Shell mold casting:

This process like die casting and investment casting it gives good surfaces finish and dimension accuracy but it selected according to easy of use low time the selection depend on the conditions of use.

Process:
It is a process in which the sand is mixed with a thermo setting resin is allowed to come into contact a heated metallic pattern plate so that a them and strong shell of mold is formed around the pattern then she is removed the pattern and the cope and drag are remove together and kept in a flask with the necessary back up material and the molten metal is pored into the mold. Generally dry and fin sand which is completely free of the clay is used for preparing the shell mold in are the phenol formaldehyde rising combined with sand they hare very high strength and resistance through heat. Steps of process: 1-A metal pattern having the profile of the required casting is heated to 180-260c in an own maintained at 300-400c pattern after being heated is taken out of the own and sprayed with a solution of a lubricating agent containing silicon. It is necessary to prevent the shell from sticking to the metal pattern.

2-Metal pattern (made up of iron or steel) is then turned faced down and clamped over the open end of the dump box.

3-the dump box is inverted so that dry sand raisin mixture falls on the face of hot metal pattern. the raisin the raisin softens and fuses to form a soft and uniform sand mixture in contact with the pattern gets heat up .the rasinsoftens and fuses to form a soft and uniform shell of about 6mm thickness on the surface of pattern.

4-As the dump box is turned to its original position. Excess sand resin mixture falls beak into the dump box leaving a shell adhering closely to the pattern.

5-sand shell is heated in oven for several minutes to complete curing.

6-The shell is then stripped from the pattern plate with the help of ejector pins which are an integral part of the metal pattern.

7-After the shells so obtained have cooled. Two meeting shell are securely fastened together to from a complete mold. Two halves of the shell molds are assembled, supported by sand or metal shot in a box, and pouring is accomplished.

Conditions of use:
Materials: Cast irons. Aluminum . Copper alloys.

Controlling temperature to control the thickness of shell.

Minimum thicknesses can be as low as 1.5 mm (0.062 in) to 6.25 mm (0.25 in), depending on the material. Size limits of 30 g to 12 kg (1 to 25 lb).

Applications:
12345Crankshaft fabrication. Steel casting parts, fittings. Molded tubing fabrication. Hydraulic control housing fabrication. Automotive castings (cylinder head and ribbed cylinder fabrication).

Advantages:
1- Smoother cavity surface permits easier flow of molten metal and better surface finish on casting. 2- Good dimensional accuracy. 3- A good surface finish and good size tolerance reduce the need for machining. 4- Mold collapsibility usually avoids cracks in casting. 5- Can be mechanized for mass production. 6- This process can produce complex parts with good surface finish 1.25 m to 3.75 m (50 in to 150 in) and good dimensional tolerance of +/- 0.25mm. 7- The process overall is quite cost effective due to reduced machining and cleanup costs.

Limitations:
1234More expensive metal pattern. Difficult to justify for small quantities. Size limits of 30 g to 12 kg (1 to 25 Ib). Minimum thicknesses can be as low as 1.5 mm (0.062 in) to 6.25 mm (0.25 in), depending on the material.