基于颗粒物质力学的铁粉末压制中摩擦特性对力链演化影响

结合颗粒物质力学理论,通过离散元法实现铁粉末压制过程模拟并通过压制方程进行验证,针对粉末体系中的力链演化问题,提出力链特征定量分析方式,进一步通过分析不同颗粒间摩擦系数、侧壁摩擦系数与颗粒运动状态转变的方式,探讨摩擦特性对力链量化特征的影响,从而建立摩擦行为与力链演化间的联系. 研究结果表明:随颗粒间摩擦系数增大,整体力链数目变少,力链方向系数、承载不均匀度及单位屈曲度均变大,而随侧壁摩擦系数增大,力链特征差异较小,则颗粒间摩擦系数较侧壁摩擦系数对力链特征演化具有更显著影响. 同时发现,颗粒接触状态的改变与力链特征演化间具有对应性. 研究成果将进一步拓展粉末压制中考虑摩擦行为及力链演化过程在内的粉体致密化行为理论.      

Numerical investigation into the influence of the punch shape on the mechanical behavior of pharmaceutical powders during compaction

During the production of pharmaceutical tablets using powder compaction, certain common problems can occur, such as sticking, tearing, cutting, and lamination. In the past, the compressibility of the powder was calculated only along the axis of the device; consequently, critical areas of the material throughout the volume could not be identified. Therefore, finite element method （FEM） can be used to predict these defects in conjunction with the use of an appropriate constitutive model. This article summarizes the current research in the field of powder compaction, describes the Drucker-Prager Cap model calibration procedure and its implementation in FEM, and also examines the mechanical behavior of powder during compaction. In addition, the mechanical behavior of pharmaceutical powders in relation to changes in friction at the wall of the system is examined, and the dependence of lubrication effect on the geometry of the compaction space is also investigated. The influence of friction on the compaction process for the flat-face, fiat-face radius edge, and standard convex tablets is examined while highlighting how the effects of friction change depending on the shape of these tablets.     

A new computational algorithm for contact friction modeling of large plastic deformation in powder compaction processes

In this paper, the large deformation frictional contact of powder forming process is modeled based on a new computational algorithm by imposing the contact constraints and modifying the contact properties of frictional slip. A simple and efficient numerical algorithm is presented for imposing the contact constraints and frictional contact properties based on the node-to-surface contact technique to simulate the large deformation contact problem in the compaction process of powder. The Coulomb friction law is used to simulate the friction between the rigid punch and the workpiece by the use of penalty approach. A double-surface cap plasticity model is employed together with the nonlinear contact friction algorithm within the framework of large FE deformation in order to predict the non-uniform relative density distribution during large deformation of powder die-pressing. Finally, the numerical schemes are examined for accuracy and efficiency in modeling of a set of powder components.     

Prediction of draft forces in cohesionless soil with the Discrete Element Method

The Discrete Element Method (DEM) is applied to predict draft forces of a simple implement in cohesionless granular material. Results are compared with small-scale laboratory tests in which the horizontal force is measured at a straight blade. This study is focused on the case of cohesionless material under quasi-static conditions.The DEM requires the calibration of the local contact parameters between particles to adjust the bulk material properties. The most important bulk property is the angle of internal friction ?. In the DEM, the shear resistance is limited in the case of spherical particles due to excessive particle rotations. This is cured by retaining rotations of the particles. Although this is known to prevent the material from developing shear bands, the model still turns out to be capable of predicting the reaction force on the blade.In contrast to empirical formulas for this kind of application, the DEM model can easily be extended to more complex tool geometries and trajectories. This study helps to find a simple and numerically efficient setup for the numerical model, capable of predicting draft forces correctly and so allowing for large-scale industrial simulations.     

