CADFEM GmbH - Part 1. Luca Benvenuti CADFEM Simulation ist mehr als Software
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1 Particle Titelmasterformat simulation durch with Klicken Rocky bearbeiten DEM CADFEM GmbH - Part 1 Luca Benvenuti CADFEM 2017 Simulation ist mehr als Software 1
2 Agenda DEM: Theory andapplications DEM: Calibration and Customization DEM: More Efficient Processes DEM: Longer Machine Life Multi-GPU Solver Non-Spherical Particle Shapes Fully integrated with ANSYS Software: Workbench & Mechanical CADFEM 2017 Simulation ist mehr als Software 2
3 DEM: Titelmasterformat Theory and durch Applications Klicken bearbeiten CADFEM 2017 Simulation ist mehr als Software 3
4 DEM: Granular Material Granular material Solid macroscopic material Dissipate energy by interaction, mostly friction Many industries deal with particles Mining Pharmaceutical Agriculture Cement Transport Chemical Discrete element method is used to model granular material Particulate systems are difficult to measure Method to simulate a large number of discrete objects Classic mechanics Ship loading wikipedia CADFEM 2017 Simulation ist mehr als Software 4
5 DEM: Predicting Particle Motion in Time Force and Torque balance for each particle Example: particle falling: Time = t, F= F body = mg g Time = t +Dt, F= F body = mg wall Time = t + 2Dt, Time = t + 3Dt, F= F body + F surface = mg + F(t) contact F= F body = mg CADFEM 2017 Simulation ist mehr als Software F = Force, m= mass, a = acceleration, g = acceleration due to gravity 5
6 DEM: Contact forces Soft-sphere method is the most common, Cundall and Strack (1979) Particles can have a minimum overlap Overlap is used to calculate elastic, plastic and frictional forces Normal and tangential directions Explicit time integration F F surface, norm surface,tan d ~ ( d, d&, L, E, COR...) ~ ( d, d&, L, m, m,...) s d CADFEM 2017 Simulation ist mehr als Software 6
7 DEM: Contact Models Normal Forces Hysteretic Linear Spring, Linear Spring Dashpot, Hertzian Spring Dashpot Tangential Forces Linear Spring Coulomb Limit, Coulomb Limit, Mindlin-Deresiewicz Adhesive Forces Constant, Linear, Leeds, Hertzian Spring Dashpot with JKR Cohesion CADFEM 2017 Simulation ist mehr als Software 7
8 DEM: Calculation Loop START: Make geometry, create particles, create neighbor list and contact list DETERMINE FORCES & MOMENTS: Calculate sum of ALL forces & moments (Euler s equation) acting on each particle F net = F body + F surface = ma (Euler s rotational equations of motion not shown for clarity) INTEGRATE STATES: Integrate in time to find new position DV = Dx= F net m dt; V new = V old +DV V new dt; x new = x old +Dx V= velocity, x = position, dt = time step No END: Simulation end time or particles out of range? Yes STOP CADFEM 2017 Simulation ist mehr als Software 8
9 DEM: Industrial processes Separation / Mixing Transport Source: Size reduction / Granulation Source: Storage Source: Source: CADFEM 2017 Simulation ist mehr als Software 9
10 DEM: How can modelling help? Increase equipment life and capacity Eliminate blockages Decrease product degradation Reduce equipment noise, dust and power Define material trajectories Optimize belt tracking Minimize wear and maintenance. and so on CADFEM 2017 Simulation ist mehr als Software 10
11 DEM: Applications Wood chips (biomass handling) Tablets (pharmaceutical tablet coating) Rocks (truck dump) Wet and sticky ore (chute transfer in mining) CADFEM 2017 Simulation ist mehr als Software 11
12 DEM: Applications Eliminates need for external Multi-Body Dynamic Coupling (Unless geometry interactions are essential) Any geometry in Rocky can be a Free Body (motion can be constrained and boundary loads can be specified) Ballasted Layer Deformation Powder Compaction Building in Landslide CADFEM 2017 Simulation ist mehr als Software 12
13 DEM: Applications: e.g. Excavator CADFEM 2017 Simulation ist mehr als Software 13
14 DEM: Applications: e.g. Ring Pan Mixer CADFEM 2017 Simulation ist mehr als Software 14
15 DEM: Applications: Dust Flow Airflow (Lattice-Boltzmann) Simulation of a transfer chute with airflow vectors enabled: Show how dust and gas is affected by particle flow Simulation of a transfer chute with NO airflow vectors enabled CADFEM 2017 Simulation ist mehr als Software 15
16 DEM: Titelmasterformat Calibration and durch Customization Klicken bearbeiten CADFEM 2017 Simulation ist mehr als Software 16
17 DEM: Calibration Determination of the relevant parameters in experiments Parameter identification by matching of real & virtual experiment Quelle: TUNRA BULK SOLIDS CADFEM 2017 Simulation ist mehr als Software 17
18 DEM: Calibration and Customization Calibrate material data Automatic process Consider statistics Customized results Export particles position and orientation Automatic generation of void-volume for CFD Exported particle results ROCKY results Rebuild ROCKY results in CAD CADFEM 2017 Simulation ist mehr als Software 18
19 DEM: Titelmasterformat More Efficient durch Processes Klicken bearbeiten CADFEM 2017 Simulation ist mehr als Software 19
20 DEM: More Efficient Processes: Plow Mixer CADFEM 2017 Simulation ist mehr als Software 20
