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Pattern
Definition Role in Casting Types Pattern Allowances
Definition
Pattern is the replica of the final object to be made. The mold cavity is made with the help of pattern.
Role in Casting
Steps in Making Sand Castings There are six basic steps in making sand castings: Patternmaking Core making Molding Melting and pouring Cleaning and ejecting
Functions of Pattern
1.
2.
3.
4. 5.
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.
Characteristics of pattern
Ways in which pattern differs from an actual component:: It carries an additional allowance to compensate for metal shrinkage It carries an additional allowance over those portions which are to be machined or finished otherwise It carries an additional draft to enable its easy removal. It carries additional projection for cores. Important consideration for pattern making 1.Surface finish of casting to be produced. 2. No of casting desired from same pattern 3. Facility and ease of removal. 4. Method of withdrawal from mould. Requirement of pattern maker Thorough knowledge of working drawing High skill of workmanship Fully conversant with techniques and process of moulding and casting Knowledge of properties of metals, non metals and alloys
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: 1. Easily worked, shaped and joined 2. Light in weight 3. Strong, hard and durable 4. Resistant to wear and abrasion 5. Resistant to corrosion, and to chemical reactions 6. Dimensionally stable and unaffected by variations in temperature and humidity 7. 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
Pattern Material
The selection of pattern material consists of the following factors: Service requirement Type of production of casting and type of moulding process Possibility of design changes Number of casting to be produced
Requirement of good pattern material easily worked, shaped, joined Light weight Strong, hard, durable Dimensionally stable Easily available at low cost Repairable and reusable Able to take good surface finish
Pattern material used Wood Metal cast iron, brass, aluminum, white metal Plastic Rubber, plasters, waxes
Types of pattern
Types of patterns used in sand casting: (a) solid pattern (e) Gated pattern (b) split pattern (f) Skeleton pattern (c) match-plate pattern (g) Segmental pattern (d) cope and drag pattern (h) Built up pattern (i) Boxed up pattern
Types of pattern
Solid pattern Pattern made without joints, partings or any loose piece in its construction is called a single piece or solid pattern. These are cheaper . Split pattern made of two parts, and held in their proper position by means of dowel pins fastened in one piece and fitting holes bored in another Match-plate pattern when split pattern are mounted with one half on one side of the plate and other half directly opposite on the other side of the plate, the pattern is called match plate pattern and a single or no of pattern are mounted on match plate. Cope and drag pattern to facilitate handling in large casting, the cope and drag patterns used are made in halves, split on convenient joint lines and separately mounted on individual plates or boards. Gated pattern In mass production , number of castings are produced in a single multi cavity mould by joining a group of patterns by gate and runners and gates ensure proper flow of material into the mould. Loose piece pattern Produced as assembly of loose component .these are needed when the parts cannot be removed as one piece.
Types of pattern
(g) Skeleton pattern When the size of casting is large but easy to shape and only a few members are to be made , it is uneconomical to make a large solid pattern of that size. In such case a pattern consisting of wooden strip and frame is made . (h) Sweep pattern sweeps can be advantageously used for preparing a mould of large symmetrical casting , particularly of circular cross section .The full equipment consists of a base, suitably placed in the sand mass, a vertical spindle and wooden template, called sweep. The outer end of sweep carries the counter corresponding to the shape of desired casting and is rotated about the spindle to form the cavity (I) Segmental pattern it is used to prepare moulds of large circular casting and is produced in segments.
