KYAMBOGO UNIVERSITY

P.O.BOX 1, KYAMBOGO-KAMPALA UGANDA

Tel:+256-41-285272/04128734 www.kyambogo.ac.ug

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING

FOUNDRY COURSE WORK PRESENTATION

(PATTERN MAKING)

BY GROUP 03

20TH/SEPTEMBER/2019

1 KAJURA JOSEPH 18/U/EME/17636/PE

2 AISHA PATIENCE MASINDE 17/U/8572/EME/PE
3 ARINAITWE WILLIAM 18/U/EME/17626/PE
4 NYANKOJO HUDSON 17/U/8780/EME/PE
5 EPEDU GEOFREY 18/U/EME/17650/PE
6 NABWIRE FLAVIA 18/U/EME/17728/PE
7 ARINAWE DENIS 18/U/EME/17668/PE
8 NSANJA DERRICK 17/U/18582/EME/PE
9 MUJUNI DAN 17/U/16364/EME/PE
Contents
PATTERNS...................................................................................................................................................1
1.0 INTRODUCTION TO PATTERN MAKING.....................................................................................1
2.0 MATERIALS FOR MAKING PATTERNS.......................................................................................1
3.0 PATTERN MATERIALS SELECTION CRITERIA.........................................................................5
4.0 PATTERN MAKING TOOLS...........................................................................................................6
5.0 PATTERN ALLOWANCES...............................................................................................................7
6.0 TYPES OF PATTERNS....................................................................................................................11
7.0 PATERN DESIGN COSIDERATIONS............................................................................................15
8.0 PATTERN COLORS.........................................................................................................................16
9.0 THE MASTER PATTERN................................................................................................................17
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 PATTERNS

1.0 INTRODUCTION TO PATTERN MAKING

A pattern is a mold forming tool in the hands of foundry men, it is a model or the replica of the
object to be cast. Except for the various allowances a pattern exactly resembles the casting to be
made. A pattern is required even if one object has to be cast. A pattern may be defined as a
model or form around which sand is packed to give rise to a cavity known as mold cavity in
which when, molten metal is poured, the result is the cast object.

1.1 Difference between pattern and casting

• The main difference between a pattern and the casting is their dimensions.

• A pattern is slightly larger in size as compared to the casting, because a pattern, – carries
Shrinkage allowance, it may be of the order of 1 to 2 mm/ 100 mm. – is given a Machining
allowance to clean and finish the required surfaces. – carries a Draft allowance of the order of 1
and 3 degrees for external and internal surfaces respectively – carries core prints.

• A pattern may not have all holes and slots which a casting will have. Such holes and slots
unnecessarily complicate a pattern and therefore can be drilled in the casting after it has been
made.

• A pattern may be in two or three pieces whereas a casting is in one piece.

• A pattern and the casting also differ as regards the material out of which they are made.

2.0 MATERIALS FOR MAKING PATTERNS

Patterns may be constructed out of the following materials.

 Wood
 Metal
 Plastic

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  Plaster (POP)
 Wax

2.1 Wood

The most common materials for making patterns for sand casting is the wood.

2.1.1 Advantages of wood as a pattern

 Inexpensive.
 Easily available in large quantities.
 Easy to machine and to shape to different configurations and forms
 Easy to join to acquire complex and large pattern shapes
 Light in weight
 Easy to obtain good surface finish
 Wooden patterns can be preserved for quite long times with the help of suitable wood
preservatives.

2.1.2 Limitations of wood as a pattern

 Wooden patterns are susceptible to shrinkage and swelling.

 They possess poor wear resistance.
 They are abraded easily by sand action.
 They absorb moisture, consequently get deformed and change shape and size.
 They cannot withstand rough handling
 They are weak as compared to metal patterns.

Application: they are used were large sized castings are to be made

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2.2 Metal.

Metal patterns are employed where large numbers of castings have to be produced from the same
patterns. Metal patterns are cast from wooden patterns. The different metals and alloys used for
making patterns are,

 Aluminium and Aluminium alloys

 Steel
 Cast Iron
 Brass
 White Metal

2.2.1 Advantages of Metal Patterns

 Unlike wooden patterns, they do not absorb moisture. They retain their shape.
 They are stronger and accurate as compared to wooden patterns.
 They possess life much longer than wooden patterns (durable).
 They can withstand rough handling.
 They do not distort
 They possess greater resistance to abrasion. They have accurate dimensional
tolerances. They are far stable under different environments.
 It is easy to obtain smooth surface finish.
 They possess excellent wear resistance and strength to weight ratio.

