Assignment No.

4
PATTERN MAKING & CASTING
INTRODUCTION:
Pattern is the principal tool during the casting process. It
may be defined as model of anything. The process of making
a pattern is knows as pattern making.
Casting may be classified into five stages:
(1)
Pattern making (2) Moulding & Core making (3) Melting
& Casting
(4) Fettling, & (5) Testing & Inspection.
Following qualities should be there in pattern material.
1.
2.
3.
4.
5.
6.

Easily worked , shaped & joined;

Light in weight;
Dimensionally stable in all situation;
Easily available at low cost;
Repairable &reused;
Able to take good finish.

Material used in pattern:

1.
2.
3.
4.
5.

Wood
Metal
Plastics
Plaster of paris
Wax etc.

Types of pattern:
1. Solid or single piece pattern, 2. Split pattern, 3. Loose piece
pattern
4. Gated pattern, 5.Pattern with flow board, 6.Match piece
pattern,
7. Segmental pattern, 8.Sweep pattern, 9.Skeleton pattern, 10.
Shell pattern,

11. Lagged up pattern.

1. Solid Pattern: - A pattern that is made without joints,
parting or any loose piece in its construction is called single
piece pattern.

2. Split Pattern:- A pattern made in two piece by using a

plane through the centre line is called split pattern

Pattern Allowances:
1. Shrinkage allowance, 2. Draft allowance,
allowance,

3. Matching

4 . Distortion or Camber allowance, & 5. Rapping allowance etc.

MOULD:
It is a process of forming cavity of pattern in compacted sand, the
cavity is called mould. When molten metal is poured in this cavity,
the desired casting is obtained.
PROPERTIES OF MOULDING SAND:

Porosity or permeability
Refractoriness
Cohesiveness
Plasticity
Adhesiveness
Thermal stability
Flow ability
Collapsibility
Reusability.

CLASSIFICATION OF SAND:
According to nature of origin:
Natural sand
Synthetic moulding sand
According to use:

Green sand
Dry sand
Facing sand
Backing sand or floor sand
Black sand
Loam sand
Core sand
Parting sand.

General steps for sand moulding:

First of all flasks (DRAG) and pattern are placed on smooth
wooden board called as moulding board.
Then properly conditioned sand is to be pressed around and
over the pattern with fingers & then rammed with hand
rammers.
After the ramming is finished, the excess sand is leveled off
with a strike of bar. & small vent holes are to be made
through sand for escape of gases.
Then another board called (COPE) is to be placed on top and
mould is turned over.
The surface is to be first smoothed over with a trowel & then
coated with fine dry parting sand.
The cope is then placed on the drag & held properly by
dowel pins. The passage for pouring molten metal is made
by sprue pins.
The mould is then filled with sand rammed and completed
with proper provisions of went holes. The sprue pins is
withdrawn.
Before withdrawing the pattern, sand around the edges of
the pattern is moistened with swab. The pattern is shaken
slightly in all directions, to make it loose. Then it is lifted with
draw spike.
A small passage, called as gate is to cut at the bottom of
sprue hole & mould is closed.
Then molten metal is to be poured in mould through runner
till it comes out from riser.
Then give sufficient time for solidification.

MOULDING FLASKS (COPE & DRAG)

Steps for moulding & casting.