WORKSHOP PRACTICE
Lecture 4
R. S. Vidyarthy
PhD (IIT R)
Assistant Professor
BITS Pilani Mechanical Engineering Department
Hyderabad Campus BITS Pilani, Hyderabad Campus, India
WELCOME
ME F112
WORKSHOP PRACTICE
FIRST SEMESTER 2020-2021
2
Issues to address…
• How casting process is different from other
manufacturing processes?
• Step involved in sandcasting process.
• Materials used for pattern, types of pattern.
• Foundry tools.
• Gating system.
• Advantages, Limitations and applications of
casting processes.
•How casting process is different
from other manufacturing
processes?
•Principle of casting process
Casting Process
In casting process,
molten material is
poured into the
cavity (mould) of
desired shape and
size of the product
to be produced.
Product is removed
after solidification.
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Typical parts produced by casting
process
TYPICAL CASTED PART @ BITS
WORKSHOP
Range of products produced by casting
process
Range of products produced by casting
process
When Casting Process is
Inevitable?
To produce very large sized
components (i.e. Dimension in
Meters).
Products to be made from very hard
materials.
For producing parts of complicated
shapes.
BITS Pilani, Hyderabad Campus
Steps involved in Sand Casting Process
❑Pattern making.
❑Mould making.
❑Core making.
❑Melting of metal and pouring.
❑Cooling and solidification.
❑Eject the part
❑Cleaning of castings and
❑Inspection.
Steps involved in Sand Casting Process
https://www.youtube.com/watch?v=pwaXCko_Tkw&ab_channel=SHArPE
dgeGlobal
PATTERN MAKING
What is a
pattern?
Why it is
used in
casting?
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Requirements of pattern
material
• It should be easily shaped, worked,
machined and joined.
• It should be resistant to wear and
corrosion.
• It should be resistant to chemical action.
• It should be dimensionally stable and must
remain unaffected by variations in
temperature and humidity.
• It should be easily available and
economical.
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PATTERN MATERIAL
• Patterns can be made from wood,
metals, alloys, plaster, rubber, wax, etc.
• The selection of a pattern material
depends on the size and shape of the
casting, dimensional accuracy, and the
quantity of casting required
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WOOD
• Easily available.
• Low weight.
• Low cost.
• It absorbs moisture and hence dimensions
will change.
• Lower life.
• Suitable for small quantity production and
very large size castings.
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METAL
• Used for mass production
• For maintaining closer dimensional
tolerances on casting.
• More life when compared to wooden
patterns
• Few of the material used include CI, Al,
Fe, Brass etc. Al is widely used.
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PLASTIC
• Low weight
• Easier formability
• Do not absorb moisture
• Good corrosion resistance
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POLYSTYRENE
• Polystyrene changes gaseous state on
heating.
• Used for prototype (single piece) castings.
• Also known as Disposable patterns.
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TYPES OF PATTERNS
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SOLID PATTERNS
❖ A pattern that is
made without joints,
parting or any loose
pieces in the
construction is called a
single piece or solid
pattern.
❖ Used in the
manufacture of simple
shapes.
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SPLIT PATTERNS
❖Used when
patterns
cannot be
made as a
single piece
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LOOSE PIECE PATTERNS
Loose pieces
Part 2
Part 1
Dowel pin
(a) Solid pattern (b) Split pattern (c) Loose piece pattern
Used when
1. Withdrawal of pattern from mould is not possible
2. After ramming first main pattern is removed and then the loose
pieces
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GATED PATTERNS
• Used for producing
small sized cavities in
one mould.
• The gating and runner
system are integral
part of the gated
pattern.
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Match Plate Pattern
These types of pattern is made in
two pieces. One-piece mounted on
one side of the plate and the other
piece on the other side of the plate
called the match plate pattern. The
plate can only carry a pattern or a
group of patterns on its two sides
in the same way.
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Sweep Pattern
Sweep patterns are used for
preparing moulds of large
symmetrical castings,
particularly of circular cross-
section. Hence there is a large
saving in time, labor, and
material. The sweep pattern
consists of a board that
conforms to the shape of the
desired casting.
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IS PATTERN AN EXACT
REPLICA OF PART TO BE
PRODUCED?
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Pattern Allowances
Patterns are not made the exact same size
as the desired casting due to metal
shrinkage, draft, finish, distortion and
rapping. Allowances are given in the
pattern to allow these various factors.
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Types of Allowances
• Shrinkage Allowance
• Machining Allowance
• Draft or Taper Allowance
• Distortion Allowance
• Rapping or Shake Allowance
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Shrinkage Allowance
– Provided to compensate for shrinkage of
metal during solid contraction.
– Pattern is made slightly bigger.
– Amount of allowance depends upon type
of the material used, its composition,
pouring temperature etc.
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Shrinkage Allowance for different metals
Metal Allowance mm/m
Cast Iron (Grey) 10.5
Steel 21.0
Brass 16.0
Aluminum 16.0
Zinc 24.0
Lead 24.0
Tin 7.0
Silver 10.0
Machining Allowance
–Provided to compensate for
machining on casting.
–Pattern is made slightly bigger in size.
–Amount of allowance depends upon
size and shape of casting, type of
material, machining process to be
used, degree of accuracy and surface
finish required.
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Draft or Taper Allowance
–Provided to facilitate easy
withdrawal of the pattern.
–Typically it ranges from 1
degree to 3 degree for
wooden patterns
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Draft or Taper Allowance
(a) Pattern with zero (no) draft (b) Pattern with draft
(Not to scale)
Rapping or Shake Allowance
–Provided to permit easy
withdrawal of the
pattern.
–It is a negative
allowance
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Distortion Allowance
(a) (b) (c)
Required shape of Casting produced when no Pattern with distortion
casting distortion allowance is provided allowance
MOULDING SANDS
• Should have high fusion temperature.
• Good thermal stability.
• Ingredients:
Silica, Clay, Sand grains, Moisture & special
additives like coal dust, fuel oil.
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COMMON MOULDING SAND
• Green Sand:
18-30% clay, 4-8% water.
Collected from natural resources.
Maintains moisture content for long time.
• Dry sand:
It is green sand dried and baked.
Yields porosity absent castings, as there is no
moisture.
Suitable for very large size castings.
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COMMON MOULDING SAND
Loam sand:
Clay and silica are mixed in equal proportions.
Parting sand:
Used to permit easy withdrawal of the pattern from
mould cavity.
Core sand:
Sand used for making cores.
It should be stronger than moulding sand.
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Exercise 1
A job shown in below figure is made from Cast Iron by the casting process. The top
surface dimensions for the pattern after adding draft allowance are 102.62 x 11.62
mm2. Calculate the taper allowance (in degrees) provided in this case
50
100
The top surface dimensions after adding draft allowance = 102.62 ×
11.62
The taper allowance value = 1.31 mm
The side view of the pattern would be as shown in Fig
1.31
50
1.31
tan = Taper allowance = 1.50
50
Exercise 2
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 The shrinkage allowance for cast iron for size up to 2 feet is o.125 inch per feet.
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
For dimension 14 inch, allowance = 14 X 0.125 / 12 = 0.146 inch » 0.15 inch
For dimension 8 inch, allowance = 8 X 0.125 / 12 = 0.0833 inch » 0. 09 inch
For dimension 6 inch, allowance = 6 X 0.125 / 12 = 0.0625 inch » 0. 07 inch
