What is the match plate pattern in casting process?

A match plate pattern is a pattern having a plate attached to multiple split patterns used to produce complex shape casting such as brackets.

What is split pattern and match plate pattern in casting?

A match plate pattern is a pattern that has a common metallic plate having many split patterns with a variety of shapes and complexity attached by screws. Split patterns are split into two halves and assembled by screws but not mounted on any plate.

What is the match plate pattern used in machine molding?

Match plate pattern are used with machine molding to get a higher production rate as mould-cavity making process is automated giving the added advantage of all patterns of different size and shapes are assembled on a single plate mass producing multiple castings.

What is the difference between cope and drag pattern and match plate pattern?

Cope and drag pattern produces large size casting as campared to match plate pattern, while match plate pattern mass produces small size casting in one casting cycle.

Match Plate Pattern In Casting: Application, Diagram, Definition, Advantages, Disadvantages, Difference & Application

Match Plate Pattern Introduction

Match Plate Pattern In Casting

Split piece patterns and cope & drag patterns cannot mass-produce small-size casting in large quantities at one time, to address this problem match plate patterns in casting are used.

Match plate patterns are a combination of split patterns and cope & drag patterns in casting.

All patterns used here are split patterns that are split along the parting line along the cope and drag section of the mould.

I have discussed the article on match plate patterns with diagrams, applications, MCQ practice questions, and advantages and disadvantages.

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Match Plate Pattern

What is a match plate pattern in casting?

A match plate pattern is a pattern made by attaching split patterns on either side of the flat plate called a match plate in the casting process to make the small-size casting with high volume.

The match plate is made from metal (aluminium) but patterns mounted on the plate can be made from wood and plastic pattern material.

Multiple patterns are mounted on the plate called the match plate permanently to mass-produce multiple castings in one casting session.

Patterns are screwed and attached to the flat plate making one complete assembly using locating pins. This match plate also serves as a parting line.

Gating systems such as sprue, runner, gate, ingates and riser are attached to the metal match plate and are an internal part of the pattern. This reduces the moulding time.

This entire assembly of split patterns mounted on the match plate is used to make mould cavities in the drag and cope section of the mould using machine moulding.

Molten metal is poured in the mould cavity made from a match plate pattern to produce multiple castings with different sizes and shapes with high accuracy, good surface finish and reduced secondary operation like machining.

As shown below in diagram (a) patterns of different shapes and sizes are attached to a single plate called the match plate.

(a) Match Plate Pattern Diagram

This entire match plate pattern rests in the sand to make a mould cavity as shown below in diagram (b).

(b) Match Plate Pattern In Sand Casting

Molten metal is poured into this mould cavity to make sand casting as shown below in diagram (c).

What material is used for making match plates and patterns?

The most common material used for making match plates is cast iron, steel and aluminium.

Aluminium is widely used as it has good machinability and is light in weight.

Wood is widely used for producing patterns that are mounted on metal match plates.

What types of moulds are used for producing casting using match plate patterns?

The mould used with match plate patterns comprises plaster or sand.

The process of producing casting by sand mould and match plate pattern is as follows:

Gating systems such as gates and runners are produced separately and attached to the match plate which will rest in the drag side of the mould.

Sand is then poured on a match plate pattern and ramming of moulding sand is done. The ramming method used is a combination of jolting and squeezing as the metal match plate and pattern can take more compressive forces on it.

The match plate pattern creates cavities in the cope and drag sides separately.

Later, both the cope and drag sides of the mould are assembled to form a complete moulding flask.

Molten metal is poured into this mould cavity to produce casting in the sand casting process.

What is the difference between a split pattern and a match plate pattern?

The difference between split piece pattern and a match plate pattern in casting is as follows:

Split Pattern	Match Plate Pattern
1) Simple shape and design casting are manufactured using a split-piece pattern.	1) Match plate pattern produces complex design casting.
2) Multiple casting cannot be manufactured using a split pattern.	2) Match plate patterns can manufacture multiple castings on one match plate.
3) The productivity of manufacturing casting using split-piece patterns is low.	3) The productivity of manufacturing casting is high.
4) The dimensional accuracy of a pattern is less.	4) The dimensional accuracy of the match plate pattern in casting is high than the split piece pattern.
5) Cost of production for making the pattern is low than the match plate pattern.	5) Cost of production for making the pattern is higher than the split piece pattern.

