Numerical simulation of the bentonite-bonded sand mould compaction process using micro-mechanical parameter relationships

Abstract

ABSTRACT Commercial software packages for FEM analysis have been used to numerically simulate the behaviour of the complex systems of bentonite-bonded sand mould under pressure and subjected to stress distributions and to predict their performance. The Drucker-Prager model and the Mohr-Coulomb model are two well-known mathematical models used to describe the plastic non-linear behaviour of the soil. Conducting direct shear tests on varying densities of sand can provide the individual parameters necessary for the simulation of the moulding process. A new approach is based on making relationships between micro-mechanical parameters and changes in sand density during the compaction process. COMSOL Multiphysics is a popular software tool used to implement FEM simulations. The steps involved drawing geometry, inserting material properties, mesh generation and time-dependent density, and solving the model. The boundary conditions depend on the particular problem being analysed, which defines the external forces and constraints acting on the structure. The use of a coarse mesh and stationary study may be a computationally efficient approach for the evaluation of the compaction process of green sand. The study found that the maximum displacement value is 6.1*10−3 mm, the maximum volumetric strain value is 8.88*10−5, and the von Mises stress is 4.14*103 N/m2.