College of Electrical and Mechanical Engineering

Department of Mechanical Engineering

Metal Casting Technology
Assignment Ⅱ

Name: Kalid Mohammed

ID NO: ETS0688/13

Submitted To: Mr. Mohammed A.

Submission date: March 21, 2024

1. Master Pattern: is the original pattern, other patterns are made depending on the master
pattern. The master pattern has double the shrinkage allowance and other allowances and is
very accurate as it is the base line of the that specific product.
2. Core Print: is what we use open space in the mold and is supporting the positioning of the core.
The print must be strong enough to resist the buoyancy force of the molten metal
3. A wooden pattern is used to cast a gear with a smaller diameter of 100mm and larger diameter
of 150mm from aluminum.
Shrinkage allowance for aluminum is 17mm per meter
Draft allowance for wooden pattern is at a height from 21 to 50mm and taper angle from
1.5 to 2.5o

As the gear does not have any v or u-shaped parts distortion allowance is not needed

In the wooden pattern we add the shrinkage, draft and machining allowance.

The allowance added to the patten due to: shrinkage is 17mm as is the material is
aluminum

Draft is 150-100 = 50mm, by taking 1 degree

taper angle the taper length = 50*tan (1) = 0.87275. the
allowance is half of the taper length which equals to
0.87/2 = 0.436

Machining 1.5mm

i.e the dimension is going to be smaller diameter = 100 + 0.436 + 1.5 + 17 = 118.936mm and the
larger diameter = 150 + 0.436 + 1.5 + 17 = 168.936mm

4. Materials used for pattern making are: wood, plastic, metal, gypsum, ceramic, wax, etc
a. Wood: low cost, needs to be changed after a few productions, easily shaped, easily
available, low weight
b. Plastic: high precision, great repeatability, low cost, higher lead time
c. Metal: high cost, can be used for mass production, remains in tact for a long period of
time, good surface finish, high strength, good machinability
d. Gypsum: easy installation, low cost
e. Ceramic: very expensive, low maintenance,
5. Pattern: is the replica of the object to be made by the casting process with some modification
(pattern allowances and provisions for core print)
Pattern defers from the actual product because the additional dimension added to the pattern to
compensate for the shrinkage of the material while cooling, machining process, to avoid
bending, to avoid damage or distortion while removal, etc
6. Pattern material selection depends on: - Service requirement
- Possibility of design change
- Type of production of casting
- Type of molding method and equipment to be used
- Possibility of repeat

Split Pattern: also called two pieces

 Is made in two pieces which are joined at the parting line by means of dowel
pins. The splitting at the parting line is done to facilitate the withdrawal.

Sweep Pattern: shapes the cavity by rotating a wooden board along one edge.

A cavity is created in the vertical direction while the base is attached with sand

Match-Plate Pattern: is made in two halves and is mounted on the opposite sides of the wooden
or metallic plate, known as match plate.