Advantages of Match Plate Pattern

Casting made from match plate patterns is high in dimensional accuracy and surface finish.
Every pattern attached to the universal match plate can be different in shape, size and design.
Small-size casting in large quantities can be easily manufactured as a parting line is established for every pattern.
Intricate details and complex design casting can be sand cast.
The match plate reduces production time and the process can be automated with the moulding machine.
The overall cost of production is reduced as casting are manufactured in high number.
The pattern is permanently attached to the metal match plate, it eliminates the step of assembly and disassembly of the pattern from the match plate.
Reduces the number of moulds and moulding operation for producing the same number of castings if the same castings were to be produced with only a split piece pattern.
Cycle time for producing casting reduces using this pattern increasing the production rate.

Disadvantages of Match Plate Pattern

Large-size casting cannot be manufactured like in cope and drag patterns.
Match plate pattern is more expensive than patterns such as cope and drag pattern, multi-piece pattern and split piece pattern.
The cost of production of patterns is high.
Metal pattern-making is more difficult and labour-intensive than other pattern materials.
Skilled craftsmen are required to produce match plates, patterns, gates and runners and further assemble them.
The quantity of casting produced should justify the cost of producing a match plate pattern.

Match Plate Pattern Application

Application, examples and uses of the match plate pattern are as follows:

Piston rings of internal combustion (I.C) engine.
Manifolds and brake calliper.
Engine cylinders.
Stovetop plates.
Hubs and airlock valves housing.
Rocker arms used in IC engines.
Mounting brackets.
Horizontal mill table.
The impeller of the pump and turbines.
Rotor hub assembly.
Series of spur gears.

Match Plate Pattern MCQ & Practice Questions and Answers

1) Which of the following pattern are used to mass-produce castings in one casting cycle?

a) Segmental pattern.

b) Skeleton pattern.

c) Cope and drag pattern.

d) Match plate pattern.

Answer - d) Match plate pattern is used to mass produce casting. Cope and drag patterns, segmental and skeleton patterns cannot mass-produce casting.

2) Dimensional accuracy, surface finish, and alignments are higher in which of the following pattern?

a) Sweep pattern.

b) Three-piece pattern.

c) Cope and drag pattern.

d) Match plate pattern.

Answer - d) This pattern provides better dimensional accuracy, surface finish, dimensional tolerances, alignment and fitment of both the cope and drag side of the mould during the sand moulding process.

3) Gating systems such as sprue, runner, gate, runner and riser are directly attached to metal match plates in which of the following pattern?

a) Match plate pattern.

b) Follow the board pattern.

c) Gated pattern

d) Shell pattern.

Answer - a) This pattern has an advantage over another pattern as the metal plates can accommodate an entire gating system that can be screwed without any mismatch.

4) Patterns assembled on the match plate are made from the following materials.

a) Metal and plastic.

b) Wax.

c) Foarm.

d) None of the above.

Answer - a) Metal and plastic are the best pattern materials that can be attached and mounted on the plate.

5) Match plate pattern is chosen over split and multi-piece pattern due to the following reasons.

a) Short cycle time for producing high-volume casting.

b) Patterns are able to sustain high pressure during ramming operations.

c) Making a cavity for the gating system is easy as the system is directly attached to the plate.

d) All of the above

Answer - d) This pattern has all the benefits over the cope and drag pattern and split pattern in the casting process.

Match Plate Pattern Summary

The match plate pattern is one of the patterns among 17 types of patterns in casting and is used in the high-production industry.

Match Plate Pattern

These match plates made from steel and cast iron are accurately machined on CNC machines.

The mismatch of plates that we see in the cope and drag side are eliminated in this pattern.

This pattern has qualities of both split pattern and cope & drag pattern in casting.