ADDIS ABABA SCIENCE AND

TECHNOLOGY UNIVERSITY
College of Engineering
Department of Mechanical Engineering
Metal Casting Technology
Assignment II

Name ID

Bereket Tekle Ets0215/13

Submitted to: Mr.Mohammed Awol

Submission date: 20-03-2024

 1. Master patterns in metal casting refer to the original patterns or models from which
multiple copies or molds are made to create metal castings. These master patterns
are typically made from materials like wood, metal, or plastic and are designed to
withstand the rigors of the casting process without deforming or warping.

The size of master patterns can vary depending on the specific casting requirements and the
complexity of the final product. In general, master patterns tend to be larger than other
patterns used in the casting process. This is because master patterns serve as the basis for
creating multiple copies or molds, so they need to be detailed and precise to ensure
accurate reproduction of the final casting.

Other patterns used in metal casting, such as matchplate patterns, cope and drag patterns,
and core boxes, are typically smaller in size compared to master patterns. These patterns
are used in specific stages of the casting process to create molds, cores, and other
components necessary for casting the final product. Their smaller size allows for easier
handling and manipulation during the casting process.

Overall, master patterns play a crucial role in metal casting as they serve as the starting
point for creating molds and ultimately producing accurate and high-quality metal castings.

2. Core prints in metal casting are protruding features or extensions on a pattern or core
box that serve as guides for positioning and supporting cores within the mold cavity.
Cores are used in casting to create internal cavities, recesses, or complex shapes in
the final metal casting.

When designing a core print pattern, several considerations are necessary to ensure
effective and accurate casting:

1. Size and Shape: The size and shape of the core print should be designed to match the
corresponding core and mold cavity. It should provide adequate support and alignment
without interfering with the casting process.

2. Location: The placement of core prints on the pattern or core box is critical. They should
be positioned in such a way that they guide the core into the correct position within the mold
cavity and allow for easy removal after casting.

3. Strength and Stability: Core prints should be robust and stable to withstand the forces
exerted during the casting process, including the weight of the metal, sand, and any other
materials used in the mold.

4. Draft Angle: A draft angle is often incorporated into core prints to facilitate easy removal
of the pattern or core from the mold without damaging the casting or the mold cavity.

5. Material Selection: The material used for core prints should be compatible with the
casting process and the materials used in the mold. It should also have good thermal
stability to withstand the heat of molten metal during casting.
6. Alignment and Tolerance:Proper alignment of core prints is essential to ensure accurate
positioning of cores within the mold. Tolerances should be considered to account for any
shrinkage or dimensional changes that may occur during the casting process.

7. Venting and Gating:Core prints should be designed to allow for proper venting and
gating of the mold to ensure smooth flow of molten metal and minimize defects in the final
casting.

By taking these considerations into account, designers can create effective core print
patterns that contribute to the successful and efficient metal casting process.

3. Pattern allowance refers to the additional dimensions or allowances added to a

pattern to compensate for various factors that occur during the casting process.
These factors include shrinkage, machining, finishing, and other dimensional
changes that affect the final casting. Here's an analysis of pattern allowance
considerations using examples of production parts like a flywheel, pulley, bed, and
column, along with appropriate materials and dimensions:

1. Flywheel:
- Material: For a flywheel, a durable and heat-resistant material like cast iron or steel is
suitable.
- Dimension: The pattern for the flywheel should include allowances for shrinkage during
cooling after casting, as well as machining allowances for turning the outer diameter and
facing the ends.
- Considerations: The pattern allowance should account for the thickness of the flywheel,
any hub or spoke configurations, and any additional features required for balancing.

2. Pulley:
- Material: Pulleys are often made from materials like aluminum, steel, or cast iron,
depending on the application and load requirements.
- Dimension: The pattern for a pulley should include allowances for shrinkage, machining
allowances for turning the outer diameter, drilling holes for mounting or belts, and keyway
slots if needed.
- Considerations: The pattern allowance should also consider any specific requirements for
pulley grooves, flanges, or other features based on the intended use.

