Dynamics Discrete Element Method Research Articles

Quantifying the effects of inlet gas and collision models in direct metal deposition using a CFD-DEM approach

Simulations of the powder jet in direct metal deposition (DMD) are often made with significant simplifications such as being incompressible, steady-state, or single-component, and do not provide explanation for the choice of parameters in the collision model. This work presents a coupled Computational Fluid Dynamics–Discrete Element Method model for the powder jet in DMD that considers all of the following features: compressibility effects, particle–wall and particle–particle collisions, turbulence, gas mixing, and melt pool boundaries. The goal of the simulation is to optimize the operating conditions and to predict the outcomes of experiments. After effective validation against experimental results, the effects of inlet gas, collision models and different boundary conditions in DMD have been comprehensively studied. It is demonstrated that gases with higher diffusivities, such as helium, are less effective shielding gases than those with lower diffusivities, such as argon. The increased wall temperature arising from the melt pool and track has little influence on the particle distribution.

Effect of magnetic needle magnetic particle grinding process on the performance of metal aluminum plates

Magnetic needle grinding processing technology is one of the magnetic grinding processing techniques. It possesses the characteristics of micro-cutting removal, small increase in processing temperature, flexible processing, high-quality, and high-precision processing. It is mainly utilized to remove burrs at the edge of the workpiece and the edge of the hole, as well as to finish the surface of the workpiece. It is frequently employed in civil, aerospace, navigation, and other fields. Due to the randomness and complexity of magnetic needle movement in magnetic abrasive finishing, it is difficult to quantify the processing parameters and predict processing effects. Therefore, this paper establishes a simulation model of magnetic needle in magnetic abrasive finishing by the coupling numerical simulation method of fluid dynamics discrete element method (CFD-DEM) to analyze the working state parameters of the magnetic needle. Through the simulation of actual working conditions, the machining process and parameters of magnetic abrasive finishing are quantified and analyzed, and the motion trend of magnetic needles during the machining process is studied. Then, the residual stress of single magnetic needle impact is analyzed with ABAQUS, and the performance enhancement of the workpiece is predicted. Finally, observations of surface morphology and validation of residual stress prediction were conducted through experiments on an aluminum plate. The results show that the residual stress of the aluminum plate is positively correlated with the number of strikes of the magnetic needle. The residual stress changes from tensile stress (+0.1 MPa) to compressive stress (-16.5 MPa). The comparison between simulation results and experimental results is good, indicating that the simulation model can comprehensively consider multiple factors such as magnetic field, particle motion, and fluid flow, and establish a magnetic needle magnetic grinding process model that is suitable for actual working conditions.

Micromechanical analysis of contact erosion under cyclic loads using the coupled CFD‒DEM method

Different layers of soil often have distinct particle sizes. When exposed to the natural environment, soil is easily affected by natural rainfall, rising groundwater levels, and human activities, leading to particle contact erosion, which reduces the safety and service performance of the soil structure. In this paper, a coupled computational fluid dynamics–discrete element method (CFD–DEM) model was employed to investigate the particle migration phenomena, mechanical response of contact interfaces, variations in flow fields, and macroscopic deformation during the contact erosion process under cyclic loads at different frequencies and amplitudes. The conclusions are presented as follows: (1) Within one cycle of cyclic loading, both compression during loading and stress relaxation during unloading are the main factors triggering the migration of fine particles. (2) The migration and loss of fine particles mainly occur in the early stages of cyclic loading, where strong contact force chains are formed within the fine particle layer, leading to significant plastic deformation of the soil at the macroscopic level. (3) Under cyclic loading, changes in the soil pore structure cause an upwards hydraulic gradient in the initial quiescent water flow field. This hydraulic gradient can rupture weak contact force chains and cause particle pumping. (4) Increasing the frequency and amplitude of cyclic loading intensifies the erosion of fine particles, causing greater axial deformation of the soil. Compared to cyclic loading frequency, the amplitude of cyclic loading has a greater impact on contact erosion.

