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  • Pattern Design by B. Rupert Kiley, Henry, E. Hall - 1939

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    Wellington Domingues
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    Pattern Design by B. Rupert; Kiley, Henry, E. Hall - 1939

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    Pattern Design by B. Rupert Kiley, Henry, E. Hall - 1939

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    Wellington Domingues

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    © All Rights Reserved
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    PATTERN DESIGN By B. RUPERT HALL HENRY E. KILEY, 8.B. Covet, 19, mv Avengers Decrmon Cra ‘Cormier i Gaur Dara INTRODUCTION The age of metals, aveording to some historians, had its Inception in the accidental casting of some low-melting alloy When ore-bearing stones were heated in an ancient camp fire The molten metal, on solidifying beneath the camp fre, may Inve assumed by chance alone a shape suggestive of a usefl Wool or weapon, Such an accident would suggest the pos sibility of controlling the shape of the solidified met forming cavities in the sand info which the molten metal ld flow. Satisted for but a while with shaping each cavity by hand, the ancient foundryinan must have discovered before a very long time the se of a wooden facsimile in making a nomber identical molds of the desired casting. Thus man became first molder and then a patersmaker and, in a broad sense institted the Bist foundry The cieamstanees surrounding the frst use of pattems can not be aceurataly detrmined, bet from some very humble Ininning, pattermaking bas grown into a trade which has a very important place in the manufacture of machines. Next lo the designer the pattemmaker is responsible for detail of form end consteuetion; and it is he who creates the Brx Uangible evidence of she machine which is to be. Until the atteramalker begins his work a machine is at best a pictur fn the drafting board, but under the patternmaker’s hand this two-dimensional, scaled representation soon assis fullsize solid form, ‘A patteramaker is essentially a worker in wood, a3 this ruaterial is sniversally used in_ pattern construction,» Indeed a'Fattemimaleer's work similar in almost every detail that of a cabinetmaker, Doth atust be skilled in joinery and In the manipsltion of woodworking tools. However, ia one detail their crafts difler, and that js in the Goal use 10 Which the product of each is put. Cabinets and furniture are ‘i INTRODUCTION sed a8 such while patterns conitste means to an end, tmamely the production of metal castings. Nevertheless, a well desigued pattern has a carein aesthetic value and, isn cigineering sense at lest, has just-as much beauty a8 3 Aelcately exceuted desk or chair Serving us intermediary between the designer and the foundryman, the patternmaker “must be able to. interpret rechanical dravings, to visualize an object in three dimen: ‘sous, cad finally to produce a fallsize counterpart of the ‘object in wood or plaster, He must be acquainted wit the molder’s craft, for patiermiakcing is more closely allied with nolding than’ with any other branch of machine manufae- ture, and it is important that the patternnuker be able to incorporate in his product constructional features which will facilitate work in the foundry. That a pattern be a facsimile of the desired casting is but ‘oe of the requirements of goad pattern design. Due to the Timitations of sand molding there are other features which a patie mist have if it Hs to be molded stoccssully. It tmsict ave sufeient draft for easy withdrawal from the sand ‘eran details of shape must be provided by the nse of bakes! Sand cores and loose pices, and ote itis necessary to com Strict patter in several sections if is shape will ot permit removal from the sand iy one piece, Adequaté allowances tmust te made 20 that the shrinkage accompanying. cooling will not couse wndersized castings, and from time to time i Tay even be necessary to counteract the effects of warping by daliteritely designing pattems which are warped in an ‘opposite direction, Today ‘with the ineessed ue of molding machines fis often a patt of a patteramaker's work to design tales and runaers, and to do this properly lmowledge of the Fhavior of molten rma i esental. Tecase of this clote alliance hetween pattern design and molding practice, it is unsatisfactory to reat the former withe font discussing certain phases of the latter. For this reason jin an early chapter description of green sand molding is presented which will belp to aequsint the render with the ‘vay in which pattems are use. INTRODUCTION i Recently am increasing ase of pressed and wrought metal Jostein machines has given rite to an impression that the ting industry has begun to dectne. This impression does to be warranted, however, for the construction of the very machines used in forging and pressing involves the tive of many castings. At che same time that certain machin fy parts are being redesigned for fabrication front wrought Insteral certain other pars are being redesigned for manu scture by casting. Taproved casting alloys, novel pattern fsign, and improved molding technique can very often alter an entire production picture anf-open up an eatitely new market for east metal products, CONTENTS Parnie Das Pater Parinlin™ One ince Pate Bester “Section Patera Crem Sand Cores Dry