BMEE302L Metal Casting and

Welding

L2.5 Pattern allowance, Numerical problems based on

allowance, Pattern Material

Dr. Ashish Kumar Saxena,

Assistant Professor, CIMR
ashishkumar@vit.ac.in
 Pattern Making

Pattern Modification
I. Addition of pattern allowance

II. Provision of core prints

III. Elimination of fine details, which can’t be obtained by casting

and hence are to be obtained by further machining.

Dr. Ashish Kumar Saxena, BMEE302L 2

 Pattern Allowance

➢ Pattern allowance is a vital feature as it affects the dimensional

characteristics of the casting.
➢ The selection of correct allowances greatly helps to reduce
machining costs and avoid rejections. The allowances usually
considered on patterns are as follows:

1. Shrinkage or contraction allowance

2. Draft or taper allowance
3. Machining or finish allowance
4. Distortion or camber allowance
5. Rapping allowance

Dr. Ashish Kumar Saxena, BMEE302L 3

 1. Shrinkage Allowance
Metal shrinks on cooling → [except Bismuth (Bi)]
1. Metals used for casting shrink after solidification in the mould
and therefore, the pattern must be made larger than the
required casting.

Liquid shrinkage Solid shrinkage

• Reduction in volume • Reduction in volume when
when metal changes metal loose heat in solid state
from liquid to solid state. • Shrinkage allowance are
• Riser are provided provided

Dr. Ashish Kumar Saxena, BMEE302L 4

5
 2 Machining Allowance
• The finishing and accuracy obtained in sand casting are generally
poor. Ferrous materials have scales on surface of cast product. The
machining allowance is provided on the pattern which need to be
machined.
• This allowance is given in addition to shrinkage allowance. The
amount of this allowance varies from 1.6 to 12.5 mm which
depends on
a) Type of casting material
b) Finishing requirement
c) Types of molding
d) Size and the shape

The machining allowances is specified by mm/side.

Dr. Ashish Kumar Saxena, BMEE302L 6

3. Draft Allowance

Dr. Ashish Kumar Saxena, BMEE302L 7

 4. Distortion Allowance
A casting will distort or wrap if:
• It is of irregular shape. All parts do not shrink uniformly, i.e. Some parts
shrinks while others are restricted from during casting process
• The part which have u, v, I and T sections, the arms possess unequal
thickness, because one portion of the casting cools at a faster rate

Dr. Ashish Kumar Saxena, BMEE302L 8

 5. Rapping or Shrinkage Allowance

The amount of rapping allowance depends upon factors such as

a)extent of rapping,
b)degree of compaction of sand, and
c)size of mould, most of these are difficult to evaluate.

• It is negative allowance and applied to dimension parallel to parting line /

plane.

• Draft allowance can be increased to reduce shake allowance and removed

in machining.

Dr. Ashish Kumar Saxena, BMEE302L 9

18 January 2024

Dr. Ashish Kumar Saxena, BMEE302L 10

Q1: Casting shown in figure need to be made by steel using wooden
pattern. Assume shrinkage allowance for steel as per table is 21
mm/m, up to 600mm length. Calculate the dimension of pattern, if
machining and draft allowance also need to take care in pattern
design.
80 φ

80 φ

150
50

50 200
200

Dr. Ashish Kumar Saxena, BMEE302L 11

From table 7.1 shrinkage for steel is 21 mm/m
L=200 mm
B=150 mm
H= 50 mm
Dia (D) =80 mm
Allowance
Lallowance = 200 x 21/1000 = 4.2 mm
Ballowance = 150 x 21/1000 = 3.15 mm ≃ 3.2
Hallowance = 50 x 21/1000 = 1.05 mm ≃ 1.1
Dallowance = 80 x 21/1000 = 1.68 ≃ 1.7 mm
Pattern dimensions 78.3 φ
Lp = 200 + 4.2 = 204.2 mm
Bp = 150 + 3.15 = 153.2 mm
Hp = 50 + 1.1 = 51.1 mm
Dp = 80 - 1.7 = 78.3 mm 153.2
In case of the internal features like holes
the dimension of the hole will be reduced 51.1
to provide the extra material.
204.2
Dr. Ashish Kumar Saxena, BMEE302L 12
Step 2: Now adding the machining allowances in previous slide
answer. (Assuming machining allowance 2 mm)
74.3