SKELETON PATTERN
When the size of casting is large but easy to shape and only a few members are to be made , it is uneconomical to make a large solid pattern of that size. In such case a pattern consisting of wooden strip and frame is made
SKELETON PATTERN
Pattern Allowances
The dimensions of the pattern are different from the final dimensions of the casting required. This dimension difference is known as Allowance. 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: 1. 2. 3. 4. 5. Shrinkage or contraction allowance Draft or taper allowance Machining or finish allowance Distortion or camber allowance Rapping allowance
Shrinkage Allowance
Shrinkage or Contraction Allowance ( click on Table 1 to view various rate of contraction of various materials) All most all cast metals shrink or contract volumetrically on cooling. The metal shrinkage is of two types: i. 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. ii. Solid Shrinkage: it refers to the reduction in volume caused when metal loses temperature in solid state. To account for shrinkage allowance is provided on the patterns. The rate of contraction with temperature is dependent on the material. For example steel contracts to a higher degree compared to aluminum. To compensate the solid shrinkage, a shrink rule must be used in laying out the measurements for the pattern. A shrink rule for cast iron is 1/8 inch longer per foot than a standard rule. If a gear blank of 4 inch in diameter was planned to produce out of cast iron, the shrink rule in measuring it 4 inch would actually measure 4 -1/24 inch, thus compensating for the shrinkage. The various rate of contraction of various materials are given in Table 1.
0.125 0.105 0.083 0.251 0.191 0.155 0.155 0.143 0.125 0.173 0.155
Cast Steel
Aluminum
Magnesium
Exercise 1
The casting shown is to be made in cast iron using a wooden pattern. Assuming only shrinkage allowance, calculate the dimension of the pattern. All Dimensions are in Inches
Solution 1
The shrinkage allowance for cast iron for size up to 2 feet is o.125 inch per feet (as per Table 1) For dimension 18 inch, allowance = 18 X 0.125 / 12 = 0.1875 inch 0.2 inch
Before
After
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. Table 2 provides a general guide lines for the draft allowance. Table 2 : Draft Allowances of Various Metals
Exercise 2 The casting shown is to be made in cast iron using a wooden pattern. Assuming only machining allowance, calculate the dimension of the pattern. All Dimensions are in Inches
Solution 2
The machining allowance for cast iron for size, up to 12 inch is o.12 inch and from 12 inch to 20 inch is 0.20 inch ( (Table 3) For dimension 18 inch, allowance = 0.20 inch For dimension 14 inch, allowance = 0.20 inch For dimension 8 inch, allowance = 0.12 inch For dimension 6 inch, allowance = 0.12 inch The pattern drawing with required dimension is shown in Figure below
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: i. Modification of casting design ii. Providing sufficient machining allowance to cover the distortion affect iii. 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.
MOULDING TOOLS
(1) Vent wire (2) Pattern lifter. (3) Joint trowel and (4) heart trowel (5) Gate cutter and pattern lifter. 6) Slick and oval spoon (7) (8) Sand lifters and slicks. (9) Yankee heel lifter and flat slick. (10) Flange and bead slick.
Sand casting
Sand casting is a method involving
pouring a molten metal into a sand mold.
Sand casting
A sand casting or a sand molded casting is a cast part produced by forming a mold from a sand mixture and pouring molten liquid metal into the cavity in the mold. The mold is then cooled until the metal has solidified. In the last stage the casting is separated from the mold. There are six steps in this process: Place a pattern in sand to create a mold. Incorporate a gating system. Remove the pattern. Fill the mold cavity with molten metal. Allow the metal to cool. Break away the sand mold and remove the casting.
Sand casting
Sand moulding
Vertical cores
Horizontal cores
Gating system
A mould cavity must be filled with clean metal in a controlled manner to ensure smooth, uniform and complete filling, for the casting to be free of discontinuities, solid inclusions and voids. This can be achieved by a well-designed gating system
Gating system
Gating systems can be classified depending on the orientation of the parting plane (which contains the sprue, runner and ingates), as horizontal or vertical. Depending on the position of the ingate(s), gating systems can be classified as top, parting and bottom. Horizontal gating systems are suitable for flat castings filled under gravity. They are widely used in sand casting of ferrous metals, as well as gravity diecasting of non-ferrous metals.
Vertical gating systems are suitable for tall castings. They are employed in high-pressure sand mould, shell mould and diecasting processes, where the parting plane is vertical.
Top gating systems, in which hot molten metal enters at the top of the casting, promote directional solidification from bottom to top of the casting. These are however, suitable only for flat castings to limit the damage to metal as well as the mould by free fall of the molten metal during initial filling.
