By

Prof. Huzaifa Fidvi

Asst. Professor, Mechanical Engineering Department
Anjuman College of Engineering and Technology,
Nagpur
 Pattern Making
• Pattern is a REPLICA of the object to be cast.
• It is used to prepare the mould cavity into
which molten material will be poured during
the casting process.
• Patterns used in sand casting may be made of
wood, metal, plastics or other materials.
 Pattern Materials
1. Wood – White pine, Teak, Shisham, Deodar
Advantages:
 Wood is the most popular and commonly used material for
pattern making.
 It is cheap.
 Easily available in abundance.
 Repairable.
 It is very light and can produce highly smooth surface.
 Wood can preserve its surface by application of a shellac
coating for longer life of the pattern.
 Easy to join to acquire complex shapes.
 Good surface finish can be obtained
 Pattern Materials
1. Wood – White pine, Teak, Shisham, Deodar
Limitations:
 It is susceptible to shrinkage and warpage and therefore its life
is short.
 It is highly affected by moisture of the molding sand and swells
resulting in change in shape and size.
 They do not withstand rough handling.
 Poor wear resistance.
 It is weak in comparison to metal.
Applications:
 It is used when quantity of castings to be produces are small.
 It is used when pattern size is large.
2. Metal – Cast Iron, Aluminum alloys, steel, brass…
Metallic patterns are preferred when the number of castings
required is large enough to justify their cost.
Advantages:
 These patterns are not much affected by moisture as
wooden pattern.
 The wear and tear of this pattern is very less.
 Metal is easier to shape the pattern with good precision,
surface finish.
 It can withstand corrosion and handling for longer period.
 It possesses excellent strength to weight ratio.
 They do not absorb water and retain their shape.
 They have greater resistance to abrasion.
 They have longer life.
2. Metal – Cast Iron, Aluminum alloys, steel, brass…
Limitations:
 Expensive
 Higher weight
 Tendency of rusting.
 Not easily repaired. (aluminum patters are difficult to weld)
 Machining is difficult compared to wooden patterns.
Applications: Metal patterns are used where –
 Large number of castings are required i.e. for mass
production.
 For repetitive orders.
 Where high dimensional accuracy is required.
3. Plastic
Advantages: Plastics are getting more popularity now a days as they are:
 Lighter
 Stronger and durable
 moisture and wear resistant.
 They are not affected by the moisture of the molding sand.
 have smooth surface finish.
 Corrosion resistant.
 Easy to make
 Do not stick with the mould cavity, hence provide easy
withdrawal.
3. Plastic
Limitations:
 Light sections are fragile
 less resistant to sudden loading and their section may
need metal reinforcement.
 Do not work well when subjected to severe shocks as
in machine moulding.
Applications: They are used where
 Quantity is more
 High dimensional accuracy is required
 For repetitive orders
4. Plaster – Plaster of Paris, Gypsum cement
Advantages:
 It can be easily worked on with wood working tools.
 Intricate shapes can be easily cast.
 It has high compressive strength.
 Unlike metal it expands on solidification.
 It is cheap and easily available.
 Light in weight.
Limitations:
 Possesses low strength.
Applications: Plaster is used for making
1. Small and Intricate patterns.
2. Core Boxes
5. Wax
 Wax patterns are made by pouring wax into split moulds.
After cooling it is taken out and used for moulding.
 From the mould it is not drawn out but removed by
simply heating the mould.
Advantages:
 Wax patterns provide good dimensional accuracy.
 Good Surface finish.
 Mould cavity does not get damaged while removing the
pattern.
Applications:
 It is used in Investment Casting Process.