Conceptualisation of an Efficient Particle-Based Simulation of a Twin-Screw Granulator.

Discrete Element Method (DEM) simulations have the potential to provide particle-scale understanding of twin-screw granulators. This is difficult to obtain experimentally because of the closed, tightly confined geometry. An essential prerequisite for successful DEM modelling of a twin-screw granulator is making the simulations tractable, i.e., reducing the significant computational cost while retaining the key physics. Four methods are evaluated in this paper to achieve this goal: (i) develop reduced-scale periodic simulations to reduce the number of particles; (ii) further reduce this number by scaling particle sizes appropriately; (iii) adopt an adhesive, elasto-plastic contact model to capture the effect of the liquid binder rather than fluid coupling; (iv) identify the subset of model parameters that are influential for calibration. All DEM simulations considered a GEA ConsiGma™ 1 twin-screw granulator with a 60° rearward configuration for kneading elements. Periodic simulations yielded similar results to a full-scale simulation at significantly reduced computational cost. If the level of cohesion in the contact model is calibrated using laboratory testing, valid results can be obtained without fluid coupling. Friction between granules and the internal surfaces of the granulator is a very influential parameter because the response of this system is dominated by interactions with the geometry.

Use of elastic stability analysis to explain the stress-dependent nature of soil strength.

The peak and critical state strengths of sands are linearly related to the stress level, just as the frictional resistance to sliding along an interface is related to the normal force. The analogy with frictional sliding has led to the use of a 'friction angle' to describe the relationship between strength and stress for soils. The term 'friction angle' implies that the underlying mechanism is frictional resistance at the particle contacts. However, experiments and discrete element simulations indicate that the material friction angle is not simply related to the friction angle at the particle contacts. Experiments and particle-scale simulations of model sands have also revealed the presence of strong force chains, aligned with the major principal stress. Buckling of these strong force chains has been proposed as an alternative to the frictional-sliding failure mechanism. Here, using an idealized abstraction of a strong force chain, the resistance is shown to be linearly proportional to the magnitude of the lateral forces supporting the force chain. Considering a triaxial stress state, and drawing an analogy between the lateral forces and the confining pressure in a triaxial test, a linear relationship between stress level and strength is seen to emerge from the failure-by-buckling hypothesis.