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PATTERN MAKING SHOP

Aim : - To studv lil" · .. • .

J t: Vanous types ot wooden patterns «1151 lhc1r allow;rnccs.

Pattern .· - A 11 ·1 tt,•1·1·11·s·
· " '-'
· ( <.;opy,) 0 t· tIle
tl1 C rq.J 1!Ca 1·
part prrn U<.:l lo I.lC I· . ·'
cw-; t <Ill( IS USt:u
l
l.l

prepare !he mould cavity. Pattern is made either of wood or metal. There are <liffen.~

type of pattcm depending upon the material , the job shape, an<l No. of castings required.

Types of P{tHcrn: - The commonly use<l patterns arc clas~ified as. follows : -

l . Single piece Pattern or solid Pattern .

•-• 2. Split Pattern.

-•
-~
J. Gated Pattern.

,t fvt\tch Plate J>att-::m.

-- ~ 5. Cnpc 81; drng Pattern,.

4
• {J. Loose piece Pattern.

7. Skeieton Pattern.
~
_. :-i. Sw8cp Fattern.
,
1). :~cg.rne11td i\ .iltern.
~

J.. .1O. Shell Pnttem.

_,. 1 J. L:1~gd up Pattern.

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n. L,.~n &, : igbt hand P;1ltcrn
L~ ;-. .. , ()._f Ja11·,
,1·1·,,.~ ,,.ypc · will
..- ,.,e,Jcclcd for a ,u,1rticulm c::.iE;tmg · ,JL"pen d , 1n t'r1 , · 1·O\' I,t .,' ,:,",
L~ - 1 •. vi 11 '
1. , c=

Ji1. - cc_111dition ~~ -
v~
r~ ij Si ?c and shapeof cnsting.
l --j l'lo. of' c1stings required
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Method of lv1 .
ou/ding used.
iv)
Qifficulty of mould.
ing used.
VJ Ch
aracteristics of Castrngs.
1. SinuJc Pi . ,
,:, ccc or Solid Pattern · _ c.. .
· ull1g1e pier..:c or sol'1J pattern 1s
· mauc of one piece
·
only It does not have any ·oin . . . .
J t, parting, or loose piece m its construction. The
single piece pattern 15
·
generally used for large Casting of simple sha,c. From
ccci1omy point of view
,
s·mg1e .piece
.
patterns are usually made of woos. For
forge and intricate cast"rngs
7 ti 1ey are made from metal to avoid warp age.

2. Split Pattern •· - ;\ SjJrt t..:,n 1s marJc of lwo or more part~ joineJ together by
"It... ·
1 JJ«

dowel pins. Whe11 the casting is peculiar design and intricate shape, its .P?Jt!e::rn

c;uu:ot be madt: in single- piece because it cn11Dot be wilh drawn from the mould .

Therefore. such a pattern is made iu two or more pieces. Depending upon the

num/Jer of parts it is kJ1mv11 .as two-piece split pattern or three pieces split pattern

cl:i show,~ in figure. 'i

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3. Gated Pattern~ - Gared patlerns are used for :nass productio~smoJl ca~ling~~- ,,;
r

The passage through >vl·1ich the molten metal flows· is called gate. Numbers of

sma!i castings are produced in a single multicavity mould by joining rmmbrr ~)f

puUem;:; through gc1tes. fhc gates are Jcmncd by conoecting parts bclwern the

;nd i vidtwi pa Cle-ms these group of patterns wil ii ga!e forrn _crs J t1acl1ccl tl, l l1e111 an.:

called gated patterns. The molten metal is poured into mould thrnugh a ~ingle

gare ,md il J1ows to every mould through the individu:1/ g~:tcs .

4. ,1\,f;i!ch flatc JJ~ttcrns: - Whrn split µntterns arc mountd wi ih (1ne half on the

one :::iJe of plate ,mrl nnoli1cr VH'. clirecily cppusik side of plate. Tk· pntlern is
 Drag pattern

-. -- -.. ..---..-_-.. -~
. -- . . - .
-. -- - - ,-
-~

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Loose piec~ patll'rn

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 "!IT. ·1
Gdlcd match plate r>atte1·11 .
The match pl t,
. a c. patterns arc us, I 1· . - .
. .· . _, t:l OJ produc1110 small
u1st1n,,s in lar J • . c-
,"c-· ' ge quant1t1cs in moulding maclti11cs whic ..
i . • h gives nccuratc and ·rapid
pn)L_1uct 1011 .