Influence of particle stacking modes on the fluidization characteristics of biomass particles in binary particle systems

Spouted bed is widely used in biomass combustion and other industrial production due to the advantages of good heat transfer performance and sufficient gas–solid mixing. In order to achieve higher heat and mass transfer performance and conversion efficiency, inert particles are often added to assist in the fluidization of biomass particles. However, the stacking patterns of different particles in a binary particle system can have some effects on particle flow, distribution, and bed stability. Therefore, in this study, the computational fluid dynamics–discrete element method was used to analyze the particle fluidization characteristics under four different particle stacking modes in a spouted bed. The results show that the average bed height of larger spherocylindrical particles is prioritized in binary particle systems. The void fraction of spherocylindrical particles tends to increase in the near-wall region, whereas spherical particles tend to decrease. When the binary particles are mixed at the initial moment, the change rule of vertical velocity of the two particles remains consistent. In addition, the vertical velocities of two kinds of particles when layered stacking is used are gradually close to each other only after a period of time. In addition, the orientation angle of the spherocylindrical particles in the spouted bed tends to be horizontal for both the single-component spherocylindrical particle system and the wall effect attenuates this phenomenon.

Hydromechanical analysis of slurry infiltration with coupled CFD–DEM method

AbstractThe tunnel face stability is closely related to the migration behavior and clogging mechanism of the slurry particles in granular soils, which is not yet fully understood. In this study, the coupled computational fluid dynamics–discrete element method (CFD–DEM) is adopted to investigate the infiltration behavior of slurry at the particle scale. The full Johnson–Kendall–Roberts (JKR) contact model describing interparticle behavior that accounts for cohesion present even when particles are microseparated after collisions is adopted for clay‐clay or clay‐sand particles and the Hertz–Mindlin model is used for sand‐sand particles. Through simulations, the mechanism of the slurry particle's blockage is identified as physical, frictional and cohesive modes, and slurry particle migration usually undergoes the process of aggregation‐destruction‐migration‐reassembly. Meanwhile, the influences of pressure, cohesive force, and particle shape on infiltration are also analyzed. The results indicate that high pressure lengthens the infiltration path and increases the infiltration rate. The increase in cohesion enhances the effective clogging of the sand column by the slurry, and particles with smaller sphericity are more likely to clog in the sand column. These findings may enhance our understanding of the slurry infiltration mechanism and its practical application in TBM tunneling.

Sustainable dye extraction: Annatto powder production in a fountain confined spouted bed

AbstractThis study proposes an efficient and sustainable process for annatto powder production using a fountain confined spouted bed. With widespread applications in industries such as food, pharmaceuticals, and cosmetics, conventional extraction methods face environmental and economic challenges. Our study explores a solvent‐free and eco‐friendly approach using mechanical attrition within a fountain confined spouted bed, offering a cost‐effective solution for annatto cultivation. We systematically investigated the impact of four parameters—fountain confiner position and length, draft tube diameter, and airflow velocity—employing experimental design, multiple regression analysis, particle swarm optimization, and computational fluid dynamics–discrete element method (CFD‐DEM) simulations. The proposed optimization condition shows significantly higher collision intensity, improving annatto powder production compared to other central composite design tests. This study contributes to developing of a sustainable and economically viable method for dye production, with potential implications for annatto‐producing regions globally.

Effects of natural fracture reopening on proppant transport in supercritical CO2 fracturing: A CFD-DEM study

