Abstract
Filling characteristics of granular particles into a small die cavity were investigated by experiment using model die filling system and 3D distinct element method (DEM) simulation. The influences of particle properties including flowability and speed of die shoe on filling fraction of granules, which is the ratio of the volume of filling particle to the volume of die cavity, were investigated experimentally, and it is shown that the filling fraction depends on the flow behavior of granular particles and geometry of die cavity. Three dimensional, large scale DEM simulation has been constructed to obtain detailed insights into complicated filling phenomena and apply to design of filling process. The determination method of simulation parameters in DEM model was discussed to get quantitative design parameters of filling operation by the simulation. Simulation results agreed well with experimental ones and DEM simulation can give detailed information of filling behavior of granular particles into small die cavity. Particle size-induced segregation generated in a moving shoe leads to non-uniformity of particle packing structure in the die cavity. There is optimum filling condition to minimize the segregation during die filling.
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