The engineering design of shell moulding machine

Roni Kusnowo, and Sophiadi Gunara

Citation: AIP Conference Proceedings 1977, 030025 (2018); doi: 10.1063/1.5042945

View online: https://doi.org/10.1063/1.5042945
View Table of Contents: http://aip.scitation.org/toc/apc/1977/1
Published by the American Institute of Physics
 The Engineering Design of Shell Moulding Machine
Roni Kusnowo1, a) and Sophiadi Gunara1, b)
1
Foundry Engineering Technology Department, Politeknik Manufaktur Negeri Bandung,
Jl. Kanayakan No. 21 Dago, Bandung, Indonesia, 40135

a)
corresponding author: roni@polman-bandung.ac.id
b)
sophiadi@polman-bandung.ac.id

Abstract. Shell mold is one form of sand mold with resin adhesive and thin contours following the pattern shape. The
Department of Metal Casting Engineering, Politeknik Manufaktur Bandung, has been investigating this leather mold as
one of the mold processes that is important to be developed. Nevertheless, the department currently has insufficient facilities
to develop it. The main factor that inhibits the development of this mold process is the shortage of tools and the existing
process. This study aimed to design and make a prototype machine shell molding at laboratory scale. The design of the
machine was done in reference to Design Engineering, which generated design drawings with dimension of 1500 x 1000 x
500 mm.

INTRODUCTION
Shell molding, also known as shell-mould casting, is an expendable mold casting process that uses a resin covered
sand to form the mold [1]. Compared to sand casting, this process has better dimensional accuracy, higher productivity
rate, and lower labor requirements. It is widely used for small to medium parts that require high precision [2].
Moreover, Shell mold casting is a metal casting process similar to sand casting where molten metal is poured into an
expendable mold. In shell mold casting, the mold is a thin-walled shell created from applying a sand-resin mixture
around a pattern. The pattern, a metal piece in the shape of the desired part, is reused to form multiple shell molds. A
reusable pattern allows for higher production rates, while the disposable molds enable complex geometries to be cast.
Shell mold casting requires the use of a metal pattern, oven, sand-resin mixture, dump box, and molten metal. Shell
mold casting allows the use of both ferrous and non-ferrous metals, most commonly using cast iron, carbon steel, alloy
steel, stainless steel, aluminum 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. Fig. 1 shows an example of shell
molding objects in the automotive industry.

Human-Dedicated Sustainable Product and Process Design: Materials, Resources, and Energy
AIP Conf. Proc. 1977, 030025-1–030025-7; https://doi.org/10.1063/1.5042945
Published by AIP Publishing. 978-0-7354-1687-1/$30.00

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 FIGURE 1. Shell Molding.

FIGURE 2. The process of shell molding.

The shell mold casting process (Fig. 2) consists of several steps as follows [3]:
x Pattern creation - A two-piece metal pattern is created in the shape of the desired part, typically from
iron or steel. Other materials are sometimes used, such as aluminum for low volume production or
graphite for casting reactive materials. In mold creation, initially, each pattern half is heated to 175-370°C
(350-700°F) and coated with a lubricant to facilitate the removal. Subsequently, the heated pattern is
clamped to a dump box that contains a mixture of sand and a resin binder. The dump box is inverted,
allowing this sand-resin mixture to coat the pattern. The heated pattern partially cures the mixture, which
now forms a shell around the pattern. Each pattern half and surrounding shell is cured to completion in
an oven and then the shell is ejected from the pattern.

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 x Mold assembly - The two shell halves are joined together and securely clamped to form the complete
shell mold. If any cores are required, they are inserted prior to closing the mold. The shell mold is then
placed into a flask and supported by a backing material.
x Pouring - The mold is securely clamped together while the molten metal is poured from a ladle into the
gating system, to fill the mold cavity.
x Cooling - After the mold has been filled, the molten metal is allowed to cool and solidify into the shape
of the final casting.
x Casting removal - After the molten metal has cooled down, the mold is broken and the casting is
removed. Trimming and cleaning processes are required to remove any excess metal from the feed system
and any sand from the mold.

ENGINEERING DESIGN
The design method is a step-by-step systematic approach in the process of thinking to achieve the desired goal of
realizing the idea or ideas and to build bridges between ideas or between ideas and the product. The process of making
the design requires a lot of consideration in order to obtain the design that suits the needs. There are several stages in
the creation of design that must be considered in order to obtain an appropriate design. According to [4] in Engineering
Design, the design method is conducted in stages as illustrated in Fig. 3.

FIGURE 3. Stages of engineering design.

The engineering design is made to obtain the shell molding machine. The design of the machine includes the
drawing machine, the engine part, the manufacture process, the plan of manufacture and the assembly plan.

Conceptual Design
Conceptual design is the process of collecting data relating to the design to be created [4]. The results of this
process are acquired possibilities of design that is suitable for the needs. Some measures that must be done in the
process of design concepts are:
x The problems definition - The main problem of making this shell molding is the manual making process.
Heating using a heater from below the pattern, hence the heating time is relatively long, and sand sowing
manually leads the thickness of the resulting mold is uneven. During the removal of the mold from the
pattern, the pattern is still attached to the mold.
x Information gathering - To gain information from literature, the internet will be a consideration in the
process of making the prototype engine design.
x Concept generation - Once information and data are obtained, a concept of how to work the machine is
invented as shown in Fig. 4.

