A hybrid approach for modeling of breakable granular materials using combined finite-discrete element method

It is well known that particle breakage plays a critical role in the mechanical behavior of granular materials and has been a topic subject to intensive studies. This paper presents a three dimensional fracture model in the context of combined finite-discrete element method (FDEM) to simulate the breakage of irregular shaped granular materials, e.g., sands, gravels, and rockfills. In this method, each particle is discretized into a finite element mesh. The potential fracture paths are represented by pre-inserted non-thickness cohesive interface elements with a progressive damage model. The Mohr–Coulomb model with tension cut-off is employed as the damage initiation criterion to rupture the predominant failure mode at the particle scale. The particle breakage modeling using combined FDEM is validated by the qualitative agreement between the results of simulated single particle crushing tests and those obtained from laboratory tests and prior DEM simulations. A comprehensive numerical triaxial tests are carried out on both the unbreakable and breakable particle assemblies with varied confining pressure and particle crushability. The simulated stress–strain–dilation responses of breakable granular assembly are qualitatively in good agreement with the experimental observations. The effects of particle breakage on the compressibility, shear strength, volumetric response of the fairly dense breakable granular assembly are thoroughly investigated through a variety of mechanism demonstrations and micromechanical analysis. This paper also reports the energy input and dissipation behavior and its relation to the mechanical response.     

Segregation of cohesive granular materials during discharge from a rectangular hopper

Granular materials may readily segregate due to differences in particle properties such as size, shape, and density. Segregation is common in industrial processes involving granular materials and can occur even after a material has been uniformly blended. The specific objective of this work is to investigate via simulation the effect of particle cohesion due to liquid bridging on particle segregation. Specifically, a bi-disperse granular material flowing from a 3-D hopper is simulated using the discrete element method (DEM) for cohesive particles and the extent of discharge segregation is characterized over time. The cohesion between the particles is described by a pendular liquid bridge force model and the strength of the cohesive bond is characterized by the Bond number determined with respect to the smaller particle species. As the Bond number of the system increases, the extent of discharge segregation in the system decreases. A critical value of Bo = 1 is identified as the condition where the primary mechanism of segregation in the cohesionless hopper system, i.e. gravity-induced percolation, is essentially eliminated due to the liquid bridges between particles.     

DEM study of monodisperse granular flow in a pipe

Flow of granular material through a pipe has several industrial applications but maintaining a uniform mass flux is quite challenging. In this work, monodisperse granular flow (non-turbulent and non-dense phase particle transport) through a vertical pipe was simulated using discrete element method (DEM). Effects of different geometric and granular parameters on mass flux of cohesive and non-cohesive solids were analyzed and evaluated. Several important parameters and their effects on mass flux were studied like: L/D ratio, pipe diameter to particle diameter ratio (D/D_p), Poisson ratio, and pipe inclination angle. Furthermore, effects of moisture content and Bond number on mass flux were also investigated. These parameters influenced mass flux except Poisson ratio which showed no significant improvement in mass flux upon increasing the value of this ratio.     

Study on a large-scale discrete element model for fine particles in a fluidized bed

The discrete element method (DEM) is widely used to comprehend complicated phenomena such as gas–solid flows. This is because the DEM enables us to investigate the characteristics of the granular flow at the particle level. The DEM is a Lagrangian approach where each individual particle is calculated based on Newton’s second law of motion. However, it is difficult to use the DEM to model industrial powder processes, where over a billion particles are dealt with, because the calculation cost becomes too expensive when the number of particles is huge. To solve this issue, we have developed a coarse grain model to simulate the non-cohesive particle behavior in large-scale powder systems. The coarse grain particle represents a group of original particles. Accordingly, the coarse grain model makes it possible to perform the simulations by using a smaller number of calculated particles than are physically present. As might be expected, handling of fine particles involving cohesive force is often required in industry. In the present study, we evolved the coarse grain model to simulate these fine particles. Numerical simulations were performed to show the adequacy of this model in a fluidized bed, which is a typical gas–solid flow situation. The results obtained from our model and for the original particle systems were compared in terms of the transient change of the bed height and pressure drop. The new model can simulate the original particle behavior accurately.     

