SHELL MOLDING

Presented By:
Suraj Kute.
Ambarish Bhoga.
INDEX
1) Molding definition
2) Types of molding
3) What is Shell molding?
4) Manufacturing of shell sand.
5) Shell molding raw materials
6) Molding procedure
7) Defects in shell molding
8) Advantages
9) Disadvantages
10)Recent advancement in shell technology
11)Applications
1) Molding Definition
 Molding is the process of
manufacturing by shaping
pliable raw material using a
rigid frame or model called a
pattern.
2) Types of Molding
 Injection molding
 Compression molding
 Transfer molding
 Extrusion molding
 Blow molding
 Rotational molding
 Shell molding
3) The Shell Moulding Process:
A German Innovation

 Shell moulding processes

was invented by
Johannes Croning.
 The process was developed
and patented by Croning in
Germany during World War
II and is sometimes
referred to as the Croning
shell process.
 3) What is Shell molding?
 Shell molding 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.
 It is a process well suited to rapid,
automated, repetitive and high-
volume production. The most
common method for producing shell
moulds is to use a dump box.
Why SHELL MOULDING ?
 SAND CASTING IS MOST COMMONLY
USED CASTING PROCESS.
 BUT NOT SUITABLE FOR ECONOMICAL
IN MANY APPLICATION.
 SO WE MAKE USE OF SPECIAL CASTING
PROCESSES AND SHELL MOULDING IS
ONE OF IT .
Machine tools used
 1. Conventional dump-box method
 2. Modern automated method
4) Manufacturing of shell
sand.
 The various methods used are as
follows.

1. Warm air process

2. hot coating process.

Warm air process
 Pre weighted sand along with hexa catalyst is
mixed in mixer.
 Phenolic resins are then added (liquid resins )
 alcohol or water is then removed by passing
hot air.
 During coating process there can be lump
formation.
 But they can be easily disintegrated .
 After this sand is send to cyclone for removal
of the siliceous particles.
Hot coating process
 Sand is heated between temperature of 125-150
deg.
 Resins are added which melts at such high
temperature and sand gets coated.
 Hexamine is then added which is aqueous
solution.
 Lubricant is then added to avoid lump formation.
 Water is then removed by means of hot air.
 By disintegrator the sand lumps are broken
 At the last the sand is sent to cyclone.
5) Shell molding raw
materials
 Silica sand.
 Zircon sand .
 Chromite sand.
 Aluminium silicate sand .
 Phenol formaldehyde resins.
 Hexa catalyst with lubricants.
 Additives.
Silica sand
 Basic raw material required.
 Ideal silica sand should have following
composition.
1) chlorides 0%
2) carbonates 0%
3) Acid demand value <6 ml of KOH/100
gm of sand.
4) Silica content 98% minimum.
5) Loss on ignition (max. 0.2% )
6) Some amount of clay content.
 Zircon sand
 Much costlier than silica sand.
 Following are its advantages.
1) Low thermal expansion.
2) high sintering point (2150 -2250
deg)
 generally not blended with silica sand
Aluminium Silicate
and Chromite Sand

 Has got same advantages of

that of zircon sand.

 It is rarely used.
Phenol formaldehyde Resins.
 Used as binder.
 form of the resin may be liquid or
flake.
 Liquid resins are resins
dissolved in alcohol.
 mostly liquid resins are used
due to their easiness.
Properties to be checked for
resins

 Clarity
 viscosity
 Specific gravity.
 Solid content .
 PH values.
Properties to be checked
for solid resins

 Softening point .

 Flow rate.

 Particle size
Hexa catalyst
 It is nothing but blend of
hexamethylene tetramine and lubricant.
 It is supplied in powder form.
 used mainly to develop the
thermosetting characteristics in the
shell sand .
 Added in the proportion of 14 to 16
%.
Additives
 The function of the additives are.
1) To improve surface finish.
2) To avoid thermal cracking .

 The commonly used additives are .