FIGURE 4. Concept of the working of the machine.

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 After the structured design concepts are determined, the concept of prototype machine is formulated. Table 1
explains the concept of how this machine works. The heating functions, heating energy, drive pattern system and sand
sowing are the main considerations in this concept.
TABLE 1. Concept of shell molding machine
No Function A B
1 Heating transport system heater box lifted The heater box is shifted
2 Energy heater Heat elements (electric) LPG
3 Pattern drive system Hinge pen Gears
4 Sand sowing system Sandbox in rotation 180 with shaft Sandbox in rotation 180 with stir

From Table 1, the variants of the concept of prototype shell molding machine are presented in Table 2.
TABLE 2. Variants of the concept of prototype machine
Step
Variant
1 2 3 4
Variant I The process using the initial concept
Variant II 1.B 2.A 3.A 4.A
Variant III 1.A 2.A 3.B 4.B

Evaluation Concept
From the developed concept design, it appears a few variants of the working mechanism of the machine that are
subsequently evaluated using weighted evaluation criteria shown in Table 3. Weight of evaluation criteria ranges from
value 1 to 4.
TABLE 3. Evaluation of Concepts Variants
No Engineering parameter I II III
1 Easy in obtaining materials 4 4 2
2 Easy to assemble 4 4 2
3 Easy to operate 1 4 4
4 Easy to maintain 4 4 3
5 Economic factors 4 4 2
TOTAL VALUE 17 20 13

Description: 4= Good, 3= Enough, 2= Less, 1= Bad.

From Table 3, it can be seen that Variant II is a variant selected in the design, and will be followed up on the next
process, following a description of how the machine works according to the selected concept.

Embodiment Design
After the design concept is established, an embodiment is conducted. This design will become a reference for the
process of the machine. This design is made by considering the material, size, shape and so on. Several measures that
must be done in the embodiment process are demonstrated in Fig. 5.

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 FIGURE 5. Product architecture

Some components of the machine are required to build an architectural product as shown in Fig. 6, i.e., frame,
sand box, base pattern, box heater, shaft, wheel, pillow block, shaft lock, bolt M10 and nut M10.

a Frame f Wheel

Sandbox, Pillow
croning g
b block
sand hopper
/RCS

h ShaftLock
c Base Pattern

i Bolt M10
d Box Heater

j Nut M10
e Shaft

FIGURE 6. Machine Parts

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 Configuration Design
The manufacturing process requires cutting machines, drilling machines, welding machines and lathes as presented
in Table 4. The materials are mild steel, ST-60, and aluminium.
TABLE 4. Configuration design
No Part Description Quantity Process Materials
1 Frame 1 set CW MG W QC Steel 40x40
2 Box Heater 1 set CW MG W QC Plate steel
3 Pattern holder 1 set CW MG W QC Plate steel
4 Sand hoper 1 set CW MG W QC Plate steel

Parametric Design
At the time of manufacturing the machine components, the tolerance of size is used to provide an allowable size
deviation limit. In the manufacture of multiple parts, the standard of accuracy of the size to be adhered to and used as
a guideline in working on an object is required so that the components of the machine can be assembled. Tolerance to
be used is a general tolerance, amounting to 0.3.

Detail Design
After the design concept is realized, the design is drawn in detail to facilitate the next process. In Fig. 7, design
drawings with 2D top, bottom and side view and 3D image are presented.

FIGURE 7. Detail of Design.

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 Bill Of Materials
Bill of material (BOM) or list of material requirements is a list of components or materials needed to construct a
complete assembled product. The bill of materials in this product is shown in Table 5.
TABLE 5. Bill of Materials
Engine Part List
No Part Qty/Engine Materials Part Number
Description
1 Frame 1 Steel A-RRM-02
2 Box Heater 1 Mild steel 0.8 mm A-RKP-02
3 Sandbox 1 Mild steel 0.8 mm A-TPP-02
4 Base Pattern 1 Steel A-TPP-03
5 Shaft 1 Steel dia 25 x 600 05
6 Wheel 4 ST-60 06
7 Pillow block 2 Standard 07
8 Lock sandbox 2 Bolt and Nut M10 08
9 Bolt M10 4 Standard 09
10 Nut M10 4 Standard 10

CONCLUSION
Engine design has been created in such a way to follow the engineering design. From the created design, a shell
molding machine is invented with the machine specification as follows:
x Dimensions: 1500 x 1000 x 500 mm
x Pattern size: 320x300x40 mm
x Mechanism: rotate and sheering
x Dimension mould: 400 x 350 x 50 mm

REFERENCES
1. D. E. Paul, J. T. Black, and R. A. Kohser, Materials and Processes in Manufacturing (9th ed.), (Wiley, 2003).
2. R. H. Todd, Robert H., D. K. Allen, and L. Alting, Manufacturing Processes Reference Guide, (Industrial Press
Inc., 1994).
3. M. E. Mechanical Team. Shell mould casting process, (serial online Sep 23, 2015), Available at https://me-
mechanicalengineering.com/shell-mold-casting-process/. Accessed November 10, 2017.
4. G. E. Dieter, and L. C. Schmid, Engineering Design (New York, 2000).

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