Gating system
Bottom gating systems have the opposite characteristics: the metal enters at the bottom of the casting and gradually fills up the mould with minimal disturbances. It is recommended for tall castings, where free fall of molten metal (from top or parting gates) has to be avoided. Middle or side or parting gating systems combine the characteristics of top and bottom gating systems. If the gating channels are at the parting plane, they are also easier to produce and modify if necessary, during trial runs.
Gating system
Casting defects
There are numerous opportunities for things to go wrong in a casting operation, resulting in quality defects in the product The defects can be classified as follows: Defects common to -all casting processes Defects related to sand casting process
Casting defects
Cold Shot Metal splatters during pouring and solid globule form and become entrapped in casting Shrinkage Cavity Depression in surface or internal void caused by solidification shrinkage that restricts amount of molten metal available in last region to freeze Sand Blow Balloon-shaped gas cavity caused by release of mold gases during pouring Pin Holes Formation of many small gas cavities at or slightly below surface of casting
Casting defects
Penetration When fluidity of liquid metal is high, it may penetrate into sand mold or sand core, causing casting surface to consist of a mixture of sand grains and metal Mold Shift A step in cast product at parting line caused by side wise relative displacement of cope and drag Misrun A casting that has solidified before completely filling mould cavity Cold Shut Two portions of metal flow together but there is a lack of fusion due to premature freezing
Slush Casting - As in permanent mold casting, the molten metal is poured into the mold and begins to solidify at the cavity surface. When the amount of solidified material is equal to the desired wall thickness, the remaining slush (material that has yet to completely solidify) is poured out of the mold. As a result, slush casting is used to produce hollow parts without the use of cores. Low Pressure Permanent Mold Casting - Instead of being poured, the molten metal is forced into the mold by low pressure air (< 1 bar). The application of pressure allows the mold to remain filled and reduces shrinkage during cooling. Also, finer details and thinner walls can be molded. Vacuum Permanent Mold Casting - Similar to low pressure casting, but vacuum pressure is used to fill the mold. As a result, finer details and thin walls can be molded and the mechanical properties of the castings are improved.
Disadvantages:
High tooling cost Long lead time
PossibleApplications:
Gears, wheels, housings, engine components
Die Casting
A permanent mold casting process in which molten metal is injected into mold cavity under high pressure Pressure is maintained during solidification, then mold is opened and part is removed Molds in this casting operation are called dies; hence the name die casting Use of high pressure to force metal into die cavity is what distinguishes this from other permanent mold processes
Die Casting
Cycle in hotchamber casting: (1) with die closed and (2) plunger withdrawn, molten metal flows into the chamber
Die Casting
Centrifugal casting
Centrifugal casting, sometimes called rotocasting, is a metal casting process that uses centrifugal force to form cylindrical parts. This differs from most metal casting processes, which use gravity or pressure to fill the mold. In centrifugal casting, a permanent mold made from steel, cast iron, or graphite is typically used. However, the use of expendable sand molds is also possible. The casting process is usually performed on a horizontal centrifugal casting machine (vertical machines are also available) and includes the following steps:
Centrifugal casting
Investment casting
Investment casting is one of the oldest manufacturing processes, dating back thousands of years, in which molten metal is poured into an expendable ceramic mold. The mold is formed by using a wax pattern - a disposable piece in the shape of the desired part. The pattern is surrounded, or "invested", into ceramic slurry that hardens into the mold. Investment casting is often referred to as "lost-wax casting" because the wax pattern is melted out of the mold after it has been formed. Lox-wax processes are one-to-one (one pattern creates one part), which increases production time and costs relative to other casting processes. However, since the mold is destroyed during the process, parts with complex geometries and intricate details can be created.
Investment casting
Investment casting can make use of most metals, most commonly using aluminum alloys, bronze alloys, magnesium alloys, cast iron, stainless steel, and tool steel. This process is beneficial for casting metals with high melting temperatures that can not be molded in plaster or metal. Parts that are typically made by investment casting include those with complex geometry such as turbine blades or firearm components. High temperature applications are also common, which includes parts for the automotive, aircraft, and military industries. Investment casting requires the use of a metal die, wax, ceramic slurry, furnace, molten metal, and any machines needed for sandblasting, cutting, or grinding. The process steps include the following:
Investment casting