5. Cope and Brag. Pattern: If

- the casting is large, the co111plc1L: 111ould is too
heavy anc.l di.fficull to lwndle ! b · I. , .. . _ .
. l ya s111g e ope1,1to1 . hir s11ch easl111 g the c~)pe and
I
c,rng patterns are used The p tt > • • d · .
- · a 1.::rn 1s mc1 c Ill l\Vo halves, split 011 a cu11vcnicnt

jtli'nt line . One 1 If II· ·

1a mou c ts m cope and other half i:, in dra~t- Aner r~~moving Ilic

two halves from the mould_ing _sand , the cope and drag a1c then as~;en1blcd to

rn cJ:e lhe complete mould .

G. L,m~r Pi..:cc Pattern: - Loose piece pattern is made of ~sc oomroucat piL~cr~:;
I
.is.•,cniblcd logclht:r hy dO\vcl pins. The whole pattern can be rcm1)\\: ~I from th...:

sand rnouid ~1 y taking out al! the component pieces one by one . . The 1nain piece:. is

usu-1l!y removed first , a1\er _that the separate loose pieces, which may have to he

turned or moved before laking out, are removed .

7. Skclch>n Pl:lttcrn: - Skeleton pattern is used mainly for mc.mldiJJg large ca~l.ing .

censists of skeleton structure for confinement of moulding sand. ln int ric atc w· ick

~l skeleton pattern carrying some __ of parts, which ·must be loq~t-~ ;_,((..'\ iralt.'! \'. i'.:

rnJdc . Such a ·patl.cm is m:!<le of wooden frame and i·ib conslrnctiui1 y; and ~;_: vc :,;

l~irgc ..irnouwt of timber/pattern material, · ,vhich would hav1.' hccn :-; j)L' tll in
1
prcp:11 ing t_hc fully solid pattern. Thc ribbed con~trudion wi1 h a l,irt r m·1mb ,:r 1
P :·

squarr or rectangular opening bct\vccn the rib:-; is iilkd ·c111J rarn·11,::t' \L),m :;:1ll:..I .

SiidJc board is u:;ed to n:lllL'IVC cx;:ess sand out of spaces bc '. \ve1:.·n ril•s ~1, ;1' : 11,

I ll;\kl'. e~terio1: surface C\' ·~11 with I he out~idc or ti IC ~kektu1 ~.

y,
• • I
 sweep Cu~plctcJ
Spi 1iJle moult!

(a) : (c)
(b}; -
Sweep Fattern

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Follow board
Folio"' boJrd r ..·,tt err--.
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8. Sweep l'attcrlJ' - S w ,
· ccp pattern are used to prepare moulds of symmetrical and
j
regular shapes . t' . -
p ..ir icu 1ar 1Y in large sizes. A sweep pattern consists of wooden

'• born·d fi xed to metal rod . The outer contour of the board js similar to the contour
I

• o f CJ s t_ing. The rod is fixed in position in the sand and the board is sweep'ed or

• moved about the axis of the rod , so as to give the sand a revised shape of mould .

• The ramming of sand and sweeping of board is continuously done till the mould is

• Cl ).111rlclc .

• 9. Segmental Pattern: - Th / segmental patterns are used .to prepare circular moulds

• o f larg~ iz~~ like wheels, rims, gear, rings etc. Segmental patter:ns are sections of

,• ' full pattern, ench section forms a part of the mould for preparing a mould by
t
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s 1.:gmcnlal patterns , a vcrtical spindle is fixed in the center of the drag flask ~ The
.-
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nroulcl bo ttom is rarnm ~4 and swept to level. Now a segment is fastened to the

~ spindle. Moulding sand is rammed between the outside of the pattern and the

,• flask anJ on the inside, except at the ends of the pattern. After ramming one

:;cg mcnt. next seg ment is rnmmec! anJ so on , until the complete perilllclc r uf" tlv~
• mould is prepared .
•
• 10. Shell Pattern: - The sheJJ pattern is c:1 hollow construction like a s hell. Its outside

share i;; used as a pattern to make the mould alld the insid e sl1apc_j.s u~cd a~ o i.: o r c

box for making core:;\ The shell pattern is usual_ly mad r up or me.tal. ' Jt j ~,

11,wuni<.;d on a plaLc and pa1ted aiong the centcrlir:c . T!ic two halve~; are corrcc i.! v

duwd eci together. The ~hell patterns arc \videly used for drainag,_; 1i,.iing~. pi ~Jc

work , hc11ds etc .

