Pattern

A Pattern is a replica of the object to be made by the casting process,

with some modification. The main modifications are:
1. The addition of pattern allowances,
2. The provision of core prints, and
3. Elimination of fine details which cannot be obtained by casting and
hence are to be obtained by further processing

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Pattern Allowances
The dimension of the pattern are different from the final dimensions of the casting required. This is
required because of various reasons.

Shrinkage allowance
Shrinkage can again be classified into Liquid shrinkage and solid shrinkage. Liquid shrinkage is
the reduction in volume during the process of solidification, and Solid shrinkage is the reduction
in volume during the cooling of the cast metal.

Finishing or Machining allowance

The surface finish obtained in sand castings is generally poor (dimensionally inaccurate), and
hence in many cases, the cast product is subjected to machining processes like turning or grinding
in order to improve the surface finish. During machining processes, some metal is removed from
the piece. To compensate for this, a machining allowance (additional material) should be given in
the casting.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Draft Allowance
When the pattern is to be removed from the sand mold, there is a possibility that any
leading edges may break off, or get damaged in the process. To avoid this, a taper is
provided on the pattern, so as to facilitate easy removal of the pattern from the mold,
and hence reduce damage to edges. The taper angle provided is called the Draft
angle. The value of the draft angle depends upon the complexity of the pattern, the
type of molding (hand molding or machine molding), height of the surface, etc.
Draft provided on the casting 1 to 3 degrees on external surface ( 5 to 8 internal
castings)

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Shake Allowance
Usually during removal of the pattern from the mold cavity, the pattern is rapped all
around the faces, in order to facilitate easy removal. In this process, the final cavity is
enlarged. To compensate for this, the pattern dimensions need to be reduced. There are
no standard values for this allowance, as it is heavily dependent on the personnel. This
allowance is a negative allowance, and a common way of going around this allowance is
to increase the draft allowance. Shaking of pattern causes enlargement of mould cavity
and results in a bigger casting.

Distortion allowance
During cooling of the mold, stresses developed in the solid metal may induce distortions
in the cast. This is more evident when the mold is thinner in width as compared to its
length. This can be eliminated by initially distorting the pattern in the opposite direction.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Types of Pattern
There are various types of patterns depending upon the complexity of the job,
the number of castings required and the moulding procedure adopted.

Single-piece pattern
Split pattern
Follow board pattern
Cope and drag pattern
Match plate pattern
Loose-piece pattern
Sweep pattern
Skeleton pattern

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Single Piece Pattern

used for applications in very small scale production
It is used where the job is very small and does not create any withdrawal
problems
This pattern is expected to be entirely in the drag

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Split Pattern
When the contour of the castings makes its withdrawal from the mould
difficult, or when the depth of the casting is too high, then the pattern is
split into two parts.
Using of dowel pins which are fitted to the cope half.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Cope and Drag Pattern

These are similar to split patterns.

In addition to splitting the pattern, the cope and drag halves of the pattern
along with the gating and risering systems are attached separately to the
metal or wooden plates along with the alignment pins.
It is used for casting which are heavy and inconvenient for handling as also
for continuous production.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Match Plate Pattern

These are extensions of the cope and drag pattern.
Here the cope and drag patterns along with the gating and the risering
are mounted on a single matching metal or wooden plate on either side.
One side of the match plate the cope flask is prepared and on the other,
the drag flask.
After moulding when the match plate is removed, a complete mould
with gating is obtained by joining the cope and the drag together.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Loose Piece Pattern

This type of pattern is also used when the contour of the part is such that
withdrawing the pattern from the mould is not possible. Hence during
moulding the obstructing part of the contour is held as a loose piece by a
wire.
After moulding is over, first the main pattern is removed and then the loose
pieces are recovered through the gap generated by the main pattern
Moulding with loose pieces is a highly skilled job and is generally
expensive and therefore, should be avoided where possible.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Amit Roy, Lecturer, Dept. of ME,

