This document provides information about shell casting production technology. It discusses shell casting as a metal casting process where a resin-coated sand forms an expendable mold, allowing for higher precision and productivity than sand casting. The document outlines the shell casting process which involves pattern creation, mold creation by coating a heated pattern with sand-resin mixture, mold assembly, pouring molten metal, cooling, and casting removal. Typical applications include small to medium parts for industries like automotive and defense.

1. Production Technology:
shell casting
COURSE CODE: C211
REGULATION: R19
2nd BTECH 2nd SEM
PREPARED BY :
POLAYYA CHINTADA M.TECH,M.B.A,(PhD)
ASSISTANT PROFESSOR
LENDI INSTITUTE OF ENGINEERING AND
TECHNOLOGY

2. 2
PRODUCTION TECHNOLOGY
SYLLABUS
UNIT 1:
Introduction: Importance and selection of manufacturing processes.
Casting Processes: Introduction to casting process, process steps; pattern: types, materials
and allowance; Cores: Types of cores, core prints, principles and design of gating system;
Solidification of casting: Concept, solidification of pure metal and alloy; Special casting
processes: Shell casting, investment casting, die casting, centrifugal casting, casting defects
and remedies.
provide insight into Working
principles of different metal casting
processes and gating system
COURSE OBJECTIVE:
COURSE OUTCOMES:
Explain different metal
casting processes and
gating systems. (L2)
APPLICATIONS:
Identify different patterns and
their allowances (L3)
1. Heavy Equipment : Construction,
farming and mining
2. Defence : Vehicles, artillery,
munitions, storage and supporting
equipment
3. Hardware : Plumbing industry
pipes, joints, valves and fitting
Identify the various casting
defects. (L3)

3. • Shell molding, 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.
Shell casting
https://www.youtube.com/watch?v=OtG-ox3i0kQ

4. •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, aluminium
alloys, and copper alloys
Shell casting
https://www.youtube.com/watch?v=kRoXt3qJviw
•Typical parts are small-to-medium in size and
require high accuracy, such as gear housings,
cylinder heads, connecting rods, and lever arms

5. Steps involved in Shell Molding processes
•Pattern creation
•Mould creation
•Mould assembly
• Pouring
• Cooling
•Casting removal

6. •A two-piece metal pattern is created in the shape of
the desired part, typically from iron or steel.
PATTERN CREATION
•A two piece metal pattern is created in the shape of the
the desired part typically from iron and steel.
•Other materials are sometimes used such as aluminum
for low volume production or graphite for casting
reactive material.

7. First, each pattern half is heated to 175°C - 370°C 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 resin binder.
The dump box inverted allowing this sand-resin
mixture to coat the pattern.
The heated pattern partially cures the mixture which
now forms a shell around the patterns.
Each pattern half and surrounding shell is cured to
completion in an oven and then the shell halves are
joined together.
Mould Creation

8. The two shell halves are joined 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
MOULD ASSEMBLY

9. The mould is securely clamped together while the
molten metal is poured from a ladle into the gating
system and fills the mould cavity.
POURING

10. After the mould has been filled, the molten metal is
allowed to cool and solidify into the shape of the
final casting.
COOLING

11. •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.
Casting removal

12. APPLICATIONS
Shell casting
Crankshaft
Model tubing Fabrications
Automotive components
Hydraulic control Housing etc

13. EXAMPLES PRODUCTS

14. Yours:
POLAYYA CHINTADA M.TECH,M.B.A,(PhD)
ASSISTANT PROFESSOR