Research on forming mechanism of digitalized frozen sand mold green casting

Purpose This study aims to promote the sustainable green development of the casting industry. Design/methodology/approach This paper presents an innovative frozen sand mold green casting technology that utilizes water as a novel alternative to conventional organic or inorganic binders in the sand mold production process. The sand is solidified through cryogenic treatment and subsequently transformed into complex, high-quality structures utilizing Computer Numerical Control machining or 3D printing methods. Findings In contrast to conventional sand mold manufacturing technology, this method has advantages in environmental conservation and sustainable production practices, especially its ability to minimize the emission of harmful gases and dust to nearly zero throughout the casting process. Additionally, the high thermal conductivity of the frozen sand molds significantly enhances the performance of the castings. Furthermore, by implementing an economic and efficient thermal dissipation circulation, it is possible to directly recycle more than 90% of the casting sand. This approach helps to avoid tedious procedures associated with traditional sand mold recovery methods that rely on physical and chemical techniques. Social implications This technology not only facilitates the green transformation of the contemporary casting industry but also establishes a new technology standard for more sustainable and environmentally friendly production processes. Originality/value This paper presents an innovative frozen sand mold green casting technology that utilizes water as a novel alternative to conventional organic or inorganic binders in the sand mold production process.