Contact Parameters Research Articles

Design of nonlinear locking mechanism for shape memory alloy archwire of miniature orthodontic device

The locking mechanism between bracket and shape memory alloy (SMA) archwire in the newly developed domestic orthodontic device is the key to controlling the precise alignment of the teeth. To meet the demand of locking force in clinical treatment, the tightening torque angle of the locking bolt and the required torque magnitude need to be precisely designed. For this purpose, a design study of the locking mechanism is carried out to analyze the correspondence between the tightening torque angle and the locking force and to determine the effective torque value, which involves complex coupling of contact, material and geometric nonlinear characteristics. Firstly, a simulation analysis based on parametric orthogonal experimental design is carried out to determine the SMA hyperelastic material parameters for the experimental data of SMA archwire with three-point bending. Secondly, a two-stage fine finite-element simulation model for bolt tightening and archwire pulling is established, and the nonlinear analysis is converged through the optimization of key contact parameters. Finally, multiple sets of calibration experiments are carried out for three tightening torsion angles. The comparison results between the design analysis and the calibration experiments show that the deviation between the design analysis and the calibration mean value of the locking force in each case is within 10%, and the design analysis method is valid and reliable. The final tightening torque angle for clinical application is determined to be 10° and the rated torque is 2.8 N∙mm. The key data obtained can be used in the design of clinical protocols and subsequent mechanical optimization of novel orthodontic devices, and the research methodology can provide a valuable reference for force analysis of medical devices containing SMA materials.

Innovative centrifugal airflow upgrading for coal gasification fine slag based on experiment and CFD-DEM approach

In this work, an innovative process combining centrifugal airflow upgrading and sieving was proposed to achieve enrichment of residual carbon. The separation mechanism and macroscopic flow behavior in centrifugal air classifier were explained and predicted by constructing a coupled CFD-DEM model considering particle contact parameters. Compared the grinding, dry sieving pre-treatment had a better promotion effect on the enrichment of residual carbon. The general flow pattern was composed of an upward swirling flow and a horizontal rotation flow, facilitating dispersion and secondary elution of carbon. However, the tangential inlet and horizontally mounted rotor cage were the main cause of secondary vortex formation, leading to severe particle entrainment. Increasing inlet gas velocity at appropriate rotor speed was conducive to obtaining higher carbon content and carbon yield. By regulating the inlet gas velocity and rotor speed, higher carbon content and yield could be achieved at particle size fractions of 78–160 μm.

Dynamic contact and stiffness characteristic analysis of angular contact ball bearings under combined external loads

A nonlinear dynamic model of angular contact ball bearing under combined external loads is established based on the nonlinear elastic Hertz contact theory and raceless control theory. The established dynamic model is solved by employing variable step size Newton Raphson iteration method and the validation of model is verified by comparing the proposed results with the corresponding results come from the existing literatures. The solution of the presented model has high accuracy compared with the existing experimental results. In addition, the computational efficiency of the proposed model is improved significantly by introducing iteration step size adjustment factor. According to the proposed model, the dynamic contact and stiffness characteristics of angular contact ball are studied systematically by investigating the effects of combined external load working conditions on the contact parameters including contact angle and contact force and the stiffness parameters including diagonal stiffness and off-diagonal stiffness. This research can provide the theoretical basis and technique guidance for the designation and manufacture of angular contact ball bearing under combined external loads.

Contact parameter calibration for flax threshing materials using machine learning and the Brazil nut effect

Contact parameters between agricultural granular mixtures are crucial for the development and simulation optimization of agricultural machinery but are challenging to measure experimentally. This study utilizes the Brazil nut effect (BNE) to use particle volume concentration as a macroscopic response indicator and to calibrate six contact parameters of flax threshing material. By combining optimized Latin hypercube sampling with vibration segregation simulation tests, the study generates input parameters for training the PSO-BP model, which is optimized using an improved Non-dominated Sorting Genetic Algorithm (NSGA-II). The objective is to minimize the volume concentration error of flax seeds, short stems, and capsule shells between simulation and physical tests, resulting in an optimal Pareto set. Validation through static and dynamic repose angle tests shows errors within 5% (static) and 4% (dynamic), respectively, confirming the reliability of the calibration results and the research method.