RUET

Follow Board Pattern

This type of pattern is adopted for those castings where there are some
portions which are structurally weak and if not supported properly are
likely to break under the force of ramming.
Hence the bottom board is modified as a follow board to closely fit the
contour of the weak pattern and thus support it during the ramming of the
drag.
During the preparation of the cope, no follow board is necessary because
the sand which is compacted in the drag will support the fragile pattern.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Sweep Pattern
A sweep is a section or board (wooden) of proper contour that is rotated
about one edge to shape mould cavities having shapes of rotational
symmetry. This type of pattern is used when a casting of large size is to be
produced in a short time. Large kettles of C.I. are made by sweep patterns. -

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Skeleton Pattern
For large castings having simple geometrical shapes, skeleton patterns are
used. Just like sweep patterns, these are simple wooden frames that outline the
shape of the part to be cast and are also used as guides by the molder in the hand
shaping
of
the mould.
This type of pattern is also used in pit or floor molding process.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Pattern Color Code

The patterns are normally painted with contrasting colors such that the mold
maker would be able to understand the functions clearly. The color code used
is Red or orange on surfaces not to be finished and left as cast.
Yellow on surfaces to be machined.
Black on core prints for un-machined openings.
Diagonal black stripes with clear varnish on to strengthen the weak
patterns or to shorten a casting.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Core
A core is a device used in casting and molding processes to produce
internal cavities and reentrant angles. The core is normally a disposable
item that is destroyed to get it out of the piece. They are most commonly
used in sand casting, but are also used in injection molding.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Chaplet
As mentioned earlier, cores are usually supported by two core prints in the mold. However,
there are situations where a core only uses one core print so other means are required to
support the cantilevered end. These are usually supplied in the form of chaplets

Chaplets are metallic support.

These are the same composition as that of the pouring metal so that the molten metal would
provide enough heat to completely melt them and thus fuse with it during solidification.
Amit Roy, Assistant Professor, Dept. of
ME, RUET

Chill
A chill is an object used to promote solidification in a specific portion of a metal casting
mold. Normally the metal in the mold cools at a certain rate relative to thickness of the
casting. When the geometry of the molding cavity prevents directional solidification
from occurring naturally, a chill can be strategically placed to help promote it.

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Molding Materials
A large variety of molding materials are used in foundries for manufacturing molds and cores. They
are:
Molding sand
System sand (backing sand)
Facing sand
Parting sand and
core sand

Requirements of molding sand are:

(a) Refractoriness
(b) Cohesiveness
(c) Permeability
(d) Collapsibility
The performance of mold depends on following factors:
(e) Permeability
(f) Green strength
(g) Dry strength

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Properties of Molding Material

Refractoriness: It is the ability of the molding material to withstand the high
temperatures of the molten metal so that it does not cause fusion.
Green Strength: The molding sand that contains moisture is termed as green sand. The
green sand should have enough strength so that the constructed mold retains its shape.
Dry Strength: When the moisture in the molding sand is completely expelled, it is
called dry strength.
Hot strength: After all the moisture is eliminate, the sand would reach a high
temperature when the metal in the mold is still in the liquid state. The strength of the
sand that is required to hold the shape of the mold cavity then, is called hot strength.
Permeability: The molding sand should be sufficiently porous so that the gases are
allowed to escape from the mold. This gas evolution capability of the molding sand is
termed as permeability.

Thermal stability: to resist cracking on contact with molten metal

Collapsibility: ability to give way and allow casting to shrink without cracking
the casting
Reusability: can sand from broken mold be reused to make other molds?
Amit Roy, Assistant Professor, Dept. of
ME, RUET

Binders Used with Foundry Sand

Sand is held together by a mixture of water and bonding clay
Typical mix: 90% sand, 3% water, and 7% clay
Other bonding agents also used in sand molds:
Organic resins (e g , phenolic resins)
Inorganic binders (e g , sodium silicate and phosphate)
Additives are sometimes combined with the mixture to increase
strength and/or permeability

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Types of Sand Mold

Greensand molds - mixture of sand, clay, and water
Green" means mold contains moisture at time of pouring
Drysand mold - organic binders rather than clay
Mold is baked to improve strength
Skindried mold - drying mold cavity surface of a greensand mold to a depth
of 10 to 25 mm, using torches or heating lamps

Amit Roy, Assistant Professor, Dept. of

ME, RUET

Effect of moisture, grain size and shape on mold quality

Amit Roy, Lecturer, Dept. of ME,

RUET