63490274 Numerical Coupling Dem Fem Minecrush 2010 Ragc v2
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Transcript of 63490274 Numerical Coupling Dem Fem Minecrush 2010 Ragc v2
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Nicolas Spogis, Ph.D.; Daniel Nasato, Eng.ESSS Brasil – www.esss.com.br
Rafael Angelo Tozzo, Eng.VALE – www.vale.com
Andrés González - M.Sc. ; Víctor SandovalESSS Chile – www.esss.cl
NUMERICAL COUPLING BETWEEN DEM (DISCRETE
ELEMENT METHOD) AND FEA (FINITE ELEMENTS
ANALYSIS).
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Nicolas Spogis, Ph.D.Business Manager
E-mail: [email protected]
Daniel Nasato, Eng.Business Analyst
E-mail: [email protected]
Rafael Angelo Tozzo, Eng.Mechanical Engineering
E-mail: [email protected]
Authors
Andrés González, M.Sc.Account Manager
E-mail: [email protected]
Tel: +56 (2) 946 -1941
Cel: +56 (9) 9319-1576
Víctor SandovalNew Business Manager
E-mail: [email protected]
Tel: +56 (2) 946 -1941
Cel: +56 (9) 9319-1593
www.esss.cl www.vale.com
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FlorianópolisBrazil
São PauloBrazil
Rio de JaneiroBrazil
SantiagoChile
ESSS at a Glance
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.
WHAT WE DO
SINCE 1995 LOCATIONS
15 years providing the most comprehensive simulation solutions to the market.
NEW OFFICES
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VALE at a Glance
• Vale is the world’s 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 world’s
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.
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1º- Objectives
2º - DEM Method
3º - EDEM ANSYS Coupling
4º- Validation & Real Case
5º - Conclusions
Agenda
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Objectives
• Develop an 1-way coupling between
Discrete Element Method (DEM) and
Finite Element Method (FEM).
• Propose a numerical validation to
evaluate the method accuracy.
• Simulate a transfer chute using the
developed method to solve a real
problem.
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1º- Objectives
2º - DEM Method
3º - EDEM ANSYS Coupling
4º- Validation & Real Case
5º - Conclusions
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• Governing equations for the translational and rotational
motion of particle i with mass mi and moment of inertia Ii:
DEM Method - Mathematics
• vi and ωi are the translational and angular velocities of particle i,
• Fcij 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,
• Ffi is the particle–fluid interaction force on particle i,
• Fgi is the gravitational force.
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• To detect contacts between particles and structure, EDEM splits the
geometry in triangular surface mesh (StL file format), a 3-dimensional
surface geometry;
• The surface is tessellated or broken down logically into a series of
small triangles (facets);
• Each facet is described by a perpendicular direction and three points
representing the vertices (corners) of the triangle.
DEM Contact Detection
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Track each
particle and
boundary element
Detect contact
between elements
Calculate contact forces on
each particle
Calculate body
forces acting on
each particle:
gravity, fluid drag,
electrostatic, …..
Update particle acceleration
and velocity
Update particle and boundary
element positions
DEM Method - Basic Numerical Cycle
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1º- Objectives
2º - DEM Method
3º - EDEM ANSYS Coupling
4º- Validation & Real Case
5º - Conclusions
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EDEM-ANSYS Coupling
• EDEM was used as Discrete Element Method (DEM) tool and ANSYS
was used as Finite Element Method (FEM) tool.
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EDEM-ANSYS 1-way couplingSetup ANSYS Model Run EDEM Model
Export EDEM
LoadsCreate Named
Surface
Interpolate Loads
Python Script
And ANSYS APDL
Solve and Evaluate
ANSYS Results
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EDEM-ANSYS coupling methods
• 1-Way DEM-FEA
– Coupling - Steady State
– Static Structural Analysis
• 1-Way DEM-FEA
– Coupling - Transient
– Transient Structural Analysis
• 2-Way DEM-FEA
– Coupling - Transient
Developed
Under development
Force
Displacement
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• 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
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• 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
Interpolation Method
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1º- Objectives
2º - DEM Method
3º - EDEM ANSYS Coupling
4º- Validation & Real Case
5º - Conclusions
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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.
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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
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• Case Vale – Mina de Brucutu
Industrial Application
Modeling of ore flows and loads on transfer‐chutes.
A case study for Vale Brucutuusing EDEM and Ansys.
