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(c)
(a)
(b) (d)
Figure: (a) Typical gray-iron castings used in automobiles, including the transmission valve body (left) and
the hub rotor with disk-brake cylinder (front).
(b) A cast transmission housing.
(c) The Polaroid PDC-2000 digital camera with a AZ191D die-cast high-purity magnesium case.
(d) A two-piece Polaroid camera case made by the hot-chamber die-casting process. Source: Courtesy
of Polaroid Corporation and Chicago White Metal Casting, Inc.
A large sand casting weighing 680 kg for an air compressor frame
CASTING PROCESS
In this process, the metal is first
liquefied by heating it in a
suitable furnace.
Then, the liquid metal is poured
into a previously prepared
mould cavity where it is allowed
to solidify.
Finally, the product is taken out
of the mould cavity.
PARTS PRODUCED BY CASTING
PROCESS
Pattern
Sand
Low weight
Easier formability
Do not absorb moisture
Good corrosion resistance
POLYSTYRENE
It is very easy to make pattern as
it is soft.
Polystyrene changes gaseous
state on heating.
Used for prototype (single piece)
castings.
Also known as Disposable
patterns.
TYPES OF PATTERNS
SOLID PATTERN
A pattern that is made
without joints, parting or any
loose pieces in the
construction is called a single
piece or solid pattern.
Loose pieces
Part 2
Part 1
Dowel pin
(a) Solid pattern (b) Split pattern (c) Loose piece pattern
SPLIT PATTERN
It is the most widely used type of
pattern for intricate castings.
Used When
The depth of the casting is too high.
Loose pieces
Part
2 Part 1
Dowel pin
(a) Solid pattern (b) Split pattern (c) Loose piece pattern
Loose Piece Pattern
Used when
Withdrawal of pattern from mould is
not possible.
Castings is having projections,
undercuts and etc.
The obstructing part of the contour is
held as loose piece by a wire.
After the molding is over, first the
main part is removed and then loose
pieces are recovered through gap
generated by the main pattern.
TYPES OF PATTERNS
Loose pieces
Part 2
Part 1
Dowel pin
(a) Solid pattern (b) Split pattern (c) Loose piece patter
Match Plate Pattern
Here the cope and drag halves of the
pattern along with the gating system
and riser are mounted on a single
matching plate on either side.
When match plate is removed after
moulding, a complete mould with gating
system is obtained.
These patterns are used for rapid
production of small and accurate
casting.
The match plate may be of wood, steel,
magnesium or aluminum.
Match Plate Pattern
Runner
Match plate
Pattern
Gate
Pattern
(a) Gated pattern for 8 castings (b) Match plate patt
Gated Pattern
It is used for producing small
sized cavities in one mould.
The gating and runner system are
integral part of the gated pattern.
So a single runner is used for
feeding all cavities and
considerable amount of the
moulding time is saved.
Removable and Disposable pattern
A removable pattern is removed from
the sand and is used for producing
multiple identical moulds.
In case of disposable patterns, the
pattern is left in the mould instead of
being removed from sand.
The pattern material vaporizes when the
molten metal is poured
cavity thus created is filled with molten
metal. The method is also known as full
mould process or cavity less method.
Disposable pattern
(a) Pattern with zero (no) draft (b) Pattern with draft
(Not to scale)
Distortion Allowance
Casting which has an irregular shape
and some such design that the
contraction is not uniform throughout
will distort during cooling.
To eliminate this defect an opposite
distortion is provided in the pattern
so that the effect is neutralized and the
correct casting is obtained.
This can be done in trial and error
basis to get the distortion amount.
Distortion Allowance
80
20
50
It is given that machining allowance of 2 mm on
each side is to be given. Thus, each side is
increased by 2 mm resulting in the basic dimension
of the pattern as shown in Figure (a). The required
casting is shown with dotted lines.
84
24
54
The taper allowance value x is calculated from the
geometry of the Figure (b) as x = 24 tan 1 = 0.419
mm. Thus, the top surface dimension is increased to
provide for draft allowance from 54 84 mm to
54.838 84.838 mm.
x
84
24 24
54
(a) (b)
Now, the dimensions of pattern are increased
by 2% on all sides. That is, dimension 54 mm
will become
54 + (54*2)/100 = 55.08mm or 55.1mm
The dimension 54.838 will become
54.838 + (54.838*2)/100 = 55.9mm
86.5
85.7
24.5
55.1
EXAMPLE #2
A job shown in Figure is to be made from steel by
casting process. The mold for this job is made from
wooden pattern. Determine the dimensions of the
wooden pattern assuming machining allowance of 3
mm on each side, shaking allowance of 1 mm on
length and width, shrinkage allowance of 3%.
EXAMPLE #2
40
30 80
EXAMPLE #2
Solution Since given machining allowance is 3 mm
on each side, add 3 mm on each side of the part
shown in Figure. The dimensions of the pattern after
machining allowance will be:
L = 80 + 2 3 = 86 mm
W = 40 + 2 3 = 46 mm
H = 30 + 2 3 = 36 mm
EXAMPLE #2
The dimensions of the pattern after adding machining
allowance are shown in the following figure
EXAMPLE #2
46
36
86
EXAMPLE #2
The shrinkage allowance of 3% is added to all the
dimensions of the pattern shown in Figure 11.22.
Dimension of the pattern after providing shrinkage
allowance of 3% will be:
L = 86 + 86 3/100 = 88.58 mm,
W = 46 + 46 3/100 = 47.38 mm
H = 36 + 36 3/100 = 37.08 mm
EXAMPLE #2
88.58
37.08 47.38
EXAMPLE #2
Given shaking allowance is 1 mm on length and
width. Recall that, shaking allowance is a negative
allowance. Hence, 1 mm has to be reduced from the
calculated values of length and width side. Students
are advised to note that the height of the pattern
doesnt require any shaking allowance.
EXAMPLE #2
Therefore, final dimension of the pattern will be:
L = 88.58 1 = 87.58 mm
W = 47.38 1 = 46.38 mm
H = 37.08 mm
EXAMPLE #2
87.58
37.08 46.38