High-Performance Green Sand Mold made by Particle Sand Distribution Controlled using Green Sand Particle Modeling

• Project/Area Number: 16K06816
• Research Category: Grant-in-Aid for Scientific Research (C)
• Allocation Type: Multi-year Fund
• Section: 一般
• Research Field: Metal making/Resorce production engineering
• Research Institution: Daido University
• Principal Investigator: Maeda Yasuhiro 大同大学, 工学部, 教授 (10240813)
• Research Collaborator: Makino Hiroyasu ; Ito Yuuka ; Yoshida Shingo
• Project Period (FY): 2016-04-01 – 2019-03-31
• Project Status: Completed (Fiscal Year 2018)
• Budget Amount: ¥4,940,000 (Direct Cost: ¥3,800,000、Indirect Cost: ¥1,140,000); Fiscal Year 2018: ¥650,000 (Direct Cost: ¥500,000、Indirect Cost: ¥150,000); Fiscal Year 2017: ¥520,000 (Direct Cost: ¥400,000、Indirect Cost: ¥120,000); Fiscal Year 2016: ¥3,770,000 (Direct Cost: ¥2,900,000、Indirect Cost: ¥870,000)
• Keywords: 離散要素法 / スクィーズ造型 / 粒度分布 / 空隙率 / シミュレーション / 粘着力 / 生型砂 / 圧縮機構 / 人工セラミック砂 / 砂層圧縮 / コンパクタビリティ / 個別要素法 / 鋳型強度 / 生砂型

Outline of Final Research Achievements

Sand mols making simulation is useful tool for designing and controlling for the sand molding, so the demand for molding simulation is increasing. In the present study, the squeeze molding simulation are carried out considering the green sand properties. Especially, the characteristics of green sand with particle size distribution and cohesion are modeled. From the simulation with several kinds of sands using proposed model, the identification method from a real particle size distribution to the discrete element is useful for molding simulation using DEM. As a result, it was clear that the relationship between the void fraction and the compacting pressure during squeeze molding was clarified. The influence of the particle size distribution on the compacting behavior of the molding sand layers was also clarified. Further, the three-dimensional visualization of the green sand molding was shown in the present study.

Academic Significance and Societal Importance of the Research Achievements

鋳鉄鋳物で使用される生砂型の造型に対して有用な造型シミュレーションを開発している。特に、粒度分布の重要性を示唆するとともに、粘着力を考慮するモデルを開発している。本研究で開発された解析モデルは、生砂型のみならず、自硬性鋳型、シェル鋳型の主型へ、また中子造型へも展開が容易に推測される。
現在の日本は、高品質な鋳造製品を大量かつ安価に製造する技術で世界の優位に立っているが、今後はコンピュータを活用したモノづくりが求められており、本研究成果は非常に有意義であると考える。

Research Products

• [Journal Article] Effects of Green Sand Particle Distribution on Squeeze Compacting Behavior Analyzed by Discrete Element Method (2018)
  • Author(s): Maeda Yasuhiro、Ito Yuuka、Yoshida Shingo、Makino Hiroyasu
  • Journal Title: International Journal of Metalcasting Volume: Online Issue: 3 Pages: 1-7
  • DOI: 10.1007/s40962-018-0284-6
  • Peer Reviewed
• [Journal Article] Three-Dimensional Modeling of Green Sand and Squeeze Molding Simulation (2018)
  • Author(s): Y. Ito and Y. Maeda
  • Journal Title: Material Science Forum Volume: 925 Pages: 473-480
  • DOI: 10.4028/www.scientific.net/msf.925.473
  • Peer Reviewed
• [Presentation] Effects of Green Sand Particle Size Distribution on Squeeze Compacting Behavior Analyzed by Discrete Element Method (2018)
  • Author(s): Y. Ito, S. Yoshida, Y. Maeda and H. Makino
  • Organizer: The 73rd World Foundry Congress
  • Int'l Joint Research
• [Presentation] 生型砂造型のつき固め機構の解明と湯流れ・凝固に関する鋳造CAE (2018)
  • Author(s): 前田安郭
  • Organizer: 日本鋳造工学会，第172回全国講演大会
• [Presentation] 粒度分布を考慮した離散要素法(DEM)を用いたスクィーズ圧縮シミュレーション (2018)
  • Author(s): 吉田信吾，伊藤由華，前田安郭
  • Organizer: 日本鋳造工学会，第171回全国講演大会
• [Presentation] Three-Dimensional Modeling of Green Sand and Squeeze Molding Simulation (2017)
  • Author(s): Yuuka Ito and Yasuhiro Maeda
  • Organizer: International Symposium on The Science and Processing of Cast Iron SPXI-XI
  • Int'l Joint Research