Dynamic coupling of fluid and structural mechanics for simulating particle motion and interaction in high speed compressible gas particle laden flow

In this work, structural finite element analyses of particles moving and interacting within high speed compressible flow are directly coupled to computational fluid dynamics and heat transfer analyses to provide more detailed and improved simulations of particle laden flow under these operating conditions. For a given solid material model, stresses and displacements throughout the solid body are determined with the particle–particle contact following an element to element local spring force model and local fluid induced forces directly calculated from the finite volume flow solution. Plasticity and particle deformation common in such a flow regime can be incorporated in a more rigorous manner than typical discrete element models where structural conditions are not directly modeled. Using the developed techniques, simulations of normal collisions between two 1 mm radius particles with initial particle velocities of 50–150 m/s are conducted with different levels of pressure driven gas flow moving normal to the initial particle motion for elastic and elastic–plastic with strain hardening based solid material models. In this manner, the relationships between the collision velocity, the material behavior models, and the fluid flow and the particle motion and deformation can be investigated. The elastic–plastic material behavior results in post collision velocities 16–50% of their pre-collision values while the elastic-based particle collisions nearly regained their initial velocity upon rebound. The elastic–plastic material models produce contact forces less than half of those for elastic collisions, longer contact times, and greater particle deformation. Fluid flow forces affect the particle motion even at high collision speeds regardless of the solid material behavior model. With the elastic models, the collision force varied little with the strength of the gas flow driver. For the elastic–plastic models, the larger particle deformation and the resulting increasingly asymmetric loading lead to growing differences in the collision force magnitudes and directions as the gas flow strength increased. The coupled finite volume flow and finite element structural analyses provide a capability to capture the interdependencies between the interaction of the particles, the particle deformation, the fluid flow and the particle motion.     

基于超二次曲面的非球形离散单元模型研究

通过对颗粒体系接触过程的运动学和动力学分析,建立了一种基于超二次曲面的非球形离散单元模型,该模型避免了球形接触模型描述颗粒形状的局限性,使离散单元法更接近物理事实,并在此基础上提出了计算求解模型的数值方法,实现了对复杂形状的颗粒体系的模拟计算。将所建立的数值计算方法进行了编程实现,并对模型和算法进行了算例测试,证实了本文所建立的非球形离散单元模型的可行性和正确性。测试结果表明,本文的模型能够比较准确地模拟复杂颗粒体系的真实运动,可为复杂颗粒体系的模拟研究提供一种新的数值计算方法。     

The elastic response of a cohesive aggregate—a discrete element model with coupled particle interaction

A model is presented for the deformation of a cohesive aggregate of elastic particles that incorporates two important effects of large-sized inter-particle junctions. A finite element model is used to derive a particle response rule, for both normal and tangential relative deformations between pairs of particles. This model agrees with the Hertzian contact theory for small junctions, and is valid for junctions as large as half the nominal particle size. Further, the aggregate model uses elastic superposition to account for the coupled force–displacement response due to the simultaneous displacement of all of the neighbors of each particle in the aggregate. A particle stiffness matrix is developed, relating the forces at each junction to the three displacement degrees of freedom at all of the neighboring-particle junctions. The particle response satisfies force and moment equilibrium, so that the model is properly posed to allow for rigid rotation of the particle without introducing rotational degrees of freedom. A computer-simulated sintering algorithm is used to generate a random particle packing, and the stiffness matrix is derived for each particle. The effective elastic response is then estimated using a mean field or affine displacement calculation, and is also found exactly by a discrete element model, solving for the equilibrium response of the aggregate to uniform-strain boundary conditions. Both the estimate and the exact solution compare favorably with experimental data for the bulk modulus of sintered alumina, whereas Hertzian contact-based models underestimate the modulus significantly. Poisson's ratio is, however, accurately determined only by the full equilibrium discrete element solution, and shown to depend significantly on whether or not rigid particle rotation is permitted in the model. Moreover, this discrete element model is sufficiently robust, so it can be applied to problems involving non-homogeneous deformations in such cohesive aggregates.     