21 DEM: More Efficient Processes: Plow Mixer GUI based post-processing Qualitative analyses: 3D visualization Animations Plots by color Quantitative analyses: XY plots time plots histograms CADFEM 2017 Simulation ist mehr als Software 21
22 DEM: Titelmasterformat Longer Machine durch Life Klicken bearbeiten CADFEM 2017 Simulation ist mehr als Software 22
23 DEM: Longer Machine Life: Transfer Chutes Boundary Surface Wear Wall forces due to particles interactions (instantaneous and time average) are calculated CADFEM 2017 Simulation ist mehr als Software 23
24 DEM: Longer Machine Life: Transfer Chutes Boundary Surface Wear Mean Shear Power (W/m 2 ) Shear Intensity X Belt Width Impact Intensity X Belt Width Shear Intensity (W W/m 2 ) Im mpact Intensity (W/m 2 ) Belt Width (m) CADFEM 2017 Simulation ist mehr als Software 24
25 Multi-GPU Titelmasterformat Solver durch Klicken bearbeiten CADFEM 2017 Simulation ist mehr als Software 25
26 Multi-GPU Solver: Flexible Operating System CADFEM 2017 Simulation ist mehr als Software 26
27 Multi-GPU Solver: Tablet Coater Shared-parallel memory for both GPU and CPU Commercial scale tablet coater rotating at 10 RPM Gaming cards 242,000 custom convex particles with 222 vertices each Advances in DEM Computing Which Improve Predictive Capability for Processes, AIChE 2016, Stomata et al. Computing cards CADFEM 2017 Simulation ist mehr als Software 27
28 Multi-GPU Solver: High Shear Wet Granulation Scale up of high shear wet granulation Advances in Discrete Element Modeling of high-shear wet granulation process using Rocky-DEM, AIChE 2016, Pandey et al. CADFEM 2017 Simulation ist mehr als Software 28
29 Multi-GPU Solver: High Shear Wet Granulation Scale up of high shear wet granulation Suggestion: each 500k particles use 1 GPU (e.g. 2MM 4 GPU) 10 L granulator wall-clock-time-speed-up VS Particles-number-speed-up Relation Scalability (and memory) for large particle numbers on multi-gpu CADFEM 2017 Simulation ist mehr als Software 29
30 Multi-GPU Solver: SAG Mill 9.8m SAG mill (Section: 0.5 m) Fill: 25% (20% Ball) Speed: 10.3 RPM 1MM spherical particles Ore particles ( m) Ball particles ( m) CADFEM 2017 Simulation ist mehr als Software 30
31 Multi-GPU Solver: V-Blender V-Blender is filled (Top-Bottom) and rotates at 10 RPM Two particle groups of diferent materials are mixed 300,000 spherical particles Gaming cards Computing cards CADFEM 2017 Simulation ist mehr als Software 31
32 Titelmasterformat Non-Spherical Particle durch Shapes Klicken bearbeiten CADFEM 2017 Simulation ist mehr als Software 32
33 Non-Spherical Particle Shapes Default particle shapes in Rocky: Spherical Faceted Rounded Cylinder Rocky shape examples: Rounded Polygon Rounded Polyhedron Briquette rock rice capsule pill potato pea rod chip orange barley metal coal CADFEM 2017 Simulation ist mehr als Software 33
34 Non-Spherical Particle Shapes: Does Shape Really Matter? Glued spheres Polyhedral shape Almond Shape Tablet Representation CADFEM 2017 Simulation ist mehr als Software 34
35 Non-Spherical Particle Shapes: STL import Scan any shape and import it into Rocky: CADFEM 2017 Simulation ist mehr als Software 35
36 Non-Spherical Particle Shapes: Improved Concave Particle Simulation CADFEM 2017 Simulation ist mehr als Software 36
37 Non-Spherical Particle Shapes: Improved Concave Particle Simulation Concave shapes: Thin Potato Chip CADFEM 2017 Simulation ist mehr als Software 37
38 Non-Spherical Particle Shapes: Real case Screening/sorting Real particle Vibration movement CADFEM 2017 Simulation ist mehr als Software 38
39 Titelmasterformat Fully integrated with durch ANSYS Klicken Software bearbeiten Workbench & Mechanical CADFEM 2017 Simulation ist mehr als Software 39
40 ROCKY and ANSYS: Workbench integration Geometry parameterization using SpaceClaim (CAD) ROCKY parameters exposed into ANSYS Workbench environment Automated project-level update mechanism DOE/Optimization/Sensitivity analysis using OptiSLang or Desing Explorer CADFEM 2017 Simulation ist mehr als Software 40
41 ROCKY and ANSYS: Mechanical Coupling CADFEM 2017 Simulation ist mehr als Software 41
42 ROCKY and ANSYS: Mechanical Coupling Static Structural Rocky calculates the particle forces and the pressure (force over triangle area) on the boundary. The pressures components are then exported to Workbench Mechanical. CADFEM 2017 Simulation ist mehr als Software 42
43 ROCKY and ANSYS: Mechanical Coupling Static Structural Stresses and vibration analyses of a screen in ANSYS Inputs come from Rocky simulation CADFEM 2017 Simulation ist mehr als Software 43
44 ROCKY and ANSYS: Mechanical Coupling Static Structural ANSYS Mechanical results ANSYS SpaceClaim Rocky results CADFEM 2017 Simulation ist mehr als Software 44
45 ROCKY and ANSYS: Mechanical Coupling Transient Structural When there is boundary s motion, Rocky translate and rotate the loads from the atual position to the initial position, so in WB Mechanical the strututure remais stopped while the loads moves. User defines the output frequency and the time range to export to the Mechanical In Mechanical, user has to setup the imported pressure to Components and fill the Tabular Data CADFEM 2017 Simulation ist mehr als Software 45
46 FULLY INTEGRATED with ANSYS tools CADFEM 2017 Simulation ist mehr als Software 46
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