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This document discusses the different types of allowances that must be included in patterns for metal castings:
1. Shrinkage allowance accounts for the contraction of the metal as it cools and solidifies. It is typically 1/75 for aluminum alloys and 1/96 for iron castings. However, predicting exact shrinkage is difficult due to factors like core and mold materials.
2. Machining allowance is included to allow for removing casting imperfections through machining to achieve the final product dimensions and surface finish.
3. Draft allowance tapers vertical faces of the pattern to ease removal from sand molds without damaging the mold cavity. More draft is typically needed for inner pattern details.
This document discusses the different types of allowances that must be included in patterns for metal castings:
1. Shrinkage allowance accounts for the contraction of the metal as it cools and solidifies. It is typically 1/75 for aluminum alloys and 1/96 for iron castings. However, predicting exact shrinkage is difficult due to factors like core and mold materials.
2. Machining allowance is included to allow for removing casting imperfections through machining to achieve the final product dimensions and surface finish.
3. Draft allowance tapers vertical faces of the pattern to ease removal from sand molds without damaging the mold cavity. More draft is typically needed for inner pattern details.
This document discusses the different types of allowances that must be included in patterns for metal castings:
1. Shrinkage allowance accounts for the contraction of the metal as it cools and solidifies. It is typically 1/75 for aluminum alloys and 1/96 for iron castings. However, predicting exact shrinkage is difficult due to factors like core and mold materials.
2. Machining allowance is included to allow for removing casting imperfections through machining to achieve the final product dimensions and surface finish.
3. Draft allowance tapers vertical faces of the pattern to ease removal from sand molds without damaging the mold cavity. More draft is typically needed for inner pattern details.
Dept. of Manufacturing and Industrial Engineering Faculty of Mechanical Engineering Pattern Allowance Castings are always smaller in dimensions than the pattern from which they are made. The excess in dimensions is referred to pattern allowance.
There are 3 allowances included in a pattern: 1. Shrinkage allowance 2. Machining allowance 3. Draft allowance
Shrinkage Allowance Shrinkage allowance is provided to compensate the contractions of a casting. The contraction of a casting takes place in 3 stages.
1. The contraction of the liquid from the pouring temperature to the freezing temperature 2. The contraction associated with change of phase from liquid to solid 3. The contraction of the solid casting from freezing temperature to the room temperature Shrinkage Allowance (cont) However, only the last stage of the contraction will be considered in pattern making. Incorporation of contraction allowance was done by using a specially engraved rules known as the contraction rules.
Contraction allowance: 1 in 75 for aluminium alloys 1 in 96 for iron castings Shrinkage Allowance (cont) Predicting casting contraction can never be precise. Examples; 1. Rigidity of the mould. When iron castings are made in green sand moulds, the mould walls move under pressure of the liquid metal, causing the expansion of the mould cavity, thus compensating for some of the metal contraction 2. Restriction by the core. Cored castings may not contract as much as expected, because the presence of a strong core may restrict movement of the casting as it is cooling. Shrinkage Allowance (cont) 3. Expansion of core binder. Some core binders expand with the heat of the cast metal causing the casting to be larger than otherwise expected.
For these reasons, and others, it is only possible to predict contractions approximately. Precise contraction allowances can be built into the patterns based on experience. Machining Allowance Normally, a cast surfaceis rough to be used for the final product. Machining is therefore required to obtain the final surface texture or dimensions.
The total machining allowance depends on the material and the overall dimension of the job. Machining Allowance (cont) Draft Allowance At the time of withdrawing the pattern from the sand mould, the vertical faces of the pattern are in continual contact with the sand, which may damage the mould cavity. To reduce the chances of this happening, vertical faces of the pattern are always tapered from the parting line. This provision is called draft allowance. In general, inner details of the pattern require higher draft than outer surfaces Draft Allowance (cont)