LAB: Determining Particle Flow Calibrations: ROCKY Particle Calibration Supplement

ROCKY Particle Calibration Supplement
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LAB: Determining Particle Flow Calibrations

Calibrating particles is the method by which you determine what ROCKY settings will best replicate your real-
world particles. Use the following images and ROCKY settings to get a rough guideline for how to calibrate
particles using ROCKY.
The basic calibration process is as follows:

1. Using real-world particles, determine:
 the various shapes and size ranges within the particle set
 the tonnage, density, and friction values
 the stockpile and withdrawal angles of repose
Note: This information is typically gathered by using established
industry methods, such as observing existing stockpiles. It is not
necessary to recreate in real life the lab geometries described below;
though for smaller particles (for example, less than 6 mm) this is
feasible if desired. See image at right for an example.
2. Using ROCKY and the examples that follow, set up simulation

labs using particles of similar shape, size, tonnage, density, and
friction values as your real particles.
3. As you run your labs, adjust the following values until your angles
of repose in ROCKY matches that of your real-world particles:
 Rolling Resistance
 Static Friction
Figure 1: Example of a real-world
 Adhesive Properties angle of repose tester built by GDI.
Note: It can take several separate simulations to properly calibrate Useful for testing small particles (less
your particles. Especially if you are using non-round particle shapes, than 6 mm).
plan for this time accordingly before project onset.
Page 1 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
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This section contains the following topics:

 Lab 1: 37/60 “Typical” Scenario
 Lab 2: 40/50 “Slot” Scenario
 Lab 3: 35/63 “No Rolling Resistance” Scenario
 Lab 4: 42/72 “Higher Rolling Resistance and Static Friction” Scenario
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Lab 1: 37/60 “Typical” Scenario

Description:
Reclaim opening – hole configuration
using non-round particles that results
in a “typical” 37 degree stockpile and
a 60 degree withdrawal angle.
Labs 3 and 4 will be variations of this

lab.
Key Boundary Settings:

Hole Size: 70 mm diameter
Key Particle Settings:

Shape: Rounded Polyhedron
Size: 0.011 @ 100%
Rolling Resistance: 0.05
(surface asperity)
Figure A: Stockpile Angles of Repose Static Friction: 0.5
Boundary Adhesive Fraction:
0.015
Particle Adhesive Fraction: 0.015
Figure B: Withdrawal Angles of Repose
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Particle Group Settings

Lab 1: ROCKY settings for duplicating Figures A-B.
Solids Fraction for Bulk Density Calculations:
File: RP-240-650-660-70-440-R02.rcy 0.6 (default)
Name: Particle Group 01

Number of Processors: 24 Release Point: Inlet 01
Over the Network (Y/N): Y (default) Rotations: Checked (default)
Start Time: 4/28/2011 12:58 PM Density: 1650
End Time: 4/29/2011 9:58 AM Bulk Density: Unchecked
Total Processing Time: 21 hours 0 Minutes Restitution: 0.3 (default)
Static Friction: 0.5
Simulation Summary Dynamic Friction: 0.5
Total Number of Particles: 21221 Tonnage (mt/h): 22
Total Number of Enabled Air Nodes: 0 Loading Stiffness per Size: 100000000
Total Number of Boundary Triangles: 3068 (default)
Area of Broken Particle Surfaces: 0 Material Size: 0.011 = 100%
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z- Shape: Rounded Polyhedron
0.335,0.335 Vertical Aspect Ratio: 1.6
Time Step: 3.28749e-006 Horizontal Aspect Ratio: 0.8
Smoothness: 0.25
Simulation Settings Rolling Resistance (Round): 0.05
Simulation Title: RP-240-650-660-70-440-R02 (surface asperity)
Customer Name: CDI Side Angle: (disabled)
Duration: 20 (default) Number of Corners: 10
Output Frequency: 0.05 (default) Superquadric Degree: 2
Statistics Start Time: 10 (default) Breakage Properties: Not used.
Loading N-Steps (10-30): 8
Boundary Adhesive Distance: 0.0001 (default) Boundary Component Settings
Boundary Adhesive Fraction: 0.015 Static Friction (for all): 0.3 (default)
Particles Adhesive Distance: 0.0001 (default) Dynamic Friction (for all): 0.3 (default)
Cylinder Size: 240 mm Diameter x 650 mm
Height
Simulation Description Upper Plate Size: 660 mm Diameter
Overall Time Duration: 20.0 seconds Hole Size: 70 mm Diameter
Cylinder fills for 3.0 seconds Lower Plate Size: 440 mm Diameter
Cylinder moves on the Y axis from 3.0 to 9.5
seconds at 0.05 meters per second
Gate moves on the X axis from 9.5 to 9.51 at 7.0
meters per second
Case stopped at: 12.350 seconds
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Lab 2: 40/50 “Slot” Scenario
Description:
Reclaim opening – slot configuration
using round particles that results in
a 40 degree stockpile and a 50
degree withdrawal angle.

