Shell molding

From Wikipedia, the free encyclopedia

Shell molding, also known as shell-mold casting,[1] is an expendable mold casting process that uses a resin covered sand to form the mold. As compared to sand casting, this process has better dimensional accuracy, a higher productivity rate, and lower labor requirements. It is used for small to medium parts that require high precision.[2] Examples of shell molded items include gear housings, cylinder heads and connecting rods. It is also used to make high-precision molding cores.
Contents
[hide]

1 Process 2 Details 3 Advantages and disadvantages 4 References

o o

4.1 Notes 4.2 Bibliography

[edit]Process
The process of creating a shell mold consists of six steps:[2][3] 1. Fine silica sand that is covered in a thin (36%) thermosetting phenolic resin and liquid catalyst is dumped, blown, or shot onto a hot pattern. The pattern is usually made from cast iron and is heated to 230 to 315 C (450 to 600 F). The sand is allowed to sit on the pattern for a few minutes to allow the sand to partially cure. 2. The pattern and sand are then inverted so the excess sand drops free of the pattern, leaving just the "shell". Depending on the time and temperature of the pattern the thickness of the shell is 10 to 20 mm (0.4 to 0.8 in). 3. The pattern and shell together are placed in an oven to finish curing the sand. The shell now has a tensile strength of 350 to 450 psi (2.4 to 3.1 MPa). 4. The hardened shell is then stripped from the pattern. 5. Two or more shells are then combined, via clamping or gluing using a thermoset adhesive, to form a mold. This finished mold can then be used immediately or stored almost indefinitely. 6. For casting the shell mold is placed inside a flask and surrounded with shot, sand, or gravel to reinforce the shell.[4] The machine that is used for this process is called a shell molding machine. It heats the pattern, applies the sand mixture, and bakes the shell.

[edit]Details
Setup and production of shell mold patterns takes weeks, after which an output of 550 pieces/hr-mold is attainable.[citation needed] Common materials include cast iron, aluminum and copperalloys.[1] Aluminum and magnesium products average about 13.5 kg (30 lb) as a normal limit, but it is possible to cast items in the 4590 kg (100200 lb) range.[citation needed] The small end of the limit is 30 g (1 oz). Depending on the material, the thinnest cross-section castable is 1.5 to 6 mm (0.06 to 0.24 in). The minimum draft is 0.25 to 0.5 degrees.[1] Typical tolerances are 0.005 mm/mm or in/in because the sand compound is designed to barely shrink and a metal pattern is used. The cast surface finish is 0.34.0 micrometers (50150 in) because a finer sand is used. The resin also assists in forming a very smooth surface. The process, in general, produces very consistent castings from one casting to the next.[3] The sand-resin mix can be recycled by burning off the resin at high temperatures.[4]

[edit]Advantages

and disadvantages

One of the greatest advantages of this process is that it can be completely automated for mass production.[2] The high productivity, low labor costs, good surface finishes, and precision of the process can more than pay for itself if it reduces machining costs. There are also few problems due to gases, because of the absence of moisture in the shell, and the little gas that is still present easily escapes through the thin shell. When the metal is poured some of the resin binder burns out on the surface of the shell, which makes shaking out easy.[1][3] One disadvantage is that the gating system must be part of the pattern because the entire mold is formed from the pattern, which can be expensive. Another is the resin for the sand is expensive, however not much is required because only a shell is being formed.[3]

[edit]References [edit]Notes
1. 2. 3. 4. ^ ^ ^ ^
a b c d a b c

Degarmo 2003, p. 310.

Degarmo 2003, p. 308. Degarmo 2003, p. 309.

a b c d a b

Todd, Allen & Alting 1994, p. 267.

2. 3.

INTRODUCTION TO THE SHELL MOULDING PROCESS

4. 5.

Amit M Joshi
6.

7.

Dept. of Metallurgical Engineering & Materials Science, 8. Indian Institute of Technology Bombay, India. 9. Email - amitjoshi@iitb.ac.in 10. mechamit2002@yahoo.co.uk

11. 12. Shell

moulding is a process for producing simple or complex near net shape castings, maintaining tight tolerances and a high degree of dimensional stability. Shell moulding is a method for making high quality castings. These qualities of precision can be obtained in a wider range of alloys and with greater flexibility in design than die-casting and at a lower cost than investment casting. The process was developed and patented by Croning in Germany during World War II and is sometimes referred to as the Croning shell process. DETAILS

13. 14. EXPERIMENTAL 15. 16. Raw 17. 18.

Materials, Equipments

Resin coated sand. 19. Chromel Alumel Thermocouple, digital panel meter. 20. Muffle Furnace. 21. 2 Kg Aluminium Silicon Alloy (LM6) scrap.

22.

Clay Graphite crucible. 23. Fireclay. 24. Asbestos Gloves, Tongs, safety goggles.
25. 26. 27. THE 28. 29.

