MEM 103 Unit 3, Lesson 6
LESSON 6 TYPES OF PATTERN
STRUCTURE
6.1 INTRODUCTION
6.2 PATTERN ALLOWANCES
6.3 COLOR CODES FOR PATTERNS
6.4 PATTERN DESIGN CONSIDERATIONS
6.5 CORE
6.6 TYPES OF CORES
6.7 CORE PRINTS
6.8 CORE BOXES
MEM 103 Unit 3, Lesson 6
6.1 Types of Pattern
The types of pattern used for a specific application depends primarily on the
number of castings required, the moulding or casting process to be used, the size of the
pattern and the casting tolerances that are required.
The common types of pattern are listed and described below:
(1) Solid or Single piece Pattern
(2) Split Pattern
(3) Match Plate Pattern
(4) Gated Pattern
(5) Cope and Drag Pattern
(6) Loose Piece Pattern
(7) Skeleton Pattern
(8) Sweep Pattern
(9) Left hand and Right hand Pattern
(10) Shell Pattern
(11) Segmental Pattern
(12) Follow Board Pattern
6.1.1 Solid or Single Piece Pattern
A single or solid piece pattern is made with out joints, loose pieces or partings. It
has usually one board surface that serves as a parting surface in the mould. This type of
pattern is used for a limited number of castings because most of the moulding
operations like providing runners and risers, withdrawal of pattern etc. is done by hand.
Soil temper glands of steam engines are made by solid or single piece pattern.
Fig. 6.1 Single, solid pattern
6.1.2 Split Pattern
This type of pattern is used when the pattern if made is single piece will give rise
to withdrawal difficulties from the mould. Split pattern consists of two pieces; one half of
the pattern rests in the drag (lower part of the moulding box) and the other half in the
cope (upper part of the moulding box).
MEM 103 Unit 3, Lesson 6
Fig. 6.2 Split patterns
The split patterns are commonly used for the casting of steam valve bodies, small
pulleys, wheels and cylinders etc.
6.1.3 Match Plate Pattern
It is split pattern in which the cope and drag portions are mounted on opposite
side of a plate, called match plate, conforming to the parting line. The pattern, as well as
the associated gating and rising system, is usually made separately and then mounted
on match plate, but can be cast integrally with the plate. The size of the match plate
corresponds to the size of the flask used to make the final mould. Multiple patterns of
small parts can be mounted on a single match plate can often be shared by the multiple
patterns on the match plate. Interlocking features can be added to the cope and drag
sides of the match plate to ensure accurate alignment of the cope and drag mould
halves after removal of the pattern.
Match plate pattern are used for moderate to high volume production of small and
medium size castings with considerable dimensional accuracy.
Fig. 6.3 Match plate pattern
MEM 103 Unit 3, Lesson 6
Match plate pattern are used for moderate to high volume production of small and
medium size castings with considerable dimensional accuracy.
6.1.4 Gated Pattern
The gated pattern is used for mass production. For small castings, multi cavity
moulds are prepared i.e. single moulds carry a number of cavities. Each pattern may be
provided with a gate pattern with it examples are Vice Handle, Nuts and bolts etc.
(a)
(b)
Fig. 6.4 Gated patterns
6.1.5 Cope and Drag Pattern
When large cavities are to be manufactured, the moulds are to be very heavy to
handle. Separate pieces of pattern are made on a convenient joint line and mounted on
boards with slots and holes provided with easier fittings. This arrangement helps the
moulder to work on each piece separately. This ensures higher strength and durability.
6.1.6 Loose Piece Pattern
The loose piece pattern are needed when the casting is such that the pattern
cannot be removed as one piece, even though the pattern is split and the parting line is
made on more than one plane. In loose piece pattern the main pattern is removed first.
Then the separate pieces which may have to be turned or moved before they can be
taken out or removed.
MEM 103 Unit 3, Lesson 6
Fig. 6.5 Loose piece pattern
6.1.7 Skeleton Pattern
For large castings pattern would require a considerable amount of timber for fully
solid pattern. In such cases the pattern is made of wooden frame and rib construction so
that it will form an exterior or interior outline of casting. This framework is known as
skeleton. Skeleton patterns are generally employed for symmetrical castings. Castings,
which are generally made by making skeleton pattern, are valve bodies, pipe bends,
water pipes and boxes.