Dimension of pattern
Length = 204.2 +2x2 = 208.2 mm
Width = 153.2 +2x2 = 157.2 mm
157.2
Height = 51.1 + 2x2 = 55.1 mm
55.1
Dia of hole = 78.3 -2x2 = 74.3 mm

208.2

Wooden Pattern size considering the

shrinkage and machining allowances

In case of the internal features like holes the dimension of the hole
will be reduced to provide the extra material.
Dr. Ashish Kumar Saxena, BMEE302L 13
Step 3 : Now considering the draft allowances. (Assume 1° taper for
external details and 3° for internal)
74.3 External
55.1 x tan (1) = 0.9617 ≃ 1.0 mm
Internal
55.1 x tan (3) = 2.8876 ≃ 2.9 mm

Length = 208.2 + 2 x 1 = 210.2 mm (only top side dimen.)

157.2Width = 157.2 + 2 x 1 = 159.2 mm (only top side dimen.)
Dia. of core = 74.3 - 2 x 2.9 = 68.5 mm (only top diameter)
55.1

208.2 210.2
68.5
Wooden Pattern size considering the
shrinkage and machining allowances Parting line

74.3
208.2
Wooden Pattern size considering the shrinkage,
machining and draft allowances
Dr. Ashish Kumar Saxena, BMEE302L 14
Q: What will be actual part dimensions if the pattern dimensions are
shown in figure below? Assuming machining allowance 2 mm for all sides.

A. Pattern dimension = Actual dimension + Machining allowance

For 84 mm side
84 (Pattern dimension ) = L (Actual dimension)
+ 2*2 (total machining allowance for both side)
L = 84 - 4 = 80 mm
Similarly B = 54 - 4 = 50 mm, C= 20 mm

Note : in question, 2 mm machining allowance means

2 mm allowance per side.

If machining is needed for the component; allowance must

be added in the outer dimension.

Dr. Ashish Kumar Saxena, BMEE302L 15

Q. A job shown in the Figure is to be made of steel by casting
process. The mold for this job is made from a wooden pattern.
Determine the dimensions of the wooden pattern. Assume
machining allowance of 2 mm on each side, shrinkage allowance of
2% and a taper allowance of 1 degree.

Dr. Ashish Kumar Saxena, BMEE302L 16

Step-1: Machining Allowance
It is given that machining allowance of 2 mm on each side is to be given.
Thus, each side is increased by 2 mm resulting in the basic dimension of
the pattern as shown in Figure (a).
L = 80 + 2*2 = 84 mm
B = 50 + 2*2 = 54 mm
H = 20 + 2*2 = 24 mm

Dr. Ashish Kumar Saxena, BMEE302L 17

Step-2 : Taper Allowance
We decide to cast the job horizontally and use a solid pattern for this
casting. For this design, the draft allowance is to be provided on the vertical
sides (24 mm long).
The taper allowance value x is calculated from the geometry of the Figure
(b) as

x = 24 tan 1 = 0.419 mm.

Thus, the top surface dimension is increased to provide for draft allowance
from

54 * 84 mm to 54.838 * 84.838 mm.

Dr. Ashish Kumar Saxena, BMEE302L 18

Step-3 Shrinkage Allowance: Given shrinkage allowance is 2%. Now, the
dimensions of pattern are increased by 2% on all sides.

That is,
➢ 54 mm will become, 54 + (54*2)/100 = 55.08 mm or 55.1 mm

➢ 54.838 mm will become 54.838 + (54.838*2)/100 = 55.9 mm

Dr. Ashish Kumar Saxena, BMEE302L 19

 Pattern Making
A pattern for multiple uses must last long and therefore must be made from
a suitable material. Modification

The materials commonly used for

1. Wood
2. Metals and alloys
3. Plasters
4. Plastic
5. Rubber
6. Wax

The selection of the material for a pattern depends upon the

1. Types of moulding material used
2. Number of casting to be produced
3. Degree of dimensional accuracy required etc.

Dr. Ashish Kumar Saxena, BMEE302L 20

 Pattern Materials Requirement

The basic requirements of a good pattern material are:

1. It should be easily shaped
2. It should be resistant to wear and corrosion.
3. It should be resistant to chemical action.
4. It should be dimensionally stable and must remain unaffected by
variations in temperature and humidity.
5. It should be easily available and economical.