2.2.2 Limitations of Metal Patterns

 Expensive as compared to wood patterns.

 Are not easily repaired e.g. (Aluminium patterns).
 Ferrous patterns get rusted.
 They (ferrous patterns) are heavier than wooden patterns,

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  They cannot be machined so easily as wooden ones.

2.3 Plastic

2.3.1 Advantages of plastic patterns

 Durable
 Provides a smooth surface.
 Moisture resistant.
 A plastic pattern does not involve any appreciable change in its size or shape.
 Lightweight.
 Wear and corrosion resistant.
 Provides good surface finish.
 It possesses low solid shrinkage.

2.3.2 Limitations of plastic pattern

 Plastic patterns are fragile and thus light sections may need metal reinforcements.
 Plastic patterns may not work well when subject to conditions of severe shock as
in machine moulding.

2.4 PLASTER

2.4.1 Advantages plaster patterns

 Can be easily worked by using wood working tools.

 Intricate shapes can be cast without any difficulty.
 It has high compressive strength (up to 285 kg/cm2)

2.4.2 Disadvantages plaster patterns

 Can be used for small castings only

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2.4.3 Plaster Patterns Material: Plaster patterns may be made out of Plaster of Paris or Gypsum
cement.

2.4.4 Applications: Plaster is used for making

 Small and intricate patterns, and

 Core boxes.

2.5 WAX

2.5.1 Advantages of wax patterns

 Wax patterns provide very good surface finish

 They impart high accuracy to the castings.
 After being molded, the wax pattern is not taken out of the mold like other patterns;
rather the mold is inverted and heated; the molten wax comes out and/or is evaporated.
Thus there is no chance of the mold cavity getting damaged while removing the pattern.

2.5.3 Applications • Wax patterns find applications in Investment casting process.

3.0 PATTERN MATERIALS SELECTION CRITERIA

The following factors assist in selecting proper pattern material:

 The number of castings to be produced. Metal patterns are preferred when the production
quantity is large.
 The desired dimensional accuracy and surface finish required for the castings.
 Nature of molding process i.e., sand casting, permanent mold casting, shell molding,
investment casting etc.
 Method of molding i.e., hand or machine molding.
 Shape, complexity and size of the casting.
 Type of molding materials i.e., sand etc.
 The high probability of changing the casting and hence the pattern in near future.
Selection of pattern materials

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4.0 PATTERN MAKING TOOLS

Some of the commonly used pattern making tools are showel, trowel, riddle, rammer, draw
spike, swab, vent wire and slick tool.
4.1 Showel:
Showel tool is used for mixing and tempering moulding sand and for moving
the sand pile to flask.

4.2 Trowel:
Trowel tool is used to shape and smooth the surfaces of the mould and for doing
small repairs. They are made of steel and are relatively long and narrow.

4.3 Riddle:
Riddle tool is a screen or sieve used to remove small pieces of metal and
foreign particles from the moulding sand.

4.4 Rammer:
Rammer tool is used to compress the moulding sand. The hand rammer is
made of tool and resembles like a handless mallet with one end flat and the
other end blunt edge.

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4.5 Draw spike:
Draw spike tool is used to remove the pattern from the mould and also used
for rapping the pattern gently the loosen it from the sand to assure a clean
draw.

4.6 Swab:
Swab tool is made of flax or hemp and is used for applying water to the
mould around the corners and edges of the patterns. This tool prevents the
sand edges from crumbling, when the pattern removed from the mould.

4.7 Vent wire:

Vent wire is a thin rod or wire carrying a pointed edge at one end and a wooden handle at the
other end. Vent wire is used to make small holes called vents in the sand mould.
4.8 Slick tool:
Slicks tools are the spoon shaped trowels used for repairing or smoothening a mould surface.

5.0 PATTERN ALLOWANCES

A pattern is always larger in size as compared to the final casting, because it carries certain
allowances. The various pattern allowances are: Shrinkage or contraction allowance, Machining
or Finish allowance, Draft or Taper allowance, Distortion or camber allowance and Shake or
rapping allowance.

