Metal Casting By: Dr Rakesh Goyal Professor, Research CURIN, Chitkara University, PunjabPattern * A Pattern is a model or the replica of the object to be cast. * A Pattern exactly resembles the casting Except for the various allowances. * Patterns may be in two or three pieces, where as casting are in a single piece. * The quality of casting and the final product will be effected to a great extent by the planning of pattern. * A Pattern prepares a mould cavity for the purpose of making a casting.Selection of Pattern Materials The material of the pattern is selected on the basis of following factors : Snow wWN No. of castings to be produced. Metal to be cast. Dimensional accuracy & surface finish. Shape, complexity and size of casting. Type of molding materials. The chance of repeat orders. Nature of molding process. Position of core print.The pattern material should be: . Easily workable. . 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. 7. Available at low cost. UARWN Pe oOPattern Materials Materials for making patterns are: a. Wood b. Metal c. Plastic d. Plaster e. Wax.1. Wood Patterns: These are used where the no. of castings to be produced is small and pattern size is large. Advantages: 1. . Easily available in large quantities . Easy to fabricate . Light in weight . They can be repaired easily . Easy to obtain good surface finish am Bb WN InexpensiveLimitations: 1. ouRwN Susceptible to shrinkage and swelling Possess poor wear resistance Abraded easily by sand action Absorb moisture, consequently get wrapped Cannot withstand rough handling Life is very short Commonly used woods for making patterns: a. b. c d. Teak Pine Mahogony Deodar etc..2. Metal Patterns: These are employed where large no. of castings have to be produced from same patterns. Advantages: NO wWPWN EP Do not absorb moisture More stronger Possess much longer life Do not wrap, retain their shape Greater resistance to abrasion Accurate and smooth surface finish Good machinabilityLimitations: 1. wPwn Expensive Require a lot of machining for accuracy Not easily repaired Ferrous patterns get rusted Heavy weight , thus difficult to handle Commonly used metals for making patterns: iii, iv. ve Castiron Aluminium and its alloys Steel White metal Brass etc..3. Plastic Patterns: Advantages: Durable Provides a smooth surface Moisture resistant Does not involve any appreciable change in size or shape Light weight Good strength Wear and corrosion resistance Easy to make Abrasion resistance 10. Good resistance to chemical attack Limitations: = Plastic patterns are Fragile = These are may not work well when subject to conditions of severe shock as in machine molding (jolting). WONDMNPWNP TD4, Plaster Patterns: Advantages: 1. 2. 3. Il. It can be easily worked by using wood working tools. Intricate shapes can be cast without any difficulty. It has high compressive strength. Plaster may be made out of Plaster of paris or Gypsum cement. Plaster mixture is poured into a mould made by a sweep pattern or a wooden master pattern, in order to obtain a Plaster pattern.5. Wax patterns: Advantages: 1. 2. 3. 4. Provide very good surface finish. Impart high accuracy to castings. After being molded, the wax pattern is not taken out of the mould like other patterns; rather the mould is inverted and heated; the molten wax comes out and/or is evaporated. Thus there is no chance of the mould cavity getting damaged while removing the pattern. Wax patterns find applications in Investment casting process.TYPES OF PATTERNSTypes of patterns depend upon the following factors: i. The shape and size of casting ii, No. of castings required iii, Method of moulding employed iv. Anticipated difficulty of moulding OperationPOnNaunawne Types of Patterns: Single piece pattern. Split piece pattern. Loose piece pattern. Match plate pattern. Sweep pattern. Gated pattern. Skeleton pattern Follow board pattern. Cope and Drag pattern.1. Single piece (solid) pattern: ® Made from one piece and does not contain loose pieces or joints. © Inexpensive. © Used for large size simple castings. Pattern is accommodated either in the cope or in the drag. Examples: 1. Bodies of regular shapes. 2. stuffling box of steam engine.Pattern Copyright ©2008 CustomPartNet Fig: Single piece pattern2. Split piece pattern: ® Patterns of intricate shaped castings cannot be made in one piece because of the inherent difficulties associated with the molding operations (e.g. withdrawing pattern from mould). © The upper and the lower parts of the split piece patterns are accommodated in the cope and drag portions of the mold respectively. ® Parting line of the pattern forms the parting line of the mould. © Dowel pins are used for keeping the alignment between the two parts of the pattern.