r
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 _ L,·Igg•"d up patterns are used for cylindrical casting,, 11.k"'
11 . Lagged up Pattern: .., "
barrels, pipe, columns etc. A lagged up pauern is made :it'h \eg.pby joining the"'
.d t . nsurc proper shape. Such a pattern is 11. 1
0
on two heads, one on each SJ c, c g ltcl"
ti e required contour.
in weight and easy to construe t 1

12. Left and Right Hau<l Pattern: - Such patterns are made in pairs one for left hand
5t
~nd other for right hand ~asting. Left_hand pattern is ju opposite to light . hand

. pattern. The examples ' of such patterns are J- hangers, legs for g..-den bench,

lathe, sewing machine and brackets for luggage racks in railway carriages etc.

Pattern allowances: - The allowances given 01,r Pattern- size is called pattern

allo,Vru1cc. Patlern a\lowaucc af\Ccl the dim~ ~al characteristics of the casting thus

., must Lie given. on the sizes :;pccificd ill llw.

\-Vhcn pattern IS produccd)cc rlain allO\.\'~n~es
.

lin i~;hed component drawing so that a casting with thLJ/2.Jarticular specification can be

produced . , The correct pattern allowance ._greatly. }1f~lps

- . to re( Juce machining cos t mid

avoid rejections. 1

The allowances us~mlly cons1'd ercd on pattern and core boi:c::; ..... ,,
l.Jl ' . .

explain~ her;,,: :-

L Contraction or shrinkage
.· . . AIJ .... , l rsecl fi·( •
,, owancc: - The r11.-t·1l ·
. r . . · Jl casting CfH1f r: 1,. 1
<t,tcr <:olid1fi .. t' · -- · · · -·--
. c<1 ton m the mould and II ~

r
. ie pattcm must therefore l1 , . ,
the c:1st11w. Tl , , ., l . - ·, t, larger ! lit..~n
.::, Jt; .0L con!ractwn of ti , .
, • lC Castmg C0111pl'iSCS I f ~
i.: .g. Lhc contraction of 1· . . ) thre1:. e!<'.nc1w~
1qu1ds fr 01 ,1 po .
tc111' , · · urn1111:, t
cmpcrntur ·· 1. 1.-. .
l1era,urc, co11(rn(.;tio11 c o rc ~;Z11P
on ac.:count nf cl , . - b
.. t • . . luJ'.gl:! from I' .
I..\) ;) ract,urt or ~1.1!id· ,....,L,•:t "'lip,
' :.
from f ·. . .
.ICJHul lo s011· . l
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ul "
·1r!
. ICt"Ztno
~
l"'n
. . . 1peraturc t I

u s1111uuwlings.

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C'1t ·
' s,mg would l
If the actual b.
'OJcctitslf "
c st igl' ti Ysmalle I
c is used ~or the pattern the
~
I
f
·I . · 1 1 r t ,an desi d . · , -
resuh,n, 'i
s m11k rule is used .Ill laying. out or me .re . ro compensate ror, this . possibili1v. -a i
I
I
sl .· I asu1c11H:11t r I - I
ll lll rngc illlo· W,lllt:C
.. . .
'ncs
\1'\ with ti' . . . . ur I H:: paltcrnc.,.I lI) ,<Ill u.i. I pr:K tic,
. le casting dcsi ,, . v. _,,,- ·
J
or cast111g. t ' . . g I . llnckncss. and nil .
' l r,e of metal, pouring t \Cf ,hmcnvions
. emperature etc WI
l ,) caused from the origi I .
na patterns , double stmn
. Jen metal pallcrnv are lo h.
. kage must be allowed. c
-
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lj..
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l\1atcrial Shrinkage
allowance
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Machining allowance fo r ct·1mens1ons
0-30cm .
30-60c111
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2.5mm I 4.0mm
Cast Iron l/96
C ~ ,, 4.5mm
.ast Steel (Low carboi\) 1/48 3mm
3mm

