Squeeze molding simulation using the distinct element method considering green sand properties

A three-dimensional simulation model for green sand molding analysis is developed using a typical discontinuous model, the distinct element method (DEM). This model is combined with a new algorithm and the characteristics of bonded sand and the particle size distribution are taken into consideration in the simulation. The model is applied to squeeze process simulation using several kinds of green sand. Laboratory experiments are carried out to test the validity of the model. The effect of the particle size distribution on the sand compacting behavior is clarified by both the experiment and simulation. The mold properties obtained by the simulation almost agree with the experimental ones. The present study provides new and useful information on the compacting behavior in green sand molding processes.