Different Types of Pattern Allowances in Casting- Basic Casting Design

Different Types of Pattern Allowances in Casting- Basic Casting Design 

Pattern Allowances

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. Shrinkage or contraction allowance
  2. Draft or taper allowance
  3. Machining or finish allowance
  4. Distortion or camber allowance
  5. Rapping allowance

Shrinkage or Contraction Allowance 

All most all cast metals shrink or contract volumetrically on cooling. The metal shrinkage is of two types:

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.

Solid Shrinkage: it refers to the reduction in volume caused when metal loses temperature in solid state. To account for this, shrinkage allowance is provided on the patterns.

The rate of contraction with temperature is dependent on the material.

Draft or Taper Allowance

By draft is meant the taper provided by the pattern maker on all vertical surfaces of the pattern so that it can be removed from the sand without tearing away the sides of the sand mold and without excessive rapping by the molder.

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.

Machining or Finish Allowance

The finish and accuracy achieved in sand casting are generally poor and therefore when the casting is functionally required to be of good surface finish or dimensionally accurate, it is generally achieved by subsequent machining. Machining or finish allowances are therefore added in the pattern dimension. The amount of machining allowance to be provided for is affected by the method of molding and casting used viz. hand molding or machine molding, sand casting or metal mold casting.

The amount of machining allowance is also affected by the size and shape of the casting; the casting orientation; the metal; and the degree of accuracy and finish required. 

Distortion or Camber Allowance

Sometimes castings get distorted, during solidification, due to their typical shape. For example, if the casting has the form of the letter U, V, T, or L etc. it will tend to contract at the closed end causing the vertical legs to look slightly inclined. This can be prevented by making the legs of the U, V, T, or L shaped pattern converge slightly (inward) so that the casting after distortion will have its sides vertical.

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:
  1. Modification of casting design
  2. Providing sufficient machining allowance to cover the distortion affect
  3. Providing suitable allowance on the pattern, called camber or distortion allowance (inverse reflection)
Distorted casting
Distorted casting 
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.

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