MANUFACTURING AND MATERIALS DEPARTMENT

MME1103
Workshop Technology Manual
Pattern Making

DEPARTMENT OF MANUFACTURING AND

MATERIALS

WORKSHOP TECHNOLOGY
MME 1103

PATTERN
MAKING

MANUFACTURING AND MATERIALS ENGINEERING DEPARTMENT

MME 1103
Workshop Technology Manual
Pattern Making

9.1 PATTERN MAKING EQUIPMENTS

Machines

(b) Horizontal Sander Machine

(a) Vertical Sander Machine

Other Tools

(b) Steel ruler

(a) Try square

(d) Hand Saw

(e) File
(c) Compass

(f) Sand Paper

MANUFACTURING AND MATERIALS ENGINEERING DEPARTMENT

MME 1103
Workshop Technology Manual
Pattern Making

9.2 INTRODUCTION
Pattern Material
Patterns are the foundry mans molding tool. The pattern is a replica of the part or final
object to be cast with some modifications. Patterns are usually made of wood, plastic or
metal depends on;
size of casting
the number of casting to be made from the pattern
the dimensional accuracy required
Wood is the most commonly used due to its availability, low in weight, easy to be shaped
and relatively cheap. However, wood absorbs moisture which the pattern could be
distorted and changes in dimension. Therefore, for large scale production, metal pattern is
used since it is durable, has smooth surface finish and better dimensional tolerances.
Plastic is used for pattern material for its low in weight, easier formability, smooth
surfaces and durability (Rao, 1998).

Modification in Pattern
The main modifications that have to be made in pattern are because of;
the addition of pattern allowances,
the provision of core prints,
elimination of fine details to be obtained by further processing.(i.e. machining),
modification for economical moulding, and
elimination of shapes that cause defects in casting
(Gupta, 1996)
Pattern usually is made usually larger than the cast mainly to compensate shrinkage.
Molten metals will face reduction in volume from its liquid state to solid state. Every
metal have different rate of contraction. The shrinkage allowance for steel is 2%, cast
iron 1.05% and aluminum 1.8%. Other types of pattern allowances are such as
machining, draft as in Fig 9.1 (a) (taper), shake and distortion allowances. Machining
allowances usually ranges from 2 to 5mm.Typical drafts range from 5mm/m to 15mm/m.
(Kalpakjian et.al, 2001)
Another modification that is made to the pattern is when there are cavities in the casting
product. Thus, to avoid other following processes such as machining, this requires pattern
modification that can produce core prints in the mould cavity (Fig 9.1(b)). Cores are the
materials used for making cavities and hollow projection of the cast product. Cores are
usually smaller than the actual cavity of the cast product to compensate shrinkages. Core
needs to be fitted securely and correctly positioned.
Intricate shapes and fine details are easily done with other processes (i.e machining).
Such shapes may cause defects in casting and fabrication of pattern are necessary to be
less complicated and economical in pattern making as well as in moulding process.

MANUFACTURING AND MATERIALS ENGINEERING DEPARTMENT

MME 1103
Workshop Technology Manual
Pattern Making

Figure 9.1: Modification in pattern (a) Draft and (b) Core Prints (Courtesy from
Manufacturing Technology, P.N Rao, page 70 and 73)

Types of Pattern
There are several types of patterns, each satisfying certain casting requirements such as
the shape, size and the required number of casting and method of moulding. In each case
pattern is usually constructed by simplest and cheapest way depending on the conditions
mentioned and figures shown below are few types of patterns.

(a) Single piece pattern

(b) Split pattern or two piece pattern

(c) Cope and Drag Pattern

(d) Loose piece pattern

Figure 9.2: Types of pattern (Courtesy from Manufacturing Technology, P.N Rao, page
76 - 78)
2

MANUFACTURING AND MATERIALS ENGINEERING DEPARTMENT

MME 1103
Workshop Technology Manual
Pattern Making

9.3 PROCEDURE
Note:
Please read the safety section first.
Each semester there will be changes in the shapes and dimension of the pattern.
Dimension is not included in this procedure.
Read the project drawing and follow the instruction.
1. Use either vertical or horizontal sander machine to get flat surface of the wood
block (workpiece).
2. Mark with pencil at one side material to be removed in order to get 900 of each
side of the workpiece. Make sure the two surfaces of the work piece are 90 and
smooth. Use the sander machine to remove the material.

Figure 9.3: Marking the workpiece by using try square.

3. Measure the exact value of the width and thickness of the work piece. Then,
remove the other part as shown in the Figure 9.4.

Figure 9.4: Parts to be removed

3

MANUFACTURING AND MATERIALS ENGINEERING DEPARTMENT

MME 1103
Workshop Technology Manual
Pattern Making

4. Mark the material to be removed with exact dimension and then, remove the part
by using the sander machine.
5. Finally, use sand paper for finishing.

MANUFACTURING AND MATERIALS ENGINEERING DEPARTMENT

MME 1103
Workshop Technology Manual
Pattern Making

9.5 SAFETY GUIDELINES

1. Do wear proper attire i.e. workshop jacket. Loose clothing, finger rings and other
accessories are some possible source(s) of accident.
2. Footwear must be worn at all time to prevent injury.
3. Do not run in the workshop. Be calm and serious.
4. When you are operating a machine, stand at a proper and safe distance.
5. Do not start any machine before obtaining instruction(s) from your instructor
(workshop technician or designated personnel).
6. Make sure you understand your machine before you start working on it.
7. Never let your friend to handle the starting switch for you.
8. Pay attention to details. Always think for a few minutes before you carry out your
next step. 2 minute rule
9. Always wear mask.
10. Do not use your hand(s) or finger to stop moving or rotating machines of parts of
machine.
11. It is best not to distract a person who is operating the machine. Wait till he or she
completes the operation before talking to him or her.
12. When facing with problems while using any machine, get help or advice from
your instructor.
13. You must stop the machine before leaving it. Never leave machine running
unattended.
14. Beware of power source and high temperature.

References
1. Kalpakjian, S and Schmid, S.R., (2001), Manufacturing Engineering and
Technology, 4th Edition, Prentice Hall International.
2. Rao, P.N. , (1999), Manufacturing Technology, Foundry, Forming and Welding,
2nd Edition, Tata McGraw Hill.
3. Gupta, J.K. (1996), Basic Workshop Practice, S. Chand & Company Ltd