Calibration and Validation of Simulation Parameters for Maize Straw Based on Discrete Element Method and Genetic Algorithm-Backpropagation.

There is a significant difference between the simulation effect and the actual effect in the design process of maize straw-breaking equipment due to the lack of accurate simulation model parameters in the breaking and processing of maize straw. This article used a combination of physical experiments, virtual simulation, and machine learning to calibrate the simulation parameters of maize straw. A bimodal-distribution discrete element model of maize straw was established based on the intrinsic and contact parameters measured via physical experiments. The significance analysis of the simulation parameters was conducted via the Plackett-Burman experiment. The Poisson ratio, shear modulus, and normal stiffness of the maize straw significantly impacted the peak compression force of the maize straw and steel plate. The steepest-climb test was carried out for the significance parameter, and the relative error between the peak compression force in the simulation test and the peak compression force in the physical test was used as the evaluation index. It was found that the optimal range intervals for the Poisson ratio, shear modulus, and normal stiffness of the maize straw were 0.32-0.36, 1.24 × 108-1.72 × 108 Pa, and 5.9 × 106-6.7 × 106 N/m3, respectively. Using the experimental data of the central composite design as the dataset, a GA-BP neural network prediction model for the peak compression force of maize straw was established, analyzed, and evaluated. The GA-BP prediction model's accuracy was verified via experiments. It was found that the ideal combination of parameters was a Poisson ratio of 0.357, a shear modulus of 1.511 × 108 Pa, and a normal stiffness of 6.285 × 106 N/m3 for the maize straw. The results provide a basis for analyzing the damage mechanism of maize straw during the grinding process.

Key parameters and effects in image processing and aggregate–aggregate contact calculation of asphalt mixtures

At present, there is no standard way of acquiring images, addressing errors in various image processing steps, and analyzing skeleton contact parameters. To promote the application of image processing technique in the design, construction monitoring, and quality inspection of asphalt mixtures, this study investigates the key factors affecting the two-dimensional image processing accuracy of asphalt mixtures, and the impact of parameters on the contact structure of asphalt mixture skeleton during the contact analysis is studied. Finally, data accuracy requirements for image processing and contact analysis are proposed. The results indicate that the camera lens should be parallel to the slice with a tilt angle of less than 15°, the error of the passing rate of each sieve remains within 5.0 %. The smaller the aggregate particle size, the greater the impact of aggregate edge recognition error on the aggregate particle size, aggregates with a particle size greater than 2.36 mm are less affected by edge recognition error. For aggregate–aggregate contact analysis, it is appropriate to set the contact threshold to 0.23 times the minimum calculated particle size. To ensure the accuracy of image processing and contact analysis, at least 10 cross-sectional images should be prepared, and the average value can be taken as the representative value of the indices. The conclusions can improve the accuracy and reliability of image processing, providing more accurate guidance for the design and construction of asphalt mixture.

A Frequency Domain PID Control Strategy for an In-House Friction and Wear Test Rig

The contact behavior greatly influences the damping performance of frictional interfaces. Numerous experimental studies on friction and fretting wear have investigated the evolution of contact parameters. An in-house friction and wear test rig has been developed to obtain hysteresis loops at certain normal forces. However, the test rig lacks load control and is thus unable to ensure precise stabilization at a preset normal force, which affected the hysteresis behavior. In this paper, we developed a frequency-domain PID controller to ensure the stable application of a target normal force with constant (0–300 N) and harmonic (0–50 N) components. Compared to the commonly used time-domain strategy, the control signal error is reduced from 6.30% to 0.54% at 50 Hz. With a 3% error as the standard, the controller enables stabilized control of signals with frequencies up to 300 Hz. Friction experiments on various typical materials are conducted using this improved test rig. The results indicate a general tendency for contact stiffness to increase with a rising normal force, while the relationship between the friction coefficient and the normal force does not exhibit a clear pattern. The contact stiffness is not sensitive to the relative displacement or vibration frequency.