Dr. Ashish Kumar Saxena, BMEE302L 21

 Wooden Pattern
Wood is the most common material for the pattern, the main reasons
being, Its cheapness, availability, ease of shaping, lightness.
• Ease with which it can be joined.
• Wood can be cut and fabricate into numerous forms by gluing, bending
and carving.
• Its surface can be easily made smooth by sanding.
• Its surface can be preserved by applying a coating of shellac

Drawbacks of wooden pattern

• Moisture affect: Change the shape, when the moisture dries out, and
wears out quickly, when it picks up moisture from the damp moulding
sand, wood wears out quickly as a result of sand abrasion.
• Warps: when not stored properly
• Low strength: get break while rough uses
• Suitable for small number of casting

Dr. Ashish Kumar Saxena, BMEE302L 22

 Metallic Pattern
Metallic pattern is primarily used for large scale production.
• Do not change its shape even in moisture
• Free from warping in storage
• Have good accuracy, durability and strength
• Can withstand even in abrasion and rough handling
• Can be machined to desired shape
• Can have smooth surface finish

Drawbacks of metallic pattern

• Expensive: Compare to wood thus not suitable for small production.
• Difficult to shape, work and repair
• Rusting: Tendency to get rusted
• Large weight compared to wooden pattern

Dr. Ashish Kumar Saxena, BMEE302L 23

 Metal used for making pattern
• Steel
• Cast Iron
• Brass
• Aluminium
• White metal (Tin based alloy)

White metal have less shrinkage, thus less

worry about double shrinkage

Dr. Ashish Kumar Saxena, BMEE302L 24

 Plastic Pattern
Plastic pattern are used due to their following advantages.
• Have low weight
• Can easily formable, smooth surfaces and durability
• Do not absorb moisture and are dimensionally stable
• Can be cleaned easily and have good corrosion resistance

Drawbacks of metallic pattern

• Fragile: Fragile in nature.
• Metallic reinforcement requirement: for thin sections
• Not suitable for machine moulding due to shocks

Dr. Ashish Kumar Saxena, BMEE302L 25

 Polystyrene Pattern

Polystyrene is also used for pattern making material, as it has special

property that it changes to gaseous state on heating
• Very light, easier formed to any shape, used for light duty work
• Can make disposable patterns for single casting e.g. Prototype
• Easy to make pattern as it is soft in nature
• Pattern need not taken out from the mold to create the cavity, when
the molten metal poured into the mold, the polystyrene transform into
gaseous state with negligible residue and space occupied by the
pattern is filled by the metal

Dr. Ashish Kumar Saxena, BMEE302L 26

 Wax Pattern
Wax pattern is used for investment casting process, It produces high
degree of surface finish and dimensional accuracy during casting process.
• The molten wax is poured into the split mold or a pair of dies followed
by water cooled.
• Wax pattern assembled as tree, dipped in the ceramic slurry which
makes a shell mold dried by heating was is poured out by keeping it
upside down.

Materials used for wax Pattern

• Paraffin with stearin
• Paraffin with ceresin
• Polyethylene wax
• Natural wax
• Synthetic wax

Dr. Ashish Kumar Saxena, BMEE302L 27

 Wooden Patterns with metallic coating

• When wooden pattern is not satisfactory due to low strength and lack
of high surface finish, metallic coated patterns are used for short
production.
• In this process, the wooden patterns are sprayed with a thin metallic
coating of bismuth (about 0.25mm thickness)

Dr. Ashish Kumar Saxena, BMEE302L 28

 Factors affecting the selection of patterns
material
• Design of casting: like minimum thickness desired, complexity of parts,
the degree of accuracy and finish desired in the casting.
• Number of castings required: For large quantity metal patterns are
preferred.
• Method of molding employed: e.g. hand molding, machine molding.
• Other factors affecting molding material to be used are
• Chances for repeat orders
• Life of casting

Dr. Ashish Kumar Saxena, BMEE302L 29

 Cores and Core Prints

(a) Core held in place in the mold cavity by chaplets, (b) possible chaplet design, (c) casting with
internal cavity.

Core Print

Dr. Ashish Kumar Saxena, BMEE302L 30

 Cores and Core Prints
• Core: A separate part of the mold, made of sand and generally
baked, which is used to create openings and various shaped
cavities in the castings.
• Core prints: It is the support provided to the core to hold that in
the position. Core print is more like a grove inside the mold.
• Chaplets: Chaplets are used to support the cores inside the mold
cavity to take care of its own weight and overcome the
metallostatic force.

Dr. Ashish Kumar Saxena, BMEE302L 31

 Thank You
Any Question ?

Dr. Ashish Kumar Saxena, BMEE302L 32