The reopening of natural fractures reshapes the proppant beds in hydraulic fractures, especially at fracture intersections, critically influencing subsequent proppant migration. However, studies on the effects of proppant bed shapes on post-reopening proppant migration are limited. To address this gap, a moving wall boundary technique is integrated into a Computational Fluid Dynamics–Discrete Element Method (CFD-DEM) framework to model natural fracture reopening, enabling an in-depth analysis of how proppant bed reshaping impacts subsequent proppant migration during supercritical CO2 fracturing. Results reveal that proppant migration into natural fractures is governed by both drag force-induced and gravity-induced rolling mechanisms, with the latter exerting a more significant effect. The gravity-induced rolling mechanism is enhanced by five key factors: (a) the generation of a well-developed proppant pack in proximity to the intersection; (b) the inadequately filled V-shaped gully; (c) the increased proppant transport capacity within the natural fracture; (d) the reduced bypassing of proppants at the intersection; and (e) the improved ability of proppants to enter the natural fracture. The enhanced gravity-induced rolling mechanism significantly increases the proppants flowing into natural fractures: by 35.6% between the central and rearward section cases, 168.9% from mild to severe plugging cases, 39.1% with a wider natural fracture width (1.5 mm–2.5 mm), 20.3% with decreased hydraulic fracture flow rate (0.35 m/s to 0.25 m/s), and 33% with reduced fluid temperature (160 °C–40 °C). These findings underscore the impact of natural fracture reopening on subsequent proppant migration, offering valuable insights for optimizing fracturing designs.

Fully coupled discrete element method for graded particles transport in pipes

Hydraulic conveying of graded particles is much more complex than that of uniform particles but is not fully understood. A fully coupled computational fluid dynamics–discrete element method model is established for the hydraulic conveying of graded particles, which integrally considers the particle–fluid and particle–particle interactions and turbulence modulation from particles. The proposed model accounts for the stochastic motion of particles by the discrete random walk method and applies the diffusion averaging algorithm to obtain particle concentration in arbitrary cells for smooth and cell-independent data fields on unfavorable cells (fluid cell size ≤ particle size). The particle–fluid drag force is applied to slurry flows through densely packed particle beds due to the consideration of porosity modification. The proposed model well performs in simulating the hydraulic conveying of dense graded particles. Dynamics in slurry mixtures of bi-disperse particles are investigated regarding different particle size compositions. The results show obvious stratification between coarse and fine particles, e.g., fine particles settling at the pipe bottom elevate the coarse particles and form a “lubrication layer” with high velocity. The torque caused by particle–particle/wall contact is greater than the torque caused by the fluid. The pipe cross section is divided into four regions according to the particle angular velocity. The effect of particle concentration on liquid motion is small because the difference in local particle concentration is relatively small, but the maximum pressure drop corresponds to a critical particle size composition.

Numerical investigations of the restriction effects on a ship navigating in pack-ice channel

This paper adopts Computational Fluid Dynamics (CFD) method and Discrete Element Method (DEM) to simulate a ship navigating in pack-ice channel considering the effects of channel restriction. First, from the simulations of the ship sailing in open-water channel by CFD, it is found that the effects of channel width on water resistance is more pronounced than the impacts by level-ice thickness. Then, based on the stable and converged flow field obtained by CFD simulations, the CFD-DEM coupling method is applied to reveal the effects of channel width and level ice thickness on ship-ice-water interactions and ice resistances at different ship speeds. The results indicate that as the channel width decreases, the accumulation of pack ice in the areas of bow and midship intensifies. The ice resistances on the bow and midship increase notably, and the lateral ice forces exhibit pronounced asymmetric and random characteristics. In extremely narrow pack-ice channels, lower ship speed results in lager ice resistance and lateral ice force on the ship. In addition, as the level ice thickness decreases, the pack ice is more easily squeezed below the level ice, resulting in the decreases of ice resistance and lateral ice force.

Mechanical behavior and performance evolution of railway ballast track under dynamic stabiliser based on the hybrid MBD-DEM simulation