THE COMPACTION OF TIME-DEPENDENT VISCOUS GRANULAR MATERIALS CONSIDERING INERTIAL FORCES

In the present paper, compactions of time-dependent viscous granular materials are simulated step by step using the automatic adaptive mesh generation schemes. Inertial forces of the viscous incompressible aggregates are taken into account. The corresponding conservation equations, the weighted-integral formulations, and penalty finite element model are investigated. The fully discrete finite element equations for the simulation are derived. Polygonal particles of aggregates are simplified as mixed three-node and four-node elements. The automatic adaptive mesh generation schemes include contact detection algorithms, and mesh upgrade schemes. Solutions of the numerical simulation are in good agreement with some results from literatures. With minor modification, the proposed numerical model can be applied in several industries, including the pharmaceutical, ceramic, food, and household product manufacturing.     

凹形多面体离散单元的水平集函数接触算法

多面体模型理论上可构造任意颗粒形态,然而受单元接触算法的限制,仅用于凸形颗粒材料的离散元模拟。对于具有凹形特征的多面体单元,单个接触点的搜索算法难以精确计算单元间的作用力。考虑多面体单元间存在单个或多个接触点的计算特性,本文发展了适用于凸形和凹形多面体颗粒材料的水平集函数接触算法。该方法通过点-三角形单元距离计算方法和奇-偶数判定方法建立多面体单元的零水平集函数和空间水平集函数,并对水平集函数进行三线性插值,可得到多面体单元间的单个或多个接触点。为检验水平集函数接触算法的可靠性,对球形和凹形多面体颗粒材料的堆积和倒塌过程进行离散元模拟,并分析颗粒形状对堆积密度和休止角的影响规律。     

Numerical simulation of polygonal particles moving in incompressible viscous fluids

A two-dimensional coupled lattice Boltzmann immersed boundary discrete element method is introduced for the simulation of polygonal particles moving in incompressible viscous fluids. A collision model of polygonal particles is used in the discrete element method. Instead of a collision model of circular particles, the collision model used in our method can deal with particles of more complex shape and efficiently simulate the effects of shape on particle–particle and particle–wall interactions. For two particles falling under gravity, because of the edges and corners, different collision patterns for circular and polygonal particles are found in our simulations. The complex vortexes generated near the corners of polygonal particles affect the flow field and lead to a difference in particle motions between circular and polygonal particles. For multiple particles falling under gravity, the polygonal particles easily become stuck owing to their corners and edges, while circular particles slip along contact areas. The present method provides an efficient approach for understanding the effects of particle shape on the dynamics of non-circular particles in fluids.     

Revisiting rolling and sliding in two-dimensional discrete element models

It has long been recognized that the rotation of single particles plays a very important role in simulations of granular flow using the discrete element method (DEM). Many researchers have also pointed out that the effect of rolling resistance at the contact points should be taken into account in DEM simulations. However, even for the simplest case involving two-dimensional circular particles, there is no agreement on the best way to define rolling and sliding, and different definitions and calculations of rolling and sliding have been proposed. It has even been suggested that a unique rolling and sliding definition is not possible. In this paper we assess results from previous studies on rolling and sliding in discrete element models and find that some researchers have overlooked the effect of particles of different sizes. After considering the particle radius in the derivation of rolling velocity, all results reach the same outcome: a unique solution. We also present a clear and simple derivation and validate our result using cases of rolling. Such a decomposition of relative motion is objective, or independent of the reference frame in which the relative motion is measured.     

