To point out some of the leading points or conditions to be taken into account in pattern-making, and which must be understood in order to manage this department, I will refer to them in consecutive order.
First.—Durability, plans of construction and cost, which all amount to the same thing. To determine this point, there is to be considered the amount of use that the patterns are likely to serve, whether they are for standard or special machines, and the quality of the castings so far as affected by the patterns. A first-class pattern, framed to withstand moisture and rapping, may cost twice as much as another that has the same outline, yet the cheaper pattern may answer almost as well to form a few moulds as an expensive one.
Second.—The manner of moulding and its expense, so far as determined by the patterns, which may be parted so as to be 'rammed up' on fallow boards or a level floor, or the patterns may be solid, and have to be bedded, as it is termed; pieces on the top may be made loose, or fastened on so as to 'cope off;' patterns may be well finished so as to draw clean, or rough so that a mould may require a great deal of time to dress up after a pattern is removed.
Third.—The soundness of such parts as are to be planed, bored, and turned in finishing; this is also a matter that is determined mainly by how the patterns are arranged, by which is the top and which the bottom or drag side, the manner of drawing, and provisions for avoiding dirt and slag.
Fourth.—Cores, where used, how vented, how supported in the mould, and I will add how made, because cores that are of an irregular form are often more expensive than external moulds, including the patterns. The expense of patterns is often greatly reduced, but is sometimes increased, by the use of cores, which may be employed to cheapen patterns, add to their durability, or to ensure sound castings.
Fifth.—Shrinkage; the allowance that has to be made for the contraction of castings in cooling, in other words, the difference between the size of a pattern and the size of the casting. This is a simple matter apparently, which may be provided for in allowing a certain amount of shrinkage in all directions, but when the inequalities of shrinkage both as to time and degree are taken into account, the allowance to be made becomes a problem of no little complication.
Sixth.—Inherent, or cooling strains, that may either spring and warp castings, or weaken them by maintained tension in certain parts—a condition that often requires a disposition of the metal quite different from what working strains demand.
Seventh.—Draught, the bevel or inclination on the sides of patterns to allow them to be withdrawn from the moulds without dragging or breaking the sand.
Eighth.—Rapping plates, draw plates, and lifting irons for drawing the patterns out of the moulds; fallow and match boards, with other details that are peculiar to patterns, and have no counterparts, neither in names nor uses, outside the foundry.