樹脂殻型鋳造
樹脂殻型は精密砂型鋳造の一種であり、モールドと鋳造品の表面仕上げと寸法精度を向上させる。様々な合金に適用可能であり、精密投資鋳造よりもコストが
低い。ゾルコーン砂を使用することで耐火性と精度がさらに向上することができる。製造プロセスは以下の通りです:
Resin Shell Molding Materials
Shell molding is used for both ferrous and non-ferrous metals. The most commonly used materials include cast iron, carbon steel, alloy steel, stainless steel alloys, copper alloys, and more. Typical part sizes produced using this process are medium to small, requiring high precision, such as gearbox housings, cylinder heads, connecting rods, and lever arms.
Resin Shell Molding Process
Mold Preparation
First, metal molds are prepared based on the shape and size of the part. These molds have the opposite shape of the final part and can accommodate the expanding material.
Shell Mold Preparation
A special silicate or siloxane-type resin is applied to the surface of the metal mold to form the shell mold. This resin is a high-temperature, melt-resistant material capable of withstanding the high temperatures and pressures during metal melting.
Shell Mold Baking
The prepared shell mold is baked to ensure it fully cures and to remove any remaining moisture. The baking temperature and time may vary depending on the resin material used.
Casting Operation
The de-waxed shell mold is placed in casting equipment and heated again to ensure the shell mold reaches the appropriate temperature range. Then, molten metal is poured into the shell mold, filling the entire cavity. After the metal cools, the desired parts are formed.
Shell Mold Breakage
After the metal has cooled and solidified, the shell mold becomes fragile. Special mechanical equipment or vibrating devices are used to break the shell mold to separate the cast metal components, which need further cleaning and processing. This may involve removing residual shell mold material, grinding or trimming surfaces, performing heat treatment, or other post-processing operations to achieve the final part shape and performance.