Discrete element method study of shear-driven granular segregation in a slowly rotating horizontal drum

Segregation and mixing of granular materials are complex processes and are not fully understood. Motivated by industrial need, we performed a simulation using the discrete element method to study size segregation of a binary mixture of granular particles in a horizontal rotating drum. Particles of two different sizes were poured into the drum until it was 50% full. Shear-driven segregation was induced by rotating the side-plates of the drum in the opposite direction to that of the cylindrical wall. We found that radial segregation diminished in these systems but did not completely vanish. In an ordinary rotating drum, a radial core of smaller particles is formed in the center of the drum, surrounded by larger revolving particles. In our system, however, the smaller particles were found to migrate toward the side-plates. The shear from anti-spinning side-plates reduces the voidage and increases the bulk density. As such, smaller particles in the mixer tend to move to denser regions. We varied the shear by changing the coefficient of friction on the side-plates to study the influence of shear rate on this migration. We also compared the extent of radial segregation with stationary side-plates and with side-plates moving in different angular directions.     

Prediction of segregation characterization based on granular velocity and concentration in rotating drum

In a binary granular system composed of two types of particles with different granule sizes and the same density, particle sorting occurs easily during the flow process. The segregation pattern structure is mainly affected by the granular velocity and granular concentration in the flow layer. This paper reports on the experimental velocity and concentration measurement results for spherical particles in a quasi-two-dimensional rotating drum. The relationship between the granular velocity along the depth direction of the flow layer and granular concentration was established to characterize structures with different degrees of segregation. The corresponding relationships between the granular velocity and concentration and the segregation pattern were further analyzed to improve the theoretical models of segregation (convection–diffusion model and continuous flow model) and provide a reference for granular segregation control in the production process.     

The effect of side walls on particles mixing in rotating drums

In this paper, we study the effects of the presence and shape of side walls and of the overall length of rotating cylindrical drums on the mixing of particles with differing sizes by application of the discrete element method (DEM). By varying the semi-axis of the spheroidally shaped side walls and the length of the overall drum, we observe the formation of circulation patterns near the side walls. Although there is a vast amount of literature studying mixing regimes in rotating drums, little is known about the effect of the side walls of the drum on particle mixing. The results of our study demonstrate that introducing curved side walls induces a strong circulation pattern near these side walls, but has, paradoxically, a negative impact on mixing and actually promotes segregation. The cause for this segregation is the difference in velocity of differently sized particles near the curved side walls. Large particles accumulate at the curved side walls, whereas small particles move away from the curved side walls. When the length of the drum is increased, the overall effect of the side walls is decreased, although it does remain observable, even in very large drums.     

Numerical simulation of tetrahedral particle mixing and motion in rotating drums

A regular tetrahedron is the simplest three-dimensional structure and has the largest non-sphericity. Mixing of tetrahedral particles in a thin drum mixer was studied by the soft-sphere-imbedded pseudo-hard particle model and compared with that of spherical particles. The two particle types were simulated with different rotation speeds and drum filling levels. The Lacey mixing index and Shannon information entropy were used to explore the effects of sphericity on the mixing and motion of particles. Moreover, the probability density functions and mean values and variances of motion velocities, including translational and rotational, were computed to quantify the differences between the motion features of tetrahedra and spheres. We found that the flow regime depended on the particle shape in addition to the rotation speed and filling level of the drum. The mixing of tetrahedral particles was better than that of spherical particles in the rolling and cascading regimes at a high filling level, whereas it may be poorer when the filling level was low. The Shannon information entropy is better than the Lacey mixing index to evaluate mixing because it can reflect the real change of flow regime from the cataracting to the centrifugal regime, whereas the mixing index cannot.     

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.     

Combining X-ray microtomography with computer simulation for analysis of granular and porous materials

The use of X-ray microtomographic (XMT) methods in analysing particulate systems has expanded rapidly in recent years with the availability of affordable desk-top apparatus. This review presents a summary of the major applications in which computer simulations are explicitly coupled with XMT in the area of granular and porous materials. We envisage two main ways of establishing the coupling between both techniques, based on the transference or exchange of information by using physical or geometrical paramet...     

Numerical simulation study on particle breakage behavior of granular materials in confined compression tests

In order to study the fragmentation law, the confined compression experiment of granular assemblies has been conducted to explore the particle breakage characteristic by DEM approach in this work. It is shown that contact and contact force during the loading process gradually transform from anisotropy to isotropy. Meanwhile, two particle failure modes caused by different contact force states are analyzed, which are single-through-crack failure and multi-short-crack failure. Considering the vertical distribution of the number of cracks and the four characteristic stress distributions (the stress related to the maximum contact force, the major principal stress, the deviatoric stress and the mean stress), it is pointed out that the stress based on the maximum contact force and the major principal stress can reflect the distribution of cracks accurately. In addition, the size effect of particle crushing indicates that small size particles are prone to break. The lateral pressure coefficient of four size particles during the loading process is analyzed to explain the reason for the size effect of particle breakage.     

