Engineering Workshop

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 Module 1
Lecture 2
Pattern, types

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 Pattern

• A pattern may be defined as a model/replica of desired

casting which when molded in sand, forms an impression
called mold.

• The mold when filled with the molten metal forms casting
after solidification of the poured metal.

• The quality and accuracy of casting depends upon the pattern

making.

• The pattern may be made of wood, metal(cast iron, brass,

aluminum and alloy steel.), plaster of paris, plastics and wax
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• If the casting is to be hollow, additional patterns called cores
are used to create these cavities in the finished product.

• The quality of the casting produced depends upon the

material of the pattern, its design, and construction.

• The costs of the pattern and the related equipment are

reflected in the cost of the casting.

• The use of an expensive pattern is justified when the quantity

of castings required is substantial

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 Functions of Patterns

• A pattern prepares a mold cavity for the purpose of

making a casting.
• A pattern may contain projections known as core
prints if the casting requires a core and need to be
made hollow.
• Runner, gates, and risers used for feeding molten
metal in the mold cavity may form a part of the
pattern.
• Patterns properly made and having finished and
smooth surfaces reduce casting defects.
• A properly constructed pattern minimizes the
overall cost of the castings.
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 Material Requirement of Pattern

• Easily worked, shaped and joined

• Light in weight
• Strong, hard and durable
• Resistant to wear and abrasion
• Resistant to corrosion and chemical reactions
• Dimensionally stable and unaffected by variations in
temperature and humidity
• Available at low cost

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 Pattern Types

• solid or single piece patterns • skeleton pattern

• split or two/multiple piece • segmental pattern
patterns • follow board pattern
• match plate pattern
• cope and drag pattern
• loose piece pattern
• gated patterns
• sweep pattern

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 Single Piece / Solid Pattern
• A single piece pattern is the simplest of all the patterns, is
made in one piece and carries no joint, partition or loose
pieces. Depending upon the shape, it can be moulded in one
or two boxes. This pattern is the cheapest but its use can be
done to a limited extent of production only since its
moulding involves a large number of manual operations like
gate cutting, providing runners and risers.

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 Two Piece / Split Pattern
• Many times the design of casting offers difficulty in mould
making and withdrawal of pattern, if a solid pattern is used.
For such castings, split or two piece pattern are employed.
They are made in two parts which are joined at the parting line
by means of dowels. While moulding one part of the pattern is
contained by the drag and the other by the cope.

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 Match - Plate Pattern
• The match plate pattern have part of the casting in the cope and part
in the drag like split piece pattern. These parts are generally attached
to the plate / board in opposite sides in the perfect positions. When
the plate is removed and mold is in close position the cavities in the
cope and drag match perfectly.

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 Cope and Drag Pattern
• When very large castings are to be made, the complete pattern becomes
too heavy to be handled by a single operator.
• Such a pattern is made in two parts which are separately moulded in
different moulding boxes. After completion of the moulds, the two boxes
are assembled to form the complete cavity of which one part is
contained by the drag and other is cope. Thus, in a way, it is nothing but
a two piece or split pattern of which both the pieces are moulded
separately instead of being moulded in the assembled position.

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 Loose Piece Pattern
• Some patterns usually single piece, are made to have loose pieces in
order to enable their easy withdrawal from the mold. These pieces form
an integral part of the pattern during moulding. After the mould
preparation, the pattern is withdrawn leaving the pieces in the sand,
which are later withdrawn separately through the cavity formed by the
pattern.

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 Gated Pattern
• Gated Pattern is used in mass production of small castings. For such
castings, multi-cavity moulds are prepared i.e. a single sand mould
carriers a number of cavities.
• Patterns for these castings are connected to each other by means of
gates which provide suitable channels in sand for feeding the molten
metal to these cavities. A single runner can be used for feeding all the
cavities.
• This enables a considerable saving in moulding time and a uniform
feeding of molten metal.

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 Sweep Pattern
• Sweeps can be advantageously used for preparing moulds of large
symmetrical castings, particularly of circular cross section.
• This effect a large saving in time, labour and material. The full equipment
consists of a base, suitably placed in the sand mass, a vertical spindle
and a wooden template called sweep.
• The outer end of sweep carries the contour corresponding to the shape
of the desired casting. The sweep is rotated about the spindle to form
the cavity. Then the sweep and the spindle are removed, leaving the
base in the sand. The hole made by the removal of spindle is patched up
by filling the sand.

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