scharpf - dem solutions - simulation of particulate solids presentation

8/17/2019 Scharpf - Dem Solutions - Simulation of Particulate Solids Presentation

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Simulation of Particulate Solids HandlingSimulation of Particulate Solids Handlingand Processing Operations Using theand Processing Operations Using the

Dan Scharpf, Ph.D.

DEM Solutions


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OutlineOutline

• Company Profile

• What is the Discrete Element Method?• EDEM Software Overview

•

NAFEMSNAFEMS 2020 2020 Vision of Engineering Analysis and SimulationVision of Engineering Analysis and Simulation

• Summary


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Company ProfileCompany Profile

• Founded in 2003.

• Offices in Edinburgh, UK (HQ); Lebanon, NH, USA;

Frankfurt, Germany and Singapore.

• Provide software and support services for


.

• Developers of EDEMTM software for DEM

simulation and analysis.

• Partnership with leading CAE software vendors toprovide multi-disciplinary solutions with DEM.


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Offices and Channel PartnersOffices and Channel Partners



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OutlineOutline

• Company Profile


•


• Summary


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Discrete Element Method (DEM)Discrete Element Method (DEM)

• Models the interaction of each

discrete object/element or

“particle” with: – Other particles,

– Objects under kinematic control,

–


(fluid, electromagnetic).

• Accounts for particle size, shape

and mechanical properties

• Solves at the particle scale• Computes the dynamics of each

object


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DEM Calculation CycleDEM Calculation Cycle

Track each

Detect contact

between elements

Calculate contact

forces on each particle

Calculate body

forces acting on

Initialise

particles

and surface

geometryelements


surfacegeometry

element

gravity, fluid drag,electrostatic, …

Update particle

acceleration and

velocity

Update particle

and boundary

element positions


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BulkBulk--Scale Information from ParticleScale Information from Particle--

Scale DataScale Data

SegregationMixing dynamics

Bulk

Residence time/

hold-upBridging

Uniformity of flow

Particle kinematics

Particle-particle contact forces

Particle size/mass/temperature

Particle


Heat transfer

Breakage

Loads onmachinery

Mechanical energy

consumption

Mixing profile

Surface coating

Agglomeration

Erosion

Particle-boundary contact forces

New particle formation

EDEM results

Particle body forces: gravitational,

fluid, electro-magnetic

and more….


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Why Industry is Using DEMWhy Industry is Using DEM

Over 70% of industrial processes involve particles BUT

• The majority of particle handling and processingoperations are empirically designed,

Problem


• Measurement and control of particulate sys ems sdifficult and costly.

Causing :o High prototyping and test costs,

o Dependence on rule-of-thumb and operator experience,

o Low rate of design and process innovation.


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• The majority of particle handling and processing

operations are empirically designed,• Measurement and control of particulate systems is

difficult and costly.

Problem


• DEM is the most accurate and computationally

efficient method for modelling particle processes.

• The price-performance of computer hardware now

Solution


aus n :o High prototyping and test costs,



enables cost effective application of DEM by industry.Providing:o Simulation of real-world processes,

o A tool for use in design and optimisation of particle handling

and processing operations,o A means of modelling interactions between particles and

other media (fluids, structures, electromagnetic fields).


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• The majority of particle handling and processingoperations are empirically designed,

• Measurement and control of particulate systems is

difficult and costly.

Problem

• DEM is the most accurate and computationallyefficient method for modelling particle processes.

• The price-performance of computer hardware now

Solution


• Lower prototyping costs,

• -

Benefits


o High prototyping and test costs,



ena es cos e ec ve app ca on o y n us ry.

Providing:o Simulation of real-world processes,

o A tool for use in design and optimisation of particle handling

and processing operations,o A means of modelling interactions between particles and

other media (fluids, structures, electromagnetic fields).

,

• Reduction in rework,

• Better product quality,

• Lower risk of system malfunction,

• Greater return on engineering resources,

• Improved understanding of product design and

process fundamentals.


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Expansion of the CAE MarketExpansion of the CAE Market

CAE

Finite Element Analysis

ComputationalFluid Dynamics

Discrete Element

Method


o tware

Electromagnetics

Multi-BodyDynamics

Noise, Vibration& Harshness

Process Design


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OutlineOutline

• Company Profile


•


• Summary


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WorkflowWorkflow

Pre-processingEDEM Creator

Model particle builder

CAD model geometry import

Various particle generation methods

Contact mechanics

Mechanical coupling: FEA, MBD


Solver EDEM Simulator

Post-processingEDEM Analyst

Change design or

operating conditions

3D video and tracking

Data extraction and export

Graphical analysis

Fluid coupling: CFD, heat &mass transfer

Electromagnetic coupling


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OutlineOutline

• Company Profile


•


• Summary


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Bulk HandlingBulk Handling

• Predict likely material hold-up andblockage relative to material

properties and system design.

