Pattern Allowances

A pattern is always made somewhat larger than the final job to be

produced. This excess in dimensions is referred to as the pattern
allowance. A number of allowances made on the pattern to ensure that
the finished casting is dimensionally correct. The following allowances
are usually provided in a pattern.

Draft
Pattern draft is defined as the taper on vertical elements in a pattern
which allows easy withdrawal of the pattern from the mold.
This draft is necessary in order that the pattern can be removed easily
from the mold causing no damage to the sand. The amount of draft
required will vary with the depth of the pattern.
pattern having no draft allowance when lifted out, its sides will remain in
contact with the walls of the mold, thus tending to break it.
Taper varies from about 1-3 degrees. The greater the taper, the easier it
is to draw the pattern out of the sand

Amount of draft
The amount of draft depends upon the following factors : Size and shape of pattern
Depth of mold cavity
Method used to withdraw pattern
Pattern material
Mold material
Molding procedure

Shrinkage
The pattern is intentionally made larger than the final] desired casting
dimensions to allow for solidification and cooling contraction of
casting.
The total contraction of a casting takes place in three stages, and
consists of:1. The contraction of the liquid from the pouring temperature to the
freezing temperature,
2. The contraction associated with the change of phase from liquid to
solid,
3. The contraction of the solid casting from the freezing temperature to
the room temperature.
The total contraction is volumetric, but usually expressed linearly.
This varies with each type of metal and the shape of the casting.
The added dimensions are incorporated into the pattern by the
pattern maker by using what is called shrink rulers. These rulers are
made of steel and the shrinkage is compensated for by having been
worked proportionately over its length. (shrink rule 12 inches long will
be actually 12 + 3/16 inches long),

Pattern maker's contraction allowance

Cast iron
Brass
Gun-metal
Phosphor bronze
Aluminum alloys
Zinc and zinc alloys

0.9-1.3%
1.3%
1.0-1.6%
1.0-1.6%
1.3%
2.6%

Temperature as a function of time for the solidification of pure metals.

Note that freezing takes place at a constant temperature. (b) Density
as a function of time.

Machining Allowance
The extra material left on casting for any surface that will be
machined called machining allowance.
The finish and accuracy achieved in sand casting are
generally poor and therefore when the casting is functionally
required to be of good surface finish or dimensionally
accurate, it is generally achieved by subsequent machining.
Machining or finish allowances are therefore added in the
pattern dimension.
The amount of machining allowance to be provided for is
affected by the method of molding and casting used viz. hand
molding or machine molding, sand casting or metal mold
casting.
The amount of machining allowance is also affected by the
size and shape of the casting; the casting orientation; the
metal; and the degree of accuracy and finish required.

Distortion or Camber Allowance

Some castings ,because of their shape and size may warp
or distort during cooling. This is due uneven metal thickness.
For example, if the casting has the form of the letter U, V, T,
or L etc. it will tend to contract at the closed end causing the
vertical legs to look slightly inclined.
To avoid this the shape of the pattern is slightly bent in the
opposite direction.
The distortion in casting may occur due to internal stresses.
These internal stresses are caused on account of unequal
cooling of different section of the casting and hindered
contraction.
Measure taken to prevent the distortion in casting include: 1. Modification of casting design
2. Providing sufficient machining allowance to cover the
distortion affect
3. Providing suitable allowance on the pattern, called camber
or distortion allowance (inverse reflection)

Rapping and Shaking Allowances

When pattern is removed from the mould , it is shaked from side to
side called rapping.
The mould cavity may become large due to rapping. To avoid this
the pattern is made slightly smaller. This allowance given on the
pattern is called rapping allowance.
In Small and medium size casting, this allowance can be neglected.
But in large casting this allowance is considered by making the
pattern slightly smaller than the casting.

Pattern Design considerations

A good pattern may produce a sound casting but a bad pattern will
always result in poor castings. Following factors should be
considered while designing a pattern:
Pattern should be accurate as regard to its dimensions and
possess very good surface finish.
Proper allowance should be provided in pattern.
Sharp corners of pattern should be avoided.
Core prints provided for the pattern should be of
optimum in size.
Changes made in the shape should be gradual, uniform
and smooth.
Proper material for making the pattern should be selected.
The wall thickness and section should be kept uniform.
Pattern made for expected repeat orders should be
preserved and stored properly.

Color code for patterns

Pattern makers use a color code so that it is clear to the metal caster
which surfaces are which. This is as follows:
cast' surfaces which are to be left unmachined - red or orange
Surfaces which are to be machined - yellow
Core prints for unmachined openings black
Core prints for machined openings - yellow stripes on black
Seats for loose pieces and loose core prints - green.