— i3.Loose piece pattern: © Certain patterns cannot be withdrawn once they are embedded in the molding sand. Such patterns are usually made with one or more loose pieces for facilitating from the molding box and are known as loose piece patterns. ® Loose parts or pieces remain attached with the main body of the pattern, with the help of dowel pins. © The main body of the pattern is drawn first from the molding box and thereafter as soon as the loose parts are removed, the result is the mold cavity.SSSSSSS9 ESS SSS Say Loose piece left in the mold after pattern removal (b)4. Match plate pattern: © It consists of a match plate, on either side of which each half of split patterns is fastened. © Ano. of different sized and shaped patterns may be mounted on one match plate. © The match plate with the help of locator holes can be clamped with the drag. © After the cope and drag have been rammed with the molding sand, the match plate pattern is removed from in between the cope and drag. ® Match plate patterns are normally used in machine molding. ® By using this we can eliminate mismatch of cope and drag cavities.‘Cope Pattern Copyright © 2008 CustomPantNet Fig: Match plate pattern5. Sweep pattern: © A sweep pattern is just a form made on a wooden board which sweeps the shape of the casting into the sand all around the circumference. © Sweep pattern avoids the necessity of making a full, large circular and costly three- dimensional pattern. © Asweep pattern is preferred for producing large casting of circular sections and symmetrical shapes.Fig. 2.8. Sweep pattern. Sweep pattern6. Gated pattern: ® A gated pattern is one or more patterns having attached runner and gates. ® A gated pattern can manufacture many casting at one time and thus it is used in mass production systems. ® Gated patterns are employed for producing small castings.Cope and Drag patterns: © Acope and drag pattern is another form of split pattern. ® Each half of the pattern is fixed to a separate metal/wood plate. ® Each half of the pattern(along the plate) is molded separately in a separate molding box by an independent molder or moulders. ® The two moulds of each half of the pattern are finally assembled and the mould is ready for pouring. © Cope and drag patterns are used for producing big castings which as a whole cannot be conveniently handled by one moulder alone.Cope Pattern: Riser Pattern ‘Runner Pattern Copyright © 2008 CustomPartNet Fig: Cope and drag patternPATTERN ALLOWANCESPattern Allowances: A pattern is larger in size as compared to the final casting, because it carries certain allowances due to metallurgical and mechanical reasons.Types of Pattern Allowances: The various pattern allowances are: uw FF WN . Shrinkage or contraction allowance. . Machining or finish allowance. . Draft of tapper allowances. . Distortion or chamber allowance. . Shake or rapping allowance.1.Shrinkage Allowance: Almost all cast metals shrink or contract volumetrically on cooling. To account for this, shrinkage allowance is provided on the patterns. Patterns are made oversized to compensate this shrinkage.2. Machining Allowance: Machining allowance is given: i. To remove scale and imperfections from the casting ii. To achieve exact casting dimensions. . To achieve required Surface finish on the casting.3. Draft or Taper Allowance: " Draft allowance is given so that the pattern can be easily removed from the molding material without damaging the mould cavity. * Draft allowance is imparted on internal as well as external surfaces; of course it is more on internal surfaces,The taper provided by the pattern maker on all vertical surfaces of the pattern so that it can be removed from the sand without tearing away the sides of the sand mold and without excessive rapping. Figure shows a pattern having no draft allowance being removed from the pattern. In this case, till the pattern is completely lifted out, its sides will remain in contact with the walls of the mold, thus tending to break it. Figure 3 (a) Pattern Having No Draft on Vertical EdFigure is an illustration of a pattern having proper draft allowance. Here, the moment the pattern lifting commences, all of its surfaces are well away from the sand surface. Thus the pattern can be removed without damaging the mold cavity. ese Pa storm Figure 3 (b) Pattorn Having Draft on Vertical Edaes4, Distortion or cambered allowance: A casting will distort or wrap if i. Itis of irregular shape, ii. Allit parts do not shrink uniformly i.e., some parts shrinks while others are restricted from during so, iii. Itis u or v-shape, iv. The arms possess unequal thickness, v. One portion of the casting cools at a faster rate as compared to the other.SS Required Shape Distorted Cambered of Casting Casting PatternUU DO (ii) (ili) (a) U-shaped Casting (i) Required shape of casting (li) Casting produced with distortion (ii), Pattern provided with Camber allowance 2G ag at ) (b) F-section Casting5. Shaking/ Rapping allowance: = A patter is shaken or rapped by striking the same with a wooden piece. This is done so that the pattern a little is loosened in the mold cavity and can be easily removed. = In turn, therefore, rapping enlarges the mould cavity which results in a bigger sized casting. = Hence, a -ve allowance is provided on the pattern i.e., the pattern dimensions are kept smaller in order to compensate the enlargement of mould cavity due to rapping.Thank You