PATTERN & COREBOXES

PATTERN & COREBOXES

DESIGN
STANDARDS
IMPORTANT ITEMS

G HENDERIECKX
GIETECH BV

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

CONTENT
1.
2.
3.
4.
5.
6.

WHAT?
SHRINKAGE
REQUIREMENTS
STANDARDS
IMPORTANT ITEMS
SURVEY

1. WHAT?
We talk about pattern & core boxes as the complete items as:
1.
2.
3.
4.
5.
6.
7.

pattern
pattern plate
core boxes
clamping system
items for risers & chills
pouring system
templates.

The patterns are producing the outside shape, the core boxes the inside shape.
The pattern plate will protect the pattern from damage and facilitates the removal of
the pattern from the mould.
The clamping system is important for complicated core boxes and loose parts, which
have to be fixed on the pattern.
The pouring system includes the sprue, runner and ingates as well as the vents and
sometimes the pouring box (as it is incorporated in the mould). Some loose parts can
be necessary for locating risers and chills.
The templates are necessary for assembling the cores outside the mould. The
assembly must be in a way that it can be checked concerning dimensions and
quality.
It is preferred to have a template for assembling the core(s) in the mould cavity, to
assure a consistent location.

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

2. SHRINKAGE
The dimensions of the pattern must be different from the dimensions of the casting.
This is due to the fact that the casting will shrink in dimensions during the cooling
from the solidification temperature to room temperature.
The shrinkage will be different depending on:
1.
2.
3.
4.

thermal expansion coefficient of the metal

solidification temperature
shape of the casting
strength of the mould.

For this reason, it is necessary to give, aside from the average shrinkage, a range of
shrinkage for a metal.
It is up to the foundry to build a file system to recognize the shrinkage for a particular
casting.
This can save a lot of money due to less problems (or scrap) with the test casting or
less machining due to the lack of a high safety machining stock.
The most current shrinkages are given in the table on next page. Most of the figures
are taken from the old DIN 1511 standard.

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

MATERIAL

SHRINKAGE %
AVERAGE RANGE
1,0
0,9 1,1
1,2
0,9 1,4
0,5
0,3 0,7
0,85
0,8 0,9
0,5
0,3 0,7
1,1
0,8 1,4
1,6
1,4 2,0
0,5
0,3 0,7
1,5
1,4 1,6
2,0
1,5 2,5
2,0
1,8 2,1

Grey iron
Ductile iron, as cast
Ductile iron, heat treated (ferritized)
Ductile iron, as cast (other literature)
Ductile iron, heat treated (ferritised) (other literature)
Compacted (vermicular) iron
Whitehearth malleable iron
Blackhearted malleable iron
Austenitic flake (grey) iron
Austenitic ductile (nodular) iron
Chromium nickel iron (Nihard) & Chromium iron
Carbon & Low alloyed steel
High alloyed steel (ferritic, martensitic)
High alloyed steel (austenitic)
Austenitic manganese steel (12 % Mn)

1,8
2,0
2,6
2,5

1,6 2,0
1,5 2,5
2,4 2,6
2,3 2,8

Aluminium Al-Si-(Cu)
Aluminium Al-Mg

1,2
1,2

0,9 1,3
1,0 1,4

Unalloyed and low alloyed copper

Cu Al
Cu Ni
Cu Ni Zn
Cu Pb Sn
Cu Sn (bronze)
Cu Sn Zn
Cu Zn
Cu Zn Al (aluminium bronze)
Manganese bronze
Phosphorus bronze
G CuZn15Si4 (silicon bronze)

1,9
2,1
2,0
1,1
1,4
1,5
1,25
1,1
1,5
1,0
1,3
1,4

1,6 2,2
1,8 2,4
1,6 2,4
0,8 1,4
1,2 1,7
1,0 1,8
1,0 1,5
0,8 1,4
1,0 2,0
0,8 1,6
1,0 1,6
1,3 1,5

Beryllium copper
Monel
Nickel- & nickelcopper alloys
White metal
Bismuth
Lead
Magnesium alloys
Tin
Zinc alloys

1,6
2,0
2,0
0,5
1,3
2,6
1,35
2,0
1,2

ir G Henderieckx

GIETECH BV

May 2005

1,6 2,4
0,4 0,6
1,3 1,45

PATTERN & COREBOXES

3. REQUIREMENTS
It is important to realize that the quality of the pattern & core boxes is very
influencing for the quality of the casting.
This is frequently denied or not recognized by most of the foundries.
The requirements are all important and will be:
1. Dimensional tolerances
* according to required standard
* according to particular shrinkage, which can be different for one casting,
depending on the location
* according to mould material and applied coating
* according to shape, in such a way that no draft is present on planes which
have to be perpendicular to others.
2. Quality of casting
* the split line is influencing the possibility of placing risers and chills, which
are necessary to obtain a conform casting
* the possibility to let the metal entering the mould cavity in a way that the
temperature (at the end of pouring) is homogeneous or increasing
towards the risers
* the possibility to evacuate the air and gas as well as loose sand and slag.
3. Number of moulds
The equipment must be able to produce a minimum amount of moulds or have
a life time of a number of years, without a decrease in quality or deformation in
dimensions.
This depends on
* the type of moulding
* the material, which is used to produce pattern and core boxes. Wood can
split or deform, aluminium can oxidize, and plastics can degrade in
quality due to light
* the possibility to modify pattern and core boxes if this is required by the
customer.
4. Designed in a way that the total cost is minimal
The pattern cost and the total cost for the planned amount of castings must be
the least possible. For this reason, it is preferred to realize that:
ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