Incremental Viscoelastic Damage Contact Models for Asphalt Mixture Fracture Assessment

Asphalt mixtures are widely used as a surfacing material for pavements due to their several advantages. For this reason, robust numerical models still need to be developed to improve the understanding of their fracture behaviour. Recently, an incremental generalised Kelvin (GK) contact model that relates increments in contact displacements with increments in contact forces was proposed to assess the viscoelastic behaviour of asphalt mixtures within a discrete element method (DEM) framework. In this work, the contact model is extended to allow its application to asphalt mixture fracture studies. Two damage models—a brittle and a bilinear softening—coupled with the GK contact model are proposed to consider damage initiation and propagation. A parametric study is presented that assesses the impact of the GK-Damage parameters, showing a sensitivity to the loading velocity and the Maxwell elements, particularly its viscosity element, on the stress–strain response of a single contact. A reduced-size numerical mastic is initially used to speed up the calibration process of the GK-Damage contact parameters, with subsequent validation on a specimen with real experimental dimensions. It is shown that the proposed calibrated damage models can successfully reproduce the time-dependent behaviour, peak stress, and crack path observed in experimental results, highlighting the benefits of the adopted methodology. For the GK-Bilinear model, the fracture energy and maximum contact tensile stress are shown to adjust both the peak stress and softening response. Uniaxial tensile tests on asphalt mixtures indicate that the GK-Bilinear model provides a more realistic characterisation of fracture development. A higher susceptibility to damage at aggregate-to-mastic contacts compared to contacts within the mastic phase is identified.

Determination of melon seed physical parameters and calibration of discrete element simulation parameters.

To improve the accuracy of the Hami melon discrete element model, the parameters of the Hami melon seed discrete element model were calibrated by combining practical experiments and simulation tests. The basic physical parameters of Hami melon seeds were obtained through physical experiments, including triaxial size, 100-grain mass, moisture content, density, Poisson's ratio, Young's modulus, shear modulus, angle of repose, suspension speed and various contact parameters. Taking the repose angle of seed simulation as an index, the parameters of each simulation model were significantly screened by the Plackett-Burman test. The results showed that the recovery coefficient, static friction coefficient and rolling friction coefficient of Hami melon seeds had significant effects on repose angle. Based on the steepest climbing test and quadratic regression orthogonal rotation combination test, it was determined that the significant order of the influence of various contact parameters on the angle of repose was static friction coefficient, collision recovery coefficient, and rolling friction coefficient. The optimal parameter combination was obtained through the mathematical regression model between the angle of repose and various contact parameters, namely, the collision recovery coefficient of Hami melon seeds was 0.518, the static friction coefficient of Hami melon seeds was 0.585 and the rolling friction coefficient of Hami melon seeds was 0.337. Under this condition, three static seed-dropping experiments and dynamic rolling accumulation experiments were carried out. The average simulated angle of repose was 31.93°, and the relative error with the actual value was only 1.71%. The average simulated rolling accumulation angle was 51.98°, and the relative error with the actual value was only 1.92%.

Implementation of three-dimensional contact algorithm in numerical manifold method for the structural impact simulation

Structural impact often accompanies large amounts of contacts and leads to complex mechanical phenomena. In solid mechanics, the numerical manifold method (NMM) is proposed to address problems featuring continuous-discontinuous transitions by utilizing a dual coverage system encompassing both mathematical and physical covers. In the present work, a penalty contact algorithm for 3DNMM based on cover-based contact theory is programmed and applied to impact mechanics problems. The accuracy of the developed contact algorithm is firstly calibrated through free-falling blocks and collision blocks. The influence of contact parameters on contact convergence is systematically studied, and three preliminary criteria for how to set contact parameters are provided. The effectiveness of the contact algorithm is verified by conserving system momentum during block collisions. Subsequently, the contact algorithm is applied to Taylor rod and car-streetlight impact simulation, further confirming its effectiveness in modeling high-speed collisions, large displacements, and large deformations of structures. By comparing the 3DNMM results with those from Abaqus, the contact algorithm developed here performs exceptionally well in solving collision problems and produces results consistent with commercial software. The research results in the present work verify the applicability and accuracy of the proposed contact algorithm in solving structural dynamic impact problems. The present work also provides guidance for contact parameter setting in impact problems.

