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  4. A directional contraction method to model sand-based binder jet 3D printed materials
 
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February 12, 2025
Journal Article
Title

A directional contraction method to model sand-based binder jet 3D printed materials

Abstract
The development of binder-jet sand-based 3D printing allows a quick design of complex parts for foundry molds. To ensure a good quality of casting, the mold must feature some specific mechanical, thermal and transport properties. In that context, a reliable modeling approach for the sand-core material provides a less expensive alternative to extended experimental campaigns. In the present paper, we propose a physics-based microstructure generation approach that is able to capture the experimentally observed anisotropy of the sandbinder composite. The corresponding packing algorithm features a directional contraction of the unit cell that mimics the layer-by-layer deposition of the sand. We also introduce an improved, grid-free approach to add binder between the grains. After the microstructure generation process, we compute the apparent stiffness and permeability on the generated microstructure, and show that these apparent properties are transversely isotropic in the vertical direction. We provide a parametric study on some parameters of interest, such as the volume fraction of binder or the layer thickness. Finally, the results obtained through our modeling approach are compared to experimental results available in the literature. These comparisons show that the anisotropy induced by our microstructure generation approach is similar to the one experimentally observed.
Author(s)
Donval, Elodie
Univ. Duisburg-Essen  
Schneider, Matti
Univ. Duisburg-Essen  
Grimm-Strele, Hannes  
Fraunhofer-Institut für Techno- und Wirtschaftsmathematik ITWM  
Godehardt, Michael  
Fraunhofer-Institut für Techno- und Wirtschaftsmathematik ITWM  
Burger, Raphael
Fraunhofer-Institut für Gießerei-, Composite- und Verarbeitungstechnik IGCV  
Lechner, Philipp
Univ. Augsburg  
Günther, Daniel  
Fraunhofer-Institut für Gießerei-, Composite- und Verarbeitungstechnik IGCV  
Andrä, Heiko  
Fraunhofer-Institut für Techno- und Wirtschaftsmathematik ITWM  
Journal
International Journal of Solids and Structures  
Project(s)
Beyond Representative Volume Elements for Random Heterogeneous Materials  
Multiskalensimulation von Formstoffen für den Einsatz von anorganischen Bindemitteln im Binder-Jetting-3D-Druck  
Funder
European Commission  
Deutsche Forschungsgemeinschaft -DFG-, Bonn  
Open Access
File(s)
Download (4.77 MB)
Rights
CC BY 4.0: Creative Commons Attribution
DOI
10.1016/j.ijsolstr.2025.113260
10.24406/publica-4741
Additional full text version
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Language
English
Fraunhofer-Institut für Gießerei-, Composite- und Verarbeitungstechnik IGCV  
Fraunhofer-Institut für Techno- und Wirtschaftsmathematik ITWM  
Fraunhofer Group
Fraunhofer-Verbund Produktion  
Keyword(s)
  • additive manufacturing

  • binder jetting

  • sand casting

  • computer simulation

  • microstructure <material property>

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