San CiteeGorehones Core prints Oreralancing Corps tengo Gree ore all aro Be Sharp Cormers—Files Filet Tools Allowance for ‘Sait Bee Cum 2 MoliAldlge of « Shalem PatiernBatiing-tn Drow ‘SeUoe of 2 Skelton Pritam im Molding Fipe Ofer ‘Requirements of Pattern Marials Wood aa Paticra Commerc Wane a9 Jocer 4 Boar dat Const Thickness Selesiaga Workog Face AWaness Mark Acersey in Layout WorkThe Lay og Out of Large Aver ransor of Linea Jl Bibbctd folate Oude Jot Borde apd Tenn Jone Mier ist Dove! Itt Fia Dat Joie Ft Mer Jeiot Fist Lap Joist Miclfneoes Bat Jiis—B8 inaracten Glad ip Sock Auer of Peas 0 Glia Ur for Takines—Boxing—Larse Twred Work igen —Iotrchageble Parteatone lec Carre § PATTERN DESIGN CHAPTER 1 PATTERN DETAILS Pattern —A pattern may be described as a model which is used to form a mold a which molten metal is cas. In the case of a small simple casting the pattern may be an exact facsimile, but, when the shape of a casting becomes compli ated, ite pattem may be so covered with accessories in the focm of coresprints that, at fst glance, it mieht be efile to associate them. Thevefore it may be said that the funds. imental requirement of a patter is, that it be s0 shaped and Constructed that a molder can use it to shape a sand mold in the form of the desiced casting. Parting-line Simple patterns are molded in two-part Asis and the surface which separates the two bodies of sand js commonly referred jo a8 the partingaurface or simply a5 the parting. When a pattern is in its proper position in the mold, the interstetion of the parting-surface and the surface fof the pattem is known as the parting-ine, a the subre ‘quene illustrations of patterns the partng-line will be labeled (Tig. 1), and i will help to indicate the manner in which the patera can be molded ‘When a pattern is in the conventional molding position, all potions above the putting-line are molded in the cope oF top accion of the flask, and all parts below the parting-line ars molded in the drag or bottom section of the flask. TE a fonsiderable portion of a pattern is to be in the cope itis visable to separate the pattern at the parting-line as in Fig. 8 ‘Too much consideration ean not be given to the location fof the parting-ine, since its positon establishes the method ‘of molding. Many castings ate of sich shape that a pattern taker has eonskferablelaitade in his choice of a pating-line lands although no defisite rile eau be Isid down, a wise locas 2 PATTERN DESIGN tion can often facilitate subsequent molding and machining operations. One-pioce pattern, straight parting —A one-piece pattern, partly withdrawn from the sand, 19 shown in Fig. 1, Its ing line Hes entirely ja the top surface and the entire pattern my be molded in. the frag portion of the Mask, Tn this cose the casting is to be a hollow exlnder, if one overlooks the taper which has been added to the sides of the pattern to facilitate the Iting ig, b,_Paten poly wil= One-piece putters, icegular parting.—In Fig. 2 it may be i observed that this ‘ype of pattem has no Bat sides and con I egwently some part of it snust be molded in the cope, re slightly complicates the molding, bot by vesort= ‘ution hasdwork it cam be accomplished ing t0 Single-parted or two-piece patlors:—A single-parted or two-piece pattern, separated at the parting-ine, is shown in ig. The cope portion © and the drag portion D are held jn proper reation vith eich other by dowel-pins B. These pins may be of wood or metal snd should ft snugly but not Tightly. When made of wood, as in Fig. 4, the pins shoal ‘ye rounded on the en’s and should project about of an “The dowelpins may be applied by assembling the inet PATTERN DETAILS 3 og teen and drilling holes completly two parts ofthe 1 into the drag: portion asin Fig. 3. the cope portion i Eye Cecasionally, however, it 4 desicable to locate dowel-pins without drilling through the pattern. This may be accon- plished by placing a small inch brad between the two pieces tout where a devel is to be centered. The pieces are then assembled in their proper relation and a pressure applied Which causes the feud of the brad to make an indentation which will accurately locate the point at which to hore. Th order that no doubt may arive as to the proper method fof assembling the parts of a split pattern, dowelpins are fever located. symmetrically on center Tinea, but are placed o that itis impossible to assemble the patters in any but the correct wav ae 2 Fig. 4, Woot Nig. & Bram dove Brass pins, Fig, §, are available which work muel) better than wood and which will wear longer. "The pin A and the cap B are threaded ard may be turned into place like a rood fsrewe TF the Kole is Yoeated by boring through the pattern ii is mesestary to close it up afterwards with a wood plug. 4 PATTERN DESIGN ‘Maliple-part pattern —Pattesms often consist of three or soce pieces as in the ease of the pipe Sting, Fig. 6. Here fa three or four-part flake is used, depending on which Sting, the fve-ay or six-way eros i to be made, When a fas has three or more setions the termediate sections are called Rote eens cia, Ling a te crt Fe 6 my sme She oso Nota ue en Bye Got ge eet ee Stats petTe stn ptt, tte me Siew ent ly ante wie ne 0 ie: cogs we edd acd ed Be ee ee eee Tony sare te ens come PATTERN DETAILS 5 4 a conventional pattern. The sweeps or strickles $ are ‘employed ia forming the sand between the ribs of the pat tem, Considerable handwork is. required. in molding a ‘skeleton pattem apd except on large work such as pipe east~ ings and turbine castings, the wse of such a pattern would snot be advisable ig. % ken pater for late ella. Section pattera.