CO

OURSE: METAL
M C
CASTING
Module
M No
o. 6: PATT
TERNS
Leccture No-3

Allowan
nces and Gu
uidelines in P
Pattern Maaking

Draft
ft or Taper Allowance
A

All th
he vertical surfaces of the pattern is providedd with a tapper allowancce so that thhe
patterrn can be reemoved safely from the molding sannd without ttearing awayy the sides oof
the saand. This taaper allowan
nce is also known as draaft allowancce. Fig. 6.3.11 (a) shows a
patterrn having no
o taper allow
wance. In this case, till thhe pattern iss completelyy lifted out, itts
verticcal sides will remain in contact
c with
h the verticall walls of moold, thus tennding to breaak
it. Fig
g. 6.3.1 (b) is representss a pattern with
w taper alllowance. In this case thhe mould waall
does not break when the patteern is lifted out
o of the m
mould.

As a guideline, when
w the taper allowancee is providedd on the inneer surfaces oof the patternn,
the allowance is generally hiigher than th
hat of allow
wance which is providedd on the outeer
surface. Also, thee amount of taper allowaance dependds upon the llength of thee vertical sidde
of thee pattern to be
b removed from the mo
olding sand. Table 6.3.1 provides a general guidde
lines for the draftt allowance.
Patteern material Heighht of the giv
ven Draft aangle Draft aangle
surfacce (mm) (Exterrnal surfacee) (Intern
nal surface)
Wood
d 25 3.00 3.00
25 to 50
5 1.50 2.50
50 to 100 1.00 1.50
100 to
o 200 0.75 1.00
200 to
o 800 0.50 1.00
Metaal and plasticc 25 1.50 3.00
25 to 50
5 1.00 2.00
50 to 100 0.75 1.00
100 to
o 200 0.50 1.00
200 to
o 800 0.50 0.75

Table 6.3
3.1 Draft Alllowances off Various M
Metals

Mach
hining or Fiinish Allowa
ance

The allowance
a prrovided on the
t pattern to take care of dimensioonal accuracyy and surfacce
finish
h of the end
d product iss known as machining or finish aallowance. S
Sand castinggs
proviide, in generral, poor surfface finish. In
I order to aachieve the ddesired surfaace finish, thhe
castin
ng need to be machineed. The allowance to taake care of extra metall removed tto
achieeve the surfaace finish iss called the machining allowance. the machinning or finissh
allow
wance depend
ds upon the type of molding processs, method off molding, shhape and sizze
of thee casting, orrientation off the differen
nt surfaces oof the patternn in the cavity, degree oof
finish desired, and metal of the end product. The machining allowances recommended for
different metal is given in Table 6.3.2.

Metal Dimension (mm) Allowance (mm)

Cast iron Up to 300 3
300 to 500 5
500 to 1000 6.25
Cast steel Up to 150 3
150 to 500 6.25
500 to 1000 7.50
Non ferrous Up to 200 2.25
200 to 300 3
300 to 1000 4

Table 6.3.2 Machining Allowances of Various Metals

Distortion or Camber Allowance

The distortion in casting can also happen due to its typical shape. For example, if the
casting has the form of the letter U, V, T, or L etc. it will tend to contract at the closed
end causing the vertical legs to look slightly inclined. This can be prevented by making
the legs of the U, V, T, or L shaped pattern converge slightly (inward) so that the casting
after distortion will have its sides vertical (Fig. 6.3.2). This allowance is known as
distortion allowance.

The distortion in the casting, because of the shape of the casting may occur due to
internal stresses, which are developed due to unequal cooling of different section of the
casting and hindered contraction. Measure taken to prevent the distortion in casting
include:

i. Modification of casting design

ii. Providing sufficient machining allowance to cover the distortion affect
iii. Providing suitable allowance on the pattern, called camber or distortion allowance
(inverse deflection)
Rapp
ping Allowa
ance

When
n a pattern is
i removed from the molding
m sandd aggregate, the pattern is rapped aall
aroun
nd its verticaal sides. Thiis rapping off the patternn is done to enlarge the mould cavitty
on itss vertical sid
des so that th
he pattern removal from the mould bbecomes sm
mooth. Since it
enlarges the finall casting maade, it is dessirable that th
the original ppattern dimeension shoulld
be reeduced to account
a for this increase. There iis no sure w
way of quaantifying this
allow
wance, since it is highly dependent
d on
o the foundrry personnell practice invvolved. It is a
negattive allowan
nce and is to
o be applied only to thosse dimensionns that are pparallel to thhe
partin
ng plane.

Somee Guideliness for Makin

ng Patterns

1. Alw
ways try to avoid
a sharp angles and corners
c
Sharp
p angles and
d corner maay result into
o either the internal shrrinkage or tearing (stresss
conceentration) at the corner points
p of the casting afteer the solidifi
fication as shhown in 6.3.33.
Hencce, corner an
nd sharp ang
gles are prov
vided with raadii or while making mouuld, chills arre
proviided and riseers on such sections
s may
y be providedd as indicateed in 6.3.4.
2. Always
A avoid
d abrupt secttion thicknesss as shown iin fig. 6.3.5

ways try to design

3. Alw d the seection as uniiform in thicckness (section) as possibble
4. Alw
ways avoid th
he section of casting of sh
hapes as U, V
V, T, or L. If needed proviide the reversse
cambeer allowance as discussed above.