5.1 Shrinkage/Contraction Allowance

Almost all cast metals shrink or contract volumetrically after

solidification and therefore to obtain a particular sized casting.
Shrinkage can be classified into liquid and solid shrinkage;

Liquid shrinkage is the reduction in volume during the

solidification process and solid shrinkage is the reduction in volume during the cooling of the
cast metal, the pattern is made larger by an amount equal to that of shrinkage or contraction.

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Different metals shrink at different rates because shrinkage is the property of the cast metal or
alloy.

The metal shrinkage depends upon

• The cast metal or alloy. (Shrinkage rate)

• Pouring temperature of the metal or alloy, i.e. pouring at high temperature will take long in
liquid form that shrinks a lot

• Casting dimensions (size).

• Casting design aspects.

• Molding conditions (i.e., mold materials and molding methods employed).

• Cast iron poured at higher temperatures will shrink more than that poured at lower temperature.

• Wood patterns used to make metallic patterns are given double allowance; one for the
shrinkage of the metal of the pattern and the other for that of metal to be cast.

5.2 Machining/finishing Allowance

A casting is given an allowance for machining, because:

 Castings get oxidized in the mold and during heat treatment; scales etc., thus
formed need to be removed.

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  It is intended to remove surface roughness and other imperfections from the
castings.
 It is required to achieve exact casting dimensions.

How much extra metal or how much Machining allowance should be provided, depends upon:

• Nature of metal i.e., ferrous or non-ferrous. Ferrous metals get scaled whereas non-ferrous ones
do not.

• Size and shape of the casting. Longer castings tend to warp and need more material (i.e.,
allowance) to be added to ensure that after machining the casting will be alright. • The type of
machining operation (i.e., grinding, turning, milling, boring etc.) to be employed for cleaning the'
castings. Grinding removes much lesser metal as compared to turning.

• Casting conditions i.e., whether casting conditions result in a rough casting or a semi-finished
one. Casting conditions include the characteristics of mold-materials etc.

• Molding process employed. Die casting produces parts which need little machining (allowance)
whereas sand- casting, require more machining allowance.

• Number of cuts to be taken. Machining allowance is directly proportional to the number of cuts
required for finishing the casting.

• The degree of surface finish desired on the cast part.

5.3 Draft or Taper Allowance

It is given to all surfaces perpendicular to the parting

line. Draft allowance is given so that the pattern can be
easily removed from the molding material tightly packed
around it without damaging the mold cavity (i.e. the
pattern is curved at the center for easy removal). The
amount of Taper depends upon:

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  Shape and size (length) of the pattern in the depth direction in contact with the
mold cavity.
 Molding method.
 Mold materials.

Draft allowance is imparted on internal as well as external surfaces but it is more on internal
surfaces.

5.4 Distortion(camber) Allowance

A Casting will distort or warp if:

 It is of irregular shape,
 All its parts do not shrink uniformly i.e., some parts shrink while others are restricted from doing
so,
 It is u or v-shaped,
 It has long, rangy arms as those of the propeller strut for the ship,
 It is a long flat casting,
 The arms possess unequal thickness,
 One portion of the casting cools at a faster rate as compared to the other, etc.

Distortion can be practically eliminated by providing an allowance and constructing the pattern
initially distorted i.e., outsize in the opposite direction so that the casting after cooling neutralizes
the initial distortion given on the pattern and acquires the correct shape. • The amount of
distortion allowance may vary from 2 to 20 mm depending upon the size, shape and material of
the casting.

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5.5 Shake Allowance

A pattern is shaken by striking the same with a wooden piece from side to side. This is done so
that the pattern is loosened a little in the mold cavity and can be easily removed.

In turn, therefore, shaking enlarges the mold cavity which results in a bigger sized casting.

Shake allowance (i.e. a negative allowance and it caters for the enlargement during removal), it is
normally provided only to large castings because it is negligible in case of small castings and is
thus ignored.

The magnitude of shake allowance can be reduced by increasing the taper.

6.0 TYPES OF PATTERNS

For selecting a particular kind of pattern for making a casting, one may consider the following
points: – Quantity of castings to be produced. – The size and the complexity of the shape of the
casting to be produced. – Type of molding method to be used (i.e., hand or machine molding). –
Problems associated with the molding operation such as withdrawing the pattern from the mold
etc. – Other difficulties resulting from poor casting design or pattern design.