1)Coal dust.
2)pulverised slag.
3)manganese dioxide.
4)Calcium carbonate.
 6) Shell Molding process
 1. A match‑plate
or cope‑and‑drag
metal pattern is
heated and placed
over a box
containing sand
mixed with
thermosetting
resin.
 2. Box is inverted so
that sand and resin fall
onto the hot pattern,
causing a layer of the
mixture to partially
cure on the surface to
form a hard shell;
 3. Box is repositioned
so that loose uncured
particles drop away;
 4. Sand shell is
heated in oven for
several minutes
to complete
curing;
 5. Shell mold is
stripped from the
pattern;
 6. Two halves of
the shell mold are
assembled,
supported by sand
or metal shot in a
box, and pouring
is accomplished;
 7. The finished
casting with sprue
removed.
 Figure shows
that typical shell
thicknesses that
can be obtained
with various
pattern
temperatures
and contact
times.
VIDEO

Real time automate

d process
7) Defects in shell molding
 1. Bonding defects  7. Seizure
 2. Bubble on back of  8. Sticking
shell  9. Thermal shock
 3. Distortion  10. Thick shell
 4. Drop off  11. Thin Shell
 5. Lack of uniformly in  12. Warping of
shell mold
 6. peel back  13. Weak shells
1. Bonding defects
 Appearance :
1. Casting fins, possible run out of metal
when weakness is extreme.
 Possible causes:
1. Too viscous a bonding resin can cause
the mold to close improperly.
2. A resin much too fluid to have good
surface finish.
3. Delay in bonding can also cause the
mold to close improperly.
2. Bubble on back of shell
 Appearance :
1. Resin ‘bubbles’ or ‘beads’ appear on
the back of moulds.
 Possible causes:
1. Poor distribution of resin in sand.
2. Inadequate melt of resin on hot
coated sand.
3. Additives not properly dispersed.
4. Over mulling of coated sand causing
resin to break loose.
3. Distortion
 Appearance :
1. Cores or moulds out of shape.
 Possible causes:
1. Too much plasticity due to insufficient
care.
2. Too little hexamthylene tetramine.
3. Ejection or moulding pins may be out
of adjustment causing uneven pressure
with resulting distortion on removal.
4. Drop off
 Appearance :
1. Sections of shell wall break off
 Possible causes:
1. Over lubrication preventing proper
adhesiveness of resin-sand mix to pattern.
2. Too much resin
3. Pattern temperatures below those needed to
bond resin and sand properly.
5. Lack of uniformly in shell
 Appearance :
1. Low density ares.
2. solid resin chunks.
 Possible causes:
1. Moist sand restricting flowability.
2. Low stick point of coated sand.
3. Corebox below pressure too low or to
high.
 6. peel back
 Appearance :
1.Pattern set sand brakes off leaving weak spots.
2. Moulds break and cores collapse when poured
 Possible causes:
1. Too much resin.
2. Time in contact with pattern too long.
3. Pattern temperature too high or too low.
4. Too much vibration.
5. Wrong resin for the job.
6. Hot or cold spots on plate or core box.
 7. Seizure
 Appearance :
1. Mould difficult to remove though there
is no sand adhesion to the pattern.
 Possible causes:
1. Insufficient or improper lubicant.
2. temperature too high.
3. cure time excessive.
4. Excessive resin shrinkage during cure.
8. Sticking
 Appearance :
1.Moule will not remove easily from pattern
or core plate.

 Possible causes:
1. Rough surfaces of pattern or corebox.
2. Insufficient or improper lubrication.
9. Thermal shock
 Appearance :
1. Cracks in mould before metal solidifies
causing run-out.
 Possible causes:
1. Pattern design may contribute to
problem.
2. Sand grains expansion during pouring
causes thermal shock and cracks which
stem from it.
10. Thick shell
 Appearance :
1. Excessive wall thickness.
 Possible causes:
1. Dwell time excessive.
2. Temperature too high.
3. Resin stick point too low.
11. Thin Shell
 Appearance :
1.Shell thinner than normal in given dwell
time.
 Possible causes:
1. Dwell cycle too short.
2. Pattern temperature too low.
3. Resin flow may be too short for the
job..
12. Warping of mold
 Appearance :
1. Moulds distorted when compared to
patterns they are made from.
 Possible causes:
1. Temperature differential between
pattern and oven may be too great.
2. Resin may be too slow or may not cure
rigid enough.
13. Weak shells
 Appearance :
1.Lack of strength