The critical-state yield stress (termination locus) of adhesive powders from a single numerical experiment

Dry granular materials in a split-bottom ring shear cell geometry show wide shear bands under slow, quasi-static, large deformation. This system is studied in the presence of contact adhesion, using the discrete element method (DEM). Several continuum fields like the density, the deformation gradient and the stress tensor are computed locally and are analyzed with the goal to formulate objective constitutive relations for the flow behavior of cohesive powders. From a single simulation only, by applying time- and (local) space-averaging, and focusing on the regions of the system that experienced considerable deformations, the critical-state yield stress (termination locus) can be obtained. It is close to linear, for non-cohesive granular materials, and nonlinear with peculiar pressure dependence, for adhesive powders—due to the nonlinear dependence of the contact adhesion on the confining forces. The contact model is simplified and possibly will need refinements and additional effects in order to resemble realistic powders. However, the promising method of how to obtain a critical-state yield stress from a single numerical test of one material is generally applicable and waits for calibration and validation.     

Mixing assessment of non-cohesive particles in a paddle mixer through experiments and discrete element method (DEM)

In this study the mixing kinetics and flow patterns of non-cohesive, monodisperse, spherical particles in a horizontal paddle blender were investigated using experiments, statistical analysis and discrete element method (DEM). EDEM 2.7 commercial software was used as the DEM solver. The experiment and simulation results were found to be in a good agreement. The calibrated DEM model was then utilized to examine the effects of the impeller rotational speed, vessel fill level and particle loading arrangement on the overall mixing quality quantified by the relative standard deviation (RSD) mixing index. The simulation results revealed as the impeller rotational speed was increased from 10?RPM to 40?RPM, generally a better degree of mixing was reached for all particle loading arrangements and vessel fill levels. As the impeller rotational speed was increased further from 40?RPM to 70?RPM the mixing quality was affected, for a vessel fill level of 60% and irrespective of the particle loading arrangement. Increasing the vessel fill level from 40% to 60% enhanced the mixing performance when impeller rotational speed of 40?RPM and 70?RPM were used. However, the mixing quality was independent of vessel fill level for almost all simulation cases when 10?RPM was applied, regardless of the particle loading arrangement. Furthermore, it was concluded that the particle loading arrangement did not have a considerable effect on the mixing index. ANOVA showed that impeller rotational speed had the strongest influence on the mixing quality, followed by the quadratic effect of impeller rotational speed, and lastly the vessel fill level. The granular temperature data indicated that increasing the impeller rotational speed from 10?RPM to 70?RPM resulted in higher granular temperature values. By evaluating the diffusivity coefficient and Peclet number, it was concluded that the dominant mixing mechanism in the current mixing system was diffusion.     

DEM investigations of failure mode of sands under oedometric loading

It will be practically useful to explore the evolutions of the failure modes of sand grains within a sand specimen subject to compression for the particle breakage research. This paper attempts to deal with this challenge by conducting a discrete element method (DEM) simulation study on oedometric compression of two kinds of sands (spherical and non-spherical particles). In this study, particle morphologies reconstructed by the spherical harmonic (SH) analysis were created using the agglomerate method, and the micro-parameters used to define the contact model and the properties of walls and balls were adopted based on the single particle crushing tests. The effects of particle shape on the crushing behavior of granular materials and on the evolutions of failure modes of sand grains were captured, and the experimental data was used to evaluate the feasibility and reliability of the proposed DEM modelling strategy. The simulation results show that particle shape affects not only the number, type and orientation of cracks but also the evolution of the particle failure modes. The failure mode of chipping is the most common way to crush for both spherical and non-spherical particles. The particles that have less aspect ratio, sphericity and convexity are more likely to experience the failure mode of comminution. These findings shed light on the key role of particle shape in the investigation of the failure mode of sand grains and facilitate a better understanding of grain-scale behavior of granular materials.     