Discrete element modeling of a Mars Exploration Rover wheel in granular material

Three-dimensional discrete element method (DEM) simulations were developed for the Mars Exploration Rover (MER) mission to investigate: (1) rover wheel interactions with martian regolith; and (2) regolith deformation in a geotechnical triaxial strength cell (GTSC). These DEM models were developed to improve interpretations of laboratory and in situ rover data, and can simulate complicated regolith conditions. A DEM simulation was created of a laboratory experiment that involved a MER wheel digging into lunar regolith simulant. Sinkage and torques measured in the experiment were compared with those predicted numerically using simulated particles of increasing shape complexity (spheres, ellipsoids, and poly-ellipsoids). GTSC simulations, using the same model regolith used in the MER simulations, indicate a peak friction angle of approximately 37–38° compared to internal friction angles of 36.5–37.7° determined from the wheel digging experiments. Density of the DEM regolith was 1820 kg/m³ compared to 1660 kg/m³ for the lunar simulant used in the wheel digging experiment indicating that the number of grain contacts and grain contact resistance determined bulk strength in the DEM simulations, not density. An improved correspondence of DEM and actual test regolith densities is needed to simulate the evolution of regolith properties as density changes.     

Modeling particle sedimentation in viscous fluids with a coupled immersed boundary method and discrete element method

Numerical techniques have increasingly been used to model fluid–particle two-phase flows. Coupling the immersed boundary method (IBM) and discrete element method (DEM) is one promising approach for modeling particulate flows. In this study, IBM was coupled with DEM to improve the reliability and accuracy of IBM for determining the positions of particles during the sedimentation process within viscous fluids. The required ratio of the particle diameter to the grid size (D/dx) was determined by comparing the simulation results with the analytical solution and experimental data. A dynamic mesh refinement model was utilised in the IBM model to refine the computational fluid dynamics grid near the particles. In addition, an optimum coupling interval between the IBM and DEM models was determined based on the experimental results of a single particle sedimentation within silicon oil at a Reynolds number of 1.5. The experimental results and the analytical solution were then utilised to validate the IBM–DEM model at Reynolds numbers of 4.1, 11.6, and 31.9. Finally, the validated model was utilised to investigate the sedimentation process for more than one particle by modeling the drafting-kissing-tumbling process and the Boycott phenomenon. Benchmark tests showed that the IBM–DEM technique preserves the advantages of DEM for tracking a group of particles, while the IBM provides a reliable and accurate approach for modeling the particle–fluid interaction.     

Modeling of high-density compaction of granular materials by the Discrete Element Method

Cold compaction of metal powders is now commonly studied at a microscopic scale, to further our understanding of contact mechanics between grains. The Discrete Element Method (DEM) is therefore, a good compromise between calculation time and precision. DEM simulations are in general limited to a relative density of about 0.8, because the existing contact laws do not reproduce all the physical phenomena involved in the densification of granular media. Local contact mechanics can be studied by finite element analyses on meshed distinct elements (MDEM, Meshed Distinct Element Method). However, this method is too time-consuming when in the presence of a large number of grains. In the following work, a new analytical contact law will be formulated with MDEM which will subsequently be used to validate the DEM model. Thus, it will be possible with DEM modeling to reproduce high-density compaction of random packings up to a relative density of about 0.95. By introducing a local relative density parameter in the force–displacement relationship, the incompressibility effects which rule high-density behaviors can be introduced in the modeling of powder compaction.     

Elasticity, fracture and yielding of cold compacted metal powders

The behaviour of powder compacts is modelled by explicitly introducing the possibility of plastic loading, elastic unloading and decohesion at contacts. The study is limited to cold compaction and to perfectly plastic materials for which the analysis of Mesarovic and Johnson (J. Mech. Phys. 48 (2000) 2009) is used. We model the compact behaviour both with an analytical approach based upon a mean field assumption and with the discrete element method (DEM) that allows force equilibrium to be treated in a realistic manner. Using these two approaches, we are able to predict the effective elastic properties of a powder compact at the onset of unloading. The knowledge of the conditions that lead to decohesion at the contact scale is used to model the fracture of the powder compact (green strength). It is shown that, in first approximation, green strength is inversely proportional to the size of the powder particles. The two methods are used to generate failure and yield surfaces for axisymmetric conditions. Both isostatic and close die conditions are studied.     