 Possible causes:
1. Not enough binder.
2. Too much moisture.
3. Uneven distribution of resin.
4. Undercure.
5. Overcure.
6.Resin melt point too high.
8) Advantages
 Excellent Surface Finish: Shell sand
process has ability to produce casting with
excellent surface finish & capacity to produce
fine detail.
 Dimensional Accuracy: The process has
an ability to produce casting to tight
dimensional tolerance. Due to this
characteristic machining allowance can be
reduced which ultimately helps for reduction
in fettling and finishing cost.
 Sand to Metal Ratio: This is the only
process which given hollow cores & thin
walled mould, which results in substantial
weight reduction and material saving.
Normally sand to metal ration is 1:1 which
is much lower than other processes.
 Ease of Handling: Shell Sand moulds
and cores are exceptionally resistance to
damage through handling and storage.
This happens due to high resistance to
humidly. The shell cores and moulds can
be stored for month without difficulty.
 Resistant to Moisture Pickup: The
shell process is resistant to moisture pick
up. The shell cores and moulds can be
stored for long period even in high humid
conditions. The resin used for shell process
is stable and moisture resistant.
 No Skill is Required: Since every thing
is ready to use, with minimum training any
worker can produce, repeatedly, precision
moulds and cores.
 Little or No Pattern Wear: Since
patterns are made up of cast iron, very little
or no wear is observed resulting longer
pattern life. This helps to produce “N”
number of casting without any dimensional
problems.
 Longer Shelf Life: Shell sand has
indefinite shelf life, if properly stored. Thus
shell sand can be stored and used as
needed by the foundry.
 Low Capital Investments: Molds
and cores making equipments is of moderate
cost and where necessary can be added as
cells. In shell process, bases sand can be
easily changed to suit specific requirement of
the casting.
 Economics: Though the basic of shell sand
is more than any other processes hollow cores,
contoured shells, back up systems low fettling
and cleaning, with good dimensional accuracy,
makes process economically viable.
 High rate of production is possible with
limited floor space.
9) Disadvantages:
 High Cost of The Process:
Phenolic resins used for the shell
process are costly & at the same time
% usage of resins are high compared
to other processes. Hence process
requires a tight control of the shell
thickness otherwise competitiveness
of the process will be sacrificed.
 High Tooling Cost: Shell process
is thermoset & requires high
temperature to cure, hence patterns
used are of cast iron with smooth
surface have very low expansion
coefficient. All these results in costly
affair compared to other processes.
 High Energy Cost: Shell process
operates at around 250 C toding
temperature which requires energy
either by the way of electricity or L.P.G.
The cost of energy is very high, when
compared with other processes.
 Cycle Time: Comparatively cycle
time required for shell process in more
than either cold box or CO processes.
 Limited Casting Weight: Shell
process in best for small intricate light
weight casting. With shell process casting
weight up to 200kg is produced.
 Highly complicated shapes cannot be
obtained.
 More sophisticated equipment is needed
for handling the shell moulding such as
those required for heated metal
patterns.
 Sand inputs need to be of
higher quality than traditional
sand casting.
 Emissions from the process are
noxious, so effective extraction
systems are required.
10) Recent advancement
in shell technology
 Application oriented special sand is
available.
 Faster curing resins are available.
 Faster builtups.
 Faster shakeout shell sand .
 All these things have greatly
reduced casting cost and improved
productivity.
 One of the latest technology in shell
molding is new formulation which gives
great help for better shakeout for
aluminium casting.
 Many time the casting needs to be baked
at 400-500deg to brake down cores and
remove the casting.This is an expensive
process.
 By means of new shake out shell this
problem can be easily solved.
11) Applications

 Crankshaft
fabrication

 Molded tubing
fabrication
 Automotive
castings (cylinder
head fabrication).

 Hydraulic control
housing
fabrication
 cylinders and cylinder
heads for air cooled IC
engines,

 automobile
transmission parts,
 cast tooth bevel gears,
brake beam

 track rollers for crawler

tractors,
 transmission planet
carrier,
 steel eyes, gear
blanks, refrigerator
valve plates are
some of the common
applications of shell
mould casting.
Thank you