Advanced Materials Research Submitted: 2018-04-14

ISSN: 1662-8985, Vol. 1148, pp 204-210 Accepted: 2018-05-03

doi:10.4028/www.scientific.net/AMR.1148.204 Online: 2018-06-22
© 2018 Trans Tech Publications, Switzerland

A Feasibility Report on the Comparsion of the Characteristics of

Manufacturing a Bearing Cover by the Processes of Sand Casting and
Shell Moulding
M.Madhu Vamsi1,a, V.Pradeep Kumar2,b, SK.H. Shariff3,d
1
Asst.Professor, Department of Mechanical Engineering, Avanthi Institute of Engineering and
Technology, Visakhapatnam, Andhra Pradesh, India.
2
Assoc.Professor, Department of Mechanical Engineering, Avanthi Institute of Engineering and
Technology, Visakhapatnam, Andhra Pradesh, India.
3
Assoc.Professor, Department of Mechanical Engineering, Avanthi Institute of Engineering and
Technology, Visakhapatnam, Andhra Pradesh, India.
a
madhus.btech@gmail.com, bpradeepvommi@gmail.com, csharief.iitm@gmail.com

Keywords: Sand casting, Shell moulding, LM9, Hardness, Porosity, Roughness, Mechanical
properties, Micro structure

Abstract. The comparison of different casting process has enabled the foundry engineer on the
selection of the best casting process to obtain product quality and thus eliminate extensive and
costly plant trails. The purpose of this study was to assess how crucial the selection of a casting
process can be and how they can be used to solve casting problems. In the present work, comparison
of sand casting and shell moulding were made to determine optimal casting conditions, in terms of
quality and reliability. For a typical component a bearing cover fineness of sand casting and shell
moulding are considered and studies are made on surface finish, porosity, hardness and micro
structure. Working on the shell moulding machine and making the manually operated machine to
automatically operated machine.
The mechanical properties of typical product of cast aluminum components made by sand
casting and shell moulding are compared. For each type of casting a total of 4 tests are performed.
The different tests such as porosity, hardness, surface finish and the microstructure are done and
compared. Finally, the results are analyzed.

1. Introduction
The application of aluminium alloy casting in many mechanical components, especially for cars and
rail vehicles, has gradually increased in the last years, thanks to the great potential of these materials
as replacements for ferrous alloys. In particular, for those applications in which the necessity of high
mechanical properties is combined with the need of a substantial weight saving, aluminium castings
are extremely interesting solutions.

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 Advanced Materials Research Vol. 1148 205

Table 1.1: LM Alloy Composition

Alloy Composition (Lm 9)
Name %
Copper 0.1 max.
Magnesium 0.2 - 0.6
Silicon 10.0 - 13.0
Iron 0.6 max.
Manganese 0.3-0.7
Nickel 0.1 max.
Zinc 0.1 max.
Lead 0.1 max.
Tin 0.05 max.
Titanium 0.2 max.
Aluminium Remainder
At present, the main demand toward a wide use of aluminium alloys for high performance
products requires the complete understanding of their properties and of the relationship to casting
process and defects, together with micro structural features, in particular porosity and surface
roughness being among the most appreciated aspects.
The present work addresses the comparison of characteristics and micro structure properties
of LM alloy produced by different casting processes, namely sand casting and shell moulding.
Different casting processes are available, sand casting, loast foam, low pressure mould casting,
rheocasting, squeeze casting, high pressure die-casting, shell mould casting, this last one being a
process with the highest productivity, excellent casting finishes and accurate dimensions of castings.

2. Literature Review
Many attempts have been made in the past decade to co-relate micro structure with mechanical
properties Kyuhong Lee [1] this paper deals with Correlation of microstructure with mechanical
properties and fracture toughness of three cast A356 aluminium alloys fabricated by low-pressure-
casting, rheo-casting, and casting– forging Micro fracture observation results showed that eutectic
Si particles were cracked first, but that the aluminium matrix played a role in blocking crack
propagation.
R. Ashiri et al [2] reported on effect of casting process on microstructure and tribological behaviour
of LM13 alloy. In this research effect of casting process on wear behaviour of LM13 alloy was
investigated. First, samples were produced using two casting processes and heat treated. Then wear
behaviour of these samples under dry sliding condition was examined. Results of hardness and
strength tests indicated that squeeze cast specimens exhibited higher mechanical properties H. Mae
et al [3] compares mechanical properties of two types of cast aluminium components made in sand
moulds and cast iron moulds, respectively. For each type of the castings, a total of 12 fracture tests
are performed under a wide range of stress states including 6 tensile tests on notched and unnotched
round bars and 6 biaxial loading tests on butterfly specimens. Using a combined experimental–
numerical approach, the plasticity and fracture properties of the components are Characterized in
terms of the true stress–strain curve and the ductile fracture locus. It is found that the sand-moulding
component is of higher yield resistance and lower ductility than the metal-moulding one.

