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    Experiment No: - 4 Shell Moulding Process Aim

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    Dhananjay Shimpi
    The document summarizes the shell moulding process. Shell moulding involves forming a thin sand-resin shell on a heated metal pattern. A sand-resin mixture is dumped onto the heated pattern, and the pattern is inverted, allowing unbound sand to fall away and leaving the shell adhered to the pattern. The shell is then stripped and cured. Key advantages are thin shells with high definition that provide good insulation and surface finish for castings. Applications include small, intricate ferrous and non-ferrous castings like automotive parts.

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    Experiment No: - 4 Shell Moulding Process Aim

    Uploaded by

    Dhananjay Shimpi
    100 views5 pages
    The document summarizes the shell moulding process. Shell moulding involves forming a thin sand-resin shell on a heated metal pattern. A sand-resin mixture is dumped onto the heated pattern, and the pattern is inverted, allowing unbound sand to fall away and leaving the shell adhered to the pattern. The shell is then stripped and cured. Key advantages are thin shells with high definition that provide good insulation and surface finish for castings. Applications include small, intricate ferrous and non-ferrous castings like automotive parts.

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    4Shell moulding

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    The document summarizes the shell moulding process. Shell moulding involves forming a thin sand-resin shell on a heated metal pattern. A sand-resin mixture is dumped onto the heated pattern, and the pattern is inverted, allowing unbound sand to fall away and leaving the shell adhered to the pattern. The shell is then stripped and cured. Key advantages are thin shells with high definition that provide good insulation and surface finish for castings. Applications include small, intricate ferrous and non-ferrous castings like automotive parts.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    100 views5 pages

    Experiment No: - 4 Shell Moulding Process Aim

    Uploaded by

    Dhananjay Shimpi
    The document summarizes the shell moulding process. Shell moulding involves forming a thin sand-resin shell on a heated metal pattern. A sand-resin mixture is dumped onto the heated pattern, and the pattern is inverted, allowing unbound sand to fall away and leaving the shell adhered to the pattern. The shell is then stripped and cured. Key advantages are thin shells with high definition that provide good insulation and surface finish for castings. Applications include small, intricate ferrous and non-ferrous castings like automotive parts.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 5

    Experiment No.

    4
    Shell Moulding Process

    Aim: To study Shell Moulding Process.

    Introduction –
    Shell moulding is the newest of the casting process. It was developed in Germany during
    world war II by J. Croning. They form thin , rigid shells of approximately.

    Principle –
    A sand resin mixture is dumped on to the heated metallic pattern and present time, the
    pattern is turned over to allow the unbounded sand to be removed, leaving the shell on the
    pattern. The shell is then stripped mechanically and further heated or baked if curing is required.

    Raw Materials –
    Resin coated sand (phenol formaldehyde 3%), silicone oil (withstanding 250 degree
    celcius), thermocouple, control panel of furnace etc.
    Brush is required for applying oil on pattern, asbestos sheet that will firm the heating
    element pugs, ceramic wool for the dump box.
    Al shots and graphite powder for applying them onto the prepared shell mould.

    Dump Box –
    The dump box has capacity 47.28 kg. it can produce 31 shells each weigh 1.5 kg
    There are six heating elements used in machine, four in heating box and two below the ejecting
    plate. (Each having resistance = 66 ohms). The power requirement is 4870 W.
    Steps Involved In Shell Moulding –
    The heating box is kept on the pattern and the main supply is switched ON. Temperature
    is set at 220 oC. Metal pattern is heated to 220 oC in an oven set at 350 oC. After heating,
    silicone oil is applied over the metallic pattern by brush and it is then turned face down on the
    dump box. The dump box is then inverted. The sand in contact with the heated metallic pattern
    gets heated up, resin softens and fuses to form a uniform shell of thickness 12mm on the pattern
    surface. Additional heating cures the shell. As the dump box is brought back to its original
    position, the excess sand falls back, leaving the shell adhering to the pattern. Additional heating
    can be carried out in an oven, which strengthens the shell. Ejector pins are employed to strip the
    shell off the mould pattern. The shell is coated with refractory coating like Zirconium
    suspension. Two mating shells are securely fastened together to form a complete mould. The
    mould is now ready for pouring.

    ADVANTAGES –
     Shell thickness as low as 1.5 mm with high definition.
     Shell is an excellent insulator, there is no surface chilling or skin hardening of casting.
     Due to slower cooling rates, castings with grain size more than fine green sand castings
    produced.
     Excellent surface finish.
     Produces intricate shapes.
     Fettling and machining necessary.
     Tolerances of the order of 0.002 to 0.003 mm per meter are possible to obtain shell
    moulding casting.
     Less foundry space required.
     Semi-skilled operators can handle operation.
     Shells can be stored before use.
     Shell moulding process can easily be mechanised.
    DISADVANTAGES –
     Uneconomical for small scale production.
     Resin costs are high.
     Maximum size of casting is limited (10 kg).
     Sand cannot be recovered.
     Castings pouring proper gating and parting cannot be obtained.

    APPLICATIONS –
     Mass production of small castings with high degree of intricacy.
     Automotive rocker arms and valves.
     Ferrous and non-ferrous casting both in range of 0.1 to 10 kg.
     Hydraulic casting in stainless steel and copper alloys.
     Other components cast by shell moulding are small pipes, cam shafts, bushings, valve
    bodies, brackets, manifolds, bearing caps, shafts and gears.
    Laboratory Shell Moulding Set-up

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