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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)
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• Mass flow: 8492 t/h
• Conveyor velocity: 3.52 m/s
• Particle diameter: 25 mm
• Particle shape: Single sphere
• Dynamic repose angle: 20˚
• Static repose angle: 30˚
• Moisture: 8%
• Iron Ore density: 2500kg/m³
• Ore / Ore Interaction:
• Coeff. of Restitution: 0.4
• Static friction: 0.65
• Rolling friction: 0.1
• Ore / Belt Interaction (rubber):
• Coeff. of Restitution 0.3
• Static friction: 0.6
• Rolling friction: 0.05
• Ore / Structure Interaction (steel)
• Coeff. of Restitution 0.3
• Static friction: 0.5
• Rolling friction: 0.05
Material properties
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EDEM Factory
•Mass Flow:
•8492 t/h – 2.3589 ton/s
•Aprox. 30000 particles/s
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Conveyor dynamics
Belt Angle Vtotal Vy Vz
Slice 1 18,919 3,520 m/s -3,330 m/s 1,141 m/s
Slice 2 19,658 3,520 m/s -3,315 m/s 1,184 m/s
Slice 3 9,890 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
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Screen dynamics
x y z
Right Screen 6,87 7,92994 11,9179 996 16,6 0,5697
Left Screen 2,086 7,8384 12,0042 996 16,6 0,4988
6 DOF centerRPM Hz Angle
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EDEM Results
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EDEM Results
High impact velocities zones – Wear and structural problems.
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EDEM Results
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Screen force distribution
High impact velocities zones
(up to 7 m/s) on screen.
Wear and structural problems.
High forces on chute discharge.
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Unbalanced forces
Unbalanced forces on screen generated by
wrong chute discharge.
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Time varying forces
-8000,00
-6000,00
-4000,00
-2000,00
0,00
2000,00
4000,00
6000,00
0,00 5,00 10,00 15,00 20,00 25,00 30,00
Total Force X (N)
-15000,00
-10000,00
-5000,00
0,00
5000,00
10000,00
15000,00
20000,00
0,00 5,00 10,00 15,00 20,00 25,00 30,00
Total Force Y (N)
-140000,00
-120000,00
-100000,00
-80000,00
-60000,00
-40000,00
-20000,00
0,00
20000,00
0,00 5,00 10,00 15,00 20,00 25,00 30,00
Total Force Z (N)
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0
10000
20000
30000
40000
50000
60000
1 2 3 4 5 6
Tota
l Fo
rce
(N
)
X direction bin group
Total force on screen width
30.05
30.10
30.15
30.20
30.25
30.30
30.35
30.40
30.45
30.50
• Unbalanced forces; – Picks reaches 20 times higher forces
between one extreme to another.
Force Distribution
• EDEM can split the domain into small fraction (Bins) to do local analysis;– Domain was split into 8 regions in X-
direction, in order to investigate unbalanced forces.
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EDEM-ANSYS coupling – Conservative
Interpolation
The developed scripts and macros automatically interpolates
EDEM forces (normal and tangential) on the structural
elements.
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Total Deformation Equivalent Strain
Static Structural Analysis
The Static Analysis performed shows stresses
& Strains under the yield limit OK
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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
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FFT – Fast Fourier TransformationMode 1 - 3.3647 Hz
-8000.00
-6000.00
-4000.00
-2000.00
0.00
2000.00
4000.00
6000.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00
Total Force X (N)
-15000.00
-10000.00
-5000.00
0.00
5000.00
10000.00
15000.00
20000.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00
Total Force Y (N)
-140000.00
-120000.00
-100000.00
-80000.00
-60000.00
-40000.00
-20000.00
0.00
20000.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00
Total Force Z (N)
3.2031
3.3984
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
0 1 2 3 4 5
FFT Magnitude X
3.2031
3.3984
3.5938
0
100000
200000
300000
400000
500000
600000
700000
800000
0 1 2 3 4 5
FFT Magnitude Y
3.203125
3.359375
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
4500000
5000000
0 1 2 3 4 5
FFT Magnitude Z
RESONANCE !!!
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1º- Objectives
2º - DEM Method
3º - EDEM ANSYS Coupling
4º- Validation & Real Case
5º - Conclusions
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Bulk Handling & Structural Problems?!...
Coupled SIMULATION can solve them!Structural Problems
(FEA Simulation)Bulk Handling Problems
(DEM Simulation)Coupled Problems
Static & Dynamic effects of ore in equipment
Material Degradation & Segregation
Unbalanced Load
Inadequate SupportsChute Clogging & Uneven Feed
High Ore impact in the equipment Structure
Fatigue Cracking Conveyor Belt misalignmentEquipment Weight reduction Energy Efficiency
Wrong Springs (screens) Screen Performance
Mineral Crushing(Particle Breakage)
Spillage & Dust
Rats Holes in Discharges
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Conclusions
DEM can solve industrial bulk
material handling problems.
FEA can solve structural analysis
problems.
DEM-FEA coupling can give the right
structure for the
best particle flow!