Shell moulding casting technology
- 1. ADVANCED CASTING TECHNOLOGY SHELL MOULD CASTING Prepared by : Harsh B Joshi (M.Tech Production Engineering,1st Semester) Parul Institute of Engineering, Limda
- 2. INTRODUCTION SHELLMOULDING PROCESS ADVANTAGES AND DISADVANTAGES APPLICATIONS CONTENTAS
- 3. Shell moulding, also known as shell-mould casting, is an expendable mould casting process that uses a resin covered sand to form the mould As compared to sand casting, this process has better dimensional accuracy, a higher productivity rate, and lower labour requirements It is used for small to medium parts that require high precision. Shell mould casting is a metal casting process similar to sand casting, in that molten metal is poured into an expendable mould. INTRODUCTION
- 4. A reusable pattern allows for higher production rates, while the disposable moulds enable complex geometries to be cast Shell mould casting requires the use of a metal pattern, oven, sand-resin mixture, dump box, and molten metal Shell mould casting allows the use of both ferrous and non-ferrous metals, most commonly using cast iron, carbon steel, alloy steel, stainless steel, aluminum alloys, and copper alloys Typical parts are small-to-medium in size and require high accuracy, such as gear housings, cylinder heads, connecting rods, and lever arms INTRODUCTION
- 6. Pattern creation - A two-piece metal pattern is created in the shape of the desired part, typically from iron or steel. Mould creation - First, each pattern half is heated to 175-370 °C (350-700 °F) 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. Mould assembly - The two shell halves are joined together and securely clamped to form the complete shell mould. If any cores are required, they are inserted prior to closing the mould. The shell mould is then placed into a flask and supported by a backing material. SHELL-MOULDING PROCESS
- 7. Pouring - The mould is securely clamped together while the molten metal is poured from a ladle into the gating system and fills the mould cavity. Cooling - After the mould has been filled, the molten metal is allowed to cool and solidify into the shape of the final casting. Casting removal - After the molten metal has cooled, the mould 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 mould. SHELL-MOULDING PROCESS
- 8. Thin and complex section can be easily cast. High dimension accuracy and good surface finish. Mass production, high productivity It can be operate by an semi skilled operator. No further machining required. Special metal pattern required which makes it expensive for large casting. It is not suitable for small batch production. Shell moulds are less permeable compare to green sand mould. Size and weight limitation. ADVANTAGES AND DISADVANTAGES
- 9. Crankshaft Model tubing Fabrications Automotive components gearbox housing connecting rod Camshaft, valve body etc. are made by shell moulding. APPLICATIONS
- 10. THANK YOU For your carefully listening and attention..!