• Identif re ions of hi h im act

Simulation Objectives


Bulk transport of cohesiveBulk transport of cohesive

particles through a conveyorparticles through a conveyor

transfer pointtransfer point

loads and surface abrasion.• Minimize spillage.

• Determine conditions causing

particle segregation.


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Construction and MiningConstruction and Mining


Mixing of aggregate rock in aHot Mix Asphalt Drum Mixer

• Visualize material behavior

• Identify modes of poor mixing

• Identify potential size segregation

• Develop design improvements


(Courtesy: Astec, Inc)


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• Explore the effect of paddle

geometry on delivery of coal to

the conveyor



Pickup of coal from a long-wall

miner

• Determine optimum operatingenvelope to avoid blockage and

maximise throughput

• Estimate level of breakage and

dust generation


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Aerospace and Automotive Aerospace and Automotive

• Identify the optimal combination of

peening process parameters to

maximize peening coverage and

surface residual stress at critical

locations on the work-piece


Shot peening increases the surface yield strength of machinecomponents


Shot peening of turbine

blades

• se e s mu a on a a o op m ze

the peening process

Impact energy after one pass

Prediction of the

impact energyimparted to turbine

blades during

nozzle peening


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• Predict rock breakage

• Visualise separate components by

size and type

• Model charge size reduction

• Predict mill power draw



Rock grinding in a tumbling mill

• Estimate rate of liner wear

Lifter wear

over time


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Pharmaceutical ManufacturingPharmaceutical Manufacturing

• Determine the location and

frequency of impact forces on

tablets• Estimate the residence time of

tablets in the region of the spray



Spray coating of tablets in a pancoater

Track of a single tabletshowing its movement

from the internal to the

surface of the bulk


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MultiMulti--Disciplinary SimulationDisciplinary Simulation

EDEM coupled with:CFD, FEM, MBD, Emag

provides a solution for:


Particle-Fluid InteractionParticle-Structure Interaction

Particle-EMAG Interaction


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Drug DeliveryDrug Delivery

Coupled DEM-CFD simulation

Entrainment ofEntrainment of

powder powder from a cavity in afrom a cavity in a

dry powder inhaler dry powder inhaler


• Investigate the effect of cavity and

internal inhaler design on the powder

flow transient

• Correlate particle impacts with

distribution of drug components


0.0E+00

5.0E-06

1.0E-05

1.5E-05

2.0E-05

2.5E-05

3.0E-05

3.5E-05

4.0E-05

0 0.01 0.02 0.03 0.04

M a s s F l o w

R a t e ( k g / s )

Time (s)


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Flow of Deformable ParticlesFlow of Deformable Particles

• Study the break-up of clumps

relative to clump shear strength andfluid flow rate

• Predict blockages relative to size of

opening, fluid pressure and material

Simulation ObjectivesCoupled DEM-CFD simulation


Blockage of an opening

by a deformable clump

proper es


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Excavation Bucket DesignExcavation Bucket Design

• Prediction of bucket structural

response for different geometries

and materials.

Simulation ObjectivesCoupled DEM-FEM simulation

FE surface mesh


Digging cycle of an

excavation bucket

DEM

model

FE model:

von Mises

stress


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Electrographic PrintingElectrographic Printing

• Investigate the effect of carrier and

toner particle interaction

•


Coupled DEM-EMAG simulation


Formation of toner image on

drum

and magnetic fields on pickup anddeposition of toner particle

• Greater understanding of complex

system dynamics

• Explore of the performance of newdesign prototypes


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Pneumatic ConveyingPneumatic Conveying

Conveyance ofcohesive

material in air


• Investigate the effect of clumping

particles on the material flow rate

• Predict pressure drop due to

blockage

• Examine particle cohesion limits

based on performance


Coupled DEM-CFD simulation


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SummarySummary

• Improvements in the traditional empirically-based design of

handling and processing operations are now possible.

• DEM provides a solution for simulating particle systems.• Now being used as a CAE tool by industry.

• A lication areas ex andin due to better software and


lower-cost computer hardware.

www.dem-solutions.com

scharpf - dem solutions - simulation of particulate solids presentation

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