Abstract
To produce high quality green sand mold, it is necessary to know how green sand particles move during the molding process. A three-dimensional simulation model for green sand molding analysis was developed using a typical discontinuous model, Distinct Element Method. This model is combined with a new algorithm taking the characteristics of bonded sand and particle size distribution into consideration in the simulation. The model was applied to squeeze process simulation using several kinds of green sand. Laboratory experiments were carried out to test the validity of the model. The effect of particle size distribution on sand compaction behavior was clarified from both the experiment and simulation. The mold properties obtained by the simulation more or less agreed with those by experiments. The present study provides new and useful information on the compaction behavior in green sand molding processes.