—Tlue section pattern in Fig. 8 coussts of a hub A and one propller bade B. Tt may be emplayed ia Aokling a propeller having as many blades as desired Green sand cores—A green sand core is @ projecting ‘olan of sand which is formed on the removal of a pater from the sold, , Fig 1 itasteates the way in which such fa core smy be wad in molding hollow cylinder. Due to fis relatively low strength a green sand core must be chenky Hit ist to be Broken off when the pattem is drawn, or washed way by the inflowing metal, Tt may be observed ‘hata green sand care isnot eplindsicl bat i lightly comes! 6 PATTERN DESIGN Dry sand coros—When i is inviable to core an opening with ordinary molting sand, a special core sand may be Which is made by mixing sand with linseed oil or some of ed binder. ‘This material may be molded into cores and, on baking or drying in an oven, ie aaguzes a fairy high strength In the dey or baked condition a dry sand core can be easly handled and placed in positon in a mold Fig. 9, Coe-box fra vrien core Core-boxen Dry sand cores are mole fn bees, Fig. 9 and Fig, 10, out of which they can be raed on to irom plates | and baked, Where cores are symmetries, 2 oncshalf core PATTERN DETAILS ? Fig, 9, is all that is ccquited, ax two half-cores can be cher after baking. If this isnot the case, how: fren, & complete box or a right and left section, Fig. 139, fist be constructed "The same care is required in the making of core-boxes vs in making pattems; in fact, the designing of core-boxes is the most dificak branch of the ptternmake’s art to The pattern illustrated in Fig Jing problem and it could be molded in the po presents no particular ion ind Tie 1, ore-ox fora hovlona coe cated using a green sand core. Yet if the height A. were increased, the tse of a green sand core wold be inadvisable Inecause of the possibilty of ite erushing under its own weight or breaking down, “The advantage of sing a dry sand Core is obvious ‘The pattern might sil be molded in the vertial postion snd would be constricted as indicated in Fig. 12, The inside fetal, however, would be feraished by means of « dry sand fine molded in a cores, Fig. 9, “The necessary pattern ejuipmest thus consists 4f the soll pattern and the core-box, Tt would slso be possible to design this patter for molding inthe orizontal position, in which ease the pattern would be made in two pices, Fig: 13, and would be accompanied by 8 core-box, Fig. 10 Tn citer case, sce the pattem is symmetrical, a corebox forene-halt of the core is al that is required. This is doe tinet advantage in that cores molded ina ane-haltcore-box have a fat surface on which they may be rested daring the drying operation. If a ore ix of stich shape that it presents to lat surface, a dryer must be provided. This is light petal box ar foem in which the core may be rested while in the drying oven. Tt resembles aone= half core-box and, indeed, may very well serve as one =a Ei This is « good example of the type of decison which a pattern designer is called pom to make, In this ease a ela tively simple casting presents three possible pattern designs Tt the pattern is molded inthe vertical position, using a green sand core, the necessary pattern euioment is redaced to # minimum, bu trouble may be encountered in the molding, PATTERN DETAILS 9 IC a vertical dry sane core is used a core-box ‘must Ibe constructed which will be more expensive than the pattern itselt. The molding will be cimplied, however, and it will bre possible to prodice a casting, which is cylindrical on the iy splitting the pattern and molding it in the horizontal ition both the inner and outer surfaces of the casting tiny be cylindrical, but there is a possiblity of dirt and limpurtis being segregated in the uppermost surface or cope ig A Pat fr molding» Smbing inthe hoot atin portion, Impurities tend to segregate atthe top in any case, but except in the lst tiethod the effect could te easly over ome by inereasing the finishing allowance on the top curface| ofthe easing, (Core-prnts.—Thus far in the discussion of cores, no men. tion has been made of the methods ased 0 hold cores in their correct position ia the mold, When a mold is poured there isa decided tendency for cores 10 be swept away and even to feat on the rising metal. Therefore some provision must be made for holding them securely in place, Usually this is accomplished by affixing to the pattem smell projections Known as corepriats. These correspond te the cored openings in the casting and they form pockets ( eore-seats in the mold into which the projecting ends of the dy snd cores can ft sgl Th Fig, 12 the core-prints A necessary for the location and scouring of a vertical core, are indicate. Provision is made 0 PATTERN DESIGN inthe core-box, Fig. 9, for an extza length of core B, which will ft into the seats formed by the eore-peits. When this same pattern is redesigned for Horizontal snolding. the neces sity of the coreprints A, Fig. 13, is beter appreciated, for without them it would be dificult to hod the core in is central postion da the mold To set up hand and fast rules governing the proportions of core-prints ie unetisfacory, for usualy each patie ha individual requirements, Yee there are a few fundamentals hich should be cbserved if the core-prins