A discrete model for simulating shear strength and deformation behaviour of rockfill material, considering the particle breakage phenomenon

This study focuses on numerical modelling of rockfill material with the discrete element method (DEM). This method was used due to the special features of rockfill material, such as intense particle breakage and high contracting behaviour, which are inherently due to large particle size. Because the DEM models the interaction of separate elements, it is capable of modelling discrete structures of granular materials and particle breakage. The model used in this study uses PFC^2D and considers breakable clumps. To validate the presented model for rockfill material, numerical single crushing tests and triaxial tests on the Purulia dam’s material were simulated. Due to the size-dependant crushing strength being involved in the breakage criterion, and also considering particle confinement, size-dependant and stress level-dependant behaviour was successfully simulated on modelled rockfill material. The variation of the sample’s particle grading from before the biaxial tests and after shear failure occurred was reported. The obtained results demonstrate the accuracy of the adopted model and the model’s capability for considering a rockfill material’s strength, deformation and crushing behaviour.     

混凝土材料与结构破坏过程模拟分析

采用离散单元法对混凝土材料和混凝土结构破坏机理进行分析。在细观尺度上将混凝土材料视为由粗骨料、水泥砂浆及界面过渡区三相组成,建立了混凝土材料的离散元模型;在宏观尺度上将混凝土视为均质材料建立了混凝土结构离散单元模型。计算分析结果表明:细观尺度上的二维离散单元模型可以用来很好地模拟混凝土材料的单轴受力破坏过程,但不能很好地模拟复合受力状态下的混凝土材料的破坏;宏观尺度上的离散单元模型可以很好地模拟钢筋混凝土构件的破坏过程,但模拟结果对单元的形状有较大的依赖性;宏观尺度上的离散单元模型可以很好地模拟结构的倒塌过程,但计算效率有待提高。     

Study of sedimentation of non-cohesive particles via CFD–DEM simulations

The sedimentation process of granular materials exists ubiquitously in nature and many fields which involve the solid–liquid separation. This paper employs the coupled computational fluid dynamics and discrete element method (CFD–DEM) to investigate the sedimentation process of non-cohesive particles, including the hindered settling stage and the deposition stage. Firstly, the coupled CFD–DEM model for sedimentation is validated by the hindered settling velocity at different solid volume concentrations of suspension \(\phi _{0} \), i.e., \(\phi _0 =\) 0.05–0.6. Two typical modes of sedimentation are also presented by the concentration profiles and the equal-concentration lines. Then, the comparisons between mono- and poly-dispersed particle system are detailed. In the sedimentation of the poly-dispersed particle system, the segregation phenomenon is simulated. Furthermore, this segregation effect reduces with the increase of the initial solid concentration of suspension. From the simulations, the contact force between every pair of particles can be obtained, hence we demonstrate the “effective stress principle” from the view of the particle contact force by giving the correspondence between the particle contact force and the “effective stress”, which is a critical concept of soil mechanics. Moreover, the deposition stage can be simulated by CFD–DEM method, therefore the solid concentrations of sediment bed \(\phi _{\mathrm{max}} \) on different conditions are studied. Based on the simulation results of \(\phi _{\mathrm{max}} \) and the theory of sedimentation, this paper also discusses a method to calculate the critical time when sedimentation ends of two typical modes of sedimentation.     

Numerical study on compression processes of cohesive bimodal particles and their packing structure

In this study, the compression characteristics of bimodal cohesive particles were investigated using a discrete element method (DEM) simulation. The compression and packing processes were simulated under different conditions of size ratios of 1–4 and fine particle mixing ratios of 0–0.5. The cohesive force was expressed using the surface energy proposed by the Johnson-Kendall-Roberts (JKR) cohesion model having a surface energy of 0–0.2 J/m². The calculated results demonstrated that even in the case of cohesive particles, an increase in the particle size ratio reduced the void fraction of the powder bed during the packing and compression processes. In addition, it was found that the cohesive force decreased the contact number, especially the coarse-coarse contacts, although it had little impact on the void fraction. Our DEM simulations suggested that it is necessary to evaluate the contact numbers even under similar void fractions, which will be essential in the case of different material mixtures, such as all-solid-state batteries.     

