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Shell-moldCastingProcessME?.MEMechanicalTeam?Lastupdated:Sep23,2015Shell-moldcastingprocessisalsoknownasshellmoldingprocessisanexpendablemoldcastingprocessthatusesaresincoveredsandtoformthemold.Inshell-moldcastingprocessthemoldismadelikeashelli.e.,thethinorhollowmoldisusedsothatweightofmoldislessandhandlingofmoldbecomeseasier.Tomanufacturethethinmold,thephenolicresinwithsmalladditionofsilicasandareusedasmoldmaterial.Formakingshell-moldcastingrequirestheuseofametalpattern,oven,sand-resinmixture,dumpboxandmoltenmetal.Shell-moldcastingallowstheuseofbothferrousandnon-ferrousmetals,mostcommonlyusedmoltenmetalsarecastiron,carbonsteel,alloysteel,stainlesssteel,aluminumalloysandcopperalloys.Theshell-moldcastingprocessconsistsofthefollowingsteps:Patterncreation-Atwo-piecemetalpatterniscreatedintheshapeofthedesiredpatternrequired.Moldcreation-First,eachpatternhalfisheatedto175370°Candcoatedwithalubricanttofacilitateeasyseparationfromthepatternformed.Next,theheatedpatternisclampedtoadumpbox.Thedumpboxisinverted,allowingthissand-resinmixturetocoatthepattern.Theheatedpatternpartiallycuresthemixture,whichnowformsashellaroundthepattern.Eachpatternhalfandsurroundingshelliscuredtocompletioninanovenandthentheshellisejectedfromthepattern.Moldassembly-Thetwoshellhalvesarejoinedtogetherandsecurelyclampedtoformthecompleteshellmold.Ifanycoresarerequired,theyareinsertedpriortoclosingthemold.Theshellmoldisthenplacedintoaflaskandsupportedbyabackingmaterial.Pouring-Themoldissecurelyclampedtogetherwhilethemoltenmetalispouredfromaladleintothegatingsystemandfillsthemoldcavity.

Cooling-Afterthemoldhasbeenfilled,themoltenmetalisallowedtocoolandsolidifyintotheshapeofthedesiredcasting.Castingremoval-Afterthemoltenmetaliscooled,themoldisbrokenandthecastingisremoved.Trimmingandcleaningprocessesareperformedtoremoveanyexcessmetalfromthefeedsystemandtoseparatesmallsandparticlesfromthemold.Shell-MakingShellMoldCastingCasting(Cross-section)(Cross-section)CSampMoltenmetalLadleEjectorpinFinishedJcasting-11-Sand-restnShellmoldCSampMoltenmetalLadleEjectorpinFinishedJcasting-11-Sand-restnShellmold」Casting」1-Backtngmatenal」FlaskmatureHeatedpattern-1Shell」Copyrigm?2008CustomPartNetCeramicmoldingInshellmoldcastingprocessinplaceofphenolicresinifceramicslurryisusedasamoldmaterialthenitiscalledasceramicmolding.FeaturesofShellMoldingProcess:Inshellmoldingprocessthicknessandweightofmoldisless.Productionrateofshellmoldisveryhigh.Becauseoflowporosityofmold,throughrisermustbeused.Itisusefulforonlycircularandsymmetricaljobs.Thesizeofcastingcanbeformedislimitedto30kgonly.Highlycomplicatedshapescannotbeformedusingshellmoldcastingmethod.Thisprocessproducesmoredimensionalaccuratecastingcomparedtoothersandcastingprocess.Lowerdraftanglescanbeused.Shell-moldcastingmethodisusedformakingcylindersandcylinderheadsforICengines,automobiletransmission

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