3. Bed (e.g., machine tool bed):

- Material: Machine tool beds are commonly made from cast iron due to its stability and
damping properties.
- Dimension: The pattern for a bed should include allowances for shrinkage, machining
allowances for milling or planing the surfaces, and additional allowances for mounting holes
or slots.
- Considerations: The pattern allowance should consider the overall size and shape of the
bed, any reinforcement ribs or bosses, and provisions for precision alignment features if
required.
4. Column (e.g., support column for machinery):
- Material: Columns are often made from materials like steel or cast iron, depending on the
load-bearing requirements.
- Dimension: The pattern for a column should include allowances for shrinkage, machining
allowances for turning or milling surfaces, drilling holes for fastening or assembly, and any
decorative or functional features.
- Considerations: The pattern allowance should account for the height, diameter, wall
thickness, and any flanges, brackets, or mounting points needed for attaching other
components.

In each of these examples, the pattern allowance is crucial to ensure that the final casting
meets the required dimensions, tolerances, and surface finishes after machining and
assembly. By carefully considering material properties, dimensions, and specific production
requirements, designers can create effective patterns with the appropriate allowances for
successful metal casting.

4. Common materials used for pattern making in metal casting include wood, metal,
plastics, and composite materials. Each material has its own merits and demerits,
which are important to consider based on factors such as cost, ease of use,
durability, and the casting process itself.

1. Wood:
- Merits:
- Easily available and cost-effective.
- Can be easily shaped and carved to create intricate patterns.
- Good thermal insulation properties, which can help prevent rapid cooling and cracking
of molds during casting.
- Demerits:
- Susceptible to moisture absorption, which can lead to dimensional changes and
warping.
- Limited durability compared to metal or composite materials, especially in
high-temperature casting processes.
- Prone to wear and tear over time, requiring regular maintenance and replacement.

2. Metal (e.g., aluminum, steel):

- Merits:
- High durability and resistance to wear, suitable for long-term use and repeated castings.
- Excellent dimensional stability, maintaining shape and size accuracy over time.
- Good thermal conductivity, aiding in uniform cooling of molds during casting.
- Demerits:
- Higher cost compared to wood or plastics, especially for intricate or complex patterns.
- Requires specialized equipment and expertise for machining and fabrication.
- Heavier weight can be a consideration for large or complex patterns.

3. Plastics (e.g., polyurethane, epoxy resin):

 - Merits:
- Lightweight and easy to handle, suitable for creating detailed and complex patterns.
- Good resistance to moisture and corrosion, maintaining dimensional stability.
- Can be cost-effective for small to medium-sized patterns.
- Demerits:
- Limited heat resistance, may not be suitable for high-temperature casting processes.
- Less durable than metal, may require replacement or repair after repeated use.
- Some types of plastics may have limited machinability or surface finish options.

4. Composite Materials (e.g., fiberglass-reinforced plastics):

- Merits:
- Combines the benefits of both plastics (lightweight, easy to shape) and reinforcement
(durability, heat resistance).
- Can be tailored for specific casting processes and requirements, such as
high-temperature applications.
- Good dimensional stability and resistance to wear, suitable for long-term use.
- Demerits:
- Initial cost may be higher than traditional materials like wood or plastics.
- Requires expertise in composite fabrication techniques for optimal results.
- Variability in performance depending on the type and quality of reinforcement materials
used.

In summary, the choice of material for pattern making depends on factors such as the
casting process, budget, durability requirements, and complexity of the pattern. Each
material has its own advantages and limitations, and selecting the most appropriate one
involves considering these factors in relation to the specific casting project.

5. A pattern, in the context of manufacturing and metal casting, refers to a replica or

model of the final product that is used to create molds or cores for casting. Patterns
are typically made from materials like wood, metal, plastics, or composites and are
designed to have the same shape, dimensions, and features as the desired casting.

Here are the key aspects of a pattern and how it differs from the actual product:

1. Function:
- Pattern: The primary function of a pattern is to create molds or cores that will be used to
cast the final product. It serves as a template for shaping the mold cavity and producing the
desired casting.
- Actual Product: The final product, on the other hand, is the casting itself, which is made
using the molds or cores created from the pattern.

