patterns are Strong. And so they are dimensionally stable.