Fig. 6.6 Skeleton pattern
6.1.8 Sweep Pattern
Uniform moulds and cores are shaped by sweep pattern. The sweep pattern
consists of a wooden board having a shape corresponding to the shape of desired
casting. It is arranged to rotate about a central axis. The sand is rammed and the board
is made to rotate to get the desired shape mould. Sweep pattern is used for
manufacturing of circular parts. This method is very economical since no actual pattern
is needed and the pattern costs are kept at minimum by eliminating expensive pattern
construction.
MEM 103 Unit 3, Lesson 6
Fig. 6.7 Sweep pattern
6.1.9 Left and Right Hand Pattern
Some patterns are required to be made in pairs and when their form is such that
they can not be reversed and they have the centers of hubs etc, opposite and in line,
they must be made left and right hand separately.
A pair of left and right hand patterns is required in legs of paddle type sewing
machine, legs for wood turning lathe and legs of garden benches etc.
Fig. 6.8 Left and right pattern
6.1.10 Shell Pattern
Shell pattern is generally used for pipe work. This pattern is made of metal and
its involves its mounting on a plate with a parting at the centre line and both the parts
being pinned to each other. The shell pattern is a hollow construction like a shell. The
outside shape is used as a pattern to make the mould while the inside is used as a core
box for making cores.
Fig. 6.9 Shell pattern
MEM 103 Unit 3, Lesson 6
6.1.11 Segmental Pattern
A segmental pattern resembles a sweep pattern in the sense that for getting the
required shape, both employ a part of pattern and not the complete pattern. Both
segmental and sweep patterns generate circular shapes. When a mould is to be made
using this pattern, a vertical spindle is firmly fixed in the centre of lower moulding box.
The mould bottom is rammed and swept level. The segmental pattern is fastened to the
spindle. Moulding sand is rammed between the out side of the pattern and the flask and
on the inside, except at the end of the pattern. After ramming one segment, next
segment is rammed and so on until the entire perimeter of the mould is completed.
Fig. 6.10 Segmental pattern
6.1.12 Follow Board Pattern
Follow board is a wooden board and is used for supporting a pattern which is
thin and which may give way and collapse under pressure when the sand above the
pattern is being rammed. In some cases, the purpose of the follow board is not only to
serve as a support to the thin pattern, but also forms an irregular parting line in the
mould when the outlines of the pattern are irregular.
Fig. 6.11 Follow board pattern
MEM 103 Unit 3, Lesson 6
6.2 Pattern Allowances
Pattern is used to produce a casting of desired dimensions; it is not dimensionally
identical to the casting. A number of allowances must be made on the pattern to ensure
that the finished casting is dimensionally correct, to ensure that the pattern can be
effectively removed from the mould. The following allowances are usually provided in a
pattern.
6.2.1 Shrinkage Allowance
The various metals used for casting contract after solidification. It is the correction
factor built into the pattern to compensate for the contraction of the metal casting as it
solidifies and cools at room temperature. The pattern is intentionally made larger than
the final desired casting dimensions to allow for solidification and cooling contraction of
casting. The total contraction is volumetric, but usually expressed linearly.
Fig. 6.12 Shrinkage Allowance
Table 6.1 Shows typical pattern shrinkage allowances for various casting
materials
Material being cast Shrinkage allowance Approximate shrinkage,
(mm/ meter) %
Gray cast iron 10.5 1.0
Steel 20 to 21 1.6
Brass 16 1.4
Aluminium 16 1.3
Magnesium 18 1.3
Ductile cast iron - 0.8
Table 6.1 Typical pattern shrinkage allowances for various casting material.
The contraction rule is a special scale that eliminates the need to compute the
amount of the shrinkage allowance that must be provided on a given dimension. Each
graduation on the shrink rule is proportionately longer than its conventional length. It is
important to remember that pattern shrinkage allowances cannot be used to predict
MEM 103 Unit 3, Lesson 6
actual casting shrinkage. Other factors, such as casting shape, section thickness and
mould rigidity significantly influence the actual change in dimensions as the casting
solidifies and cools to room temperature.