2. Material and Construction:

- Pattern: Patterns can be made from various materials depending on factors such as cost,
durability, and ease of fabrication. They are usually constructed to be robust and accurately
represent the shape and details of the final product.
- Actual Product: The material used for the actual product may differ from the pattern,
depending on the casting process and the properties required for the end-use application.
For example, the pattern may be made from wood or plastic, while the final product could be
cast from metal or another material.

3. Dimensional Considerations:
- Pattern: Patterns include allowances for shrinkage, machining, and finishing processes to
ensure that the final casting meets the desired dimensions, tolerances, and surface finishes.
- Actual Product: The casting process, including solidification, cooling, and any
post-casting operations like machining or finishing, may cause dimensional changes or
variations compared to the pattern. These differences are accounted for in the design and
production of the pattern.

4. Usage and Reproducibility:

- Pattern: Patterns are typically used repeatedly to create multiple molds or cores for
casting multiple copies of the same product. They are designed for durability and ease of
use in the casting process.
- Actual Product: Each casting made from the mold or core created by the pattern will be
identical in shape and features to the pattern. However, variations may occur due to factors
like material properties, casting conditions, and post-casting operations.

In summary, a pattern is a critical component in the metal casting process, serving as the
template for creating molds or cores to produce the desired castings. While the pattern
closely resembles the final product in terms of shape and features, differences in material,
dimensions, and manufacturing processes differentiate the pattern from the actual product.

6. When selecting a particular type of pattern for metal casting, several factors need to
be considered, including the complexity of the part, the casting process, production
volume, material properties, and cost-effectiveness. Here are explanations and
sketches for split patterns, sweep patterns, and match-plate patterns
1 Split Pattern:
Explanation: A split pattern is used when the part being cast has a complex shape or
features that cannot be easily removed from a solid pattern without damaging the mold. The
split pattern consists of two or more parts that can be separated to facilitate easy removal
from the mold cavity.
- Neat Sketch:Split Pattern Sketch:(https://i.ibb.co/4SVL5M3/split-pattern-sketch.png)
- Features:
- The split pattern includes a parting line where the pattern segments are joined and can
be separated.
- Each segment of the split pattern corresponds to a section of the part to be cast,
allowing for easy removal without distortion.
- Alignment features such as dowel pins and registration marks ensure proper assembly
and alignment of the split pattern segments.

2.Sweep Pattern:
Explanation: A sweep pattern is used when the part being cast has a cylindrical or curved
shape. It consists of a single pattern that is rotated or swept along a path to create the
desired shape in the mold cavity.
- Neat Sketch: Sweep Pattern Sketch:(https://i.ibb.co/8gRrYvb/sweep-pattern-sketch.png)
 - Features:
- The sweep pattern is designed with the profile of the part to be cast, including any
curves, tapers, or contours.
- A sweeping motion is used during pattern production to create the continuous shape of
the part in the mold cavity.
- Core prints or other features may be included in the sweep pattern to guide cores or
support the part during casting.

3. Match-Plate Pattern:
- Explanation: A match-plate pattern is used in high-volume production when multiple
copies of the same part are required. It consists of a pattern mounted on a plate or board,
with cope and drag patterns on opposite sides of the plate to create two halves of the mold
simultaneously.
- Neat Sketch:
Match-Plate Pattern Sketch:(https://i.ibb.co/3YxL3KG/match-plate-pattern-sketch.png)
- Features:
- The match-plate pattern includes the entire part geometry on one side, divided into cope
and drag halves to create the mold.
- Alignment features such as dowel pins and guide rails ensure precise alignment and
registration of the cope and drag patterns.
- The match-plate pattern allows for efficient production of multiple molds in a single
molding operation, reducing cycle time and cost.

These different types of patterns are selected based on the specific requirements of the
casting process, part geometry, production volume, and cost considerations. Each pattern
type offers unique advantages in terms of ease of use, mold quality, production efficiency,
and overall casting success.