are to serve to the best advantage O © cae a: Mig. 14 Recommended propetons for Diag'prn A emevable copes, Tn the case of a hellow cylindrical pattern the cope- and ‘rag-prims, owing to their different services during molding are of different shape. ‘The deag:print A, Fig. 14, which forms a pocket in the mold jn which the core ean stand, should be provided with just enough taper for easy pattem drawing, about 4 of one degree. The copeprint B, Fig. 14, Which is ucvally equipped with a:dowel-pin, as indicated, 20 4s to be removable, should be designed with considershle taper, about 18 degrees, 2 thatthe core may be caily guided into its seat when the cope is repaced on the mold. ‘Some pattern designers recommend having the ameter PATTERN DETAILS un of the dagpint ati jonaon with te pater equal 10 eco ameter asin Fig 15. This meas that both eds on epimarcal core mast be shaped tof dnt the core Mite Pedta i seats, but the result of such a som itis that practically mo Inetal esapes around the core to form a fin on the casting Other designers make the diameter at the end of the drag- pine equal to the core diameter, This practice eliminates the Shaping of the drag end ofthe core, but a pocket is formed, ‘A, Fig 16, which will cause & sharp fia on the casting which makes for difcalty in handling and leasing. ig. a7, Overalancingeore-pit Overbalaxcing core-print-—When a horizontal opening does wot exten completly through a casting a. single long ore-rint A Fig. 17, ast be provided which will make a. feat into which the major portion of the core ean fit The R PATTERN DESIGN ncing print, as ite mame implies, is of suificient length, B, Fig. 17, so that the part ofthe core which is seated will more than Balance the part © ofthe core, Fig. 17, when itis placed in postion in the nok, When the mold is assembled and poured, any tendency of the core to feat’ will be restrained by the seated portion Hanging or cover coreprint —It is quite possible to mold this same casting in the erties! postion in Which ease_a- hanging ‘or cover- core, Fig. 18, wonld be used. The ‘seated portion of the core A conld very well serve to purposes that of holding the core B and that of covering whieh could be poured st C. Bet tr practie, however, would be to build a cope whieh wonld provide an additional pouring head and which would weigh down the core and help t9 prevent its floating | OF Bopp, Pig. 20. Corebam, aie oF Arop-print—Whien holes or bosses rust be cored entirely below the parting, a tail or dvop-print iy tsed to PATTERN DETAILS 13 ‘old the cores in place. in P, Fig. 19, such a print is shown, he core isto provide the small boss A, std would be molded in the core-hox, Fig. 20. Were a hole instead of a boss to be required, a eore-prit P, Fig 21, would be affixed to the pattern and a core-box constructed sich as i shown in Fig, 22. The cylindical projection A on the core would be located fn the mold as indicated by the dotted lines, Fig. 21, and would. make the desired hole in the casting. The eoresbox in this ease is epit tnd equipped with dowelpins in rach the same manner a8 ia splitpatter. When a core-box is so constricted itis an easy mater to remove the molded core without bresleing ‘off the small eylindrieal portion. Mig. 2, ast or érop-prnt Yin, 2 Split core-tex In designing cove-prnts and core-boxes generous tapers shold he provided, both for easy pattern removal hearing on the shape of the casting, the design should be ‘effected wih a though to easy ing. Chaplets.—In some oases itis impossible to provide a sut= ficient number of eore-prints to property position a core. In Fig. 28 this condition exists, the single small opening at the top of the casting, although it may be adequate for venting ff the core snd subsequent cleaning, not being adequate for fm seating. In a sitvation such as this, recourse mst he made tothe mse of metal chaplets which are placed betwee the mold aad core to hold the latter in place. Chaplets are 4 PATTERN DESIGN available in various shapes and sizes, Fig. 24 the single and Aone head variety being most oman, Pig, 28, Dry and core Bld plae by caplet In use, chaplets old the core in postion while the molten etal solidifies, and at the same time become fused into the that they can seireely he detected a Lad SS. ee SS shapes of chap (c( the casting. Stel chaples are generally coated with tn to prevent the formation of rast which, becrese of the moisture Fe contains, may cause Blowholes in the casting. PATTERN DETAILS 15 Stop-of—Once in a while it is desired to incorporate in terns, constructional details whish are not roqueed in the fasting, For instance, in tho construction of a thin plate tmttern it might be desirable to add eleat or batten A. Fig. to prevent splitting or warping. ‘The opening which it makes in the mold is later fled with sand and smoothed of ‘and consequently tho stop-aff detail docs not appear on the casing, This practice is recommended only where one or toro castings are to be made from an inexpensive. pattern. bw ROH ince Pig 26 Ue ofa supa a pte for tno Another useful application of the stopoff principle is shown ‘in Fig, 26 where one patter and one core-box are to be used in making two different lengths of flanged pipe. Only one or two pipes of each size are required and the job does not warrant the expense of an extra pattern and eote-bux, It is 6 PATTERN DESIGN therefore possible to-make one pattem for the longer pipe and later to adapt it for use in making the shorter pipe The tage F, Fig. 25,6 afixed to the patter atthe correct location ands mold is mide in the conventional manne. faving drawn the pattem the moléer then employs an adic tional piece of equipment to extend the coreseat formed ly the core-print A uni it reaches the flange F. When this is accomplished the core may be placed in position and the sold dosed Patera celery and markingt-—The varius paris of 2 ater shouldbe pred in contrasting colors 20 thet there tay be oo dow at to their Sanction. There ba aways ben src cofuton tothe color ensosaied rit the vtions ete a eee er creeh Gee es fe erect ate esa vey folibe sivesaly alee, Bening ta thm eye per Tere hold be eed a lls Surfaces left ufnished ace to be plated black. 