Power Point Presentation

On
“PATTERN MAKING &USAGE OF PATTERN
“

Submitted by: KOUSTAV MUKHERJEE

Semester:3rd
Branch: MECHANICAL
Subject: MANUFACTURING
Subject Code: PC-ME302
MAKAUT Roll No:16900721012

Mechanical Engineering Department

Academy of Technology
G.T. Road, Adisaptagram, P.O.: Aedconagar
Hooghly-712121, West Bengal
2022
PATTERN
• NAME – KOUSTAV MUKHERJEE
• ROLL NO- 012
• UNIVERSITY ROLL NO- 16900721012
• DEPARTMENT- MECHANICAL
• SUBJECT- MANUFACTURING PROCESS
• TOPIC- PATTERN
• SUBJECT CODE- [PCME-302]
DEFINATION
The pattern is the principal tool during the casting process. It is the
replica of the object to be made by the casting process, with some
modifications. The main modifications are the addition of pattern
allowances, and the provision of core prints. If the casting is to be
hollow, additional patterns called cores are used to create these
cavities in the finished product. The quality of the casting produced
depends upon the material of the pattern, its design, and construction.
The costs of the pattern and the related equipment are reflected in the
cost of the casting. The use of an expensive pattern is justified when
the quantity of castings required is substantial.
FUNCTIONS OF THE PATTERN
A pattern prepares a mold cavity for the purpose of making a casting.
A pattern may contain projections known as core prints if the casting
requires a core and need to be made hollow.
Runner, gates, and risers used for feeding molten metal in the mold
cavity may form a part of the pattern.
Patterns properly made and having finished and smooth surfaces
reduce casting defects.
A properly constructed pattern minimizes the overall cost of the
castings.
PATTERN MATERIAL
Patterns may be constructed from the following materials. Each material has its own advantages, limitations,
and field of application. Some materials used for making patterns are: wood, metals and alloys, plastic, plaster
of Paris, plastic and rubbers, wax, and resins. To be suitable for use, the pattern material should be:
Easily worked, shaped and joined
Light in weight
Strong, hard and durable
Resistant to wear and abrasion
Resistant to corrosion, and to chemical reactions
Dimensionally stable and unaffected by variations in temperature and humidity
Available at low cost
The usual pattern materials are wood, metal, and plastics. The most commonly used pattern material is wood,
since it is readily available and of low weight. Also, it can be easily shaped and is relatively cheap. The main
disadvantage of wood is its absorption of moisture, which can cause distortion and dimensional changes.
Hence, proper seasoning and upkeep of wood is almost a pre-requisite for large-scale use of wood as a pattern
material.
TYPES OF PATTERNS
1. Patterns are of various types, each satisfying certain casting
requirements.
2. Single piece pattern
3. Split or two piece pattern
4. Match plate pattern
SINGLE PIECE PATTERN
The one piece or single pattern is the most inexpensive of all types of
patterns. This type of pattern is used only in cases where the job is very
simple and does not create any withdrawal problems. It is also used for
application in very small-scale production or in prototype development.
This type of pattern is expected to be entirely in the drag and one of
the surface is is expected to be flat which is used as the parting plane.
A gating system is made in the mold by cutting sand with the help of
sand tools. If no such flat surface exists, the molding becomes
complicated
SPLIT /TWO PIECE PATTERN
• Split or two piece pattern is most widely used type of pattern for
intricate castings. It is split along the parting surface, the position of
which is determined by the shape of the casting. One half of the
pattern is molded in drag and the other half in cope. The two halves
of the pattern must be aligned properly by making use of the dowel
pins, which are fitted, to the cope half of the pattern. These dowel
pins match with the precisely made holes in the drag half of the
pattern. A typical split pattern of a cast iron wheel
PATTERN ALLOWANCE
• This change in the pattern is due to when the cast solidifies, it shrinks
at some limit due to metal shrinkage property at the time of cooling.
So to compensate for this, a pattern is made a little bigger. These
slight changes in the pattern are known as pattern allowance
TYPES OF PATTERN ALLOWANCES
• Pattern allowance is a vital feature as it affects the dimensional
characteristics of the casting. Thus, when the pattern is produced, certain