6.2.2 Draft Allowance
Draft is taper allowed on the vertical faces of a pattern to permit its removal from
the sand with out tearing the moulding walls. It may be represented in millimeters per
meter on a side or degrees. The amount of taper varies with the type of patterns.
Fig. 6.13 Draft Allowance
The wooden patterns require more taper than metallic patterns because of greater
frictional resistance of the wooden surfaces. The amount of draft also depends on the
shape and size of casting, the moulding process used, the method of mould production
and the condition of pattern. The draft angle of approximately 1.5o is often added to
design dimensions. Interior surfaces usually require more draft than exterior surfaces.
6.2.3 Machining Allowance
It provides for sufficient excess metal on all cast surfaces that require machining.
The required machine allowance depends on following factors:
(1) The size and shape of casting
(2) The metal to be casted.
(3) Casting surface roughness and surface defect.
(4) Method of machining to be employed.
(5) The degree of finish required on the machined portion.
MEM 103 Unit 3, Lesson 6
Fig. 6.14 Machining Allowance
Accurate patterns combined with automated moulding can often produce close tolerance
casting with a minimum finish allowance that can reduce machining cost.
Table 6.2 shows suggested machining allowances.
Pattern Allowance Allowance Allowance Material
size(mm) (mm)Bore (mm) (mm)
Surface Cope side
Upto152 3.2 2.4 4.8 Cast iron
152-305 3.2 3.2 6.4 Cast iron
305-510 4.8 4.0. 6.4 Cast iron
510-915 6.4 4.8 6.4 Cast iron
915-1524 7.9 4.8 7.9 Cast iron
Upto 152 3.2 3.2 6.4 Cast steel
152-305 6.4 4.8 6.4 Cast steel
305-510 6.4 6.4 7.9 Cast steel
510-915 7,1 6,4 9,6 Cast steel
915-1524 7.9 6.4 12.7 Cast steel
Upto 7.6 1.6 1.6 1.6 Non ferrous alloys
76-152 2.4 1.6 2.4 Non ferrous alloys
152-305 2.4 1.6 3.2 Non ferrous alloys
305-510 3.2 2.4 3.2 Non ferrous alloys
510-915 3.2 3.2 4.0 Non ferrous alloys
915-1524 4.0 3.2 4.8 Non ferrous alloys
Table 6.2 Machining allowances
MEM 103 Unit 3, Lesson 6
6.2.4 Distortion Allowance
Certain cast shape, such as large flat plates and U shaped castings, sometimes
distort when reproduced from straight or perfect patterns. This distortion is caused by the
non-uniform contraction stresses during the solidification of irregularly shaped designs.
Mechanically pressing or straighting normally corrects minor distortions. To eliminate this
defect an opposite distortion is provided in the pattern, so that the effect is neutralized
and the correct casting is obtained.
Fig. 6.15 Distortion Allowance
6.2.5 Rapping and Shaking Allowances
This allowance is provided in the pattern to compensate for the rapping of mould
because the pattern is to be rapped before removing it from mould. As a result of this the
size of the mould cavity increases a negative allowance is provided in the pattern to
compensate the same. 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.
6.3 Colour Codes for Patterns
Pattern colour coding is provided:
(1) To identify the type of metal to be casted.
(2) To show the part to be machined.
(3) To identify loose pieces, core prints.
(4) To identify the main part of the pattern from the remaining
part.
(5) To show the part to be left un machined.
MEM 103 Unit 3, Lesson 6
Table 6.3 shows the American color coding.
[Link] Colour Part
1 Red Cast surface to be machined
2 Black Cast surface to be left un machined
3 Yellow strip on Core prints for un machined openings
black back ground
4 Black strip on yellow Supports, stops offs
background (diagonal)
5 Yellow Core prints seat
6 Red strips on yellow Loose pieces
background
7 Clear or no colour Parting surfaces
Table 6.3 Pattern colours
6.4 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:
(1) Pattern should be accurate as regard to its dimensions and
possess a very good surface finish.
(2) Proper allowance should be provided in pattern.
(3) Sharp corners of pattern should be avoided.
(4) Core prints provided for the pattern should be of optimum in
size.
(5) Changes made in the shape should be gradual, uniform and
smooth.
