19ASC213A 05 Casting Patterns

Course Code: 19ASC213A
Course Title: Manufacturing Processes for

Aerospace Systems
Course Leader:
Dr. Srikari S.
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Faculty of Engineering & Technology © Ramaiah University of Applied Sciences
Lecture – 5 – Objectives
Casting Patterns
• At the end of this lecture, student will be able to:
• Describe patterns in casting process
• Explain different pattern materials
• Discuss different pattern allowances
• Classify different types of patterns
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Patterns in Casting Process
• Pattern is the solid form that is used to make the mould. Even though
a pattern generally resembles the casting being produced, it differs
from the casting in terms of certain allowances that are required for
producing the correct shape and dimensions and in eliminating some
minor details which are too complicated or small to be produced by
casting and are left to be produced later by machining
• A pattern has to be designed to facilitate moulding and ensure good
quality castings. The quality of the castings produced depends on the
design of the pattern, its material and construction. A poor casting
may result from a good pattern due to various other factors but a
poor pattern would never make a good casting
• The design of the pattern depends upon the shape and complexity of
the casting, the material of the casting and of the pattern, the type of
moulding adopted and the number of castings to be produced
3
Pattern Material
The pattern material should be:
Easily worked, shaped and joined
Light in weight
Strong, hard and durable
Resistant to wear and abrasion
Resistant to corrosion, and to chemical reactions
Dimensionally stable and unaffected by variations in
temperature and humidity
Available at low cost
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Pattern Materials
Pattern Materials
Wood : White Pine is favourite wood-Straight grained ,
• light weight,
• Easy to work
Eg : Cherry, Beech, Bass wood etc
Metal : used for production workability to withstand ram force
Do not change their shape when subjected to moist conditions
Polystrene: Consumable pattern
Molten metal vaporises the pattern
• Best suited for cases where it is difficult or impossible to
draw the pattern
5
Pattern Allowances
• To compensate for any dimensional and structural changes
which will happen during the casting or patterning process,
allowances are usually made in the pattern. A pattern is
different from the casting in dimensions and shape. The
various allowances given in patterns to obtain the correct
size and shape in the finished casting are:
• Shrinkage allowance
• Distortion allowance
• Finish allowance
• Shake allowance
• Draft allowance
•
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Reasons for Allowances
Most metals undergo noticeable
volumetric contraction when cooled
Three principle stages of
shrinkage:
• Shrinkage of liquid as it cools
from the solidification
temperature
• Solidification shrinkage as the
liquid turns into solid
• Solid metal contraction as the
solidified metal cools to room
temperature
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Shrinkage Allowance
• As the molten metal solidifies, it shrinks and contracts in
size
• To compensate for this, the pattern is made larger than
the required casting by giving contraction / shrinkage
allowances
• This is done by using shrinkage/ contraction rule like 10
mm/m length of the casting
• Different materials have different/varying shrinkages
hence according to the metal, it will be applied on pattern
making
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Shrinkage Allowance (Contd…)
• All most all cast metals shrink or contract volumetrically
on cooling
1. Liquid Shrinkage: It refers to the reduction in volume
when the metal changes from liquid state to solid state
at the solidus temperature. To account for this
shrinkage, riser which feeds the liquid metal to the
casting are provided in the mould
2. Solid Shrinkage: It refers to the reduction in volume
caused when metal loses temperature in solid state. To
account for the shrinkage allowance is provided on the
patterns
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Dimensional Allowances
Typical Allowances
• Cast Iron 0.8 to 1.0%
• Steel 1.5 to 2.0%
• Aluminium 1.0 to 1.3%
• Magnesium 1.0 to 1.3%
• Brass 1.5%
• Shrinkage allowances are incorporated into the pattern using
shrink rules
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Distortion Allowance
• Sometimes castings, because of their size, shape and
type of metal, tend to warp or distort during the
cooling period depending on the cooling speed
• This is due to the uneven shrinkage of different parts
of the casting
• Expecting the amount of warpage, a pattern may be
made with allowance of warpage. It is called
camber
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Machining/ Finishing allowance
Rough surfaces of casting are to be machined to get exact