2 Saracs tobe machined are tobe ait red 4 Stats of and for loos pieces are Co be masked by red stir on a yelow backer Br Conpean ical aes Pee energies ae tinted yellow. 5: Scopofis wo to bo incated by diagonal Vas ons on sell be. The A. FA. pateromaring sytem ie stsightforeard ncug sd snes the core trvepriarily au gue fo the Inner stems logic and iting that they be. generally ret vetaee emcee Ste oe eee te eles ieee of ce pees rate ae Tong tne before a complete agrment an be rachel i thi ‘Draft—Already in the description of patterns and core boxes casual reference has been made to the draft or taper Which js an essential feature of a pattern i it & to be she- essfully drawn irom the sand, In Fig. L the drat, exag- erated for clarity, may be observed en the inner sad outer PATTERN DETAILS. ” sueiaces of the pattern, Were it not present it would be Aiea, 4 not imposible, to withdraw the pattern withoxt Spoiling’ the sides of the mold and, indeed, there is goo oasblity thar the green sand core C would lift away with the pattern Ver with adequate draft a pattern may be exsily removed from the sand, for the sides ill elear the mold ss suo 25 upseard motion begins ‘The amount of draft depends largely on the sie and shape of the pattem, It should be sufficient to permit ready with ‘rawal of the pattern but should not be s0 great as to alter the essential dimensions of the casting, or complicate. subse (quent machining, There is no fixed rule controlling the lmiount of draft which should be allowed; but to give sone Hea of its magnitude 4 of one degree may be considered an average value. This figure may be doubled or even tebled fon small work; and on very large patterns, where the draft bevomes more noticeable, i may often be reduced to 4 of fone degree oF less Tnereased draft-—Under certain conditions it is necessary to design with iercased da‘t, a9 when small pockets extend Jno the cope or bodies of sand projet from the eope to form arven sand hanging coves ‘These have a decided ten deney to break away when the cope feed especially if they ate de oa ‘signed with sharp comers and litle drat. This tr dency can be overcome to ‘eettain degree by exag- erating the draft on the Fie. 2% tmeraped dat al ‘cape portion ofa pattern, provided i does not seriously affect the design. In Fig. 27 the draft on the sides A bs been increased, but if i is meces- ary that the sides be vertical, the pattern must be redesigned Gither by. separating it on the horizontal center line or ‘by esing a dry sand core to provide the cope detail ir PATTERN DESIGN ‘These ix tendency on the part of patiermmakers to stand. adie 100 rigidly in the matter of daft allowances and to use the same amount on all patterns, core-boxes, and core pints alike. ‘This is poor pattern design, for often the proper aplication of additional draft can miterilly assist inthe molding operation Shrinkage.—In cooling from the molten state all metals undergo an appreciable decrease im volume, Du to this Phenomenon, castings contract uniformly in all ditections| and when cold will be slightly sialler than their patterns, Ik is therefore ncessory, in order that castings be of the correct size, 10 incorporate ia the patterns an allowance for shrinkage, Shrinkage-ules.—Thie allowance may be incomporated by taking all pater measurements with shrinkage-rule the -raduations of which are oversize by an amount equal tothe unit contraction of the metal These rales are available for the common casting alloys with allowances for the asl shrinkage rates fez of an inch per foot, ete. Shrinkage rules are also graduated according fo the metric system, 30 fentimeters being approximately equivalent to 12 inches, A shrinkage of 1 millimeter in 100 ie very nearly equivalent to Hof an inch per foot SHRINKAGE RATES OF VARIOUS HETALS Alun ¥ of an inch per foot—appros, smth wh of an inch per Foot approx Briana of an inch per fout—appron. Cast Iron 1 of an inch per foot approx Copper ‘fe of an inch per footapprox, Lead soe of an inch per foot approx, Steel 2... 