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PATTERN ALLOWANCE

A duplicate of the product to be cast, modified dimensionally to reflect process of material to be cast Modification incorporated in pattern are allowance or pattern allowance Expandable mould use some form of reasonable pattern Allowances are added to the pattern and mould cavity is larger than final Casting.

TYPES OF ALLOWANCE

PURPOSE

1.SHRINKAGE ALLOWANCE

To compensate for volumetric contraction during freezing of metal, this allowance is added Shrinkage though volumetric, allowance linearly expressed as % of mass or length Pattern made larger applying shrink rule depending metal / product

TYPES OF ALLOWANCE 2. DRAFT ALLOWANCE

PURPOSE The allowance which facilitate easy withdrawal of pattern from mould walls Slight taper or draft is provided to vertical side of mould walls all around Drat allowance is additive: 1 1.5 % of length

TYPES OF ALLOWANCE
3.MACHINING ALLOWANCE

PURPOSE
To remove rough surface exhibited in casting especially sand casting by subsequent machining Allowance is added to pattern to provide compensation during machining Depends on finish requirement, product complexity and type of material to be cast Thin section or abnormal change in size of the product restrained in mould which tend to distort upon cooling U or V shaped section tends to distort more while cooling in mould 1-2 is given as allowance inwardly

Diagram

4.DISTORATION

TYPES OF ALLOWANCE 5.SHAKE or RAPPING

PURPOSE Cavity enlarge while pattern is withdrawn due to tapping Cavity made smaller. tapping of pattern results original dimension It is a subtractive allowance Added to parting surface or parallel to parting surface

Size of the final pattern

Mould Force = rhA (N)


r - density of metal (kg/m3)

H - head of metal (m) A - Projected area (m2)


Sand mould Cope mould pressure

Drag Cavity Parting line

Cores
Cores : cores are used to prepare cavity or hollow projections on
casting Complicated contour or cavity produced by cores- intricate & complex shapes Purpose of cores

Intricate & hollow parts need cores for moulding (engine block,
other hollow parts) Cores may be used to form a part of sand mould Strengthen & improve a mould surface Cores may be used as a part of gating system

Types of cores
Unbalanced core

Balanced core
Cover core Vertical core Drop core

Core prints
Purpose
Securely hold the core in position relative to mould cavity and the core print is a part of core
Core
Core print

Chaplet

Mould

Dies
Die are used as mould to produce casting of low melting metals like zinc aluminium , magnesium and copper alloys Used as permanent mould and contains product features gravity die casting Mould is permanent and used for repeat production (mass production) Better reproducability of features and dimensions & surface finish Dies of split type made from metal where product features are machined Die is hinged at on of the edge Die material melting temperature must be grater than work material melt temperature and metal should not diffuse during freezing Die contains cavity, gates, runner and riser Core are used to produce hollows core material invariably metal

DIE MATERIAL
Die steel AISI P20- for low volume production AISI H13 high volume production(Aluminium , Magnesium) AISI H20-22 usual die material (Cu alloys)

Casting Process
Sand casting process

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