PATTERN A pattern is defined as a model of a casting, constructed in such a way that it can be used for forming an impression in damp

sand. In casting the first step is to make a model known as pattern. Requirements of a good pattern Light in weight Convenient to handle Simple in design and ease of manufacture Smooth and wear resistant surface High strength and long life Cheap and readily repairable. Pattern materials Wood, metal, plastic, quick setting compounds Types of patterns Types of pattern depend upon the following factors The shape and size of casting Number of casting required Method of casting Anticipated difficulty in moulding 1. solid or single piece pattern 2. split pattern 3. loose pattern 4. gate pattern 5. match plate pattern 6. skelton pattern 7. sweep pattern 8. cope and drag pattern 9. segmental pattern 10. shell pattern Pattern allowances 1. shrinkage allowance It is the allowance added to the pattern to compensate for the metal shrinkage that take place while the metal solidifies. 2. draft or taper allowance It is the taper provided on vertical surface of a pattern to facilitate its removal from the mould without excessive rapping or breakage of cavity edges. 3. machining allowance It is the extra metal provided on certain details of a casting may b machined to exact dimensions. 4. rapping or shaking allowance It is provided to compensate for enlargement of th mould cavity because of excessive rapping 5. distortion allowance It is provided to compensate for th possible distortion of the casting because of the unequal cooling rates of different sections of the casting and uneven internal stresses.

Moulding Mould A mould is a cavity or void made in a compact sand mass, which when filled molten metal, will produce a casting of the desired shape. The mould made in the sand is known as sand mould. The process of producing a mould or cavity in the sand is called moulding. Moulding Tools Face board Riddle Trowel Slick Lifter Bellows Gate cutter Gate pin Rammers Swabs Draw spikes Vent wires etc. Mould Materials Metals Grey cast iron Steel Anodised aluminium Non-metals Moulding sands Plaster of Paris Graphites Wax Silicon carbide Ceramic Types of moulds 1. temporary moulds (eg. Sand moulds) 2. Permanent moulds (eg. Metallic moulds) Moulding processes 1. bench moulding 2. floor moulding 3. pit moulding 4. machine moulding Selection of Mould Materials The materials, selected for particular use, depend upon the quality of casting required, number of castings, material to be cast, size and shape of casting and cost etc. Moulding Sand The principal raw material used in moulding. The sand in moulding is silica, the oxide of silica. The factors to be controlled in the preparation of sand for making moulds are clay content, moisture content, grain size permeability, and strength of the sand. Types of Moulding Sands Green sand Dry sand Parting sand Facing sand

 Backing sand Molasses sand Green sand It is moist sand containing about 5% moisture. Moulds and cores may be made from green sand. Both moulds and cores may be baked to drive out the moisture. However, the most commonly used moulds are of that is not dried. They are called green sand moulds. The moisture content and permeability may be closely controlled to prevent the trapping of gases which could cause voids in the casting. Main constituents of Mould Sand Silica sand Binder Additives Water Binder impart sufficient strength and cohesiveness to the moulding sand so as to retain its shape after the mould has been rammed and the pattern withdrawn. Additives are added to the moulding sand to improve upon some of its existing properties or to impart new properties to it. Water content is mainly responsible for enabling the clay to impart the desired strength to the sand. Properties of Moulding Sands Permeability Cohesiveness Collapsibility Adhesiveness Plasticity Refractoriness Green Sand Moulds Green sand moulds are those sand moulds, in which moisture is present in the sand at the time of pouring the molten metal. The sand is mixed with water and suitable proportions of bonding agents, as this mixture, in wet (or green) state, is used for making the moulds. The mould is prepared in the usual manner. Molten metal is poured into the mould through the runner. There is no need of baking the mould before pouring. Most of the small and medium sized castings, particularly non-ferrous ones, are made by green-sand moulding.

Casting A casting can be defined as a molten material that has been poured into a prepared cavity and allowed to solidify. Sand Casting Making of castings in moulds of sand or similar material. The principal metals used are cast irons and steel, brass and other copper alloys, aluminum and magnesium alloys. The softer alloys of lead, tin etc. are usually cast in steel moulds or dies.

Advantages of Casting Complicated shapes can be obtained in quantities at low cost. Within certain limits the units are identical in size and properties. Replacement can be quickly obtained, provided the pattern is kept safe. Certain castings, being solid integral units, are more rigid than built up units. Cast metals and alloys, in general, resist creep under high temperature conditions better than the wrought product. Steps in making a Casting The making of a pattern, which may be in exactly the same form as the finished product The actual making of the mould in sand. The pouring into the mould of molten metal, which is allowed to solidify. The removal of casting from the sand, and its cleaning by removing all superfluous adherent metal a process called dressing or fettling. CORE A core is a body made of refractory material which is set into the prepared mould before closing and pouring it, for forming the hole, recesses, undercuts, and initial cavities. TYPES OF CORES Green sand Dry sand Oil sand Loam sand Metal core Horizontal cores Vertical cores Balanced core Cover core Wing core Hanging core