Shell moulding is a casting process that uses a sand-resin mixture to form a disposable mould around a reusable pattern. This allows for higher production rates than sand casting while also enabling more complex part geometries. The process involves creating a metal pattern, heating it, applying a sand-resin mixture to form shell halves, joining the shells to create the mould, pouring molten metal, and removing the casting after solidification. Shell moulding provides better dimensional accuracy, higher productivity, and lower labor costs than sand casting for small to medium precision parts.

1. SHELL MOULDING
PRODUCTION PROCESS
-VISHNU RC VIJAYAN

2. MOULDING
 Moulding is the process of manufacturing, by shaping manufacturing
by shaping pliable raw material using applicable raw material using a
rigid frame or model called a rigid frame or model called a pattern

3. INTRODUCTION
 Shell moulding, 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.
 A reusable pattern allows for higher production rates, while the disposable
moulds enable complex geometries to be cast

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
 Typical parts are small-to-medium in size and require high accuracy, such as
gear housings, cylinder heads, connecting rods, and lever arms

5. PROCESS
Shell Moulding involves the following processes
Pattern creation - A two-piece metal pattern is created in the shape of the
desired part, typically from iron or steel.
Mould creation - First, each pattern half is heated to 175-370 °C (350-700 °F)
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 a resin binder.
Mould assembly - The two shell halves are joined together 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.

6.  Pouring - The mould is securely clamped together while the molten metal is
poured from a ladle into the gating system and fills the mould cavity.
 Cooling - After the mould has been filled, the molten metal is allowed to cool
and solidify into the shape of the final casting.
 Casting removal - 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.

9. UTILITIES REQUIRED FOR THIS PROCESS
Metal Pattern
Oven
Sand-resin mixture
Dump box
Molten Metal
APPLICATIONS
Crankshaft
Model tubing Fabrications
Automotive components
Hydraulic control Housing etc

10. ADVANTAGES & DISADVANTAGES
 One of the greatest advantages of this process is that it can be completely
automated for mass production
 The high productivity, low labour costs, good surface finishes, and precision
of the process can more than pay for itself if it reduces machining costs
 One disadvantage is that the gating system must be part of the pattern
because the entire mould 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

11. 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.

13. Mould Creation
 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 anoven and
then the shell halves are joined together.

15. MOULD ASSEMBLY
 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

16. MOULD ASSEMBLY

17.  The mould is securely clamped together while the molten is poured
from a ladle into the gating system and fills the mould cavity
Pouring

18. COOLING
 After the mould has been filled the molten metal is allowed to solidify into
the shape of the final casting

19. CASTING REMOVAL
 After the molten metal has been cooled , the mold can be broken and casting
can be removed
 Trimming and cleaning process can be used to remove any excess metal from
the feed system and sand from the mould

20. REFERENCES
WEBSITE
1. www.academia.edu/6595783/Shell_Molding_Process_---_Pasa_Yaman
2. www.thelibraryofmanufacturing.com/shell_mold_casting.html
3. www.custompartnet.com/wu/shell-mold-casting
4. engineeringhut.blogspot.com/2010/10/shell-moulding.html