Spreadability of Raw Sand in Binder Jet Additive Manufacturing: Examining Feasibility Using Numerical Methods ...

In binder jet additive manufacturing (BJAM), uniformity and density of the powder layer impact green part quality. This study investigates the printability of unrefined sand using counter- roller spreading. Altair EDEM, a high-performance software powered by the Discrete Element Method (DEM), was used to simulate the BJAM process to evaluate powder bed homogeneity and density under various operating conditions, including roller rotational speed, traverse speed, powder layer thickness, and roller diameter. Utilizing high-performance computing (HPC) and graphics processing unit (GPU) clusters, time-efficient, and more realistic, simulations were performed simulating 300,000 grains. Detailed DEM simulations were executed by reconstructing representative particle shapes using two-dimensional images obtained using particle characterization equipment. The results highlight roller velocity and powder layer thickness as key determinants of sand spreadability. Optimal powder bed density (PBD) was achieved at a roller ...