Pattern
Replica of the final casting
Has the similar geometry as the required casting
with necessary modifications like:
Allowances
Provision for core prints
Elimination of fine details
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Pattern Allowances: Shrinkage Allowance
Compensates for metal shrinkage
Shrinkage may be categorized as
Liquid shrinkage:
Compensated for by the riser
Al has most liquid shrinkage
Solidification shrinkage
Compensated for by the riser
Solid shrinkage
Compensated for by shrinkage
allowance
Brass shows maximum solid
shrinkage
Total shrinkage is maximum for steel
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Shrinkage Allowances
Compensates for liquid and solidification shrinkage
Added to linear dimension
Uniform in all directions unless constrained
Grey CI expands on solidification
% V = 2 * (% graphite – 2.8)
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Pattern Allowances: Draft
For easy removal of pattern
Vertical faces are tapered from parting line (0.5
to 2 degrees)
Varies with design complexity
Inner details need higher draft allowance
Hand molding required more draft allowance
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Draft Allowances
Height of surface
Pattern Material Draft angle (degrees)
(mm)
External Surface Internal Surface
Up to 20 3.00 3.00
21 to 50 1.5 2.5
51 to 100 1 1.5
Wood 201 to 300 0.75 1
301 to 800 0.5 1
801 to 2000 0.5 0.75
Over 2000 0.35 0.5
Up to 20 0.25
21 to 50 1.5 3
51 to 100 1 2
Metal and plastic 201 to 300 0.75 1
301 to 800 0.5 0.75
801 to 2000 0.5 0.75
Over 2000 0.35 0.5
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Machining Allowance
It is required for
Superior finish
Dimensional accuracy
Ranges from 2 to 20 mm depending on
Casting method used
Metal cast: Removal of scales in ferrous casts
Surface finish, dimensional accuracy required
Complexity of surface details
May be reduced by proper positioning of parting line
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Pattern Allowance
Shake allowance
Negative allowance
Provided in sand molds
Accounts for rapping of pattern
Distortion allowance
Provided in long, flat, U or V sections
When thin sections are connected to thick sections
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Characteristics of a pattern material
Easy to work, shape and join
Light weight
Strong hard and durable
Wear and abrasion resistance
Resistance to corrosion and to other chemical
reactions
Dimensionally stable under wide range of temperature
and humidity
Affordable
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Pattern Materials
Choice of pattern material depends on:
The number of castings to be produced
Complexity and size of the casting
Dimension accuracy and surface finish requirements
Method of casting/mold material
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Pattern Materials: Wood
Most commonly used material
Suitable for large patterns and small number of castings
Commonly used woods: teak, deodar, mahogany, pine, veneer
boards etc.
Using for making master patterns: Hence double shrinkage
allowance
Advantages
Cheap and easily available
Light weight
Easily shaped and may be given a good finish
Disadvantages
Has a short life span due to
Abrasion in sand molds
Distortion in moist environment: may be controlled
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Pattern Materials: Metal
Used for large number of castings and close dimensional
tolerance
Commonly used metals: Al/ Al alloy, brass, white metal, steel,
etc.
Advantages
Long life span
High strength
Can be given better finish and tolerances
Good machinability
Disadvantages
Expensive
Machining requirements add to the cost
Patterns are very heavy
Have a tendency to rust
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Plastic
Includes thermosetting resins, epoxy, PVC, etc.
Made in sand clay/plaster of paris molds
Advantages
Light weight
Easy formability with a smooth finish
Dimensional stability: High resistance to wear and corrosion
Reasonable cost
Minimal shrinkage
Disadvantages
Fragile
Not suitable for severe shock conditions like machine molding
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Other Pattern Materials
Wax
Used exclusively in investment casting
Polyurethane foam
Used for single/ small number of castings
Light weight and easy formability
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Choice of Pattern Material
Casting size No. of castings Pattern Material
Small Castings 2000 Hard wood
(up to 600mm)
6000 Al, Plastic
100,000 Cast Iron
Medium Castings 1,000 Hard wood
(600 to 1,800 mm)
3,000
Al, Plastic
Large Castings (>1, 200 Soft wood
800mm)
500 Hard wood metal reinforced
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Types of patterns
Single piece pattern
Split or two-piece pattern
Match plate pattern
Gated pattern
Sweep pattern
Loose piece pattern
Skeleton pattern
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Single piece Pattern
Used for simple casts with no
with-drawl problems
Very small-scale production
Used entirely in the drag
Flat surface forms the parting Fig: Single piece pattern
line
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Split pattern
Used for making intricate castings when
Contour makes with-drawl difficult
Depth is too high
Dowel pins ensure alignment
Fig: Split piece pattern
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Gated patterns
Gating and runner form an integral part of the mold
Used to make multiple castings in a single mold
Usually used for making very small castings
Made of metal
Used for large production runs
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Cope and Drag Pattern
Gating and risering systems are attached to metal/
wooden plates
Used for heavy castings
Fig: Cope and drag
pattern
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Match plate pattern
Patterns, gating and risering systems are attached to a
single plate
Pattern is made of metal, usually Al
Used for
Large production runs of small castings
High dimensional accuracy
Fig: Match plate pattern
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Sweep pattern
Used for large castings with rotational symmetry
2D pattern results in lower material cost
Fig: Sweep pattern
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Loose piece pattern
Used when pattern contour does not allow withdrawl
Loose piece is held by a wire
Fig: Loose piece pattern
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Skeleton pattern
Used for huge castings and short production runs
Used to create a mould in a pit mould
It may be hollow for lower cost and weight
Has two halves
Fig: Skeletal pattern
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