Numerical simulation of fast granular flow facing obstacles on steep terrains

The interaction between fast shallow granular flow and obstacles on steep terrain is an important aspect of granular mechanics and defending against geological hazards. In this study, we used a depth-averaged model for granular flow facing obstacles on steep terrains in a bed-fitted coordinate system where the obstacle system is treated as a local bed deviation term. A second-order Riemann-free scheme is extended to compute the depth-averaged model with a wetting–drying technique, which is verified by several granular flow cases, such as aluminum bar collapse and granular flow runout on a steep slope. Numerical simulations were performed for the case of granular flow facing a (i) single hemispherical obstacle and (ii) system of three hemispherical obstacles to produce a dynamical process and deposit profile, and show good agreement with experimental results. Granular flow facing a single obstacle on a concave plane produces a detached shock wave that moves upstream and a tailing rapid transition zone that moves down, which will merge to form a new shock for deposition. Granular flows facing a three-hemisphere obstacle system produce a tailing rapid transition zone that moves downstream and a downstream wavy shock that results from the interaction of three bow shocks in front of each obstacle. The downstream wavy shock moves upstream and merges with the upstream transition zone to form a new curved shock, which later relaxes to a deposit owing to bed friction. These findings provide some supplemental understandings of flow structures of fast granular flow facing obstacles.     

Simulation of particle flow in a bell-less type charging system of a blast furnace using the discrete element method

A three-dimensional model was established by the discrete element method （DEM） to analyze the flow and segregation of particles in a charging process in detail. The simulation results of the burden falling trajectory obtained by the model were compared with the industrial charging measurements to validate the applicability of the model. The flow behavior of particles from the weighing hopper to the top layer of a blast furnace and the heaping behavior were analyzed using this model. A radial segregation index （RSI） was used to evaluate the extent of the size segregation in the charging process. In addition, the influence of the chute inclination angle on the size segregation and burden profile during the charging process was investigated.     

2D DEM simulation of particle mixing in rotating drum:A parametric study

Mixing behaviors of equal-sized glass beads in a rotating drum were investigated by both DEM simulations and experiments. The experiments indicated that higher rotation speed can significantly enhance mixing. The particle profiles predicted by 2D DEM simulation were compared with the experimental results from a quasi-2D drum, showing inconsistency due to reduction of contacts in the single-layer 2D simulation which makes the driving friction weaker than that in the quasi-2D test, better results could be rea...     

Film flow around a fast rotating roller

In this study, the film thickness around the roller is numerically estimated using the volume of fluid (VOF) method to clarify the film-formation process around the rotating roller. Parametric studies were performed to compare the effects of ink properties (viscosity, surface tension) and operational conditions (roller rotation speed, initial immersed angle) on film thickness. The viscosity of the ink and the speed of rotation of the roller were found to be the dominant factors that determine the ink film thickness. In addition, a correlation equation is proposed to predict the thickness of the ink film around a printing roller rotating at a speed of 20–30 rad/s, as a function of angular position, angular velocity, and viscosity.     

Analysis of local behaviour in granular materials

A local scale, called the meso-scale, has recently been introduced to the multi-scale approach for 2D granular materials. This local scale is defined at the level of meso-domains enclosed by particles in contact. Stress and strain have been defined at this local scale, and their relation with the local structure has been studied. The purpose of this paper is to analyse the behaviour of granular materials at the meso-scale, i.e. the stress–strain–structure relationship at this scale. Analyses are performed on a 2D numerical granular sample subjected to a biaxial compression test and simulated with the Discrete Element Method (DEM). The sample is quite dense and it is loaded at a relatively low strain rate so that the state of the sample can be considered as being quasi-static. The size of sub-domains in the sample varies largely from 3 to 12 particles. It is shown that the evolution of the internal state of the sample corresponds, at the meso-scale, to a clear evolution of the quantity of meso-domains oriented in different directions. In addition, the behaviour of meso-domains is highly governed by their orientation rather than their density, especially for the strongly elongated meso-domains: the meso-domains oriented in the compression (resp. extension) direction behave like a dense (resp. loose) granular material.     