(6) Proper material for making the pattern should be selected.
(7) The wall thickness and section should be kept uniform.
(8) Pattern made for expected repeat orders should be preserved
and stored properly.
MEM 103 Unit 3, Lesson 6
6.5 Core
Core is defined as that portion of the mould, which forms the hollow interior of the
casting or hole through the casting. Core can also be defined as a body of dry sand
generally prepared separately in a core box, baked in an oven and used to form a cavity
of desired shape.
Fig. 6.16 Core
The core should have sufficient strength and hardness in both green and dry
states so that it may be able to support its own weight. The main characteristics required
for a good core are the following:
(1) It should not carry any such constituents, which will give rise
to excessive gases on coming in contact with the molten metal.
(2) It must be sufficiently permeable to allow the gases formed to
escape easily.
(3) It should be highly refractory to withstand the high heat of the
molten metal.
(4) It should be hard and strong enough to bear its own weight and
the force of molten metal.
6.6 Types of Cores
Following are the commonly used cores:
6.6.1 Horizontal Core
The horizontal cores are used in foundry work frequently. It is usually in a
cylindrical form laid in the mould horizontally. Depending upon the shape of the cross
section of the hole to be made in the casting, it may have any shape of its cross section.
If it has a uniform cross section such that its one half remains in the cope and the
remaining half in the drag. Horizontal core is commonly used for making through holes.
Fig. 6.17 Horizontal core
MEM 103 Unit 3, Lesson 6
6.6.2 Vertical Core
It is similar in shape to that of horizontal core. But placed in the mould with its axis
vertical. The upper end of the core is placed in cope and the lower end is placed in the
drag.
Fig. 6.18 Vertical core
6.6.3 Balanced Core
When the casting has opening only on one side and only one core print is
available on the pattern a balanced core is used. It is a horizontal core and used to
produce a blind hole along a horizontal axis in the casting. It is supported only one end,
the other end remaining free in the cavity of the mould.
Fig. 6.19 Balance core
6.6.4 Wire Core
It is used, when a hole is to be obtained in the casting either above or below the
parting line. Wire core is also used when it is not possible to place the pattern in the
mould such that the recess can be cored directly. One side of the core remains flush
with the inner surface of the mould and the core acts as a stop off. Back surface of the
core has sufficient taper for easy location.
Fig. 6.20 Wire core
MEM 103 Unit 3, Lesson 6
6.6.5 Hanging Core
If the core hangs from the cope and does not have any support at the bottom in
the drag, it is known as hanging core. A hanging core may be supported on a seat made
on the parting surface in the drag.
Fig. 6.21 Hanging core
6.7 Core Prints
Core prints are extra projections provided on the pattern. These form seats for
cores in the mould. Core seats are provided to support all types of cores such as
horizontal, vertical, balanced etc.
Fig. 6.22 Core prints
MEM 103 Unit 3, Lesson 6
6.8 Core Boxes
Core boxes are used for producing cores. Following are the main types of core boxes:
6.8.1 Half core box
Half portion of the core is made in the core box at one time. Number of such half
cores made backed and passed together to make full cores.
Fig. 6.23 Half core box
6.8.2 Dump Core Box or Slab Core Box
It is employed for making rectangular, square, or trapezoidal cores. Construction
wise it is similar to half core box.
Fig. 6.24 Dump core box
6.8.3 Left and Right Hand Core Boxes
These types of core boxes generally produce Pipe bends. Each box comprises of
half of the pipe bend. The half of the pipe bends are rammed and baked and struck
together to made full core.
6.8.4 Split Core Box
The two portions of split core box can be aligned and temporarily joined together
with the help of dowels. A full core cavity is thus established. First the two halves are
joined and the sand is rammed. The core box is then spilitted to remove the core.
MEM 103 Unit 3, Lesson 6
Fig. 6.25 Split core box
6.8.5 Loose Piece Core Box
It is used to prepare two halves of a core which may be neither identical in size
nor in shape. It can be achieved by inserting loose pieces in the core box whenever
required.
Fig. 6.26 Loose piece core box
6.8.6 Strickle Core Box
It is used for producing irregular surfaces. The strickle board removes additional
sand. It is made of wood.
Fig. 6.27 Strickle core box