Shell casting,steps involved in shell casting and Apllications by polayya chintada

Shell casting,steps involved in shell casting and Apllications by polayya chintada

1. P roduction Technology: shell casting COURSE CODE: C211 REGULATION: R19 2 nd BTECH 2 nd 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. Y ours : POLAYYA CHINTADA M.TECH,M.B.A,(PhD) ASSISTANT PROFESSOR