The different types of patterns commonly used are: – One piece(Solid) pattern – Split pattern –
Loose piece pattern – Match plate pattern – Cope and Drag pattern – Sweep pattern – Gated
pattern – Skeleton pattern – Follow board pattern.

6.1 One Piece (solid) Pattern

It is the simplest type of pattern and as the name suggests the

pattern is made from one piece and does not contain loose pieces or
joints. It is inexpensive, used for making a few large size simple
castings. One piece pattern is usually made up of wood or metal

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depending upon the quantity of castings to be produced. For making the mold, one piece pattern
is accommodated either in the cope or in the drag.

6.2 Split Pattern

Patterns of intricate (shaped) castings cannot be made in one piece

because of the inherent difficulties associated with the molding
operations (e.g. withdrawing the pattern from the mold etc.), such
patterns are, then, made as split or two piece patterns.

The upper and the lower parts of the split pattern are accommodated in
the cope and drag portions of the mold respectively. Dowel pins are used for keeping the
alignment between the two parts of the pattern. The parting (surface or) line of the pattern forms
the parting (surface or) line of the mold. Patterns for still more intricate castings are made in
more than two pieces for facilitating their molding and withdrawing. A pattern having three
pieces will require a three piece flask for the molding purposes

6.3 Loose Piece Pattern

Certain patterns cannot be withdrawn once they are embedded in the

molding sand. Such patterns are usually made with one or more loose
pieces. Pieces for facilitating their removal from the molding box and
are known as loose piece patterns. Loose parts or pieces remain
attached with the main body of the pattern, with the help of dowel
pins. The main body of the pattern is drawn first from the molding box and thereafter the loose
parts are removed, the result is the mold cavity. Loose piece patterns involve more labour and
consume more time in the molding operation.

6.4 Match Plate Pattern

A match plate pattern consists of a match plate, on either side of

which each half of (a number of) split patterns is fastened. A number
of different sized and shaped patterns may be mounted on one match

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plate. The match plate with the help of locator holes can be clamped with the drag. The match
plate has runner and gates also attached with it. After the cope and drag have been rammed with
the molding sand, the match plate pattern is removed from in between the two (i.e., cope and
drag.)

Cope and drag are then assembled and this completes the mold. Patterns, match plate, runner
and gates — all may be made up of aluminium, because it is light and relatively inexpensive.
Match plate patterns are normally used in machine molding. • Match plate patterns are preferred
for producing small castings on mass scale. • They produce accurate castings and at faster rates. •
Piston rings of I.C. engines are produced with the help of match plate patterns.

6.5 Sweep Pattern

A sweep pattern is just a form made on a wooden board which sweeps

the shape of the casting into the sand all around the circumference.
The sweep pattern rotates about the post.

Once the mold is ready, sweep pattern and the post can be removed •
Sweep pattern avoids the necessity of making a full, large circular and
costly three dimensional pattern.

Making sweep pattern saves a lot of time and labor as compared to making a full pattern.

A sweep preferred for producing large castings of circular sections and symmetrical shapes.

The manufacture of large kettles of cast iron requires a sweep pattern.

6.6 Gated Pattern

Gated patterns are usually made of metal which increases their

strength and reduces the tendency to warp.

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The sections connecting different patterns serve as runner and gates. This facilitates filling of the
mold with molten metal in a better manner at the same time eliminates the time and labor
otherwise consumed in cutting runners and gates.

A gated pattern can manufacture many castings at one time and thus it is used in mass production
systems.

Gated patterns are employed for producing small castings.

6.7 Skeleton Patten

A skeleton pattern is the skeleton of a desired shape. The skeleton

frame is mounted on a metal base.

The skeleton is made from wooden strips and is thus a wooden

framework.

The skeleton pattern is filled with sand and is rammed. A strickle (board) assists in giving the
desired shape to the sand and removes extra sand.

If the object is symmetrical like a pipe, the two halves (of the pipe) can be molded by using the
same pattern and then the two molds can be assembled before pouring the molten metal.

Skeleton patterns are employed for producing a few large castings.

A skeleton pattern is very economical as compared to a solid pattern, because it involves less
material costs.

Castings for turbine castings, water pipes, channels, etc., are made with the help of skeleton
patterns.

