EXPERIMENT NO : 1

AIM : Study of Casting Process

Introduction :
Casting is the one of the oldest manufacturing process and even today is the first step in
manufacturing most products. In this process the material is first liquefied by properly
heating it in a suitable furnace. Then the liquid is poured into a previously prepared
mould cavity, where it is allowed to solidify subsequently, the product is taken out of the
mould cavity trimaned and cleaned to shape.
It is clear from the definition of process that a successful casting operation needs a
knowledge in the following areas :
i) Preparation of moulds and patterns (Use to make the mould)
ii) Melting and pouring of liquefied metal.
iii) Solidification and further cooling room temperature.
iv) Defects and inspection.
Pattern Making :
Patterns are required to make moulds. The mould is made by packing suitable moulding
material such as moulding sand around the pattern. When the pattern is with drawn the
imprint provides the mould cavity which is immediately filled with molten metal to
become casting.
Types of pattern :
The type pattern selected for particular casting depends upon the following condition:
i) The shape and size of casting.
ii) The number of casting required
iii) The method of moulding employed.
The common type of pattern are discussed below :
i) Solid or single piece patterns :
A solid or single piece pattern as shown in fig. Has a compact form. It has no joints
parting or loose piece in its construct. It has usually one broad surface that serves as a
parting surface in the mould. This type of pattern is used for a limited number of casting

because most of moulding operations like parting surface formation, calling of gating
system withdrawal of pattern etc. is done by hand.
ii) Split Patterns :
The most of the patterns are not made in a single piece because of the difficulties
encounted in moulding them in order to eleminate this difficulty. Some more patterns are
made in two or more pieces
iii) Match Plate Pattern :
The match plate patterns are used on machines for quantity production of casting. A
simple pattern or number of pattern may be mould on a match plate.
IV) Loose piece pattern :
Some the pattern has to made with projection or over hanging parts. There projection
makes the removal of the pattern difficult. Therefore such projections are made in loose
piece and are fastened loosely to the main pattern by means of wooden or wire dowel
pins/ These pins taken out during the moulding operations. After moulding the main
pattern is withdrawn first and the loose piece is removed with the help of lift.
V) Cope and drag Pattern :
When very large casting are to made the complete mould becomes to heavy to be handled
by a single operator. In order to this problem the cope and drag pattern is used. It is
nothing but two piece pattern split on convenient joint line one part is moulded in a cope
and the other part in a drag of the moulding box.
VI) Sweep Pattern : A sweep pattern is used for symmetrical moulding. It is not considered as true pattern
when compared with other. A sweep is template of wood or other material which has
counter corresponding to the shaped and size of casting. It is related about a central
spindle.
VI) The Gated Pattern :The gated pattern is used for limited production of small casting. It eliminates hand
cutting of gates and thus makes the moulding easy

PATTERN MATERIALS :The common materials of which the pattern are made are follows :
1. Wood
2. Metals
3. Plaster
4. Plastics
5. Waxes
PATTERN ALLOWANCES:A pattern is always made larger than the required size of the casting for several reasons
such as shrinkage, machining, distortion and rapping etc.
Shrinkage allowance:
Most of the metal used in casting work contract during cooling from pouring temp. to
room temp. This contraction takes place in three forms. Viz. Liquid contraction, Solid
contraction, Solidifying contraction.
Pattern Colour Code :There is no universally accepted standard for the representation of different type of
surfaces by different colurs. The practice varies with different countries and sometimes
with different manufactures in the same country. The following practice will serve as
useful guide both for pattern and core boxes.
1. Red : Surfaces to be machined.
2. Black : Surfaces to be un machined.
3. Yellow : Core prints
4. Red strips on yellow base seats for loose pieces.
5. Black strips on yellow base stop offs.
6. Clear or no colour parting surfaces.