ANALYTICAL STUDY OF DURABILITY AND CONTACT CHARACTERISTICS OF METAL-POLYMER COMPOSITE SLIDING BEARINGS FOR MEANS OF TRANSPORT

The field of application of metal-polymer bearings is vast: transport of various types, processing industry equipment, medical equipment, various types of maintenance equipment, etc. With the use of the developed generalized author's analytical method of metal-polymer plain bearings on the basis of which it is laid the author's research methodology of materials wear kinetics at sliding friction (dry, lubricated), calculation of their durability is carried out. Contact parameters are also determined. Metal-polymer bearings with a bushing made of PA6, PA66 polyamide and PA6 based composites filled with glass (PA6 + 30GF) and carbon (PA6 + 30CF) dispersed fibres, molybdenum disulphide (PA6 + MoS2) and oil filled cast polyamide (PA6 + oil) are considered. These polyamides (unfilled and filled), as self-lubricating materials, are widely used in this type of dry friction sliding bearings. The predictive estimation of durability of investigated bearings depending on loading, polymer materials Young's modulus, their wear resistance and sliding friction coefficient is executed. Regularities of change from the specified factors of bearing's durability and the maximum contact pressures are established. Experimental indicators, diagrams, and wear resistance characteristics of the specified polymeric materials are presented. The results of researches of sliding friction coefficient and modulus of elasticity for carbon steel (0.45%C) – polyamides tribocouples are presented.

Discrete element contact model and parameter calibration of sticky particles and agglomerates

The soil in southwest China is a cohesive soil in which discrete cohesive particles and aggregates coexist. In view of the problem that there are many studies on discrete cohesive particles and a lack of research on aggregates, discrete element software DEM is used to conduct a study on cohesive particles and agglomerates parameter calibration. The angle of repose is selected as the target value to calibrate the simulation parameters of sticky particles. Then, the simulation parameters of the viscous particles are used as the basis for the calibration of the contact parameters of the agglomerates, and shear experiments are conducted on the agglomerates, with the ultimate shear depth and ultimate shear force as target values. The results show that the parameters of the agglomerate are: Normal Stiffness per unit area is 5.627 × 108 N/m3, Shear Stiffness per unit area is 4.359 × 108 N/m3, Critical Normal Stress is 3.5 × 106 Pa, Critical Shear Stress is 4.5 × 106 Pa and Bonded Disk Radius is 5.43 mm. Through the particle sliding friction angle test and the agglomerate compression test, it was verified that the errors of sticky particles were 0.30 % and 0.37 % respectively, and the error of agglomerates was 1.69 %.

From micro to macro: Creep behaviour and closed-form expression of viscoelastic parameters for a rheological particle assembly

This study is devoted to analytically establish macro–micro quantitative relationships for creep characteristics of a rheological particle assembly, contributing to a more comprehensive insight into the interplay between different scales. To represent the various rheological behaviour in microscopic for a hexagonal close-packed (HCP) circular particle assembly, the contact responses are assumed as viscoelastic models. By extending the traditional homogenization method to the Laplace domain, the macroscopic one/two-dimensional creep equations of the rheological particle assembly, expressed with the microscopic contact parameters in a closed-form manner, are innovatively identified. It is found that the macroscopic creep behaviour is not always consistent with the microscopic one and in general exhibits more complex creep characteristics. The parametric analysis presents the quantitative influence of contact parameters on macroscopic creep behaviour. Extending the one-dimensional case to three dimensions (3D), the relaxation moduli as well as creep compliance, expressed in closed-form by contact parameters, are obtained in 3D viscoelastic constitutive equations. Distinct viscoelastic behaviours are observed for macroscopic shear and bulk responses. The proposed macro–micro quantitative relations of creep characteristics in this study benefit to deeply understand the macro–micro relations of viscoelastic properties, providing an alternative approach to calibrate microscopic parameters when involving the DEM simulations.

