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Draft
Pattern draft is defined as the taper on vertical elements in a pattern
which allows easy withdrawal of the pattern from the mold.
This draft is necessary in order that the pattern can be removed easily
from the mold causing no damage to the sand. The amount of draft
required will vary with the depth of the pattern.
pattern having no draft allowance when lifted out, its sides will remain in
contact with the walls of the mold, thus tending to break it.
Taper varies from about 1-3 degrees. The greater the taper, the easier it
is to draw the pattern out of the sand
Amount of draft
The amount of draft depends upon the following factors : Size and shape of pattern
Depth of mold cavity
Method used to withdraw pattern
Pattern material
Mold material
Molding procedure
Shrinkage
The pattern is intentionally made larger than the final] desired casting
dimensions to allow for solidification and cooling contraction of
casting.
The total contraction of a casting takes place in three stages, and
consists of:1. The contraction of the liquid from the pouring temperature to the
freezing temperature,
2. The contraction associated with the change of phase from liquid to
solid,
3. The contraction of the solid casting from the freezing temperature to
the room temperature.
The total contraction is volumetric, but usually expressed linearly.
This varies with each type of metal and the shape of the casting.
The added dimensions are incorporated into the pattern by the
pattern maker by using what is called shrink rulers. These rulers are
made of steel and the shrinkage is compensated for by having been
worked proportionately over its length. (shrink rule 12 inches long will
be actually 12 + 3/16 inches long),
Cast iron
Brass
Gun-metal
Phosphor bronze
Aluminum alloys
Zinc and zinc alloys
0.9-1.3%
1.3%
1.0-1.6%
1.0-1.6%
1.3%
2.6%
Machining Allowance
The extra material left on casting for any surface that will be
machined called machining allowance.
The finish and accuracy achieved in sand casting are
generally poor and therefore when the casting is functionally
required to be of good surface finish or dimensionally
accurate, it is generally achieved by subsequent machining.
Machining or finish allowances are therefore added in the
pattern dimension.
The amount of machining allowance to be provided for is
affected by the method of molding and casting used viz. hand
molding or machine molding, sand casting or metal mold
casting.
The amount of machining allowance is also affected by the
size and shape of the casting; the casting orientation; the
metal; and the degree of accuracy and finish required.