4 of an inch per foot anprox Zine se We Of an inch per foot approx Al patterns and cove-boxes uutst be laid out by using & slninkage-rule, bat’ even this practice docs not_entizely ompensate for the elfects of shrinkage. Shrinkage is fanda~ mentally a volumetric sostration aa, although it may be PATTERN DETAILS » quite ufone in 9 easing of wniform metal thickens, it ts lest impossible to predict the elect i a casting of vary ing metal sections ‘casting sn which Light and heavy sections are combined ray shrinke jn a pecllar fashion and produce the fle shown in Fig. 28 In this casting the middle bar snd ends are of rectangular eross-section, 17% 3 inches, andthe outside lars are semellpical, ¢ > yh inches. ‘The buckling iy 0 doubt be attributed to the relatively light outer bars solide fying progressively fro the middle to the ends, daring hich me hot metal was being fed to thern from the heavier a ig. 28, fort of seniage ina slminun casting. cod sections, thus making up for.any contraction, Finally ffter dhe outside hare weve solidied, the heavier ends and the middle bar became sold snd contracted, Ts contracting the macsive middle bar exerted high compressive force on the ‘outer bars causing them to buckle. This example is of ‘ourve an extreme ave, but toa lesser degree the same feature is present in many casings ened and sharp cermer—Shasp comers on a enitng Wie mec oe efecticeay en tre tone {nce and ower fv rong and therore shold be sve a Tihs motes ctl bog to Secs iv old lc tin progress {om the mold sirface tothe center of the eating by the forrtion of long erystalve sractres eon ts fends. ‘Phee dendrites, saggstive in appearance of The aon are nth TP ofthe Masa Tn spiiasns mpg’ by ne Work af ate We Zabel ipcrnendet of » PATTERN DESIGN fir or sprace tiees, strange themselves in a perpendicalar position relative to the surface of the casting ind in very eve packed formation, a» illstrated in Fig, 29. However, when Samp corners are present in a mold, as at G, Fig. 30, plane fof welmess occurs along the diagonal A where the dendrites, in groming out from the adjacent sides of the mold, Trt do not mesh perfectly fam saimony got, Tf the sharp comer is eliminated and the change in disece tion accomplished gradually, as at B, Fig, 90, there will not tea well defined cleavage plane and the strength of the caat= ing will not be impaired Fillis—Sharp corners on pattems are also objectionable | from 2 molding standpoint, in that they cause difcalty Iifting the eape and drawing the pattem. Sharp comers of sand are eaily broken and may be washed away by the hot metal. Moreover, sharp internal comers act as sires raisers PATTERN DETAILS a ‘or concentrators which may build up sttesies to many times the computed values Te is therefore customary to eliminate sbucp ntermal cor nets by the use of filets A, Fig. 31. These may be com sirvcted from a variety of material, wood, lather, wax, or composition, Leather flles—Leather is peshaps the most satisfactory material for fillets, as it ix fatty hard, Mexible nd easy 10 sly ‘On account of is fexitilty may be tsed on short Fig sie curves and irregular surfaces where it would be impose fo use wood Leather fillets are available in varios sizes aad ate casily held in place with glue or shell. If shellac is used it should be applied to both the pate and fle and slowed to dry wasil 5 becomes sticky before the fillet is rubbed into place Wax lets. Wax fillet material is available in various sires and is now commonly sold by the spool, It is less expensive than leather but is comparatively soft, is easly damaged, aad, uoles i i well covered with sh to stick to the molding send, ac i ine Was fillets wll adhere 10 the patter beter if applied after the inital coat of shellac Piet an example of which is given ig. 82, are usefal for applying fillets of either leather of wax, They may be obtained with balls coerespending radii to she various fillets. When ese on wax the tool should the warmed, preferably in hot water, so that i may shape the roe more ready islet 00 2 PATTERN DESIGN Aowaace for faishiag—Provsion ost be male on ext tunes of gsterm for the recat dai Tanking, Thi apeationshenid mot be conte wth the oneal Slowance Tor shiakage, the two being distinly arte” "Whe a tacking operation i to be pevformed ———S6 PATTERN DETAILS B allowance so that the machining may remave sll of the Vinound metal and uncover good clean acta All of these factors must be considered in deciding the aunt of stock to add for finishing. In general it may be suid that the allowance should be inereased in proportion to the size of the casting. a the ease of castings which are jvondvced in quantity snd axe known to come trae to the Jattern form, the allowance may be cut to a misinus, On hw work, however, where thee is any doubt, the allowance shoul be salfcent to. prectade the possibility of castings Ving t00 small to finish to the correct see hough stock should alWaye be allowed so that, on the hing, cu, the toot will get ander the scale and stl leave Plenty of metal for a finishing cut, At che same time it should be bore in mind that soy’ unnecessary allowance simply adds to the time required for finishing and to the uachining cost. ‘Surfaces to be ined are usually indicated on mechan leat drawings by the symbol # which is placed on the line Fpresemng the surface but not on the plan view of the func itsel. ‘This system ines been used generally in the but some manaiacsurers have adopted individual codes Indicating finished surfaces. I is felt that a system of nhols which would not only indicate the machined sur- foes but would also designate the degree of finish, would li a innprovement aver the general use off. Tn casse where all surfaces of a casting are to be fwchined, the mote, “Finish allover," or simply, "F. A. 0,” fh placed on the drawing. (Occasionally it may be necessary to add lugs or projec- Alone to patterns which will agsiet in the handing of the ‘eytngs in the machine shop. Because of their shape itis Wifcult 10 secure some castings in boring mills athes, and 4 without resorting, 10 elaborate clamping devies, cylindrical enstng, Fig. 