allowances must be given on the sizes specified in the finished component
drawing so that a casting with the particular specification can be made. The
selection of correct allowances greatly helps to reduce machining costs and
avoid rejections. The allowances usually considered on patterns and core
boxes are as follows:
• Shrinkage or contraction allowance
• Draft or taper allowance
• Machining or finish allowance
• Distortion or camber allowance
• Rapping allowance
SHRINKAGE/CONTRACTION ALLOWANCE
• All most all cast metals shrink or contract volumetrically on cooling.
The metal shrinkage is of two types:
• Liquid Shrinkage: it refers to the reduction in volume when the metal
changes from liquid state to solid state at the solidus
temperature. To account for this shrinkage; riser, which feed the
liquid metal to the casting, are provided in the mold.
• Solid Shrinkage: it refers to the reduction in volume caused when
metal loses temperature in solid state. To account for this, shrinkage
allowance is provided on the patterns.
DRAFT/TAPER ALLOWANCE
• By draft is meant the taper provided by the pattern maker on all vertical surfaces
of the pattern so that it can be removed from the sand without tearing away the
sides of the sand mold and without excessive rapping by the molder. Figure 3 (a)
shows a pattern having no draft allowance being removed from the pattern. In
this case, till the pattern is completely lifted out, its sides will remain in contact
with the walls of the mold, thus tending to break it. Figure 3 (b) is an illustration
of a pattern having proper draft allowance. Here, the moment the pattern lifting
commences, all of its surfaces are well away from the sand surface. Thus the
pattern can be removed without damaging the mold cavity.
• Draft allowance varies with the complexity of the sand job. But in general inner
details of the pattern require higher draft than outer surfaces. The amount of
draft depends upon the length of the vertical side of the pattern to be extracted;
the intricacy of the pattern; the method of molding; and pattern material
DISTORTION /CAMBER ALLOWANCE
• Sometimes castings get distorted, during solidification, due to their typical shape.
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. This
can be prevented by making the legs of the U, V, T, or L shaped pattern converge
slightly (inward) so that the casting after distortion will have its sides vertical (
(Figure 4).
• 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:
• Modification of casting design
• Providing sufficient machining allowance to cover the distortion affect
• Providing suitable allowance on the pattern, called camber or distortion
allowance (inverse reflection)
RAPPING ALLOWANCE
• Before the withdrawal from the sand mold, the pattern is rapped all
around the vertical faces to enlarge the mold cavity slightly, which
facilitate its removal. Since it enlarges the final casting made, it is
desirable that the original pattern dimension should be reduced to
account for this increase. There is no sure way of quantifying this
allowance, since it is highly dependent on the foundry personnel
practice involved. It is a negative allowance and is to be applied only
to those dimensions that are parallel to the parting plane.
CORE/CORE PRINTS
• Castings are often required to have holes, recesses, etc. Of various
sizes and shapes. These impressions can be obtained by using cores.
So where coring is required, provision should be made to support the
core inside the mold cavity. Core prints are used to serve this
purpose. The core print is an added projection on the pattern and it
forms a seat in the mold on which the sand core rests during pouring
of the mold. The core print must be of adequate size and shape so
that it can support the weight of the core during the casting
operation. Depending upon the requirement a core can be placed
horizontal, vertical and can be hanged inside the mold cavity
MACHINING/FINISH 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.
RATE OF CONTRACTION OF VARIOUS METALS
DRAFT ALLOWANCE OF VARIOS METALS
MACHINING ALLOWANCE OF VARIOUS
METALS
CONCLUSION &REFFERNCE
• Manufacturing continues to be an import aspect of industry, not just
to provide goods for the marketplace, but also to drive the economy.
As manufacturing processes continue to advance, so the skills
required have also developed, with this trend set to continue in the
future.
• REFFERENCES – sites.google.com
• Wikipedia.org
• Class notes
• Fundamentals of Modern manufacturing by Mikell p.Groover