基于离散元法的干湿颗粒系统仿真

介绍了基于离散元法的干湿颗粒系统仿真软件DEMSIM。对于干颗粒系统,DEMSIM可以分析二维和三维颗粒系统的弹性和塑性接触碰撞过程;对于湿颗粒系统,DEMSIM采用传统的液桥模型;对于颗粒-流体系统,DEMSIM采用CFD-DEM细观耦合模型模拟。一系列典型算例的模拟分析,验证了干湿颗粒系统仿真软件DEMSIM的精度和有效性。     

考虑等效曲率的超二次曲面单元非线性接触模型

基于连续函数包络的超二次曲面单元可有效地描述自然界和工业生产中的非球体颗粒形态, 并通过非线性迭代方法精确计算单元间的接触力. 对于具有复杂几何形态的超二次曲面单元, 线性接触模型不能准确地计算不同接触模式下的作用力. 考虑超二次曲面单元相互作用时不同颗粒形状及表面曲率的影响, 本文发展了相应的非线性黏弹性接触模型. 该模型将不同接触模式下的法向刚度和黏滞力统一表述为单元间局部接触点处等效曲率半径的函数; 切向接触作用则借鉴基于Mohr-Coulomb摩擦定律的球体单元非线性接触模型的计算方法. 为检验超二次曲面单元接触模型的可靠性, 对球形颗粒间的法向碰撞、椭球体颗粒间的斜冲击过程、圆柱体的静态堆积和椭球体的动态卸料过程进行离散元模拟, 并与有限元数值结果及试验结果进行对比验证. 计算表明, 考虑接触点处等效曲率半径的超二次曲面非线性接触模型可准确地计算单元间的接触碰撞作用, 并合理地反映非球形颗粒体系的运动规律. 在此基础上进一步分析了不同长宽比和表面尖锐度对卸料过程中颗粒流动特性的影响, 为非球形颗粒材料的流动特性分析提供了一种有效的离散元方法.      

Comparison of roller-spreading and blade-spreading processes in powder-bed additive manufacturing by DEM simulations

The roller-spreading and blade-spreading are main powder spreading methods in powder-bed additive manufacturing. The discrete element method was introduced to simulate nylon powder spreading by both roller and blade spreaders. The two spreading processes were compared from several aspects including particle flow behavior, particle contact forces, forces exerted on spreaders, particle segregation and powder layer density. It is found that powder spreading methods mainly affect the movement trajectory of particles, particle contact forces and forces exerted on spreaders. Complicated dispersion and circulation movement of particles occur inside the powder pile by roller-spreading, while particles have relatively weak dispersion by the blade-spreading. The normal force applied to the roller introduces a compacting effect on the powder pile and creates strong force chains that distribute uniformly in the powder pile. Therefore, the powder bed with higher density can be obtained by roller-spreading in thicker powder layer due to the compacting effect. The blade spreader sustains tangential force mainly, so the blade-spreading process limits its application to thicker powder layer. As the powder layer thickness increases, the roller-spreading is more sensitive to segregation index than that of the blade-spreading. The comprehensive comparison of two spreading processes provides criteria for selecting spreading methods.     

Superquadric DEM-SPH coupling method for interaction between non-spherical granular materials and fluids

The research on the coupling method of non-spherical granular materials and fluids aims to predict the particle–fluid interaction in this study. A coupling method based on superquadric elements is developed to describe the interaction between non-spherical solid particles and fluids. The discrete element method (DEM) and the smoothed particle hydrodynamics (SPH) are adopted to simulate granular materials and fluids. The repulsive force model is adopted to calculate the coupling force and then a contact detection method is established for the interaction between the superquadric element and the fluid particle. The contact detection method captures the shape of superquadric element and calculates the distance from the fluid particle to the surface of superquadric element. Simulation cases focusing on the coupling force model, energy transfer, and large-scale calculations have been implemented to verify the validity of the proposed coupling method. The coupling force model accurately represents the water entry process of a spherical solid particle, and reasonably reflects the difference of solid particles with different shapes. In the water entry process of multiple solid particles, the total energy of the water entry process of multiple solid particles tends to be stable. The collapse process of the partially submerged granular column is simulated and analyzed under different parameters. Therefore, this coupling method is suitable to simulate fluid–particle systems containing solid particles with multiple shapes.     

