01 — PATTERN & SHELL PREPARATION
Creating the accurate shell mould around the required component pattern.The process begins with preparing and heating the pattern according to the required component geometry. Resin-coated sand is then applied around the heated pattern to form a uniform layer that reproduces the required mould cavity.
The coated sand is allowed to cure and harden against the pattern, creating a rigid shell with the required shape and surface detail. The hardened shell is then removed carefully from the pattern while maintaining its dimensional accuracy.
Process Steps :-
- Pattern Preparation
- Pattern Heating
- Resin-Coated Sand Application
- Shell Curing
02 — SHELL ASSEMBLY & CORE PREPARATION
Preparing the complete mould for metal casting.Where internal passages or cavities are required, suitable cores are prepared according to the component design. These cores are finished and positioned accurately to create the required internal features in the final casting.
The hardened shell mould sections are then aligned and assembled together. Proper assembly ensures that the mould cavity and cores remain correctly positioned before molten metal is introduced.
Process Steps :-
- Core Preparation
- Core Finishing
- Core Placement
- Shell Assembly
03 — Shell Assembly
Filling the prepared shell mould with molten metal.The selected metal is melted in a suitable furnace and brought to the required pouring condition. Temperature and handling are controlled to ensure the molten metal is suitable for filling the shell mould.
The molten metal is then transferred and poured into the assembled shell mould through the designed gating system. The metal fills the cavity and begins to solidify, reproducing the required component geometry.
Process Steps :-
- Metal Melting
- Temperature Control
- Molten Metal Transfer
- Shell Mould Filling
04 — SHELL REMOVAL & FINISHING
Removing the casting from the shell mould and preparing it for inspection.After the metal has solidified and cooled, the hardened shell mould is broken and removed from around the casting. Core material is also removed where required to expose the complete component and its internal features.
The casting then undergoes gate and excess material removal, cleaning and finishing. The finished component is inspected for dimensional accuracy and surface condition before moving to machining or subsequent production stages.
Process Steps :-
- Shell Removal
- Core Removal
- Gate & Riser Removal
- Casting Inspection