* a cheap concept pattern leads mostly to expansive castings
* for expansive patterns, it is preferred to produce the test casting with a
cheap pattern, which after all details are checked (dimensions, surface
quality, quality of metal sections), can be replaced by a high quality
expansive pattern.
It is very important to realize that a pattern & core box is a unit, which do belong
one to the other, and all together can assure a conform casting. The unit does
consist from: pattern, pattern plate, core boxes, pouring system, templates
This initiates the old problem: each foundry has its proper calculation methods and
experience, adapted to its production: mould material, pouring, melting, fettling
When the customer is transferring the pattern & core boxes to another foundry, will
lead to a long time of discussion and extra cost to modify the system to its proper
ideas.
This is inevitable for the moment, because every foundry is responsible for the quality
of its castings and must do its utmost to obtain this.
This is a main problem for transferring the casting production to another foundry.
Most of the foundries do not have a pattern shop. The pattern is subcontracted to
independent pattern shops. The order specifications for the production are very
important and must be very clear to avoid non conformities. The pattern shops do not
have foundry specialists.
To avoid problems, it is necessary that as well the foundry and pattern shop and
customer (quality and machining requirements) do sit together and discuss about the
design.
Only than, all problems can be discussed and the lowest total cost can be achieved.

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

4. STANDARDS
There are a lot of standards. In Europe, the new EN-standards are replacing the
older, more common used ones like DIN 1511.
The new standards are more specialized to the type of production:
1. EN 12883-2001 Foundry: Patterns for Lost Wax production
2. EN 12890-2000 Foundry: Patterns and core boxes for sand production
3. EN 12892-2000 Foundry: Pattern for Lost Foam production.
The DIN-standard did describe the following items:
1. Modellgteklasse (quality classes)
2. Zulssige Maabweichungen (dimensional tolerances)
3. Formschrgen an Modellen (pattern draft)
4. Anstrich und Farbenkennzeichnung der Modelle (colour code).
1. Quality classes
The classes are depending on the type of moulding and the number of moulds or
pattern life time:
Class

Material

H1a
H1
H2
H3
M1
M2
K1
K2
S1
S2
S3

Wood
Wood
Wood
Wood
Metal
Soft metal
Plastic
Plastic
Foam
Foam
Foam

Used for
serial production
medium to serial production
small serial production
Batch production (possibly repeating production)
serial production
medium serial production
medium serial production
small serial production
usable for more moulds, smooth surface
usable for one mould, smooth surface
usable for one mould, no surface condition requirements

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

2. Tolerances
These data are given the maximum tolerance, compared to the nominal dimension.

Dimension
From to mm

Tolerance +/H1a/H1 H2/H3

M1
M2

K1

K2

S1/S2 S3

0
19
31
51
81
121
181
251
316
401
501
631
801
1001
1251
1601
2001
2501
3151

0,2
0,2
0,3
0,3
0,4
0,5
0,6
0,6
0,7
0,8
0,9
1,0
1,1
1,3
1,5
1,8
2,2
2,7
3,2

0,15
0,15
0,20
0,25
0,30
0,30
0,35
0,40
0,45
0,50
0,60
0,60
0,70
0,80
1,00
1,10
1,40
1,60
2,00

0,25
0,25
0,30
0,30
0,45
0,50
0,60
0,65
0,70
0,80
0,90
1,00
1,10
1,30
1,50
1,80
2,20
2,70
3,20

0,4
0,5
0,5
0,7
0,7
0,9
0,9
1,1
1,1
1,4
1,4
1,6
1,6
2,1
2,1
3,0
3,0
4,0
4,0

18
30
50
80
120
180
250
315
400
500
630
800
1000
1250
1600
2000
2500
3150
4000

0,4
0,4
0,5
0,6
0,7
0,8
0,9
1,0
1,1
1,2
1,4
1,6
1,8
2,1
2,5
3,0
3,5
4,3
5,0

0,10
0,10
0,15
0,15
0,20
0,20
0,25
0,25
0,30
0,30
0,40
0,40
0,50
0,50
0,60
0,70
0,80
1,00
1,30

0,15
0,15
0,20
0,25
0,30
0,30
0,35
0,40
0,45
0,50
0,60
0,60
0,70
0,80
1,00
1,10
1,40
1,60
2,00

0,6
0,8
0,8
1,1
1,1
1,5
1,5
1,8
1,8
2,2
2,2
2,5
2,5
3,3
3,3
4,6
4,6
6,5
6,5

3. Draft
The draft is the angle of a plane, which enable the pattern to be removed from the
mould without damaging the mould. The figure shows a correct draft on the left side
(no damage of the mould) and an incorrect at the right side (mould damage).