38, which fs to be machined all Wiser is typical example. ‘The lugs A or B, which the pat Win esiener takes it upon himself to add, make very con- Peet places at which to locate dampe, and it will be wnnee- Ey PATTERN DESIGN ‘evstry 10 remove them siti the entire machining operation is completed. In this case a portion € ig added from which the finished casting D i separated iy the final machining operation, "A certain amount of disreton must be used in decking | the proper size and location of clamping-lugs. The Tests | fn lathe faceplates and. boring-mill tables are commonly Me (hema located 90 deqces apart, ad lugs should be set with this fact in mind, “Their sce should be such a5 will hold the casting firmly during the machining and yet aot be broken acck dentally in handling. In this connection, Toys located on the inside, A, Fig. 33, will not be s0 exposed to possible damage hi may he lcs accessible for clamping. The pat tern designer should be prepared to meet situations such as the one described and it is his responsibility 29 add such deco pater a wil sti machining, Cae en be sted where failure to arrange for the holding of castings ring the machising ts reed isa comsideable Tos of ime and money. CHAPTER 2 MOLDING DETAILS Molding sand—The sand commonly used in foundry work wed of approximately 99 per cent silica and 6 per est altining and fs found im natural deposits in many local ites This material is peenliarly adapted to fonndry nse Ireause of a fortamate combination of properties. Whea tnised with water, in a corfect proportion, molding sand hibits a remarkable cobesion, hax a permeability which permits tie escape of gases formed when the hot metal comes In eontact with the mold, snd is suficlently refractory to wvthstand high temperatures. perience has shown that for the various types of cast Jigs there are some molding sands which work better than fiers and, in recent years, methos of examination have fieen developed which makes the accurate control of foundry pote. Formesly the burden rested on the molder ‘0 jerly condition or temper his sand ond it was customary [i test it by simply pressing 2 handful ofthe moist sand into land then observing is ability to hold together or break fheaoly without crumbling. Now, Dy means of instruments, [tis posible to measure accurately the composition of the fini, its clay and moisture content, permeability, and green ren, and, by their proper adjustment, to secure a mate- Fis best aapted for a particular type of work? Where once all molding sand was conditioned by hand, ve electric mixers, sides, and other mechanical devices fivnsay with much ofthe mana labor and individu judge Jon. Tn some of the lange production foundries the mold fine sand is prepared by a synthesis of sand, clay, sid water fis central mixer from which itis conveyed on belts to, the Yisious molding stations, The control is in the hands of TWicoe may be ebiind from the State Geologie! Survey (ME a Tellie zsh" Set ot pny tana, io at wa Mor talitie ie the stay of bord condoning. s 2% PATTERN DESIGN technics who examine samples of the sand from time to time and adjust the mixture asthe rests demand Tho molding prossss, The possibilities and imi tations of sand. melding can best by suggested by a Inlet description of the molding of several types of patterns. Attention should be concentrated of the principles employed rather than on the details of the motd’s construction. Ip exe case the method of opening the flask and of removing the pattern should be observed since succes srthdravral from the mod ist primary requisite of a well designed pattern In Fig. 3 is chown a simple pattern with a stright par: ing. The main body of this pattem canbe NOLDING DETAILS a em and drag being in an inverted position at the outset of ‘he molding provess. With che pater in this position i i completely covered with facing: sand which is applied with a Tine meal riddle. Heap sand is then shoveled into the fask unl i runmed solid sng the peen end of a raminer, Asad B, Fig. 40. Ramming is continued until the sand is packed firmly hanst the pattem and laske and the excess is then struck Wi even with the top of the ask by means of «straightedge loratrike, 8, Fig, 36. Nention thas already been made of the porosity or permeax Vility of molding sand. This property ordinarily permits the veape of steam and gases, but it fs customary to amplify the molded in the drag portion of the flak while the projecting pieces Te may bea be {| located in the cope They are therefore ine corporated a5 loose pieces, ted to the ‘main pattern by means of dowel pins ‘With the Toose pices noved, the pattern is placed on a follow. hoard B, Fig. 35, which ie simply board Slightly larger than the ask F, and is equipped with cleats which raise it above the foor or table and make for easy handling. It should be noticed that the partng-sie- face is nest to the follow-board, which accounts for the pat A sg! RS ee | ey lo = cI res hd ton Pa 7 Capt tw Intural porosity of the molding sind by venting the mold iter romming. This operation is ‘performed by making final holes inthe mold with a venting wire V, Figs. 36 and 40, which reach almost to the pattern, These holes provide eady egress for gaste and may be likened to Targe rivers hich the stall streams between the sand grains can inte their burden of gas. Venting reduces the cffective thickness of sand around the mold. Atier venting, the botiom board 3B, Fig. 37, is