DEM investigation on the effect of sample preparation on the shear behavior of granular soil

The effect of initial fabric anisotropy produced by sample preparation on the shear behavior of granular soil is investigated by performing discrete element method (DEM) simulations of fourteen biaxial tests in drained conditions. Numerical test specimens are prepared by three means: gravitational deposition, multi-layer compression, and isotropic compression, such that different initial inherent soil fabrics are created. The DEM simulation results show that initial fabric anisotropy exerts a considerable effect on the shear behavior of granular soil, and that the peak stress ratio and peak dilatancy increase with an increase in the fabric index a_n that is estimated from the contact orientations. The stress–dilatancy relationship is found to be independent of the initial fabric anisotropy. The anisotropy related to the contact orientation and contact normal force accounts for the main contribution to the mobilized friction angle. Also, the occurrence of contractive shear response in an initial shearing stage is accompanied by the most intense particle rearrangement and microstructural reorganization, regardless of the sample preparation method. Furthermore, the uniqueness of the critical state line in e–log p′ and q–p′ plots is observed, suggesting that the influence of initial fabric anisotropy is erased at large shear strains.     

煤仓内煤散料流动状态与力学行为影响因素

针对煤仓内煤散料流动问题及其力学行为,采用三维颗粒流模拟程序PFC3D建立了某型号煤仓与某种煤散料的离散元模型,简述了其力学模型与求解步骤,模拟分析了煤仓内煤散料卸料流动状态。通过分析水平向侧压力、颗粒速度场和接触力场,重点讨论了煤仓下部锥体内壁面摩擦系数、锥仓倾角和卸料口径等对煤散料颗粒流动状态和力学行为的影响。结果显示,深仓卸料流动为整体流动与中心流动混合状态,煤仓内壁摩擦系数、锥体倾角和卸料孔开口半径均对煤散料流动和水平侧压力有较大影响。     

基于离散单元法和人工神经网络的近壁颗粒动力学特征研究

颗粒与壁面的相互作用往往对颗粒流动具有显著影响. 为研究颗粒与壁面作用机理, 对滚筒内颗粒流动过程进行离散单元法(DEM)数值模拟. 基于模拟结果统计分析靠近壁面处颗粒的运动特征, 结果表明, 小摩擦系数时颗粒平动和旋转速度均近似满足正态分布, 但由于壁面影响, 摩擦系数增大时颗粒沿滚筒轴向的旋转速度偏离正态分布, 颗粒动力学理论推导壁面边界条件时应考虑速度正态分布的修正及速度脉动的各向异性. 采用人工神经网络(ANN)构建了颗粒无因次旋转温度、滑移速度和平动温度之间的函数模型, 进而可以在常规双流模型壁面边界条件中考虑颗粒旋转的影响. 基于DEM模拟及结果分析可以为壁面边界条件的理论构造和半经验修正提供基础数据和封闭模型.      

Evaluation of link-track performances using DEM

A two-dimensional discrete-element model for the interaction between link-track and soil is presented. The model was developed using commercial PFC2D code. Two different particles, sphere and clump of two spheres, were used to represent the soil. The soil parameters of the model were determined using Hertzian contact theory. Based on the model and soil parameters, simulations of biaxial tests and calculations of the internal angle of friction and cohesion were preformed. The simulation results showed that the internal angle of friction should not exceed the value of 0.65 when using the spherical particles. Based on the clumped particles model, simulations of shear tests with two grouser plates (lengths 100 and 150 mm) were performed under different soil conditions, normal pressures, and cleat heights. A curve fitting of the simulation results was performed using three semi-empirical models from Bekker, Janosi, and Wong for representing the shear stress–displacement relationship. The best fitting was achieved using Wong’s approach. The simulation results of the cleat effects were compared with Bekker’s grouser approach and McKyes’s formulation for soil–blade interaction. In most of the cases, the results of Bekker’s model were the lower bound and McKyes’s model, the upper bound of the DEM simulation results. The properties of the soil model for the DEM were determined using simulation results of shear tests by grouser plate. In the range investigated, the size of the shearing grouser plate is not significant in determining the soil model properties.     