基于非线性梁理论的有限质点法

有限质点法是以向量式力学为基础,用有限数量的质点来模拟结构的变形行为,质点的运动由牛顿运动定律来计算。在有限质点法中,质点通过构件相连,构件约束着质点的运动,并且其内力由质点的运动变量来描述。基于向量式力学的基本思想和非线性梁理论,提出了一种新的有限质点法,该方法在共旋单元坐标系中描述梁的非线性变形。以空间梁系结构为例,推导了计算构件内力的非线性公式,并考虑了弯扭耦合变形。通过两个连续欧拉角的变换公式得到共旋坐标系的旋转矩阵。与传统的有限质点法相比,本文提出的方法避免了刚体虚转动分析。通过四个结构的数值求解,验证了本文方法在计算结构大变形响应时具有较高的精度。     

基于扩展多面体的离散单元法及其作用于圆桩的冰载荷计算

对于具有复杂几何形态的多面体单元,线性接触模型不能准确地计算不同接触模式下的作用力,且接触变形和作用力方向也不易判断.基于闵可夫斯基和(Minkowski sum)方法的扩展多面体单元能够准确描述非规则颗粒单元的几何形态,并可精确计算单元间的接触碰撞作用.该方法具有接触判断简单、计算效率高的特点.它将基本多面体和扩展球体相叠加以形成具有光滑棱边和角点的扩展多面体单元.考虑扩展多面体单元相互作用过程中角点、棱边和平面之间的不同接触模式,发展了相应的非线性黏弹性接触模型. 该接触模型将不同接触模型下的法向刚度统一表述为单元接触中接触点处等效曲率半径的函数;黏滞力和切向弹性力接触模型则借鉴球体单元非线性接触模型的处理方法. 为检验扩展多面体的可靠性,对碎冰区冰块对圆桩结构的冰载荷进行了离散元分析. 采用沃洛诺伊(Voronoi)切割算法获得了碎冰的初始随机分布状态,并考虑了海冰在运动过程中的海水浮力和拖曳力.计算表明该扩展多面体单元可描述海冰在海流拖曳下的运动过程以及圆桩结构的动冰力特性.在此基础上进一步分析了冰速和冰块尺寸对圆桩冰力的影响,并确定了冰力在圆桩上的分布规律. 最后,讨论了目前扩展多面体单元在计算冰载荷方面的局限性和改进方法.      

Quasi-real-time simulation of rotating drum using discrete element method with parallel GPU computing

Real-time simulation of industrial equipment is a huge challenge nowadays. The high performance and fine-grained parallel computing provided by graphics processing units (GPUs) bring us closer to our goals. In this article, an industrial-scale rotating drum is simulated using simplified discrete element method (DEM) without consideration of the tangential components of contact force and particle rotation. A single GPU is used first to simulate a small model system with about 8000 particles in real-time, and the simulation is then scaled up to industrial scale using more than 200 GPUs in a 1D domain-decomposition parallelization mode. The overall speed is about 1/11 of the real-time. Optimization of the communication part of the parallel GPU codes can speed up the simulation further, indicating that such real-time simulations have not only methodological but also industrial implications in the near future.     

针对有砟道床动力特性分析的嵌入式离散元-有限元耦合方法

在离散元-有限元耦合方法中,离散元和有限元交界面处的耦合方式对整体有砟道床的力学行为影响显著.采用基于球形单元的镶嵌单元或粘结单元模拟有砟道床时,由于球形单元和有限单元表面的自锁能力较差,使道砟层在列车载荷作用下容易产生侧向滑移,导致数值模型不稳定.此外,在实际铁路道床中,底部道砟均不同程度地嵌入路堤.为此,发展了一种嵌入式离散元-有限元耦合方法,通过设置一层嵌入地基有限元模型中的球形颗粒传递离散元域和有限元域间的力学参数,实现离散元和有限元方法的耦合.数值结果表明,嵌入式离散元-有限元耦合模型能够有效降低有砟道床的侧向位移,数值结果更加稳定,在处理与有砟道床类似的连续介质与散体介质的耦合问题时推荐采用嵌入式耦合算法.     