Calibration of contact parameters of sandy soil for planting tiger nut based on non-linear tools

A methodology combining physical experiments with simulation was employed to acquire contact parameters of sandy soil precisely for planting tiger nuts in the desert area of Xinjiang. The stacking angle under different parameter combinations was applied as a response value. Through the Plackett–Burman test, several factors that have a significant influence were determined. The steepest ascent test was conducted to establish the finest scope of values for these parameters. The stacking angle was considered the response variable, and non-linear tools were used to optimize these parameters for simulation. The findings showed that applying response surface methodology (RSM) resulted in a relative error of 1.24%. In the case of BP-GA, the relative error compared to the physical test value was 0.34%, while for BP, it was 2.18%. After optimization using Wavelet Neural Network (WNN), the relative error was reduced to only 0.15%. Results suggest that WNN outperforms the RSM model, and the sandy soil model and parameters generated using WNN can be effectively utilized for discrete element simulation research.

A new discrete element method for small adhesive non-spherical particles

Small adhesive particles with non-spherical shapes are common in natural and industrial processes. However, it is challenging to accurately simulate the dynamic behaviors of non-spherical particulate systems, not only due to the complex local geometry at the contact region but also to the non-linear coupling between the van der Waals adhesion and the elastic deformation. In this paper, we develop a discrete element method (DEM) framework for small non-spherical particles. Particularly, we present a simple algorithm for solving the implicit equations of the dimensionless generalized JKR model, to accurately resolve the local surface geometry at the contact region and the strong coupling between the elastic deformation and the surface adhesion. New explicit expressions are established for the pull-off force, overlap and minor-to-major ratio of the contact ellipse, to naturally capture the pull-off point upon collision. Then the actual contact parameters including the contact radius, curvatures and overlap are used to modify the interparticle interactions, including the normal elastic-adhesive-dissipative force and sliding-rolling-twisting resistances. Finally, the framework is quantitatively validated by four random packing problems, including adhesive spheres, ellipsoids, spherocylinders and dimers, and the representative non-adhesive ellipsoids. Both the microscopic and macroscopic properties of packings agree well with a large number of classic theories, experiments and simulations, showing the satisfactory accuracy and effectiveness. The newly developed adhesive DEM framework has the full capability to dynamically simulate the collision-related behaviors of complex shaped particles in the presence of van der Waals adhesion and frictional forces.

Research on an Accurate Simulation Modeling and Charge Motion Quantitative Evaluation Method for Ball Mill in Confined Space

A ball mill is a type of complex grinding device. Having knowledge of its charge-load behavior is key to determining the operating conditions that provide the optimum mill throughput. An elaborate description of the charge movement inside the ball mill is essential. This study focuses on a laboratory-scale ball mill and utilizes a discrete element simulation model to investigate the impact of mill speed and ball filling on charge-load behavior. Initially, the EDEM 2.7 (Engineering Discrete Element Method) software contact parameters were calibrated through heap-angle experiments. Subsequently, four charge-motion characteristic parameters were defined and analyzed based on Powell’s theory to understand the variations in charge-load behavior. This research proposes a theoretical calculation model for predicting power in a ball mill, highlighting the significance of the CoC (Center of Circulation) and CoM (Center of Mass) in reflecting changes in charge-load behavior. The theoretical model for mill-power prediction is effective and aligns well with the EDEM simulation and experimental results, providing valuable insights for optimizing large-scale ball mill structures and controlling charge motion during production.