PROCESS DETAILS

The process was optimized to get a better shell by varying the temperature of the metal pattern, holding time of sand resin mixture and final curing time of shell and pattern. metal pattern having the desired shape of the casting is heated to 180 250o C. The pattern is sprayed with a solution of a lubricating agent or a release agent containing silicone to prevent the shell from sticking to the pattern. The sand is put in the dumpbox in sufficient quantity. The pattern is then turned down with its heated face inside the dumpbox. The dumpbox is now inverted so that the sand resin mixture falls on the heated metal pattern face. The sand mixture gets heated up and it softens the resin forming a shell on the pattern. Initially the resin becomes sticky. Further additional heat cures it. The dump box is again turned to its original position. The excess sand falls in the dump box leaving a shell on the pattern. pattern along with the shell is again kept in the heating oven. This cures the resin in the sand and shell acquires rigidity. On the pattern ejector pins are provided to strip off the shell. After the shells get cooled the two parts are joined properly to form a mould. Fireclay is applied along the edges of the mould to avoid leakage of the molten metal. Shell mould D was used as it had better thickness and had no breakage. 2 kg scrap of Aluminium Silicon alloy (LM6) was charged in a muffle furnace in a clay graphite crucible. The dross floating on the molten alloy was removed by a thin graphite plate. The molten aluminium silicon alloy was poured in the cavity of the shell mould.

30. 31. A

32. 33. The

34. 35. A

36. Later

on the shell mould was broken to remove the casting. The use of safety goggles, gloves, shoes is a must to avoid any accident.

37. 38. 39. 40.

Shell No.

Temperature of the Temp. of heated pattern pattern measured by Chromel Alumel thermocouple (oC)

Holding time

Final Curing time

Thickness of the shell. (cm)

A B C D
41.

12.5 mv 10.5 mv 10.7 mv 11 mv

325 260 264 270

40 sec 60 sec 90 sec 120 sec

Copyright

60 sec 60 sec 90 sec 120 sec

1.1 1.65 1.85 2.0

42.

Metal Pattern
Heating Coil

Hole for inserting Chromel Alumel Thermocoupl e.

45. 46. 47. Shell 48. Copyright

Moulding Pattern

49.

Two parts of the Shell on the heated pattern.

50. 51. Shells

formed on the heated metal pattern

52. Copyright Amit Joshi

53. 54. 55. Shells 56.

removed from the heated pattern

57. 58. Shells matched to form a mould. (Mould preheated to avoid moisture) 59. 60.

Copyright Amit Joshi

Aluminiu m Silicon alloy (LM6) being poured in the mould from the graphite crucible.

62. 63. 64. 65.

Copyright Amit
M Joshi

66. 67. 68. Aluminium 69. 70. 71. 72. Advantages 73. 74. 75. 76. 77. 78. 79. 80. 81. 82. 83.

Silicon alloy casting ring broken from the mould after room temperature cooling.

Better surface finish Better dimensional tolerances. Reduced Machining. Less foundry space required. Semi skilled operators can handle the process. The process can be mechanized.

Copyright

(B) Less Holding time and curing time

(A) (D) Over heated pattern, Shell with better less holding and curing time thickness

(C) Shell with good thickness

Comparison of Shells

86. 87. 88. 89. Disadvantages 90. 91.

The raw materials are relatively expensive. 92. The process generates noxious fumes which must be removed. 93. The size and weight range of castings is limited.
94. 95. Applications 96. 97. -Crankshaft

fabrication 98. -Steel casting parts, fittings 99. -Moulded tubing fabrication

-Hydraulic control housing fabrication 101. -Automotive castings (cylinder head and ribbed cylinder fabrication).
100. 102. 103. 104. 105. 106. 107. 108. 109. 110. 111. 112. 113. 114. 115.

Amit M Joshi Dept. of Metallurgical Engineering & Materials Science, Indian Institute of Technology Bombay, (I.I.T Bombay), India. Email - amitjoshi@iitb.ac.in www.iitb.ac.in

COPYRIGHT NOTICE:

The information contained within the entire Metal Web News, MWN (www.metalwebnews.com) pages are provided for the personal use of the MWN readers. No commercial use is authorized by the authors of the information provided. Each individual article is copyright protected for the respective author. No information may be copied or sold for any commercial purpose whatsoever, without written permission from the author and an exact copy such written permission delivered to Metal Web News prior to any authorized commercial use.

116. Shell molding process offers better surface finish, better dimensional tolerances, and higher throughput due to reduced cycle times. 117. A heated (200 C / 392 F) metal pattern is covered with a mixture of sand and thermoset plastic. This causes a skin of about 3.5 mm (0.125 in) of sand/plastic mixture to adhere to the pattern. This skin is removed from the pattern to form the "shell mold". The two halves of the shell mold are secured together and the metal is poured in the shell to form the part. Once the metal solidifies, the shell is broken. 118. This process can produce complex parts with good surface finish 1.25 m to 3.75 m (50 in to 150 in) rms, and dimensional tolerance of 0.5 %. Size limits of 30 g to 12 kg (1 oz to 25 lb). Minimum thicknesses can be as low as 1.5 mm (0.062 in) to 6.25 mm (0.25 in), depending on the material. A good surface finish and good size tolerance reduce the need for machining. 119. A fairly high capital investment is required, but high production rates can be achieved. The process overall is quite cost effective due to reduced machining and cleanup costs.

120.

The materials that can be used with this process are cast irons, and aluminum and copper alloys. Typical parts made with this process are connecting rods, gear housings, lever arms etc.