Scribd
Upload
68 views24 pages

Shell Casting

The shell casting process involves (1) making a pattern and using it to form a shell of cured sand around it, (2) removing the pattern to create a mold cavity, and then (3) pouring molten metal into the mold. It produces castings with great accuracy and smooth surfaces in an economical way. Some advantages are dimensional accuracy, thin sections, mass production capability, and reduced labor. Disadvantages include the expense of the binder and that the molds can only be used once.

Uploaded by

Muhammad Ishaq
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
68 views24 pages

Shell Casting

The shell casting process involves (1) making a pattern and using it to form a shell of cured sand around it, (2) removing the pattern to create a mold cavity, and then (3) pouring molten metal into the mold. It produces castings with great accuracy and smooth surfaces in an economical way. Some advantages are dimensional accuracy, thin sections, mass production capability, and reduced labor. Disadvantages include the expense of the binder and that the molds can only be used once.

Uploaded by

Muhammad Ishaq
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 24

Bearing caps

Cylinder Head

Manufacturing Processes
Shell Casting

Connecting rod

Heat sink/Cooling fins


Shell Casting

• Uses fine sand to produce castings


– Great accuracy
– Surface smoothness
• Economical alternative for great castings
Shell is term given to the cured sand in
which the metal is poured.
Crank shaft

Brackets
Shell Casting

Mold:
1. Fine silica (Dry) sand
2. Thermoset Phenolic plastic

(Mostly Phenol Formaldehyde, PF) as binder.


PF (formally known as Bakelite).
It has great binding power but it is not economical as molasses is.

Valve bodies
Shell Casting

• Mold is in two pieces.

• Both parts are prepared separately and then


– Bolted
– Glued together to make a complete shell.

Bushings

Automobile valves
Shell Casting

Pattern:
Match plate pattern is used.
It is made from metal which can Pump bodies
• Withstand 800oF
• High heat capacity (The heat capacity of a substance is a measure of how
well the substance stores heat )
• Low expansion coefficient
• Corrosion resistance
• Abrasion resistance
• Mold release quality
Shell Casting

Metals for Pattern:


• Cast iron
• Grey cast iron
• Low distortion die steel
• High Copper alloys
Motor enclosure
The pattern after being made is attached to a metal back
plate usually of same material, to make it a match plate
pattern.
Sprue, runners and gating system are part of the pattern.

Compressor part
Shell Casting

Additives:
Silicon is sprayed as a
 Parting agent
 For easy removal of pattern from shell
Zircon sand is mixed in the molding material
 To reduce Burning-in (Condition where molten metal has penetrated
into the sand, resulting in a mixture of metal and sand adhering to the
casting ).
Shell Casting

Kerosene Oil
 Reduce
 Segregation
 A concentration of alloying elements at specific regions, usually as a
result of the primary crystallization of one phase with the subsequent
concentration of other elements in the remaining liquid.
 Dusting
 Small solid particles created by the breaking up of larger particles by
a process.

Automotive part
Shell Casting

Step-1:
• Heating of pattern up to 450oF
• Uniform temperature (All parts of Pattern)
• Clamping on dump box (containing sand with resin binder)

Customized part
Shell Casting

Step-2:
• Dump box is inverted
– Sand mixture is dumped onto the hot pattern and held in place for a few
minutes

Wheel impeller
Shell Casting

• Curing:
– Heat from the pattern cures the sand mixture
– Forming a strong, solid bounded region about 1/4 - 1/8 inches thick
– Thickness of solid bounded layer depends upon the temperature of pattern and
time of contact
• Shell :
– This layer is called the shell.
– As the shell is molded to a metal pattern, so it has virtually the same
dimensional accuracy as the pattern

Suction bracket
Shell Casting

Step-3:
• Dump box is inverted so that
– The extra sand falls off.
– The shell still sticks onto the pattern.
NRV housing
Shell Casting

Step-4:
• Curing of Shell in Oven (for few minutes)
• Shell removal (Using ejector pins)
• Clamping (To make a complete mold)

Volute plate
Shell Casting

Step-5:
• Shells (Mold) are placed in pouring jacket
• Mold is backed by metal shots/Sand backing
• Molten metal is poured
• Solidification
• Mold is broken
• Finishing
Shell Casting
Shell Casting
Shell Casting
Shell Casting
Shell Casting
Shell Casting
Shell Casting
Shell Casting
Shell Casting
(Advantages)

• Greater dimensional accuracy


• Thinner sections
• Mass production
• Good surface finish
• Reduced labor requirements
• Low material consumption
• Low draft

Vane impeller
Shell Casting
(Disadvantages)

• Expensive binder
• Single use mold
• High leaded Brass (Assignment)

Pulleys
Lever arms

You might also like