dimension, surface finish etc.
Extra metal provided on the surfaces is called machine finish
allowance.
Amount of machine finish allowance depends on:
• Type of metal used in casting
• Size and shape of pattern
• Method of moulding
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Shake Allowance
• Usually during removal of the pattern from the mold cavity,
the pattern is rapped all around the faces, in order to
facilitate easy removal
• In this process, the final cavity is enlarged
• To compensate for this, the pattern dimensions need to be
reduced
• There are no standard values for this allowance, as it is
heavily dependent on the personnel
• This allowance is a negative allowance, and a common way
of going around this allowance is to increase the draft
allowance
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Draft Allowance
When the pattern is to be removed from the sand mold, there is a
possibility that any leading edges may break off, or get damaged in the
process
To avoid this, a taper is provided on the pattern, so as to facilitate easy
removal of the pattern from the mold, and hence reduce damage to
edges
The taper angle provided is called the Draft angle
The value of the draft angle depends upon the complexity of the
pattern, the type of molding (hand molding or machine molding), height
of the surface, etc.
Draft provided on the casting 1 to 3 degrees on external surface ( 5 to 8
internal castings)
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Types of Pattern
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Loose Piece Pattern
Loose pattern are patterns which are not connected to
other patterns or mounted on a plate. Loose patterns may
be further classified into:
1. Solid or Single piece pattern
2. Self core pattern
3. Split patterns
4. Loose piece pattern
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Solid Pattern
Solid or single piece patterns are the patterns with shapes having
straight draft
They are moulded with the entire cavity in one box
The simplest type of solid patterns is the one with a flat base.
Such a pattern can be moulded in one box only with flat surface
forming the parting line between the two flasks
When using solid patterns the moulder has to cut his own runners,
feeding gates and risers which take time
Such patterns are not useful except for limited production. Generally
made of wood, these patterns are most inexpensive of all patterns
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Self Core Patterns
• Self core type solid patterns are patterns having a hollow
portion with straight draft which is used for producing its
own core during moulding process itself. This type of
pattern eliminates the need for core box
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Split Patterns
• Many patterns cannot be made in a single piece because they have
back draft which does not permit their withdrawal
• Such patterns are made split into two parts. The pattern is split in
such a way that the two parts by themselves have no back draft.
• One part of the split pattern is moulded in the drag and the other
in the cope.
• The pattern parts are held in their relative position by dowel pins
so as to ensure proper location of the parts during moulding
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Loose Piece Pattern
• Some castings require patterns which have parts with back draft in
such a way that they cannot be made into split patterns
• In these patterns the parts with back draft are made into loose pieces
so that the loose pieces can be removed separately from the mould
after the main body of the pattern has been removed
• The loose pieces are initially held in a place during moulding with the
help of pins or slides but when the main body is withdrawn vertically
the loose pieces are left inside the mould
• The loose pieces are then withdrawn sideways and pulled up through
cavity made up by the main piece. Loose piece patterns have the
advantage of a low pattern cost but normal take longer in moulding
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Gated Patterns
• Gated patterns are number of loose patterns connected with a gating
system. They are moulded like a single pattern and withdrawn from
the mould in one piece thus reducing moulding time
• Gated patterns are useful when a number of small castings are to be
produced.
• Of course these patterns do add an extra operation of separating
individual castings after they have solidified along with the gating
system but the overall time for casting per piece is much lower than if
castings were produced individual moulds. Both loose piece patterns
and gated patterns are more suited for hand moulding
21
Match Plate Patterns
• These have half mounted on two sides of a pattern plate and aligned
with reference to aligning pins on the plate. They are designed to
work with match plate moulding machines for high production rates.
The two halves of the mould are made with the pattern halves on
the two sides of the pattern plate and assembled the two mould
halves match
• Match plate patterns are expensive but their cost can be justified if
the quantity of production is large. Because the moulding is done on
machines, match plate patterns produce castings which are more
accurate than those produced by hand moulding
22
Cope and Drag Patterns
• As the size of the castings increases, it becomes more and more
difficult to handle match plates. For medium and large size castings
separate pattern plates are made for the cope and drag halves. The
pattern halves are geometrically located with reference to aligning
pins or holes in the pattern plates for proper matching
• The cope and drag are separately made, may be on different
moulding machines by different workers and assembled with
proper matching for pouring
23
Pattern Devices
• When the size of the casting is too large and the number
required is only one or two, full patterns generally prove
uneconomical
• Pattern devices like sweeps, segments, skeletons and follow
boards are used in such cases to save on pattern cost
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Sweep Pattern
• It is used to sweep the complete casting by means of a plane
sweep
• These are used for generating large shapes which are axi-
symmetrical or prismatic in nature such as bell shaped or
cylindrical
• This greatly reduces the cost of a three dimensional pattern. It is
suitable for very large castings such as the bells for ornamental
purposes used which are generally cast in pit moulds
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Skeleton Pattern
• It is made of strips of wood and is used for building the final
pattern by packing sand around the skeleton. After packing the
sand, the desired form is made with the help of a strickle
• This type of pattern is useful for large castings, required in small
quantities where large expense on complete wooden pattern is
not justified
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Follow Board Pattern
• This type of pattern is adopted for those castings where
there are some portions which are structurally weak and if not
supported properly are likely to break under the force of
ramming
• Hence the bottom board is modified as a follow board to closely
fit the contour of the weak pattern and thus support it during
the ramming of the drag
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Summary
• Pattern which is the solid form and is used to make the
mould. Selection of it has to be made based on points like
light in weight, hard, strong and durable, resistant to wear
• Allowances that are required for producing the correct shape

and dimensions and in eliminating some minor details which
are too complicated or small to be produced by casting and
are left to be produced later by machining
Thank you
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Course Code: 19ASC213A

Course Title: Manufacturing Processes for

Rough surfaces of casting are to be machined to get exact

• Allowances that are required for producing the correct shape

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