placed in Jpsition and the whole assembly secured By clamps C while [tis rolled completely over. The follow-board. is then femoved, exposing the pattern and the parting surface, asin Pig. 38, The loose peses I, Fig, 4, are next placed on the pattern unl the parting-surface cleared of any Toose sand, ‘The (eajoned sand is smoothed with a trowel and the entire sur- zB PATTERN DESIGN face dusted with parting sand or Iycopodium powder to pre- vent the sticking together of the eope and drag. The cope fs then rammed up and vented in the same manner a the drag, ‘The sprue or pouring open ings, Fig, 3, may be formed doy ramming the sand aeound 1 sprue piece oF by subse quently etting through the oe ee ee either ease a pouring basin B is then formed forthe reception of metal ‘The cope is then Tifted and set aside and the pattern and foose pieves withdrawn from the sold. “This operation is cxsly performed with the ald of a lifting sted (Vy Pig. 40) Which i slong slender rod with a sharp point, which con be friven deep enough to hold s light pattem. For heavy pat- tems oF for continuous use, there are usually set into the sur- face drawing plates U, Fig. 40, which have a hole in which « rapping or lesening fron may be place and also a threaded Hole into which the Hfter W may’ be tweed. ‘These plates are available in various sizes and shapes and thle e i much to be preferred to that of the sharp pointed see! When the pattem is removed the gate 0, Fig 39, fs eat by means of & red piece of sheet ras ‘and a smal) asin formed beneath the sprue. All particles of loose sae are thea removed irom the (r= + smokd sad the fasie reas- femblod and clamped. See 7% Crmseetetion of melt ‘cross-section of mold, Fig. 39, The nee of strong clamps is ery important, for the hot metal which rises ia the sprue Creates 3 considerate hydrostatic preseare which may Kft the ‘cope and permit the metal to rim out Tn passing it may be well to mention that green sand, when Mie ah Dong nay MOLDING DETAILS 2 rammed jnto = mold, exhibits a remarkable firmness and an poncciable pressure fs reqited to make finger imprints on the surface of die sand, Dee tothe weight of sand inthe cope, ross bars have been added to the cope part of the flask to irivestrangt, and unless this is done it may collapse om Hiftng. Parting dowa.—When a pattem has no fat sutfaces or hen the pasting is ieraglar, the molding. becomes a lite tore involved than in the foregoing description and it f= heeessary to resort to a molder's trick known as parting Sor ig 6, Molders tole down. The process may’ be explained if coasieration is iuiven to the molding of a solid sphere. In Fig. 41 x cross fietion of the finished mold i shown, che ennstruction of Which i essentially the following. Tlie solid spherical pattem is loated on the follow-boar nd rammed up in the drag, The drag is thea inverted and Nincovesed and the sand removed from around the pattern fi far down as the horizontal median plane. Thea 2 new Jaingesirtace is formed which corresponds with the logical Parsng-line of the patters. The cope is then built up inthe fininary manner except for the soldiers 8, Fig. 41, which x PATTERN DESIGN teinforce the projecting body of sand, ‘These soldiers are rrooden sicips which are covered with a thin coating of @ fre-clay wash to prevent the sbaorption of moisture from ofa enere the adjacent sand, They fonction much as does steel zen forcing. in concrete constraction and are. so located as to ssgmient the strength ofthe cope where tensile treses occu. The constraction of a tworpiece pattems is perhaps the casiest way to avoid parting down, bist when a pattern does bot Ind itself to thi type of construction ie 38 potable to Ciminate the hanéwork in molding by the use of a match- Hate, The match-plte is follow-board which, ia the case Sf a aphere, is eut out fo accommodate one half of the pattern, Fig. 42. ‘The pattern i paced on the matchpiate and the drag rammed up, The drag fs then rolled over and uncovered and the rest of he pattem rammed ap i the cope, the same result being obtained as if'a two-piece patter had been sed, Pig. A Mat pe ‘A match-plate is seally a false cope and, in fact, is very ‘often constructed of green sand, Plaster is used for more Derianent constrction, but in the molding of small free lar shaped castings, moist freclay has been successfully led, MOLDING DEFANS at Molding of a section-pattern.—When itis desired to mold 8 three-blade marine propeller it ie not imperative that a Complete pattern be contracted. Instead, a bub and single ade may be mounted on a standard, Fig 43, and molded in asks of a apedal design, throe of whi will ft together forms & complete propeller. The drag is rammed up the eect position as shown in Fig. 43, the sand being tucked Pig 4, gsipmest for molding under the pattern by band, The cope is rammed up in the ial way, the sand being parly supported by perforated tors bare, The necessity Of maintaining @ fixed relation Jeeween the pattem and the fask is obvious, for otherwise the blades would not be evenly spaced on the finished casting. The special faale equipment {s expensive and would be justi fel only by: a large order. The joinery used in the construction of this pattem is shown at fy Fig. 44 The individvsl cants © ate glued 2 PATTERN DES together in an offct position and are eventually worked off to produce the correct pitch Pig 48. aren ota pcre Me

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