The uncertainty in local structure and time-variable compaction of ballast aggregates poses challenges in selecting suitable stabilization methods and parameters for ballast tracks in practical engineering, often resulting in suboptimal operational outcomes. To address this issue comprehensively, the spatial hybrid model of the double dynamic stabilisers-ballast track (MBD-DEM) is proposed in this paper. Subsequent numerical simulations of stabilisation operations are conducted to elucidate ballast vibration, migration behavior and the evolution of ballast track resistance under varying initial conditions of the ballast bed. Initially, leveraging multibody dynamics theory (MBD) and discrete element method (DEM), a MBD model of double stabilisers and a DEM ballast track model containing 6 sleepers were established respectively. Using the coupling interface, the real-time hybrid calculation of these two models is achieved through 6 sleepers in the middle of the ballast bed. Subsequently, the model's accuracy was validated by comparing test data from stabilisation vehicle operations on a Kunming Railway Bureau test line with simulation data from the dynamic double stabilisers-ballast track spatial hybrid model. Finally, utilizing the proposed hybrid model, the dynamic behavior, contact states, and movement rules of ballast particles during stabilisation operations on both loose and initially stable ballast beds (LBB and ISBB) were investigated at the mesoscopic scale. Concurrently, an in-depth analysis of lateral resistance changes in the ballast bed before and after the stabilisation operation is presented. The relevant findings effectively unveil the evolution of dynamic behavior in the ballast bed during stabilisation operations, concluding with practical suggestions for on-site operations. Simulation results illustrate that the rotation of ballast particles in the XY plane beneath each sleeper is predominantly characterized by harmonic rotation. With an increase in the depth of the ballast bed, the range of the rotation axis for combined angular velocity diminishes, leading to the phenomenon of rotation axis deflection. To ensure operational safety and efficiency, a minimum of two-times stabilization operations is recommended for loose ballast beds (LBB), with three-times operations considered optimal. For initially stable ballast beds (ISBB), one-time stabilization operation is basically sufficient.

Fully Coupled CFD–DEM Simulation of Oil Well Hole Cleaning: Effect of Mud Hydrodynamics on Cuttings Transport

This paper presents a coupled computational fluid dynamics–discrete element method (CFD–DEM) simulation to predict cuttings transport by the drilling fluid (mud) in different oil well drilling conditions. The mud rheology is expressed by the Herschel–Bulkley behaviour and modelled in a Eulerian framework (CFD), while the cuttings are modelled using the Lagrangian approach (DEM). In this work, the effects of drill string rotation, inclination angle, cutting size, mud rheology, and annular velocity on cleaning efficiency are investigated. It is found that increasing the well deviation from vertical to horizontal leads to a higher cuttings concentration. However, at low annular velocity, the cuttings concentration for the inclined (45-degree) annulus is found to be higher than the horizontal one due to the sliding motion of cuttings on the lower section of the annulus. Overall, the drill pipe rotation has little effect on decreasing the cuttings concentration, but the effect is more pronounced at low annular velocity.

A modified CFD-DEM method for accurate prediction of the minimum fluidization velocity

Monodisperse fluidized bed experiments have been carried out on 13 kinds of particles with different particle sizes in a cylindrical fluidized bed. The accuracy of nine commonly used monodisperse drag models, including the Gidsapow, BVK, and Zhou–Fan models is verified. It is found that the Zhou–Fan model is the most accurate at low and moderate values of the particle Reynolds number. It is found that with the traditional computational fluid dynamics–discrete element method (CFD-DEM) method it is difficult to obtain an accurate minimum fluidization velocity owing to difficulty in obtaining an accurate value of the minimum fluidization solid volume fraction. A modified method is proposed to increase the accuracy of prediction of the minimum fluidized solid volume fraction by using a virtual particle size in the calculation of the particle collision process. The effectiveness of the modified method is verified by comparing the CFD-DEM simulation results with experimental results for Geldart-D particles. The relative error of the minimum fluidization velocity is found to be reduced from 24.6% to 2%.

Gas–solid flow mechanism of spherocylindrical particles with various aspect ratios in spouted bed

Spherocylindrical particles encompass elongated spherical particles, such as biomass particles utilized in thermal reactions and capsule pills in the pharmaceutical industry, along with various other particles found in industrial production processes. Understanding the flow behavior of spherocylindrical particles within a spouted bed holds significant practical importance. This study delves into investigating the fluidization characteristics of spherocylindrical particles with varying aspect ratios within a spouted bed. Key parameters studied include particle void fraction, velocity, orientation, and mixing. These were analyzed using the computational fluid dynamics–discrete element method, and the simulation model's accuracy was verified through high-speed photography experiments. The findings revealed distinct void fraction distributions at different locations within the bed. Particles in the higher-bed region exhibited larger void fractions with flatter peaks compared to those in the lower-bed region. Moreover, the correlation between particle aspect ratio and void fraction varied at different heights within the bed. Notably, there was no significant correlation observed between particle aspect ratio and particle velocity. However, the larger the particle aspect ratio/gas velocity, the better the particle mixing quality. Additionally, gas velocity and particle aspect ratio had little effect on particle orientation, but there was a tendency for particle orientation angles to hover around 45°–60° near the wall region.