Simulation of cutting processes using mesh-free Lagrangian particle methods

This contribution presents the model of a ‘granular solid’ based on the Discrete Element Method which is used to model cutting processes of cohesive and ductile materials, e.g. aluminum. The model is based on a conventional three-dimensional Discrete Element approach which employs rigid spheres as it is used to model granular media. Including cohesive interactions besides the repulsive interactions of the basic model allows for the particle agglomerate to display cohesive and ductile behavior. Using the thus generated granular solid the failure modes of ductile engineering materials like aluminum can be qualitatively and quantitatively reproduced. This is shown by comparison with experiments of a tensile and a Charpy impact test. To show the applicability of the approach for manufacturing problems an orthogonal cutting process of steel and aluminum is modelled and the cutting forces are compared to experiments. To further enhance the model thermal interactions between particles are included. The thermodynamics during cutting due to dissipative phenomena is evaluated and compared to experiments.     

Modeling progressive delamination of laminated composites by discrete element method

Discrete element method (DEM) was used to model progressive delamination of fiber reinforced composite laminates. The anisotropic composite plies were constructed through a hexagonal packing of particle elements. Contacts between the particles were represented by parallel bonds with the verified normal and shear elastic properties. The ply interface was characterized by a contact softening model with a bilinear elastic behavior which is similar to the cohesive zone model in the continuum mechanics. DCB, ELS and FRMM tests were simulated by the DEM model to assess its capability of modeling mode I, mode II and mix mode fracture of delamination, respectively. Good agreements were observed between the DEM and existing numerical and experimental results of loading curves, which confirmed that the DEM model can be used to simulate initiation and propagation of composite delamination, with more insights into microscopic material behavior, such as damage extension and plastic zone.     

用3D离散元实现Ⅰ/Ⅱ型拉剪混合断裂的模拟

将变形体离散元分别与弥散式旋转裂缝模型和分离式裂缝模型耦合起来,采用上述两种非线性断裂力学模型分析了混凝土、岩石等准脆性材料的Ⅰ/Ⅱ型拉剪混合模式的开裂行为,以实现从连续介质到非连续介质转化的数值模拟。基于变形体离散元方法的界面接触本构关系提出了混凝土Ⅰ/Ⅱ混合型开裂的拉剪分区开裂准则;基于缝面法向开度增大对刚度强度的逐渐折减实现了界面裂缝扩展的模拟。作为数值验证,通过单边切口非对称三点弯梁试验的数值计算与试验结果对比,表明两种断裂力学模型均能够合理预测裂缝的起裂和扩展,在混合形式的荷载条件下,裂缝通常以Ⅰ/Ⅱ型拉剪混合模式起裂,而后以Ⅰ型为控制方式稳定扩展。文末指出,基于离散单元法的分离裂缝模型能够实现系统在外载作用下破坏全过程仿真。     

The investigation of particle flow mechanisms of bulk materials in dustiness testers

ABSTRACT

The generation of dust occurs in many bulk materials handling applications, including during free-fall, material impact on conveyor transfers, or impact with other materials. Dust has potentially serious consequences to the surrounding environment as well as workers and nearby communities. Companies need to identify and quantify the dust being generated so they can find ways to reduce or eliminate this dust generation. Dustiness testers are one method which can be used to quantify dust generation. This paper investigates the experimental material flow and the subsequent discrete element method (DEM) simulation in the rotating drums of two dustiness testers: the European Standard dustiness tester and the Australian Standard dustiness tester. Preliminary comparisons of the rotating drum designs were undertaken using particle/bulk parameters of polyethylene pellets, a granular “non-dusty” material to investigate the flow behavior, to provide a reference base to compare equivalent simulations and subsequent analysis. A calibrated DEM material model for polyethylene pellets was generated via experimental comparison. Investigations of the rotational speed, volume, and initial loading location of product sample have been performed. The motion of particles in the simulated rotating drums has been compared to visual observation from experimental testing.     