Numerical simulation method of seed pelletizing: Increasing seed size by powder adhesion

Seed pelletizing can effectively increase the seed size. However, observing the microscopic process of seed pelletizing using physical tests is challenging. This study used the discrete element method (DEM) to simulate the process. Discrete elemental simulation models and contact parameters of seed and powder had been determined by particle scaling theory and parameter calibration tests, respectively. The contact model (modified model) between the seed and powder was established, which could effectively characterize the effect of the water addition on the viscosity. The seed pelletizing numerical simulation test was carried out with the average number of contact particles as the main evaluation index. The results showed that the amount of powder adhering to the surface of individual seeds was 43. Bench test results show that the quality of pelletized seeds met relevant criteria. KeywordsDiscrete element method (DEM)Numerical simulationSeed pelletizingContact modelRepose angle

Virtual parameter calibration of pod pepper seeds based on discrete element simulation

In order to achieve numerical optimization of the pod pepper seed sowing device, the contact parameters of pod pepper seeds were calibrated, with the angle of repose used as the response value. A set of discrete element method (DEM) models of pod pepper seeds was developed to simulate the formation of seed repose angles using reverse engineering reconstruction techniques. An eight-factor, three-level response surface experiment based on the Box-Behnken central combination test method was performed to study the effects of various factors on the angle of repose of seeds. The angle of repose obtained from physical experiments with a value of 27.56° was taken as the target value. The optimal combination of parameters is obtained as follows: seed Poisson's ratio of 0.22, seed shear modulus of 15.47 MPa, seed-to-seed static friction coefficient of 0.25, seed-to-seed rolling friction coefficient of 0.67, seed-to-seed collision recovery coefficient of 0.64, seed-to-steel-plate static friction coefficient of 0.55, seed-to-steel-plate rolling friction coefficient of 0.45, and seed-to-steel plate collision recovery coefficient of 0.34. A two-sample t-test of the angle of repose obtained by the cylinder lifting method and the pumping plate method against the target value yielded P > 0.05, indicating the reliability of the simulation experiments.

A comparative study on design standards of screw conveyors in China, Germany, and the USA – Part II: Discrete element method

This part of the study aims to evaluate the advantages and disadvantages of technical standards of screw conveyors in China, Germany, and the USA for industrial applications. The source or determination method of empirical coefficients as well as the theoretical foundation of dimensioning-relevant diagrams in these standards is not explicitly documented in the literature. Therefore, instead of less efficient on-site tests, the numerical simulation by discrete element method is conducted. Based on the geometrical and operational designs determined in three standards for horizontal, slightly inclined, and vertical conveyance of three representative bulk solids (barley, lignite, and sand), the potential influencing factors are discussed. With constant particle and contact parameters, the potential deviations caused by particle models are eliminated. Furthermore, the accuracy of power consumption calculation of each standard and the divergence between accessible and required mass flows is comprehensively assessed based on the analysis of simulated outcomes. Two main conclusions are drawn: (1) Particle fall back is barely considered by all three standards and leads to overestimated mass throughput; (2) The decrease in mass throughput caused by an increasing degree of filling can be compensated by slowing down the rotational speed.

Exploring the micro-to-macro response of granular soils with real particle shapes by way of μCT-aided DEM analyses

This contribution provides high-fidelity images of real granular materials with the aid of X-ray micro-computed tomography (μCT), and employs a multi-sphere representation to reconstruct non-spherical particles. Through discrete-element method (DEM) simulations of granular samples composed of these non-spherical clumps, the effect of particle shape on the macroscopic mechanical response and microscopic soil fabric evolution is examined for soil assemblies under triaxial compression. Simulation results indicate that materials with more irregular particles tend to show higher shear resistance in both peak and critical states, while exhibiting higher void ratio under isotropic loading conditions and in the critical state. The proposed critical state parameters for describing the sensitivity of the mean coordination number to confining pressures are larger as particles become more irregular. At a microscopic level of observation, directional and scalar parameters of particle contacts are sensitive to predefined particle shapes. More irregular materials appear to exhibit higher fabric anisotropy with respect to particle orientation in the critical state, while the branch vector is affected by both contact modes and particle shape. The critical stress ratio from the simulation results is validated by comparing with experimental results, and further found to be linearly linked to the shape-weighted fabric anisotropy indices.