Effects of nozzle angles of a double-row jet collector on harvesting performance

Owing to its high collection efficiency, the double-row jet collector is an important application in industrial operations. Presently, few studies on its collection efficiency and impact from its front and rear nozzle angles are available. In this paper, the computational fluid dynamics–discrete element method is employed to numerically study the jet parameters of a typical double-row jet collector from three aspects: flow characteristics, particle movement and collection efficiency. Defining α as the front nozzle and β as the rear nozzle, five different combinations of jet angles were first selected and an optimal configuration of the front nozzle at 30°and the rear nozzle at 55° was last obtained, the simulation results were confirmed via the performance experiment. The influence of the change in the front and rear jet angles on the flow field of the collection is shown, and the results indicate that of the angle α and β, α plays a dominant role, while β has relatively little influence on the whole collecting process, which guides for the optimal design.

Novel drag and Nusselt number models based on direct numerical simulations of a bidisperse gas–solid system

AbstractFlow and heat transfer in a bidisperse gas–solid system with freely moving spheres are simulated by particle‐resolved direct numerical simulation (PR‐DNS). Gas–solid coupling is enforced by the direct‐forcing immersed boundary method. Compard with the DNS database, it is found that the existing polydisperse drag correction model developed from static systems combined with various monodisperse drag models underestimates the drag force on dynamic arrays of particles. The existing Nusselt number correction model developed from static systems combined with various monodisperse models overestimates the Nusselt number of dynamic arrays of particles. Sensitivity analysis indicates that the effects of the granular temperature on the drag force and Nusselt number are negligible. Novel polydisperse drag and Nusselt number models are derived based on the database. The advantages of the derived polydisperse drag and Nusselt number models are demonstrated and confirmed by comparing the results of the computational fluid dynamics–discrete element method using various drag and Nusselt number models with experimental or additional PR‐DNS data.

Study on the Mechanism of Water and Sand Leakage in a Foundation Pit Retaining Structure Based on the Computational Fluid Dynamics–Discrete Element Method

The existence of defects in the enclosure structure is the primary cause of water and sand leakage in foundation pits, as well as being a significant source of danger in pit construction, but current research lacks an in-depth investigation of the generation mechanism and gestation process. In this paper, which comprehensively considers the microscopic particles and macroscopic level, the development mechanism of a water and sand leakage disaster in a foundation pit with a water-rich sand layer was studied using the principle of computational fluid dynamics and discrete element method coupled analysis (CFD–DEM); moreover, based on the anisotropy of the particle force and fluid energy analysis, the deformation of the stratum and ground stress field were analyzed. The results show that the stress field will produce a plugging effect at a certain distance from the defect, and the strata exhibit a dominant displacement tendency in the vertical direction, resulting in the emergence of a gradually concave stress relaxation zone and an elliptical contour in the strata displacement map near the defect. The fluid energy describes the displacement of the sand layer very well, and it is separated into the sand layer’s centralized loss region and the major loss area based on the high and low levels of the fluid energy class. The impact of fluid at the defect reaches the maximum kinetic energy, which penetrates the structural weakness and causes the loss of sand particles, and the cross-section of the water influx near the defect gradually expands with the loss of particles, indicating that there is a danger of further expansion of the defect under the impact of water flow. These results have technical implications for the management of water and sand leakage disasters in foundation pit engineering.

