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Shell Molding

Shell molding is a casting process that uses resin-coated sand to form molds with better dimensional accuracy and productivity than sand casting. The shell molding process involves: (1) applying resin-coated sand to a heated pattern to partially cure, (2) inverting the pattern to remove excess sand leaving a shell, and (3) finishing curing the shell and combining multiple shells to form the mold. Shell molding produces very consistent castings in small to medium batches with high precision at a lower cost than alternatives due to automation and reduced machining needs. However, it requires including gating systems in patterns and uses expensive resin.

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238 views

Shell Molding

Shell molding is a casting process that uses resin-coated sand to form molds with better dimensional accuracy and productivity than sand casting. The shell molding process involves: (1) applying resin-coated sand to a heated pattern to partially cure, (2) inverting the pattern to remove excess sand leaving a shell, and (3) finishing curing the shell and combining multiple shells to form the mold. Shell molding produces very consistent castings in small to medium batches with high precision at a lower cost than alternatives due to automation and reduced machining needs. However, it requires including gating systems in patterns and uses expensive resin.

Uploaded by

Sarjito
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Shell molding

Definition
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]

Process
The process of creating a shell mold consists of six steps:[2][3]
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. 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 (0.39 to 0.79 in). 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). The hardened shell is then stripped from the pattern. 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. For casting the shell mold is placed inside a flask and surrounded with shot, sand, or gravel to reinforce the shell.[4]

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, aluminium and copper alloys.[1] Aluminium 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 (99200 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 mm (0.059 in) to 6 mm (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 micrometres (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]

Advantages & 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.[3][1]

Advantages & disadvantages


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]

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