<p>Facing the growing demand for green manufacturing in sand mold casting, the forming method with water as a binder for sand mold casting has been introduced. In this work, an integrated manufacturing strategy of freezing-processing-assembling-testing-recycling of frozen sand molds is proposed, the macroscopic freezing behavior of frozen sand molds is investigated, the evolution process of the sand-water interface is revealed, and the formation and fracture mechanism of the interfacial ice-crystal bonding bridges are analyzed. Additionally, an in situ analysis is conducted to characterize the morphology and number of sand-water bonding bridges of the frozen sand molds. This study also investigates the influence of frozen sand mold processing parameters on the normal force and particle velocity of bonding bridges via discrete element method. The chip morphology generated by frozen sand mold processing is characterized by using a high-speed camera. Results show that with the increase of cutting speed, spindle speed, and channel cutting depth, the size of frozen sand mold chip gradually increases and shows agglomerate morphology. To balance the processing efficiency and surface quality, the optimal processing parameters of the frozen sand mold are set as follows: a spindle speed of 8000 r/min, a feed speed of 150 mm/s, and a single-pass cutting depth of 4&#xa0;mm. The surface quality of the sand mold processed with these parameter is excellent. By applying the optimized machining process parameters of the engine block sand mold in a multi-material frozen sand application, results verified that the frozen dimensional accuracy reaches CT8 level, meeting the sand casting process requirements.</p>