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Numerical Coupling Dem Fem Minecrush 2010 Ragc v2
Numerical Coupling Dem Fem Minecrush 2010 Ragc v2
Authors
Nicolas Spogis, Ph.D.
Business Manager E-mail: nicolas.spogis@esss.com.br
www.esss.cl
www.vale.com
Vctor Sandoval
New Business Manager E-mail: victor.sandoval@esss.cl Tel: +56 (2) 946 -1941 Cel: +56 (9) 9319-1593
ESSS at a Glance
SINCE 1995
15 years providing the most comprehensive simulation solutions to the market.
LOCATIONS
WHAT WE DO
ESSS develops, markets, and supports engineering simulation software to shortening and improve product development cycles in a broad range of industries, by technology transfer or providing simulation services.
Florianpolis Brazil
So Paulo Brazil
Santiago Chile
NEW OFFICES
VALE at a Glance
Vale is the worlds second-largest mining and metal company in market value, with assets of more than US$ 100 billion. Vale is the global leader in the production and export of iron ore. In 2006, Vale became the worlds largest nickel producer after the acquisition of the Canadian company Inco.
Vale is a global company headquartered in Brazil, with a workforce of over 100,000 employees, including outsourced workers.
Agenda
1- Objectives
Objectives
Develop an 1-way coupling between
1- Objectives
vi and i are the translational and angular velocities of particle i, Fc ij and Mij are the contact force and torque acting on particle i by particle j or walls, Fncik is the noncontact force acting on particle i by particle k or other sources, Ff i is the particlefluid interaction force on particle i, Fgi is the gravitational force.
Calculate body forces acting on each particle: gravity, fluid drag, electrostatic, ..
1- Objectives
EDEM-ANSYS Coupling
EDEM was used as Discrete Element Method (DEM) tool and ANSYS was used as Finite Element Method (FEM) tool.
Force
Under development
Displacement
Interpolation Method
Load is transferred from EDEM to ANSYS using a conservative interpolation; Each element face is divided into n number of IP faces, where n is the number of nodes on the face; IP faces are converted onto a two-dimensional polygon; Polygons on the sending side are intersected with the IP polygons on the receiving side; The polygon intersection creates many overlapped areas used to transfer loads between the two sides.
Interpolation Method
During interpolation, the total force balance over the surface is preserved. For loss less data transfer between particle and structural code, both numerical models must be coincident in space
1- Objectives
Validation Tests
It was built a small box with 1x1x1m in EDEM and it was created 2000 particles with 40mm diameter and 2500kg/m3 density; It was performed 3s of simulation to ensure that particles have no velocity in Y direction; Total forces (X, Y and Z) and surface mesh nodes position are exported from EDEM in a single time step. Force on Y direction calculated on EDEM was compared with analytical results.
Validation Tests
Test 1 - ANSYS coarse mesh, EDEM coarse mesh Test 2 - ANSYS intermediate mesh, EDEM coarse mesh Test 3 - ANSYS refined mesh, EDEM coarse mesh
Analytical EDEM force Test 1 - Coarse Test 2 - Intermediate Test 3 - Refined Force Y (N) 1643,8 1645,8 1575,2 1617,6 1663,5 Error % 0,1 4,3 1,7 1,1
Industrial Application
Case Vale Mina de Brucutu
Geometry
Geometry directly imported from CAD on ACIS (.sat) format.
Simulation: Conveyor belt Transfer chute Vibrating screens Dynamics: Sinusoidal translation Sinusoidal rotation Moving plane (for belt)
Material properties
Mass flow: 8492 t/h Conveyor velocity: 3.52 m/s Iron Ore density: 2500kg/m Ore / Ore Interaction:
Coeff. of Restitution: 0.4 Static friction: 0.65 Rolling friction: 0.1
Particle diameter: 25 mm
Particle shape: Single sphere Dynamic repose angle: 20 Static repose angle: 30 Moisture: 8%
EDEM Factory
Conveyor dynamics
Vtotal Vy Vz 3,520 m/s -3,330 m/s 1,141 m/s 3,520 m/s -3,315 m/s 1,184 m/s 3,520 m/s -3,468 m/s 0,605 m/s
Cylinder Radius 0,659 m Perimeter 4,141 m Vtotal 2,816 m/s RPS 0,680 RPM 40,805
Screen dynamics
Hz 16,6 16,6
EDEM Results
EDEM Results
EDEM Results
High impact velocities zones (up to 7 m/s) on screen. Wear and structural problems.
Unbalanced forces
4000,00
2000,00
0,00
0,00 5,00 10,00 15,00 20,00 25,00 30,00
-2000,00
-4000,00
-6000,00
-8000,00
15000,00
10000,00
5000,00
-10000,00
-15000,00
Force Distribution
Total force on screen width
60000 50000 40000
30000
20000 10000 0 1 2 3 4 5 6
EDEM can split the domain into small fraction (Bins) to do local analysis;
Domain was split into 8 regions in Xdirection, in order to investigate unbalanced forces.
Unbalanced forces;
Picks reaches 20 times higher forces between one extreme to another.
The developed scripts and macros automatically interpolates EDEM forces (normal and tangential) on the structural elements.
Total Deformation The Static Analysis performed shows stresses & Strains under the yield limit OK
Equivalent Strain
Modal Analysis
Mode 1 - 3.3647 Hz Mode 2 - 6.874 Hz Mode 3 - 14.121 Hz
Mode 4 - 21.454 Hz
Mode 5 - 25.309 Hz
Mode 6 - 26.261 Hz
FFT Magnitude X
450000 400000 350000 300000
4000.00
3.3984
2000.00
0.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00
250000 200000
150000 100000 50000 0 0 1 2 3 4 5 3.2031
-2000.00
-4000.00
-6000.00
-8000.00
FFT Magnitude Y
800000 700000 3.3984
15000.00
10000.00
600000
500000
3.2031
5000.00
400000 300000
0.00 5.00 10.00 15.00 20.00 25.00 30.00
0.00
200000
100000
-5000.00
3.5938
-10000.00
0 0 1 2 3 4 5
-15000.00
FFT Magnitude Z
5000000 4500000 4000000 3500000 3000000 2500000 2000000 1500000 1000000 500000 0 0 1 2 3 3.203125
3.359375
RESONANCE !!!
1- Objectives
Bulk Handling & Structural Problems?!... Coupled SIMULATION can solve them!
Structural Problems (FEA Simulation) Bulk Handling Problems (DEM Simulation) Coupled Problems
Unbalanced Load
High Ore impact in the equipment Structure Equipment Weight reduction Energy Efficiency
Conclusions
DEM can solve industrial bulk material handling problems.
DEM-FEA coupling can give the right structure for the best particle flow!