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

A survey of the rules is given below:

Minimum draft in or mm for planes according to the parting line (DIN 1511)
height
till 10 mm
10 - 18 mm
18 - 30 mm
30 - 50 mm
50 - 80 mm
80 - 180 mm
180 - 250 mm
250 - 315 mm
315 - 400 mm

draft
3
2
1,5
1,0
0,75
0,5
1,5 mm
2,0 mm
2,5 mm

height

draft

400 - 500 mm
3,0 mm
500 - 630 mm
3,5 mm
630 - 800 mm
4,5 mm
800 - 1000 mm
5,5 mm
1000 - 1250 mm
7,0 mm
1250 - 1600 mm
9,0 mm
1600 - 2000 mm
11,0 mm
2000 - 2500 mm
13,5 mm
2500 - 3150 mm
17,0 mm
3150 - 4000 mm
21,0 mm

For small details as bosses, as well as for core prints:

till 70 mm height
> 70 mm height

5
33

If the draft is not allowed:

1. using a core is one possibility to avoid this. The use of a core does increase the
pattern cost (extra core box) and production cost (extra core and core
assembly).
3. using draft on a plane, which has to be machined is the other possibility. The draft
material is removed by the machining operation.

ir G Henderieckx

GIETECH BV

May 2005

PATTERN & COREBOXES

4. Pattern Colour
The standard does indicate colours, depending on the type of casting material. This
indication must prevent that an incorrect (concerning shrinkage) pattern is used.
Bleu
Pink
Red

for cast steel

for ductile iron
for grey (flake) iron

Yellow
Green
Gray

for copper (heavy) alloys

for aluminium (light) alloys
for malleable iron
.

Planes to be machined: yellow except for copper (heavy) materials, where it is red.
Core prints: black
Location of loose parts (for pattern or core box): black surrounded indication.
Location of chills:
Red
Red
Bleu

for cast steel

for ductile iron
for grey (flake) iron

Bleu
Bleu
Red

for copper (heavy) alloys

for aluminium (light) alloys
for malleable iron
.

5. Proposal for use

For iron, the following proposal is valid:
Weight range
Casting

Number parts
Total

Pattern
Class

< 100 kg

< 500
> 500
> 1.000
> 5.000
1
< 50
< 100
> 100
> 500
< 50
> 50

H1a
K2
K2, M2
M1
S1
H2
H 1, H1a
H 1a, K 2
K1
H1
H 1a

< 5.000 kg

> 5.000 kg

ir G Henderieckx

GIETECH BV

May 2005

10

PATTERN & COREBOXES

5. IMPORTANT ITEMS
It is important that pattern and core boxes are designed in a way that:
1. Use a correct draft, preferable on machined surfaces.
2. Evaluate all possibilities for the split line concerning cost, number of cores,
possibilities to set cores and chills
3. Check continuously the condition of the pattern and core boxes
4. Design core boxes that they can be hand moulded. Complicated cores can
only be properly air blasted (shooted).
5. Do assemble the cores outside the mould and check the assembly with
templates
6. Do coat the core assembly after checking dimensions and quality
7. Locate the core assembly in the mould with the help of a template to assure
consistent dimensions and shape
8. Use a zero location, which is equal the zero location for the machining!

ir G Henderieckx

GIETECH BV

May 2005

11

PATTERN & COREBOXES

6. SURVEY
1. Old casting
Cheap pattern, high cost and difficult moulding. Mostly not possible for
castings with a holes (core is needed).
2. Rotary template moulding for cylindrical castings
Cheap pattern, need for experienced moulder. The core can be made
with the same type of equipment. Moulding is very expensive.
3. Foam pattern with low dimensional accuracy
Cheap, can be worked without core boxes. The dimensions are less
accurate and mostly, the surface condition is low.
4. Loose wooden pattern
Cheap method, suitable for batch and small serial production.
5. Plastic and metal patterns
Expensive pattern, suited for small casting in medium to high serial
production.
6. Patterns (wood, plastic, metal) on pattern plate
Expensive, suited for medium serial production.
7. Patterns for Shell moulding, baked moulds
Very expensive pattern, suited for serial production and high accuracy.
8. Patterns for precision casting, loss wax casting
Very expensive, suited for small sized castings in serial production and
very high accuracy.
9. Lost Foam patterns with increased dimensional stability
Expensive, but very suitable for serial castings with medium accuracy.
10. Coquille pattern (metal moulds)
Expensive pattern. It is very well suited for castings without cores (or
sand cores are used), in a restricted number of metals, mostly
nonferrous metals.
11. Dies for pressure pouring
Expensive pattern, only used for high serial production of low melting
alloys (nonferrous alloys).
12. Metal or ceramic moulds or dies for centrifugal- and continuous
pouring
Expensive die cost. Low cost for production of round bars, tubes and
other cylindrical castings.

ir G Henderieckx

GIETECH BV

May 2005

12