CORES

 Used for casting with internal

cavities

 Should have same properties as mold

 Made of sand or wood.

 Supported by core prints or chaplets

(recesses added to the pattern to
support the core and to provide
vents)
 PATTERN

TYPE OF PATTERN
Patterns

Patterns are used for making mold

cavity
 made of wood, plastic or metal
 material depends on size, shape,
accuracy, quantity and molding process

 Patterns are usually coated with a

parting agent to facilitate their
removal from the molds

6
Pattern Types
(A) One-piece pattern: simpler shape, low
quantity, Figure (a).
(B) Split patterns: two piece, complicated
shapes, Figure (b) & (c).

7
D) Match‑plate patterns: (Shown in Fig. 3)

Match-plate: two piece on opposite sides

of a plate, large production rate.

8
9
E) Cope‑and‑drag pattern:
 Cope and drag halves are attached to
separate plates

 The gates, risers, etc. are included on the

respective plates so that the entire operation
is completed as one

 When the two halves of the mold are closed, a

complete cavity results

 This method is used when the molds are so

large that they cannot be handled easily

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F) Loose‑piece pattern: (Shown in Fig. 4)
Object has protruding sections such that neither
a one‑piece pattern nor one split along a single
parting plane can be removed from the molding

11
G) Sweep pattern: (Shown in Fig.)

 Forms used to sweep the desired shape into the sand

mold
 These eliminate the need for costly 3D patterns.
 They may be used on green or dry sand

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 EVAPORATIVE PATTERN CASTING

 The evaporative pattern casting

process uses a polystyrene pattern,
which evaporates upon contact with
molten metal to form a cavity for the
casting.

 The process is also named lost-foam

or lost-pattern casting under the
trade name Full-Mold process.
Schematic illustration of the expendable pattern casting
process also known as lost foam or evaporative casting.
 First the pattern is made by a plastic
forming method in a die or cut from
polystyrene sheets and assembled to
shape

 The process is relatively simple because

there are no parting lines or cores

 Pattern material is inexpensive and may be

easily processed into complex shapes.
 Typical applications are cylinder
heads, crankshafts, brake
components, and manifolds for
automobiles and machine bases

 The pattern is usually coated with

refractory slurry, dried, and placed
in a flask

 The flask is filled with sand, which

surrounds and supports the pattern
 Without removing the pattern, the
molten metal is poured into the mold

 This action immediately vaporizes the

pattern and fills the mold cavity,
completely replacing the space
previously occupied by the polystyrene
Design Considerations In Sand
Casting
 Location of Parting Plane

The proper location of the parting

plane of the mold leads to:

Eliminating the utilization of cores.

Effective and economical gating.

Reduced casting weight.

Eliminating defects in casting.

 Machining Allowance

Figure: Aluminum piston for an internal combustion

engine. (a) As cast; (b) after machining.
 Finish/Machining Allowance
The machining allowance is a function
of the

 size and shape of the casting,

 the type of metal used,
 the machining operation,
 the number of cuts to be taken,
 Several cuts mean, more material
must be added to the casting
 Iron or Steel casting will have scale
(or oxides), and this must be taken
into consideration
 Non-ferrous casting will not have
allowance for scale
 The finishing allowance may be 3 mm
for most medium-size cast iron
castings
 For large castings the allowance can range up to 19
mm

 Brass and Aluminum have allowances which vary from

0.8 mm to 3 mm.

 For outside dimensions the finishing allowances are

added to the part dimensions

 whereas for inside dimensions (holes) finishing

allowances are subtracted

 diameters will have double allowance because

opposite sides of a diameter must be cleaned up
Shrinkage Allowances

Shrinkage of metal on cooling is

related to the :
 material of the casting,

 the design and size of the

casting,
 the temperature of the melt,
 Brass will shrink more than cast iron
but less than steel
Taper in patterns for ease of
removal from the sand mold
Draft Allowances
 Taper applied to the pattern to
facilitate drawing the pattern out
of the mold without damage to
the mold
 If no draft were applied, the
pattern would be in contact with
the sand mold all the time that it
is being withdrawn from the mold
 In general 1 mm/100 mm depth of
the surface to be drawn is applied
to each side of the pattern

 The taper may be less than 1

mm/100 mm for small castings

 As a general rule the amount of

draft is a function of the length of
the contact surface to be withdrawn
from the mold
 Also,if the pattern is
complicated, it might
require more draft, possibly
as much as 2 mm/100 mm.
 Internal draft may range to
as much as 6 mm/100 mm.
 Example
 Design the pattern for the part showing in
the next slide. Consider the following
allowances.
 Machine allowance, 3mm for each surface.
 Shrinkage allowance, 1% for external
surface and .8% for internal surface.
 Draft allowance,1% for external surface
and 2% for internal surface.
Machine Allowance
Shrinkage Allowance
Draft Allowance
Oginal Size Dia 150 Dia 100 Dia 75 Size 200 Size 50
Machine Allowance 156 106 69 206 56
Shrinkage Allowance 157.6 107.1 69.6 208.1 56.6
Draft Allowance 158.7 110.1 63.3 208.1 56.6
Video lesson

https://www.youtube.com/watch?
v=bvklUlD1YBo