,.
Aluminum . 3/l 92 1.5mm
!~ Bronze 3/192 1.5mm 3mm
;
- . 1.5mm 3mm
Brass 1/48

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' 1en a_ ra ts man raws up the dcl:lils o( a pa r\ 1 be
Machining alfowancc: _ WI d f d
, c o _e mac 11ne 1s 1nd1cated by a h111sh mark. n,emark ,n<licalcs 1lu
ri1adc each smfo -c t b ·l · "d · · · · · · ·
~ addit!uual metal must h•c provided at tl1is point so that their will be some 111<:tal 10 /
~ -
machine. The amount that is added depends upon the size. shape, and ma lerial of casti n~-
.
l~
,
'., ~
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but in general. the allowance for small casting and average size casting 3 111111 for !'c11 ,,1\S
I
c;istin:; and t .5 mm for non--fcrrous casting. For internal surfaces. the all owance
i~,
,rovidcd should be negative and external surfaces the allowances pro vided ,,hali l,c-
19
1
L9
~ ~,
v~~'
. _;i1in',. JI . . . When a pauern is drawn out frmn a inould the ten•.knn· 1I"
· ti y 1-c rL··· sed i1· 1 1r
l.1r:•.ft or t:i per a "" anc c. · ' ' .
.a
..
•.car ,,w.iy the -edges of the mouiJ in coutacl with the patt ern is ~rca uc " .1
1

•
. ,· . l!. () 11 1'..,,•1llr,I lO whi cl1 :( i~ h. i• ~
• 1· j-t t er 1n ·1 011cc } <- • • ·-

•,.
I

-- smi';ccv·s of 1!,v, paltcr\1 arc g1VC'i a CC ig ap '

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•
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 Parting
t
74 . l cp
~ -'---- line

(b)
Effect of drt1ft on pattern h·ithdra-..,ving
 w ith drawn from th . . . . ,:JZI[
p
c mould cavity h .
as s own Ill Fig ·1·1 . . .
·
IS c~dlcJ dra.n ·-n ·
\
·I 11stapcrofth es1ccsofthcpntkm
·1
. le amount of the urat't r .
equtrcd c.kpcnu I I
cti sl i . · s on tic s 1apc and the size or
. ng, mould1ng method d . .
, pro uct1011 method , intricacv of J)attcrn •'le 't1·11c., . I
. · " ·I .. vc1agcvaue
of the drart ranges from 1/20 to 20. / .
_,
llapping or shake Allowance:-
When a pattern 1s rnppcd in the mould before it is
withdraw11 the c.: ·t, · . .
' avt ) 111 t11c mould 1s slightly increased . .The shake allowance must be

considered by n~aking the pattern slightly smaller.

Di st orlion of camber allowance : - This aliowancc applies only to those casting or

irregular shapes such as U-shapc or those having large flat ar~a , which arc distorted in the

process of cooling as result of metal shrinkage. For instance, casting of U-Shape will be

disto~tc<l with the legs Jivc.:rgcnt. instcaJ of parallel. Tu compensate this, lhc pallt.:m is
. .r
111~dc such th;-it legs convcr~c, but on cooling the c~sting legs should be straight. Such ~n

allowance depe nds on the j uJgmcnt and experience of the pattern maker. who

uml<.T~Umd.s the shrinkage clw.ractcristics of the metal.

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 - ·- - ~ - .. 4" •'·

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Ai rn · · T pre Pm e a Wooden pattern nf hand le con:iideri ng all owa 11ce.1 t1<.
J
loot required : - Kail wood piece ·Try square, Slcci Ruic Jack plane, marking gauge,
)
scriber, haud saw, ten on saw wnoden lite, mallet radius gauge half round wooden rasp
~ file etc.
a r

» Sequence of operation : -

'I.
! .• .,.j'

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f-irfit of all the given wood 1s~~kcd for dimcnsio,~s.
, ./ ..
2.
I
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One side is planed with jackplane
I ' ,.
and checked for straight ncs:i.

~
3.

f'~ 4.
-
The adjacent ~idc is also planed.

Tile two surfaces .ire chcck,~d for fiquarc nc:;:; with a try sriuarc.
5,
'3 Marking gausc is set and lines arc marked at 35 mm and 55 mm to mark the

·t~ ! j

thickness and widtl1 of the model respc<.:tivcly.

,

,~
~ ML\
~ 1
6_

7_
The excess 111aterial is first planed lo correct size.

Marking gauge is again s,;t and lines a,,:e marked at Radius -25 and radius -55

on both edges of job. A line at 35 mm is also marked,

r»~i 8, Usir.g tenon saw the portion to be re1J1oved arc cut in the .iob,
,~~

,I,, 9. Using half round rasp cut file to form th~ rndiu:; in the job. r~ept sl,rinkagc

allowance on th~ pattern.

.,

~1
41\
] 0, Using radius gauge to check the radius.
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4 , ,ft
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