Hole Size: 60 mm x 300 mm Slot

Shape: Spheres
Size: 0.01 @ 100%
Rolling Resistance: 0.16
0.015
Particle Adhesive Fraction:
0.015
Figure C: Slot Configuration (Head-On)
Figure D: Slot Configuration (Side View)
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Figure E: Looking Across the Smallest Side of the Slot
Figure F: Looking Across the Longest Side of the Slot
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Lab 2: ROCKY settings for duplicating Figures C-F. Particle Group Settings
Solids Fraction for Bulk Density Calculations: 0.6
File: S-240x650-600-60x300-440-R00.rcy
(default)
Name: 10 mm Spheres
Release Point: Inlet 01
Number of Processors: 24 (hyperthreads-12 cores)
Rotations: Checked (default)
Over the Network (Y/N): Y (default)
Density: 1650
Start Time: 4/28/2011 8:34 AM
Bulk Density: Unchecked
End Time: 4/28/2011 10:32 AM
Restitution: 0.3 (default)
Total Processing Time: 1 hour 58 minutes
Dynamic Friction: 0.5
Simulation Summary
Tonnage (mt/h): 22
Total Number of Particles: 21221
Loading Stiffness per Size: 100000000 (default)
Total Number of Enabled Air Nodes: 0
Material Size: 0.01 = 100%
Total Number of Boundary Triangles: 2780
Shape: Spherical (default)
Area of Broken Particle Surfaces: 0
Vertical Aspect Ratio: (disabled)
Mass of Broken Particles: 0
Horizontal Aspect Ratio: (disabled)
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z-
Smoothness: (disabled)
0.335,0.335
Rolling Resistance (Round): 0.16
Time Step: 3.46276e-006
Side Angle: (disabled)
Number of Corners: (disabled)
Simulation Settings
Superquadric Degree: (disabled)
Simulation Title: S-240x650-600-60x300-440-R00
Breakage Properties: Not used.
Customer Name: CDI
Duration: 30
Boundary Component Settings
Output Frequency: 0.05 (default)
Static Friction (for all): 0.3 (default)
Statistics Start Time: 10 (default)
Dynamic Friction (for all): 0.3 (default)
Loading N-Steps (10-30): 15 (default)
Boundary Adhesive Distance: 0.0001 (default)
Cylinder Size: 240 mm Diameter x 650 mm Height
Boundary Adhesive Fraction: 0.015
Upper Plate Size: 660 mm Diameter
Particles Adhesive Distance: 0.0001 (default)
Hole Size: 60 mm x 300 mm Slot
Lower Plate Size: 440 mm Diameter
Simulation Description
Overall Time Duration: 30.0 seconds
Cylinder fills for 3.0 seconds
Cylinder moves on the Y axis from 3.0 to 7.0 seconds at 0.05 meters per second
Gate moves on the X axis from 7.0 to 7.1 at 6.0 meters per second
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Lab 3: 35/63 “No Rolling Resistance” Scenario
Description:
Reclaim opening – hole
configuration using non-round
particles that results in a 35 degree
stockpile and 63 degree withdrawal
angle.
This lab uses the same setup as

Lab 1, but has no rolling
resistance.

Hole Size: 70 mm Diameter

Size: 0.0111 @ 100%
Figure G: Stockpile Angle
Rolling Resistance: 0
(no asperity)
0.015
Particle Adhesive Fraction:
0.015
Figure E: Withdrawal Angle
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Lab 3: ROCKY settings for duplicating Figures G-H. Particle Group Settings
File: RP-240-650-660-70-440-R03.rcy Solids Fraction for Bulk Density Calculations:

0.6 (default)