Discrete and continuum modelling of excavator bucket filling

Two-dimensional discrete and continuum modelling of excavator bucket filling is presented. The discrete element method (DEM) is used for the discrete modelling and the material-point method (MPM) for continuum modelling. MPM is a so-called particle method or meshless finite element method. Standard finite element methods have difficulty in modelling the entire bucket filling process due to large displacements and distortions of the mesh. The use of a meshless method overcomes this problem. DEM and MPM simulations (plane strain) of bucket filling are compared to two-dimensional experimental results. Cohesionless corn grains were used as material and the simulated force acting on the bucket and flow patterns were compared with experimental results. The corn macro (continuum) and micro (DEM) properties were obtained from shear and oedometer tests. As part of the MPM simulations, both the classic (nonpolar) and the Cosserat (polar) continuums were used. Results show that the nonpolar continuum is the most accurate in predicting the bucket force while the polar and DEM methods predict lower forces. The DEM model does not accurately predict the material flow during filling, while the polar and nonpolar methods are more accurate. Different flow zones develop during filling and it is shown that DEM, the polar and the nonpolar methods can accurately predict the position and orientation of these different flow zones.     

DEM analysis of the effect of electrostatic interaction on particle mixing for carrier-based dry powder inhaler formulations

Particle interactions play a significant role in controlling the performance of dry powder inhalers (DPIs), which mainly arise through van der Waals potentials, electrostatic interactions, and capillary forces. Our aim is to investigate the influence of electrostatic charge on the performance of DPIs as a basis for improving the formulation of the particle ingredients. The mixing process of carrier and active pharmaceutical ingredient (API) particles in a vibrating container is investigated using a discrete element method (DEM). The number of API particles attaching to the carrier particle (i.e., contact number) increases with increasing charge and decreases with increasing container size. The contact number decreases with increasing vibrational velocity amplitude and frequency. Moreover, a mechanism governed by the electrostatic force is proposed for the mixing process. This mechanism is different from that previously proposed for the mixing process governed by van der Waals forces, indicating that long-range and short-range adhesive forces can result in different mixing behaviours.     

基于水平集-离散元方法的球谐函数颗粒材料缓冲性能分析

在自然环境与工业领域中,颗粒材料是一种常见的缓冲材料,其中大量形态各异的非球形颗粒表现出复杂的力学特性并应用于不同工程领域。本文采用球谐函数构造不同球面度和表面凹凸特性的非规则颗粒,通过水平集方法计算球谐函数颗粒间的接触点和碰撞力,并对冲击过程中球形和凹形颗粒的缓冲性能进行离散元分析。数值结果表明,颗粒床厚度、冲击速度和颗粒形状显著影响球谐函数颗粒材料的缓冲性能。颗粒床底部的冲击力峰值随着颗粒床厚度和表面凹凸性的增加而降低,同时冲击力峰值随着冲击速度和颗粒球面度的增加而增加。与球形颗粒相比,球谐函数颗粒具有凹凸表面和多接触点特性,这有利于冲击荷载向四周扩展并提高凹形颗粒的缓冲效果。     

Application of DEM modified with enlarged particle model to simulation of bead motion in a bead mill

We applied the discrete element method （DEM） of simulation modified by an enlarged particle model to simulate bead motion in a large bead mill. The stainless-steel bead mill has inner diameter of 102 mm and mill length of 198 mm. The bead diameter and filling ratio were fixed respectively at 0.5 mm and 85%. The agitator rotational speed was changed from 1863 to 3261 rpm. The bead motion was monitored experimentally using a high-speed video camera through a transparent mill body. For the simulation, enlarged particle sizes were set as 3-6 mm in diameter. With the DEM modified by the enlarged particle model, the motion of enlarged particles in a mill was simulated.The velocity data of the simulated enlarged particles were compared with those obtained in the experiment. The simulated velocity of the enlarged particles depends on the virtual frictional coefficient in the DEM model. The optimized value of the virtual frictional coefficient can be determined by considering the accumulated mean value. Results show that the velocity of the enlarged particles simulated increases with an increase in the optimum virtual frictional coefficient, but the simulated velocity agrees well with that determined experimentally by optimizing the virtual frictional coefficient in the simulation. The computing time in the simulation decreases with increased particle size.