Discrete simulation and micromechanical analysis of two-dimensional saturated granular media

In this study, a novel approach to incorporate the pore water pressure in the discrete element method (DEM) to comprehensively model saturated granular media was developed. A numerical model was constructed based on the DEM by implanting additional routines in the basic DEM code; pore water pressure calculations were used with a two-dimensional (2D) model to simulate the undrained behavior of saturated granular media. This model coupled the interaction of solid particles and the pore fluid in saturated granular media. Finally, several 2D undrained shear tests were simulated. The test results showed that the model could predict the response of the saturated granular soil to shear loading. The effect of initial compaction was investigated. Biaxial tests on dense and loose specimens were conducted, and the effect of the initial density on the change in shear strength and the volume change of the system was investigated. The overall behavior of loose and dense specimens was phenomenologically similar to the real granular material. Constant volume tests were simulated, and the results were compared to those from the coupled model. Induced anisotropy was micromechanically investigated by studying the contact force orientation. The change in anisotropy depended on the modeling scheme. However, the overall responses of the media obtained using the coupled and constant volume methods were similar.     

Discrete simulation and micromechanical analysis of two-dimensional saturated granular media

In this study, a novel approach to incorporate the pore water pressure in the discrete element method （DEM） to comprehensively model saturated granular media was developed. A numerical model was constructed based on the DEM by implanting additional routines in the basic DEM code; pore water pressure calculations were used with a two-dimensional （2D） model to simulate the undrained behavior of satu- rated granular media. This model coupled the interaction of solid particles and the pore fluid in saturated granular media. Finally, several 2D undrained shear tests were simulated. The test results showed that the model could predict the response of the saturated granular soil to shear loading. The effect of initial compaction was investigated. Biaxial tests on dense and loose specimens were conducted, and the effect of the initial density on the change in shear strength and the volume change of the system was inves- tigated. The overall behavior of loose and dense specimens was phenomenologically similar to the real granular material. Constant volume tests were simulated, and the results were compared to those from the coupled model. Induced anisotropy was micromechanically investigated by studying the contact force orientation. The change in anisotropy depended on the modeling scheme. However, the overall responses of the media obtained usinz the couoled and constant volume methods were similar.     

On oblique contact of creeping solids

Oblique indentation of power-law creeping solids by a rigid die is analysed in three dimensions with perfectly plastic behaviour emerging as an asymptotic case. Indenter profiles are prescribed to be axisymmetric for simplicity but not by necessity. Invariance and generality is aimed at, as the problem is governed by only four essential parameters, i.e. the die profile, p, the indentation angle, γ, the power-law exponent, n, and the coefficient of friction, μ. The solution strategy is based on a self-similar transformation resulting in a reduced problem corresponding to flat die indentation of complete contact. The reduced auxiliary problem, being independent of loading, history and time, was solved by a three-dimensional finite element analysis characterized by high accuracy. Subsequently, cumulative superposition was used to resolve the original problem and global and invariant relations between force, depth and contact area were determined. Detailed results are given for the location and shape of the contact region and stick/slip contours as well as for local states of surface stresses and deformation at flat and spherical indenters. Due to the asymmetry prevailing, it was found that in the spherical case, contact contours proved to be oval and shifted, although with normal and tangential forces only weakly coupled. Finite friction as compared to full adhesion proved to have only a minor effect on global relations. The framework laid down may be applied to the contact of structural assemblies subjected especially to elevated temperatures and also to various issues such as compaction of powder aggregates, flattening of rough surfaces and plastic impact.     

Angle of repose in the numerical modeling of ballast particles focusing on particle-dependent specifications: Parametric study

The discrete element method (DEM) is widely used in the realistic simulation of the shapes of particles. Researchers have considered the simplification of particle shapes owing to the high computational cost of such simulation. In this regard, the modeling of calibrated particles is a major challenge owing to the simultaneous effects of particle properties. The angle-of-repose test is a standard test method used to calibrate the bulk behavior of simulated particles. In the present study, the hollow-cylinder (slump) test was modeled for the verification of discrete element simulations. In this regard, a sensitivity analysis was conducted for all effective parameters, namely the static friction, rolling friction, restitution coefficient, sphericity, roundness, particle size distribution, and number of ballast particles. The results indicate that the rolling friction, roundness, number of particles, and size of particles are the most important parameters in the determination of the angle of repose (AOR). For particles in the range of ballast (20–60 mm), the effect of the number of particles on the angle of repose is reduced when the number is greater than 426. Additionally, it is concluded that angular particles can be replaced with sub-angular particles (R ≈ 0.2–0.45) with a higher rolling friction coefficient (μ_r > 0.14).     