Numerical analysis of the rotating viscous flow approaching a solid sphere

A numerical simulation is performed to investigate the flow induced by a sphere moving along the axis of a rotating cylindrical container filled with the viscous fluid. Three‐dimensional incompressible Navier–Stokes equations are solved using a finite element method. The objective of this study is to examine the feature of waves generated by the Coriolis force at moderate Rossby numbers and that to what extent the Taylor–Proudman theorem is valid for the viscous rotating flow at small Rossby number and large Reynolds number. Calculations have been undertaken at the Rossby numbers (R_o) of 1 and 0.02 and the Reynolds numbers (R_e) of 200 and 500. When R_o=O(1), inertia waves are exhibited in the rotating flow past a sphere. The effects of the Reynolds number and the ratio of the radius of the sphere and that of the rotating cylinder on the flow structure are examined. When R_o ? 1, as predicted by the Taylor–Proudman theorem for inviscid flow, the so‐called ‘Taylor column’ is also generated in the viscous fluid flow after an evolutionary course of vortical flow structures. The initial evolution and final formation of the ‘Taylor column’ are exhibited. According to the present calculation, it has been verified that major theoretical statement about the rotating flow of the inviscid fluid may still approximately predict the rotating flow structure of the viscous fluid in a certain regime of the Reynolds number. Copyright © 2004 John Wiley & Sons, Ltd.     

Numerical investigation of two-phase rotating flow

Finite difference solutions of the two-fluid equations of motion for a particle (droplet)-fluid mixture in a rotating finite axisymmetric cylinder are presented. The numerical method, which can be regarded as an extension of the Harlow & Amsden approach, employs forward time and centred space discretization and treats implicitly the pressure, Coriolis and volume flux terms. The computed flow fields are examined via a detailed comparison to previous analytic approximations, which illuminates both the physical and numerical aspects and the validity of these approximations.     

Numerical analysis of the developing fluid flow in a circular duct rotating steadily about a parallel axis

A numerical analysis of the flow pattern in the inlet region of a circular pipe rotating steadily about an axis parallel to its own is presented. Both finite cell and finite element methods are used to analyse the problem and they give qualitatively similar results which show that a swirling fluid motion is induced in the pipe inlet region. The analyses show that the direction of swirl is opposite to that of the pipe rotation when viewed along the flow axis and that its magnitude depends on the speed of pipe rotation and throughflow Reynolds number. Neither numerical analysis predicts the marked upturn in friction factor (or pressure drop) which has been observed experimentally. However, a dependence on the pipe inlet boundary conditions is demonstrated.     

Extracting inter-particle forces in opaque granular materials: Beyond photoelasticity

This paper presents the first example of inter-particle force inference in real granular materials using an improved version of the methodology known as the Granular Element Method (GEM). GEM combines experimental imaging techniques with equations governing particle behavior to allow force inference in cohesionless materials with grains of arbitrary shape, texture, and opacity. This novel capability serves as a useful tool for experimentally characterizing granular materials, and provides a new means for investigating force networks. In addition to an experimental example, this paper presents a precise mathematical formulation of the inverse problem involving the governing equations and illustrates solution strategies.     

A discrete element model for simulating saturated granular soil

A numerical model is developed to simulate saturated granular soil, based on the discrete element method. Soil particles are represented by Lagrangian discrete elements, and pore fluid, by appropriate discrete elements which represent alternately Lagrangian mass of water and Eulerian volume of space. Macro-scale behavior of the model is verified by simulating undrained biaxial compression tests. Micro-scale behavior is compared to previous literature through pore pressure pattern visualization during shear tests. It is demonstrated that dynamic pore pressure patterns are generated by superposed stress waves. These pore-pressure patterns travel much faster than average drainage rate of the pore fluid and may initiate soil fabric change, ultimately leading to liquefaction in loose sands. Thus, this work demonstrates a tool to roughly link dynamic stress wave patterns to initiation of liquefaction phenomena.     

Fluid flow in a rotating cylindrical container with a rotating disk at the fluid surface

Fluid flow in a rotating cylindrical container of radius R_w and height H with a co-axially rotating disk of radius R_d at the fluid surface is numerically investigated. The container and the disk rotate with angular velocities Ω_w and Ω_d, respectively. We solve the axisymmetric Navier-Stokes equations using a finite-volume method. The effects of the relative directions and magnitudes of the disk and container rotations are studied. The calculations are carried out with various ratios of Ω_w and Ω_d for H/R_w = 2 and R_d/R_w = 0.7. Streamlines and velocity vectors in the meridional plane and azimuthal velocities are obtained. The flow fields in the meridional plane are discussed with relation to azimuthal velocities in the interior of the container. The numerical results are also compared with experimental data.     

Numerical solution to the shearing flow of granular materials between two plates

We study the shearing flow of granular materials between two horizontal flat plates where the top plate is moving with a constant speed. The constitutive relation used for the stress is based on the continuum model proposed by Rajagopal and Massoudi (DOE Report, DOE/PETC/TR-90/3, 1990). The material coefficients such as viscosity and normal stress coefficients are based on the model of Boyle and Massoudi (Int. J. Eng. Sci 28 (1990) 1261). The governing equations are non-dimensionalized and the resulting system of non-linear differential equations is solved numerically using finite difference technique.