The importance of pattern in iron casting is oven overlooked. Patterns can have a huge impact on the design, cost and manufacture of iron castings. Often times it is the pattern that defines how good an iron casting piece is. And therein is its significance.
Let us see in detail what patterns do, how patterns are made and how the planning of patterns early in the planning process can actually help save time, effort, money and give best results.
What is a pattern?
A pattern simply is an accurate model of what is to be cast. Previously, the material used for it was wood, but now other materials such as plastics, fibreglass, etc go into making patterns. To create a pattern, first, the sand mould is formed that match the pattern in size. Then, the metal is poured into this mould. Thus the sand mould is formed around the pattern. The pattern formed is isolated and this will leave a hole or dent into which one pours the molten iron to form the casting. For mould making, sand is packed firmly that is firmly held in a box. If there are multiple castings, the pattern is recycled several times and thus needs to be robust enough to withstand the process.
For the iron casting to be perfect, the mould has to come out really good. Good patterns can help achieve higher consistency, save money and time throughout the procedure. The biggest advantage of a pattern in wood is that one can make hundreds of new sand moulds. The customers can select any design or pattern. While most designs are simple, others are complicated that will, of course, cost more depending upon the complexity.
The pattern should be an exact replication of the original design. Minimum wastage guarantees cost-effectiveness. This means the pattern maker must fully understand the design process in advance to give the best quality along with lower production cost. The pattern making method is equally important. The right method ensures a smooth and precise flow of the metal into the mould. The flow should be neither slow nor too fast. Neither it should be too hot or cold as well. Pattern makers need to have a thorough understanding of how to replicate precisely the article to be cast, in addition to a good know-how of the foundry process.
A precise pattern is incomplete without exact drawings having the precise measurements. Patterns can also be formed using photographs having detailed measurements. An incorrect or an erroneous original can only lead to a tainted or a faulty casting. If at all the original casting is used, it should be used for forming a pattern after restoring it to its original version. Patterns, therefore, when planned correctly, as discussed above, ensure the manufacturer obtain the best results in terms of waste reduction, imitation and manufacturing cost.