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2types of Molding Sand, Patterns and Pattern Allowances Etc.
2types of Molding Sand, Patterns and Pattern Allowances Etc.
2types of Molding Sand, Patterns and Pattern Allowances Etc.
Green sand:
Natural sand with moisture
Dry sand:
Not suitable for large castings
Facing sand:
This sand is used directly next to the surface of the pattern and comes into contact with the
molten metal when the mould is poured.
As a result, it is subjected to the severest conditions and must possess, therefore, high strength
and refractoriness. This sand also provides a smoother casting surface and should be of fine texture.
It is made of silica sand and clay, and some additives without the addition of used sand.
Facing sand is always used to make dry sand moulds while system sand is frequently used for
green sand molding.
Parting sand:
This sand is used to prevent adhering of two halves of mould surfaces in each molding box
when they are separated. Thus, to ensure good parting, the mould surface (at contact of cope and
Drag) should be treated with parting sand or some other parting material.
It is also sprinkled or applied on the pattern surface (before the molding sand is put over it) to
avoid its sticking and permit its easy withdrawal from the mould. The parting sand is fine dry sand.
Backing or floor or black sand:
This is the sand which is used to back up the facing sand and to fill the whole volume of the
flask. Old, repeatedly used molding sand is mainly employed for this purpose.
Core sand:
The core sand mainly consists of silica sand and an organic binder, with very little, if any, clay
content. The presence of clay in core sand reduces its permeability and collapsibility. The core sand
may contain small percentages of other constituents also, to enhance its properties.
Loam sand:
50 % of clay and dried hard and using for large castings
Types of patterns:
The following factors affect the choice of a pattern.
(i) Number of Castings to be produced.
(ii) Size and complexity of the shape and size of casting
(iii) Type of molding and castings method to be used.
(iv) Machining operation
(v) Characteristics of castings
Split pattern:
These patterns are split along the parting plane (which may be flat or irregular surface) to facilitate
the extraction of the pattern out of the mould before the pouring operation. For a
more complex casting, the pattern may be split in more than two parts.
It is just a similar to that of a sweep pattern. The working structure of segmental pattern and sweep
pattern is almost similar. For designing require shape or structure of mold they both employ a part
of pattern. As the name suggest segmental pattern is in the form of segments and used for molding
circular or round structures. In sweep pattern there is complete rotation but in segmental pattern
there is no complete rotation. For creating mold, we can rotate partly to get required output.
Shell pattern:
1. Shrinkage allowance:
After solidification of the metal from further cooling (room temp.) dimensions of the patterns
increases. So pattern size is bigger than that of the finished cast products. This is known as
shrinkage allowance.
It depends on:
a) Dimensions of casting
b) Design and intricacy of casting
c) Resistance of mol to shrinkage
d) Molding materials used
e) Method of molding used
f) Pouring temp of the molten metal
2. Draft or taper allowance:
Pattern draft is the taper placed on the pattern surfaces that are parallel to the direction in
which the pattern is withdrawn from the mould (that is perpendicular to the parting plane),
to allow removal of the pattern without damaging the mould cavity.
It depends on:
a) the method of molding
b) the sand mixture used
c) the design (shape and length of the vertical side of the pattern)
d) economic restrictions imposed on the casting
e) intricacy of the pattern
3. Distortion allowance:
This allowance is taken into consideration when casting products of irregular shapes. When
these are cooled they are distorted due to metal shrinkage.
It depends on:
a) Machining operation
b) Characteristics of metal
c) Methods of castings
d) Size, shapes and volumes of castings
e) Degree of finish required in castings
f) configuration of the casting
To take the pattern out of the mould cavity it is slightly rapped to detach it from the mould cavity. So
the cavity is increased a little.
TYPES of Patterns