A novel approach for modelling of physical interactions between slurry, grinding media and mill structure in wet stirred media mills

Larsson, Simon; Pålsson, Bertil; Parian, Mehdi; Jonsén, Pär

doi:10.1016/j.mineng.2019.106180

Cited by 30 publications

(11 citation statements)

References 54 publications

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“…As PFEM uses a Lagrangian formulation no convective terms and their inherent numerical difficulties are present in the balance equations. Since its original development, the application of PFEM has spread to problems in solid mechanics [41], thermo-mechanics [9,42], granular materials [43][44][45][46][47], fluid-structure interaction [43,48], contact of deformable bodies [49] and additive manufacturing processes [50]. Both explicit and implicit time integration schemes can be used for PFEM, although most of the times an implicit time integration has been preferred [51].…”

Section: The Particle Finite Element Methodsmentioning

confidence: 99%

Implicit or explicit time integration schemes in the PFEM modeling of metal cutting processes

et al. 2021

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This work presents the development of an explicit/implicit particle finite element method (PFEM) for the 2D modeling of metal cutting processes. The purpose is to study the efficiency of implicit and explicit time integration schemes in terms of precision, accuracy and computing time. The formulation for implicit and explicit time marching schemes is developed, and a detailed study on the explicit solution steps is presented. The PFEM remeshing procedures for insertion and removal of particles have been improved to model the multiple scales of time and/or space of the solution. The detection and treatment of the rigid tool contact are presented for both, implicit and explicit schemes. The performance of explicit/implicit integration is studied with a set of different two-dimensional orthogonal cutting tests of AISI 4340 steel at cutting speeds ranging from 1 m/s up to 30 m/s. It was shown that if the correct selection of the time integration scheme is made, the computing time can decrease up to 40 times. It allows us to affirm that the computing time of the PFEM simulations can be excessive due to the used time marching scheme independently of the meshing process. As a practical result, a set of recommendations to select the time integration schemes for a given cutting speed are given. This is intended to minimize one of the negative constraints pointed out by the industry when using metal cutting simulators.

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Section: The Particle Finite Element Methodsmentioning

confidence: 99%

Implicit or explicit time integration schemes in the PFEM modeling of metal cutting processes

et al. 2021

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“…The PFEM emerges also to explore the possibilities of using a Lagrangian description of the fluid domains in the modelling of fluid structure interaction, traditionally used to study the problems in solid mechanics. Nowadays, the PFEM is applied in the modeling of a wide range of engineering applications, such as: fluid structure interaction in port engineering, erosion processes in rivers, mixing processes, fluid coupling with thermal effects, slurry in stirred media mills, the pulp fluid in tumbling mills and granular flows [44][45][46][47][48][49]. An early approach for the modelling of cutting, riveting and excavation problems is presented in References [25,[50][51][52].…”

Section: The Particle Finite Element Methodsmentioning

confidence: 99%

Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

et al. 2020

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Machining of metals is an essential operation in the manufacturing industry. Chip formation in metal cutting is associated with large plastic strains, large deformations, high strain rates and high temperatures, mainly located in the primary and in the secondary shear zones. During the last decades, there has been significant progress in numerical methods and constitutive modeling for machining operations. In this work, the Particle Finite Element Method (PFEM) together with a dislocation density (DD) constitutive model are introduced to simulate the machining of Ti-6Al-4V. The work includes a study of two constitutive models for the titanium material, the physically based plasticity DD model and the phenomenology based Johnson–Cook model. Both constitutive models were implemented into an in-house PFEM software and setup to simulate deformation behaviour of titanium Ti6Al4V during an orthogonal cutting process. Validation show that numerical and experimental results are in agreement for different cutting speeds and feeds. The dislocation density model, although it needs more thorough calibration, shows an excellent match with the results. This paper shows that the combination of PFEM together with a dislocation density constitutive model is an excellent candidate for future numerical simulations of mechanical cutting.

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“…In this section, the modeling approach of the present study is briefly reviewed. A more detailed presentation can be found in [40]. The grinding media is modeled with DEM, the grinding fluid is modeled with PFEM, and the mill structure is modeled with FEM.…”

Section: Modeling and Simulationmentioning

confidence: 99%

“…More recently, a PFEM-DEM approach was used by [38] to model particle-laden flows with free surface. Coupled particle finite element method (PFEM), FEM, and DEM models were used in a recent work by [39] for a tumbling mill and in [40] for a wet stirred media mill.…”

Section: Introductionmentioning

confidence: 99%

A Novel Particle-Based Approach for Modeling a Wet Vertical Stirred Media Mill

et al. 2021

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Modeling of wet stirred media mill processes is challenging since it requires the simultaneous modeling of the complex multiphysics in the interactions between grinding media, the moving internal agitator elements, and the grinding fluid. In the present study, a multiphysics model of an HIG5 pilot vertical stirred media mill with a nominal power of 7.5 kW is developed. The model is based on a particle-based coupled solver approach, where the grinding fluid is modeled with the particle finite element method (PFEM), the grinding media are modeled with the discrete element method (DEM), and the mill structure is modeled with the finite element method (FEM). The interactions between the different constituents are treated by loose (or weak) two-way couplings between the PFEM, DEM, and FEM models. Both water and a mineral slurry are used as grinding fluids, and they are modeled as Newtonian and non-Newtonian fluids, respectively. In the present work, a novel approach for transferring forces between grinding fluid and grinding media based on the Reynolds number is implemented. This force transfer is realized by specifying the drag coefficient as a function of the Reynolds number. The stirred media mill model is used to predict the mill power consumption, dynamics of both grinding fluid and grinding media, interparticle contacts of the grinding media, and the wear development on the mill structure. The numerical results obtained within the present study show good agreement with experimental measurements.

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A novel approach for modelling of physical interactions between slurry, grinding media and mill structure in wet stirred media mills

Cited by 30 publications

References 54 publications

Implicit or explicit time integration schemes in the PFEM modeling of metal cutting processes

Implicit or explicit time integration schemes in the PFEM modeling of metal cutting processes

Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

A Novel Particle-Based Approach for Modeling a Wet Vertical Stirred Media Mill

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