Pattern

Mr. Ankur Chaurasia

Faculty,
School of Technology,
PDPU, Gandhinagar
PATTERN
PATTERN
 PATTERN

Pattern
Function of Pattern
Ideal Characteristics of Pattern Material
Pattern Material
 Pattern Material
 Wood
 Advantages
1. Light in weight , inexpensive, good workability
2. Easy gluing and joining, varnish and paintings and easily
repaired.

 Limitations:
1. Non uniform structure ,poor wear and abrasion resistance
can not withstand rough handling.
2. Absorbs and gives off moisture.
 Pattern Material
 METAL
 Advantages
1. More durable, accurate, smooth surface
2. Resistance to Wear, abrasion, swelling.
3. Withstand rough handling.

 Limitations
1. Expensive, not easily repaired, heavier than wood.
2. Rusting

 Types of metal used for pattern

 C.I., Brass, Aluminum, white metal
 Pattern Material
 PLASTICS
 Advantages
1. Economical , highly resistance to corrosion, lighter and stronger.
2. Moulding sand stick less to plastic than wood.
3. No moisture absorption, smooth surface of patterns.
4. Dimensionally stable.
 Types of Pattern
 For selecting a particular kind of pattern for making a casting, one
may consider the following points.
 Quantity of casting to be produced.

 The size and complexity of the shape of the casting to be

produced.

 Type of molding method to be used (i.e., hand or machine

molding).

 Problems associated with molding operations such as

withdrawing the pattern from the mold etc.
 Types of Pattern
 One piece pattern
 Split pattern
 Loose piece pattern
 Match plate pattern
 Cope and drag pattern
 Sweep pattern
 Gated pattern
 Skeleton pattern
One piece pattern Or Solid Pattern
 One piece pattern Or Solid Pattern
 Simplest type of pattern
 Split along the parting surface
 Made up of one piece (does not contain loose pieces or joints)
 Inexpensive
 Used for making large size simple casting
 Usually made up of wood or metal depending on quality of
casting to be produced.
 For making the mold, one piece is accommodated either in
cope or in the drag.
Split pattern
Split pattern
 Split pattern
 Patterns of intricate (shaped) castings cannot be made in one
piece because of the inherent difficulties associated with the
molding operations (e.g. withdrawing the pattern from the
mold etc.)
 Such patterns are, then, Made as split or two piece patterns.
 The upper and the lower parts of the splits pattern are
accommodated in the cope and drag portions of the mold
respectively.
 Dowel pins are used for keeping the alignment between the
two parts of the pattern.
 Casting like those of taps and water stop cocks are produced
with the help of split patterns.
Loose piece pattern
 Loose piece pattern
Another example of Loose piece pattern
 Loose piece pattern
 Certain patterns can not be withdrawn once they are embedded
in the molding sand. Such patterns are usually made with one
or more loose pieces for facilitating their removal from the
moulding box.
 Loose parts or pieces remain attached with the main body of
the pattern, with the help of dowel pins.
 Loose piece pattern consume more labour and more time in
molding operation.
Cope and drag pattern
 Cope and drag pattern
 Cope and drag pattern is another form of split pattern.
 The pattern is split about a convenient and suitable surface or
line.
 Each half of the pattern is fixed to a separate metal/wood plate.
 Each metal plate, besides the pattern, has the provision for
molding runner and gates.
 Each half of the pattern (along the plate) is molded separately
in separate molding box by an independent molder.
 The two molds of each half of the pattern are finally assembled
and the mold is ready for pouring.
 It is used to produce big casting.
Match plate patterns
 Match plate patterns
 It is a special type of cope and drag pattern
 Consists match plate on either side of which each half of
number of split pattern fastened.
 Number of different size and shaped patterns may be
mounted on one match plate.
 The match plate with the help of locator hole can be clamped
with the drag.
 Runner and gates also attached with match plate.
 After the cope and drag have been rammed with the molding
sand, the match plate pattern is removed from in between two.
 Cope and drag are then assembled and this completes the
mold.
 Match plate patterns
 Patterns, match plate, runner and gates-all may be made up of
aluminum because it is light and relatively inexpensive.

 Material of pattern is always METAL

 Match plate patterns are usually used in machined molding.

 It is preferred for producing small castings or mass scale.

 Produce accurate casting and faster rate.

 Piston rings of IC engine are produced with the help of match

plate patterns.
Sweep pattern

FRONT View

TOP View
 Sweep pattern
 These are 2D pattern
 Sweep pattern can be used LOAM SAND.
 It is just a form made on a wooden board which sweeps the shape
of the casting into the sand all around the circumference.
 The sweep pattern rotates very slowly about the center.
 sweep pattern avoids the necessity of making full, large circular and
costly three dimensional pattern.
Limitation :
Preferred for producing large castings of circular sections and
symmetrical shapes.
Application :
 The manufacture of large kettles of cast iron requires a sweep
pattern.
Gated pattern
 Gated pattern
 Sections connecting different patterns serve as runner and gates.

 This facilitates filling of the mold with molten metal in a better

manner and at the same time eliminates the time and labour
otherwise consumed in cutting runners and gates.

 A match when used with gates pattern saves still more time.

 It manufactures many castings at one time and thus it is used in

mass production systems.

 Gated patterns are employed for producing small castings.

Skeleton pattern
Skeleton pattern
Skeleton pattern
 Skeleton pattern

 The skeleton is made from wooden strips and is thus a wooden

framework.

 The skeleton pattern is filled with sand and is rammed.

 Skeleton pattern
 Cores, if necessary, can be produced separately.
 Skeleton patterns are employed for producing a few large
castings.
 A skeleton pattern is very economical as compared to a solid
pattern, because it involves less material costs.
 water pipes, L-bends etc are made with the help of skeleton
patterns.
Pattern Allowances
Pattern Allowances
Liquid and Solid shrinkage
Shrinkage Allowances
Shrinkage Allowances
Shrinkage Allowances
Shrinkage Allowances
Draft Allowances
 3.TAPER or DRAFT ALLOWANCE
 Given to all surfaces perpendicular to the parting line.

 Draft allowance can be given so that the pattern can be easily

removed from the molding material tightly packed around it
without damaging the mold cavity.
Draft Allowances
Draft Allowances
 Machining Allowances

Need of Machining allowance for casting-

Poor Surface finish

 Machining Allowances
• It indicates how much larger the rough casting over the
finished casting so that further machining can be carried out.

• Casting get oxidized in the mold and during heat treatment;

Therefore scale formed need to be removed.

• Require to achieve exact size of casting dimensions

 Machining Allowances
 Machining allowances depends on factors mentioned below

 Nature of metal i.e. ferrous or non-ferrous.

 Ferrous metals get scaled whereas nonferrous ones do
not.
 Size and shape of Casting
 Type of machining operation i.e. grinding, turning, milling,
boring, etc
 Casting surface conditions (Rough, semifinished, smooth)
 Number of cuts to be taken
Machining Allowances
Machining Allowances
Machining Allowances
Machining Allowances
Distortion/Camber Allowances
Distortion Allowances
Distortion Allowances
Rapping/Shaking Allowances