Dispersion of particles in wall-bounded particle-laden turbulent flows with high wall permeability

A series of numerical simulations were performed to investigate the distribution and deposition properties of particles in turbulent flows bounded by permeable walls using the Large Eddy Simulation (LES) with a Lagrangian trajectory approach. The wall permeation speeds were taken from 10⁻⁴ to 10⁻² of the bulk velocity. The directions of the permeation speed were the same at both walls, and they were inward on one wall but outward on the other wall to reserve the fluid mass. Particles with Stokes number (respecting viscous time scale) around 0.1, 1 and 10 were released in the fully developed turbulent channel flow. The particle–particle interaction and the retroaction from particles to the fluid were neglected. The fluid-phase turbulence statistical properties and particle's transport characteristics by vortexes were then analyzed in details. If the wall permeation exists, the turbulence intensities will be depressed close to the outward permeable wall but increased near the inward permeable wall. Not influenced by the wall permeation, the suspended particles with St⁺ ∼O(1) tend to accumulate in the less vortical zones away from the wall, while those particles in the flow regions near the outward permeable wall will distribute disregarding of the vorticity. The turbulence structures near the outward permeable wall are found to exert promotional effects on the particle deposition rate, but such effects are different for particles with various Stokes number. A distribution tendency of streamwise streaks for the deposited particles is also found on the wall imposed by the high outward permeation speed and the clustering deposition pattern is more obvious with increasing particle Stokes number.     

Discrete element method simulations of Mars Exploration Rover wheel performance

Mars Exploration Rovers (MERs) experienced mobility problems during traverses. Three-dimensional discrete element method (DEM) simulations of MER wheel mobility tests for wheel slips of i = 0, 0.1, 0.3, 0.5, 0.7, 0.9, and 0.99 were done to examine high wheel slip mobility to improve the ARTEMIS MER traverse planning tool. Simulations of wheel drawbar pull and sinkage MIT data for i ⩽ 0.5 were used to determine DEM particle packing density (0.62) and contact friction (0.8) to represent the simulant used in mobility tests. The DEM simulations are in good agreement with MIT data for i = 0.5 and 0.7, with reasonable but less agreement at lower wheel slip. Three mobility stages include low slip (i < 0.3) controlled by soil strength, intermediate slip (i ∼ 0.3–0.6) controlled by residual soil strength, and high slip (i > 0.6) controlled by residual soil strength and wheel sinkage depth. Equilibrium sinkage occurred for i < 0.9, but continuously increased for i = 0.99. Improved DEM simulation accuracy of low-slip mobility can be achieved using polyhedral particles, rather than tri-sphere particles, to represent soil. The DEM simulations of MER wheel mobility can improve ARTEMIS accuracy.     

Particle behavior in a turbulent pipe flow with a flat bed

Particle behavior in a turbulent flow in a circular pipe with a bed height h = 0.5R is studied at Re_b = 40,000 and for two sizes of particles (5 μm and 50 μm) using large eddy simulation, one-way coupled with a Lagrangian particle tracking technique. Turbulent secondary flows are found within the pipe, with the curved upper wall affecting the secondary flow formation giving rise to a pair of large upper vortices above two smaller vortices close to the pipe floor. The behavior of the two sizes of particle is found to be quite different. The 50 μm particles deposit forming irregular elongated particle streaks close to the pipe floor, particularly at the center of the flow and the pipe corners due to the impact of the secondary flows. The deposition and resuspension rate of the 5 μm particles is high near the center of the floor and at the pipe corners, while values for the 50 μm particles are greatest near the corners. Near the curved upper wall of the pipe, the deposition rate of the 5 μm particles increases in moving from the wall center to the corners, and is greater than that for the larger particles due to the effects of the secondary flow. The maximum resuspension rate of the smaller particles occurs above the pipe corners, with the 50 μm particles showing their highest resuspension rate above and at the corners of the pipe.