Simulation of proppant conductivity test: effect of particle size dispersion

A conductivity test of proppant material consists in confining a sample of the granulate at high pressure and then set a flow through the pack. The proppant particle size is the main variable controlling conductivity, but also particle size dispersion is considered important. Even though several studies consider mixtures of proppants of different meshes, there are not clear evidences as to whether the changes in conductivity with respect to a monosized proppant are caused by the mix itself or by the overall change in mean particle size. Hence, we use numerical simulations to answer the question: Does particle size dispersion significantly affects the proppant conductivity if mean particle size is kept the same? We measure conductivity and permeability by simulating (via a coupled Computational Fluid Dynamics–Discrete Element Method) the flow of water through binary granular packs. We find that size dispersion does not affect conductivity (in the dispersion range explored) if the mean particle size is conserved. However, we observe that in a binary mixture the large particles are subjected to larger stresses than in a monosized system, which makes them prone to crushing.

Settling dynamics and thresholds for breakup and separation of bi-disperse particle clouds

Settling dynamics and thresholds for breakup and separation of bi-disperse particle clouds

Numerical Simulation and Experimental Study of Corn Straw Grinding Process Based on Computational Fluid Dynamics–Discrete Element Method

To improve the operational efficiency of a hammer mill and delve into a high-efficiency, energy-saving grinding mechanism, the crucial parameters influencing the grinding of corn straw were identified as the spindle speed, hammer–sieve gap, and sieve pore diameter. According to the force analysis and kinematics analysis, the key factors affecting corn straw grinding were the spindle speed, the hammer–sieve gap, and the sieve pore diameter. The grinding process of corn straw was studied using computational fluid dynamics (CFDs) and the discrete element method (DEM) gas–solid coupling numerical simulation and experiment. The numerical simulation results showed that with the growth of time, the higher the spindle speed, the faster the bonds broke in each part, and the higher the grinding efficiency. When the energy loss of the hammer component was in the range of 985.6~1312.2 J, and the total collision force of the corn straw was greater than 47,032.5 N, the straw grinding effect was better, and the per kW·h yield was higher. The experimental results showed that the optimum combination of operating parameters was a spindle speed of 2625 r/min, a hammer-screen gap of 14 mm, and a sieve pore diameter of 8 mm. Finally, the CFD–DEM gas–solid coupling numerical simulation validation tests were performed based on the optimal combination of the operating parameters. The results showed that the energy loss of the hammer component was 1189.5 J, and the total collision force of the corn straw was 49,523.5 N, both of which were within the range of better results in terms of numerical simulation. Thus, the CFD–DEM gas–solid coupling numerical simulation could accurately predict the corn straw grinding process. This study provides a theoretical basis for improving a hammer mill’s key components and grinding performance. Meanwhile, the proposed gas–solid two-phase flow method provided theoretical references for other research in agricultural machinery.

A new method for preventing sidewall preferential flow in the internal erosion simulation using un-resolved CFD–DEM

AbstractAccurately assessing the erodibility of geomaterials is of great significance for the design of earthen structures and the prevention of the associated failure induced by seepage force. Recently, the un-resolved Computational Fluid Dynamics–Discrete Element Method (CFD–DEM) has been widely used to investigate internal erosion. However, due to the use of wall boundary and the fact that the fixed CFD domain cannot be changed with the soil sample’s volume contraction during the erosion test, a larger porosity at the boundary of the CFD domain is commonly formed, resulting in sidewall preferential flow (i.e., relatively more fine particles migrate along the boundary of the DEM domain) and thereby overestimating the soil erodibility. In this study, a new method based on particle boundary is developed to tackle this problem. The newly proposed particle boundary can prevent its particles from erosion via inter-particle bonding and transfer stress from servo walls to the simulated sample. An optimal particle boundary thickness is determined by considering sample contraction and computational efficiency. The performance of the new method was compared with the conventional method and also verified using experimental results. The results show that the newly proposed method has significantly improved the uniformity of fluid velocity distribution. Furthermore, the cumulative eroded mass of fine particles in the new model is approximately 15% lower than in the conventional model. It is convincingly demonstrated that the new method can simulate internal erosion better and give a more accurate assessment of geomaterial erodibility.