6.8 Follow Board Pattern

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 A follow board is a wooden board and is used for supporting a pattern
which is very thin and fragile and which may collapse under the
pressure when the sand above the pattern is being rammed.

With the follow board support under the weak pattern, the drag is
rammed, and then the follow board is withdrawn.

The rammed drag is inverted; cope is mounted on it and rammed. During this operation pattern
remains over the inverted drag and gets support from the rammed sand of the drag under it.

Ultimately, the pattern is removed and the cope and drag are assembled.

7.0 PATERN DESIGN COSIDERATIONS

Many factors have to be taken into consideration when designing a pattern to ensure the best and
most cost-effective results. For example, some designs are simple and allow for easy removal
from the mould. However some castings are complex and require careful pattern design /
manufacture which can include the need for core assemblies to ensure patterns can be removed
easily from the moulds.

The following considerations should always be kept in mind while designing a pattern.
 All Abrupt changes in section of the pattern should be avoided as far as possible.
 Parting line should be selected carefully, so as to allow as small portion of the pattern as
far as possible in the cope area
 The thickness and section of the pattern should be kept as uniform as possible.
 Sharp corners and edges should be supported by suitable fillets or otherwise rounded of.
It will facilitate easy withdrawal of pattern, smooth flow of molten metal and ensure a
sound casting.
 Surfaces of the casting which are specifically required to be perfectly sound and clean
should be so designed that they will be molded in the drag because the possible defects
due to loose sand and inclusions will occur in the cope.
 As far as possible, full cores should be used instead of cemented half cores for reducing
cost and for accuracy.

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  For mass production, the use of several patterns in a mould with common riser is to be
preferred.
 The pattern should have very good surface finish as it directly affects the
corresponding finish of the casting.
 Shape and size of the casting and that of the core should be carefully considered
to decide the size and location of the core prints.
 Proper material should always be selected for the pattern after carefully analyzing the
factors responsible for their selection.
 Try to employ full cores always instead of jointed half cores as far as possible. This will
reduce cost and ensure greater dimensional accuracy.
 The use of offset parting, instead of cores as for as possible should be encouraged to the
great extent.
 For large scale production of small castings, the use of gated or match- plate patterns
should be preferred wherever the existing facilities permit.
 If gates, runners and risers are required to be attached with the pattern, they should be
properly located and their sudden variation in dimensions should be avoided.
 Wherever there is a sharp corner, a fillet should be provided, and the corners may be
rounded up for easy withdrawal of patterns as well as easy flow of molten metal in the
mould.
 Proper allowances should be provided, wherever necessary.
 As for as possible, the pattern should have a good surface finish because the surface
finish of the casting depends totally on the surface finish of the pattern and the kind of
facing of the mold cavity

8.0 PATTERN COLORS

 Clear/no color; denotes the parting face of the split pattern

 Yellow: the seats for the loose core print painted yellow
 Yellow strips on red: indicates seats for loose pieces
 Red strips on yellow background: for support/stop offs

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  Black: the surface must be left as in the casting, indicates no need for further work of
finishing operations
 Red: the surface requires to be machined

8.1 Reason for color coding

 Patterns are usually color coded to enable the mold maker to understand how to treat a
particular surface

9.0 THE MASTER PATTERN

Master patterns are used for preparing the moulds for metal casting which then used later for
further moulding, works called metal patterns

A master pattern is made out of wood that has been accurately finished having double allowance,
for instance double shrinkage allowance the casting made from the master pattern is used making
duplicate pattern with double shrinkage allowance for a particular metal required for the final
casting. I.e. an allowance is made not only for the shrinkage of the metal pattern but a second
allowance is added for the shrinkage of the casting to be produced from the metal pattern.

For example

A wooden master pattern made for an aluminum pattern to be used in the production of brass
castings, if the shrinkage allowance for aluminum and brass are 13.5mm/m and 15.3mm/m
respectively, calculate the length of the master pattern if the length of the casting required is
100mm.

If the final casting is to be machined, further allowance is to be made for the finishing of the
metal pattern and the final casting. Thus:

Allowance for brass = (15.3/100)×100

=1.53m

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Allowance for aluminum = (13.3/1000)×100

=1.33m

Double allowance =allowance of brass +allowance of aluminum

=1.53+1.33

=2.86m

Dimensions of the wooden master pattern = double allowance + length of the required casting

=2.86+(100/1000)

=2.96m

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