3. Specimen Preparation & Experimentation

Experiments were carried out with LM alloy for sand casting and shell molding. Different
mechanical tests are conducted on the cast alloy. The different tests conducted are hardness,
porosity, surface roughness and micro structure
206 Advanced Materials and Manufacturing Processes

Fig 3.1: Flow chart for present investigation

Final cast of aluminum bearing cover

Fig 3.2: a) cast part of Sand cast Fig 3.2: b) cast part of Shell cast

4. Results & Discussion

Hardness:
Hardness is a characteristic of a solid material expressing its resistance to permanent deformation.
Some of the scales used for indentation hardness in engineering - Rockwell, Vickers and Brinell.
The scale used here is Vickers and the load applied is 5kg.The hardness value for shell moulding is
more compared to that of sand casting because of the fine grain structure for shell moulding.
Test: - Vickers hardness test
Applied load = 5kg
Hardness number = 1.854L/d2
For Sand casting For Shell moulding
D =0.299 D=0.293
L = 5 kg L = 5 kg
H. V= 1.854*5/0.2992 H.V =1.854*5/0.2932
= 103.6 HV = 107.9 HV
Hardness value for
Sand casting=103.6 HV shell moulding=107.9 HV
Surface roughness test:
Surface roughness of machined alloys under different conditions was evaluated using Ra
(µm) and Rz (µm) parameters with the help of surf tester.
 Advanced Materials Research Vol. 1148 207

Fig 4.1: Experimental setup for surface roughness measurement

Details about surf tester (Mitutoyo SJ-301, Japan)
Table 4.1: Surf tester
Conditions Standard ISO 1999
Profile R
Cut off length 0.8mm
Range Auto
Speed 0.25 mm/s
Ra Average roughness
Rz Maximum peak height
Surface roughness:
Roughness is a measure of the texture of a surface. It is quantified by the vertical deviations of a real
surface from its ideal form. If these deviations are large, the surface is rough. The roughness is
calculated in a cut off length of 0.25mm at 3 different places. Filters are used to remove the
waviness and measure the roughness. Roughness value is less for the shell moulding because of the
fineness of sand used in shell moulding. So, shell moulding can be used in casting where we require
excellent surface finish.
Cut off length =0.25 mm x=5
Filters: - JIS 1994 Gauss
Surface roughness value

Sand casting Ra= 5.17µm Shell moulding Ra= 3.82µm

Porosity:
First the specimens were cut to proper dimensions to accommodate for polishing operation.
Then the specimens were polished with emery papers of grade 80,100,220,280,320 and 400. The
main problem faced while polishing the specimens in disc type polishing machine was the curvature
effect observed at the specimen end surface, also it was difficult to polish the specimen by holding it
directly in hand.
The porosity test is done by using the optical microscope. Samples of the photographs taken from
the optical microscope is shown below
208 Advanced Materials and Manufacturing Processes

Sand casting Shell moulding

Fig 4.2: Measurement of porosity
The porosity for shell moulding is less compared to that of the sand casting because of the thickness
of the mould used. The thickness of the shell mould is small so that the gases can escape easily and
in case of sand casting the thickness of shell mould is very large so the gases cannot escape and gets
entrapped inside
Sand casting Shell moulding
Mean = 6790.92 μm2 Mean = 69336.83 μm2
Width = 714.8 μm Width = 2.877 mm
Height = 530.6 μm Height = 2.136 mm
Resolution = 2080*1544* 24 Resolution = 2080*1544*24
Volume fraction= 1.79% Volume fraction= 1.128
=14.32% =9.0304%
Micro structure:
The micro structure obtained for sand casting and shell moulding is a dendritic structure and the
shell moulding is having relative fine grain structure because of the rapid solidification in shell
moulding

Fig 4.3: Micro structure of

a) Shell moulding b) sand casting
 Advanced Materials Research Vol. 1148 209

Comparison:
Table 4.2: Results
Test sand casting Shell moulding

Hardness 103.6 HV 107.9 HV

Porosity 14.32% 9.03%

Surface roughness 5.17 µm 3.82 µm

References
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properties and fracture toughness of A356 aluminum alloys fabricated by low-pressure-casting,
rheo-casting, and casting–forging processes,Journal of Engineering Fracture Mechanics 75
(2008) 4200–4216
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on microstructure and tribological behavior of LM13 alloy Journal of Alloys and Compounds
(2008)
[3] H. Mae, X. Teng, Y. Bai, T. Wierzbicki Comparison of ductile fracture properties of aluminum
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210 Advanced Materials and Manufacturing Processes