Discrete element analysis for shear band modes of granular materials in triaxial tests

The discrete element method (DEM) is adopted to simulate the triaxial tests of granular materials in this study. In the DEM simulations, two different membrane-forming methods are used to generate triaxial samples. One method is to pack the internal particles first, then to generate the enclosed membrane; the other is to generate the internal particles and the enclosed membrane together. A definition of the effective strain, which combines microscopic numerical results with macroscopic expression in three-dimensional space, is presented to describe the macroscopic deformation process of granular materials. With these two membrane generation methods, the effective strain distributions in longitudinal section and transverse section of the triaxial sample are described to investigate the progressive failure and the evolution of the shear bands in granular materials. Two typical shear band failure modes in triaxial tests are observed in the DEM simulations with different membrane-forming methods. One is a single shear band like a scraper bowl, and the other is an axial symmetric shear band like two hoppers stacking as the shape of rotational “X” in triaxial sample. The characteristics of the shear bands during the failure processes are discussed in detail based on the DEM simulations.     

Microstructure effects on transverse cracking in composite laminae by DEM

A particle discrete element method (DEM) was employed to simulate transverse cracking in laminated fiber reinforced composites. The microstructure of the laminates was modeled by a DEM model using different mechanical constitutive laws and materials parameters for different constituents, i.e. fiber, matrix and fiber/matrix interface. Rectangular, hexagonal and random fiber distributions were simulated to study the effect of fiber distribution on the transverse cracking. The initiation and dynamic propagation of transverse cracking and interfacial debonding were all captured by the DEM simulation, which showed similar patterns to those observed from experiments. The effect of fiber volume fraction was also studied for laminae with randomly distributed fibers. It was found that the distribution and volume fraction of fibers affected not only the transverse cracking path, but also the behavior of matrix plastic deformation and fiber/matrix interface yielding in the material.     

Effect of Compressibility and Powder Flow Properties on Tablet Weight Variation

A powder flowmeter has been designed to provide both quantitative and qualitative data relating to powder flowability. Three directly compressible powders, Emdex, Emcompress and magnesium oxide as well as a three component powder mixture was assessed for flowability, angle of repose and particle size. Compressibility indices were determined for all the above materials as well as for the fractions of each which consisted of a particle size below 315 μm. Sieve analysis was performed on the above powders in order to establish groups consisting of cohesive, mildly cohesive and non-cohesive fractions and their respective flow-time profiles were subsequently determined. Scanning electron microscopic analysis was performed to obtain information on the particle size, shape and size distribution. The interrelationships between flow rate, angle of repose, compressibility index and coefficient of tablet weight variation were established using both a single punch and a high-speed rotary tabletting machine.

A three-dimensional plot was constructed to illustrate the influences of flow rate, angle of repose and compressibility index on the coefficient of tablet weight variation. Whilst it was established that particle size has a significant effect on uniformity of flow, the data also indicated that when the compressibility index exceeded a value of about 20% a significant increase in tablet weight variation resulted irrespective of the powder flow rate.     

A new GPU-based DEM simulator for polydispersed granular systems with wide size distribution and its application in the silo discharge

While discrete element method (DEM) has been successfully established in many studies, serious problems have limited its industrial-scale applications. Considerably long runtime is one of the most critical bottlenecks of the DEM simulation applicability. Despite extensive efforts on the parallelization of DEM on the CPU or GPU, DEM runtime on the current generation of computers is so long that further improvements are demanded. Moreover, while many real-world granular systems consist of polydispersed particles with a relatively wide size distribution, the majority of DEM simulation studies have assumed monodispersed particle assemblies. Few have studied the parallelization of polydispersed systems, and fewer have developed GPU-based codes for these systems. The main purpose of this study is to provide a novel solver, NP-DEM, which is optimized for GPU-based simulation of polydispersed particle systems with a wide size distribution. Silo discharge is chosen as the case study to examine the applicability of the code.