Number of Processors: 16
Over the Network (Y/N): Y (default)
Rotations: Checked (default)
Start Time: 4/27/2011 1:29 PM (from 3 seconds)
Density: 1650
End Time: 4/29/2011 12:57 PM (to 7.35 seconds)
Bulk Density: Unchecked
Total Processing Time: 23 hours 32 minutes
Restitution: 0.3 (default)
Simulation Summary
Total Number of Particles: 21221
Tonnage (mt/h): 22
Total Number of Enabled Air Nodes: 0
Loading Stiffness per Size: 100000000 (default)
Total Number of Boundary Triangles: 3068
Material Size: 0.0111 = 100% (default)
Area of Broken Particle Surfaces: 0
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z-
0.335,0.335 Vertical Aspect Ratio: 1.6
Time Step: 3.28749e-006 Horizontal Aspect Ratio: 0.8
Smoothness: 0.25
Simulation Settings Rolling Resistance (Round): 0.0
Simulation Title: RP-240-650-660-70-440-R03 Side Angle: (disabled)
Customer Name: CDI Number of Corners: 10
Duration: 20 (default) Superquadric Degree: 2
Output Frequency: 0.05 (default) Breakage Properties: Not used.
Statistics Start Time: 10 (default)
Loading N-Steps (10-30): 8
Boundary Component Settings
Static Friction (for all): 0.3 (default)
Dynamic Friction (for all): 0.3 (default)
Particles Adhesive Distance: 0.0001 (default)
Cylinder Size: 240 mm Diameter x 650 mm
Height
Upper Plate Size: 660 mm Diameter
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Lab 4: 42/72 “Higher Rolling Resistance and Static

Friction” Scenario
Description:
Reclaim opening – hole configuration
using non-round particles that results in
a 42 degree stockpile and a 72 degree
withdrawal angles.
This lab uses the same setup as lab 1

except that it has higher Rolling
Resistance and Static Friction values.


Size: 0.0111 @ 100%
Figure I: Stockpile Angle Rolling Resistance: 0.15
Figure J: Withdrawal Angle
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Lab 4: ROCKY settings for duplicating Figures I-J.

Particle Group Settings
File: RP-240-650-660-70-440-R00.rcy Solids Fraction for Bulk Density Calculations: 0.6
(default)
Number of Processors: 64 (hyperthreads-32 cores) Rotations: Checked (default)
Over the Network (Y/N): Y (default) Density: 1650
Start Time: 4/27/2011 9:05 AM Bulk Density: Unchecked
End Time: 4/28/2011 8:24 AM Restitution: 0.3 (default)
Total Processing Time: 11 hours 19 minutes Static Friction: 1.0
Simulation Summary Tonnage (mt/h): 22
Total Number of Particles: 21221 Loading Stiffness per Size: 100000000 (default)
Total Number of Enabled Air Nodes: 0 Material Size: 0.111 = 100% (default)
Total Number of Boundary Triangles: 3068 Shape: Rounded Polyhedron
Area of Broken Particle Surfaces: 0 Vertical Aspect Ratio: 1.6
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z- Horizontal Aspect Ratio: 0.8
0.335,0.335 Smoothness: 0.25
Time Step: 3.28749e-006 Rolling Resistance (Round): 0.15
Side Angle: (disabled)
Simulation Settings Number of Corners: 10
Simulation Title: (default) Superquadric Degree: 2
Customer Name: (default) Breakage Properties: Not used.
Duration: 20 (default)
Output Frequency: 0.05 (default) Boundary Component Settings
Statistics Start Time: 10 (default) Static Friction (for all): 0.3 (default)
Loading N-Steps (10-30): 8 Dynamic Friction (for all): 0.3 (default)
Boundary Adhesive Fraction: 0.015 Cylinder Size: 240 mm Diameter x 650 mm
Particles Adhesive Distance: 0.0001 (default) Height
Particle Adhesive Fraction: 0.015 Upper Plate Size: 660 mm Diameter

LAB: Determining Particle Flow Calibrations: ROCKY Particle Calibration Supplement

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ROCKY Particle Calibration Supplement

LAB: Determining Particle Flow Calibrations

The basic calibration process is as follows:

2. Using ROCKY and the examples that follow, set up simulation

This section contains the following topics:

Lab 1: 37/60 “Typical” Scenario

Labs 3 and 4 will be variations of this

Key Boundary Settings:

Key Particle Settings:

Figure B: Withdrawal Angles of Repose

Particle Group Settings

Name: Particle Group 01

Lab 2: 40/50 “Slot” Scenario

Key Boundary Settings:

Key Particle Settings:

Figure D: Slot Configuration (Side View)

Figure E: Looking Across the Smallest Side of the Slot

Figure F: Looking Across the Longest Side of the Slot

Lab 3: 35/63 “No Rolling Resistance” Scenario

This lab uses the same setup as

Key Boundary Settings:

Key Particle Settings:

Figure E: Withdrawal Angle

File: RP-240-650-660-70-440-R03.rcy Solids Fraction for Bulk Density Calculations:

Name: Particle Group 01

Lab 4: 42/72 “Higher Rolling Resistance and Static

This lab uses the same setup as lab 1

Key Boundary Settings:

Key Particle Settings:

Figure J: Withdrawal Angle

Lab 4: ROCKY settings for duplicating Figures I-J.

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