SHELL MOLDI NG

INTRODUCTION
Shell mold casting is a metal casting process similar to sand
casting, in that molten metal is poured into an expendable
mold.
In shell mold casting, the mold is a thin-walled shell
created from applying a sand-resin mixture around a
pattern.
Shell mold casting requires the use of a metal pattern, oven,
sand-resin mixture, dump box, and molten metal.
Typical parts are small-to-medium in size and require
high accuracy, such as gear housings, cylinder heads,
connecting rods, and lever arms.

PRINCIPLE
The process is based on the principle of
capability of a thermosetting resin and sand mixture to
assume the shape of a preheated metal pattern to form a
dense, quickly hardened shell mould.

PROCESS PARAMETER OF SHELL MOLD
CASTING
Common metals: Cast irons and casting alloys of
aluminium and copper.
Size limits: 30 g minimum usually less than 10kg; mould area
usually less than 0.3 m
2

Typical tolerances: Approximately 0.005 cm
Draft allowance: 1/4 to 1/2 degree
Surface finish: 1/3 4.0 microns
Maximum wall thickness: 0.06-2 in
Shapes: Cylindrical, Cubic

RAW MATERIALS AND EQUIPMENTS

Resin coated sand.
Muffle Furnace.
Clay Graphite crucible.
Fireclay.
Asbestos Gloves, Tongs, safety goggles.

SHELL MOULDING PROCESS
The shell mold casting process consists of the
following steps:

1. Pattern creation A two-piece metal pattern is created
in the shape of the desired part, typically from iron or
steel. Other materials are sometimes used, such as
aluminum for low volume production or graphite for
casting reactive materials.
2. Mold creation - First, each pattern half is heated to 175-
370C (350F-700F) and coated with a lubricant to
facilitate removal.
Next, the heated pattern is clamped to a dump
box, which contains a mixture of sand and a resin
binder. The dump box is inverted, allowing this sand-
resin mixture coat the pattern.


The heated pattern partially cures the mixture, which now
forms a shell around the pattern. Each pattern half and
surrounding shell is cured to completion in an oven and
then the shell is ejected from the pattern.
3. Mold assembly - The two shell halves are joined together
and securely clamped to form the complete shell mold.
If any cores are required, they are inserted prior to
closing the mold. The shell mold is then placed into a
flask and supported by a backing material.


4. Pouring - The mold is securely clamped together while
the molten metal is poured from a ladle into the gating
system and fills the mold cavity.
5. Cooling - After the mold has been filled, the molten metal
is allowed to cool and solidify into the shape of the
final casting.

6. Casting removal - After the molten metal has cooled, the
mold can be broken and the casting removed. Trimming
and cleaning processes are required to remove any excess
metal from the feed system and any sand from the
mold.
PROPERTIES AND CONSIDERATIONS OF
MANUFACTURING BY SHELL MOLD
CASTING
The internal surface of the shell mold is very
smooth and rigid. This allows for an easy flow of
the liquid metal through the mold cavity during
the pouring of the casting, giving castings a very
good surface finish.

Shell mold casting enables the manufacture of
complex parts with thin sections and smaller
projections than green sand mold casting.


Manufacturing with the shell mold process also
imparts high dimensional accuracy. Tolerances of
.010 inches (.25mm) are possible. Further
machining is usually unnecessary when casting by
this process.

Shell sand molds are less permeable than
green sand molds and binder may produce a
large volume of gas as it contacts the molten
metal being poured for the casting. For these
reasons, shell molds should be well ventilated.


The expense of shell mold casting is increased
by the cost of the thermosetting resin binder, but
decreased by the fact that only a small percentage
of sand is used compared to other sand casting
processes.

Shell mold casting processes are easily automated.


The special metal patterns needed for shell mold
casting are expensive, making it a less desirable
process for short runs.

Manufacturing by shell casting may be economical
for large batch production.
Inclusions

This defect is generally nonmetallic and usually can be detected on the surface or a few
microns below the casting surface. Many subsurface inclusions become evident
during welding repair of a pinhole-type defect. Jagged in shape, inclusions sometimes
will have the ceramic from the shell, which caused the condition,embedded.
Mold Cracks
Mold handling

Prime Coat Buckle

Prime coat buckling defects usually occur on flat surfaces as an island of surplus metal,
and normally have hairline fins associated with them, usually at a casting's edges. The
most common shell-related causes for the formation of the primary slurry cracks include
the following: uneven Prime Coat Thickness, Environmental Conditions

Shell Cracking

This defect is characterized by a line(s) of positive metal on the casting surface. The
length and thickness of these fins sometimes can be correlated to the cause of the
crack. Shell cracking is most common on cylindrical casting
Process Control , Dewaxing Control , Destabilized Wax
SHELL MOLDING DEFECTS
1.UNFILLED SECTIONS
It is caused due to Insufficient material and Low
pouring temperature.
2.POROSITY
It is caused due to melt temperature is too high,
Non-uniform cooling rate, Sand has low
permeability.

3.HOT TEARING
It is caused due to non-uniform cooling rate
4.SURFACE PROJECTIONS
It is caused due to erosion of sand mold interior,
a crack in the sand mold, mold halves shift.

ADVANTAGES OF SHELL MOLDING
CASTING

Good casting detail and dimensional accuracy are
possible.
Moulds are lightweight and may be stored for extended
periods of time.
Has better flexibility in design than die-casting.
It is less expensive than investment casting.
Capital plant costs are lower than for mechanized green
sand moulding.
Metal yields are relatively high.
Sand: metal ratios are relatively low.
Gives superior surface finish and higher dimensional
accuracy, and incurs lower fettling costs than conventional
sand castings
DISADVANTAGES:

High equipment cost.
Size of casting is limited.
Serious dust and fume problems.
Poor material strength.
High porosity possible.
Poor surface finish and tolerance.
Low production rate.
High labour cost.

APPLICATIONS:
Cylinder heads.
Connecting rods.
Engine blocks and manifolds.
Machine bases.
Gears .
Pulleys.
Small crank shafts.
Automobile transmission parts.

REFERENCE
1. http://www.mechanicalengineeringblog.com/
2. http://www.custompartnet.com/