The shell moulding process was chosen by Suzy Industries Limited as being the best process to manufacture small casting parts. Using the shell moulding process and Suzy Industries Limited’s unique operational capabilities, it is possible to produce enhanced material specifications compared with other processes such as greensand manufacture. Shell moulding has gained popularity amongst our clients because of following features :
Shell molding uses phenolic resin as the sand binder, so the smooth and hard surfaces of sand molds make the castings have good surface smoothness. Moreover, this process have less sand residue during production, so could reduce some iron casting defects, such as sand inclusion, sand holes and air holes.
Shell molding material is a type of hard mold, so there will be less swell of sand molds, so the dimensional tolerance will be smaller.
Better dimensional accuracy of shell moulding casting technique is very useful for producing high accuracy rough castings and reduces machining cost.
Better dimensional accuracy requires less machining and due to reduced machining obviously the tooling cost is reduced.
Shell moulding casting procedure produces excellent surface finish, better dimensional accuracy, less machining and less rejections and hence short lead time is possible with high productivity.
Since the main work of producing shell is completed by the molding machines, this process could be operated by semi-skilled workers and there is no need to hire expensive special skilled workers.
Less than 5mm wall thickness will be taken as very thin as for sand castings. Only shell molding process could produce these cast products.In addition, hot shell and core molds are made by molding machines, so it could produce the castings with complex structures, especially complex inside structures.
The process of shell moulding casting produces near neat casting part and hence generates very little scrap. Also the generated scrap is recycled.
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