This makes a statement in brief of what comprehends a knowledge of pattern-making, and what must be understood not only by pattern-makers, but also by mechanical engineers who undertake to design machinery or manage its construction successfully.
As to the manner of cutting out or planing up the lumber for patterns, and the manner of framing them together, it is useless to devote space to the subject here; one hour's practical observation in a pattern-shop, and another hour spent in examining different kinds of patterns, is worth more to the apprentice than a whole volume written to explain how these last-named operations are performed. A pattern, unless finished with paint or opaque varnish, will show the manner in which the wood is disposed in framing the parts together.
I will now proceed to review these conditions or principles in pattern-making and casting in a more detailed way, furnishing as far as possible reasons for different modes of constructing patterns, and the various plans of moulding and casting.
In regard to the character or quality of wood patterns, they can be made, as already stated, at greater or less expense, and if necessary, capable of almost any degree of endurance. The writer has examined patterns which had been used more than two hundred times, and were apparently good for an equal amount of use. Such patterns are expensive in their first cost, but are the cheapest in the end, if they are to be employed for a large number of castings. Patterns for special pieces, or such as are to be used for a few times only, do not require to be strong nor expensive, yet with patterns, as with everything else pertaining to machinery, the safest plan is to err on the side of strength.
For pulleys, gear wheels, or other standard parts of machinery which are not likely to be modified or changed, iron patterns are preferable; patterns for gear wheels and pulleys, when made of wood, aside from their liability to spring and warp, cannot be made sufficiently strong to withstand foundry use; besides, the greatest accuracy that can be attained, even by metal patterns, is far from producing true castings, especially for tooth wheels. The more perfect patterns are, the less rapping is required in drawing them; and the less rapping done, the more perfect castings will be.
The most perfect castings for gear wheels and pulleys and other pieces which can be so moulded, are made by drawing the patterns through templates without rapping. These templates are simply plates of metal perforated so that the pattern can be forced through them by screws or levers, leaving the sand intact. Such templates are expensive to begin with, because of the accurate fitting that is required, especially around the teeth of wheels, and the mechanism that is required in drawing the patterns, but when a large number of pieces are to be made from one pattern, such as gear wheels and pulleys, the saving of labour will soon pay for the templates and machinery required, to say nothing of the saving of metal, which often amounts to ten per cent., and the increased value of the castings because of their accuracy.
Mr Ransome of Ipswich, England, where this system of template moulding originated, has invented a process of fitting templates for gear wheels and other kinds of casting by pouring melted white metal around to mould the fit instead of cutting it through the templates; this effects a great saving in expense, and answers in many cases quite as well as the old plan.
The expense of forming pattern-moulds may be considered as divided between the foundry and pattern-shop. What a pattern-maker saves a moulder may lose, and what a pattern-maker spends a moulder may save; in other words, there is a point beyond which saving expense in patterns is balanced by extra labour and waste in moulding—a fact that is not generally realised because of inaccurate records of both pattern and foundry work. What is lost or saved by judicious or careless management in the matter of patterns and moulding can only be known to those who are well skilled in both moulding and pattern-making. A moulder may cut all the fillets in a mould with a trowel; he may stop off, fill up, and print in, to save pattern-work, but it is only expedient to do so when it costs very much less than to prepare proper patterns, because patching and cutting in moulds seldom improves them.
The reader may notice how everything pertaining to patterns and moulding resolves itself into a matter of judgment on the part of workmen, and how difficult it would be to apply general rules.