Whitepaper

Conveying & Transportation

DEM Simulation of the Bulk Solid

Reaction on Vibratory Conveyors
For the design of heavily-loaded vibratory conveyors the
reaction of the conveyed material must be considered. The
paper will describe the problem of the reactive effect, some
calculation theory as well as the basics of a developed discrete
element model.

BulkEurope 2008

Authors:
G. Uryadov, A. Katterfeld, F. Krause
University of Magdeburg, Institute of Materials Handling

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 BulkEurope 2008

DEM Simulation of the Bulk Solid Reaction on Vibratory Conveyors

G. Uryadov, A. Katterfeld, F. Krause

University of Magdeburg, Institute of Materials Handling, Universitätsplatz 2, D-39106 Magdeburg, Germany

gennady_u@yahoo.com

Abstract

The vibratory conveyors have found industrial application in many branches. The possible combination of the transport
process with other technological processes like screening, mixing, feeding etc is one reason for that. But it is also because
the relatively simple design and the low energy consumption of such conveyors. The creation of a possibility for the
hermetic and safe transport of aggressive bulk material was a driving force for the development of the vibratory conveyors.

For the design of heavily-loaded vibratory conveyors the reaction of the conveyed material must be considered. The bulk
solid interaction with the trough of the vibratory conveyor, the so-called reactive effect, results partially in damping and
partially in an increase of the trough mass due to the connected mass of the bulk solid. Therefore, the reactive effect
influences the natural frequency, the amplitude and the required drive power of the conveyor. The insufficient consideration
of the bulk solid interaction can be result in

− a reduction of the volumetric flow,

− a discontinuous transport process,
− an overload of the driving gear,
− a failure of the conveyor construction.

The reactive effect depends on the operating parameters of the conveyor, on the bulk solid properties and on the height of
the bulk material on the trough. The paper will describe the problem of the reactive effect, some calculation theory as well as
the basics of a developed discrete element model. Furthermore it will show the planed verification of the simulation model
by experimental tests.

1 PROBLEMS OF ANALYSING THE BULK SOLID MOTION ON THE VIBRATING TROUGH

In spite of the simplicity of the vibratory conveyor design, the questions of the control and transportability of arbitrary bulk
solid remains still vital. The reason for that is the complex bulk solid motion on a vibrating surface.

Firstly, the motion analysis for the medium “bulk solid” is generally much more complex than for fluids or solid bodies.
Bulk solids can behave like fluids or solid bodies dependent on the stress distribution. Bulk solid can be described as a
system out of a large quantity of elements whose dimensions are much smaller than the dimensions of the whole system.
Changing’s of the inside stress distributions causes changing’s of the bulk material properties. This can happen especially
during dynamic states.

Secondly, the vibrating surface causes a complex, compound motion of the bulk solid. The vibrating surface can show
various kinds of motions: harmonic circular, elliptical or linear and non-harmonic motions. However, the vibrating mode, the
exciter force amplitude, the frequency and the trough inclination angle define the character of the bulk solid motion.
The influencing parameters, defining the handling of any bulk solid on a vibratory conveyor can be summarised as follows:

Table 1: Operating and bulk solid properties which influence the behaviour of the vibratory conveyor

conveyor bulk solid

− vibrating mode − particle shape
− frequency amplitude − particle size distribution
− inclination angle of the vibrating − angle of internal friction
conveyor surface − wall friction angle
− natural frequency − modulus of elasticity of the
− smoothness of the trough surface particles
− geometry of the trough cross section − cohesion
− modulus of elasticity of trough inner − internal dampening
surface (coated with rubber, plastic, − layer thickness
etc.) − possible electrostatic charges
− possible electrostatic charges − permeability to air

2 THE REACTIVE EFFECT OF A CONVEYED MATERIAL

The investigation of the influence of the material properties on the bulk solid interaction is the main topic of the ongoing
research work about vibratory conveyors at the Institute of Materials Handling at the University of Magdeburg, Germany.
The number of works, which cover this subject, is very low. The majority of previous works has not considered this effect.
Usually, the influence of the bulk solid properties is only considered by the implemented wall friction value and by the air
permeability. The list of influencing parameters (see table 1) shows, that there are much more influencing properties which
were not considered in the previous works. Due to these simplifications in the calculation models, the use of other empirical
factors is necessary. Hence, for every new bulk solid or new operation conditions experimental tests are necessary to
determine these factors.

A good fundament for the ongoing research of the bulk solid interaction was laid by Hoormann [1] and Steinbruck [2]. Two
general types of the reactive effect were described and how they influence the vibrating of the trough. The absolutely plastic
particle impact, which is assumed theoretically, and the wall friction of the particles were identified as the reasons for the
reactive effect. The processes inside the bulk solid were taken as negligible factors. The influence of the internal friction and
damping was only considered indirectly, as a major condition for the assumption of an absolutely plastic impact.

The reactive effect of the handled material can be divided into the material damping and mass coupling.

The material damping is an effect that tends to reduce the amplitude of the trough oscillation. Dissipative forces caused by
friction, deformation and other mechanical or non-mechanical effects are summarised in the material damping value. For the
vibratory conveyors, these are mainly the wall friction, the internal friction and the plastic or elastic particle deformation.

For the estimation of the material damping inside the vibratory conveyors, a damping constant is applied. It is defined
assuming the viscous damping law with the same energy loss over each period as the real damping.
 BulkEurope 2008

The mass coupling is defined as an effect of the vibrating mass increase, caused by the permanent interaction of the trough
load and the initial, constant vibrating mass. For an estimation of the mass coupling, a mass coupling factor is applied. It
defines a part of the load mass which is assumed to be coupled to the trough.

The work about the reactive effect has indicated a number of regularities for some of the parameters shown in table 1.
Though, these regularities can be easily used for some bulk solids with certain properties. But a general use for any bulk
solid is problematic

3 EXISTING METHODS OF VIBRATORY CONVEYOR ANALYSIS

All theoretical investigations about vibratory conveyors can be ascribed to one of two basic models. These are the point-
mass model and the mechanical-rheological layer model.

3.1 The point-mass model

This model became most popular and found practical application in many works covering the theory of the vibratory
conveyors. The model uses the following assumptions [3]:

− The through is driven harmonically in horizontal and vertical directions.

− A particle is considered as a point-mass.
− The collisions between the particles and the trough surface are completely plastic. No particle bounce occurs after a
collision.
− The particle does not rotate.
− The trough vibrating surface is ideal flat and the trough side walls have no influence.
− The inter particle friction, the wall friction, the permeability to air as well as the elastic damping properties of the
particles are neglected.

A characteristic parameter for the handling behaviour is the so-called throw number Γ :

Ω 2 A sin β
Γ= (1)
g

with
g - acceleration of gravity,

f dr - driving frequency,

A - amplitude,
β - vibration angle,

Ω - angular vibration frequency ( Ω = 2π ⋅ f dr ).

Two modes of motion are defined: with and without loss of particle-trough contact. The contact loss occurs when the
reaction force between the trough and the particle becomes equal to zero. In other words, the values Γ < 1 mean no throw
and, in the case of the values Γ ≥ 1 , a throw of particle occurs. In the last case the given vertical particle acceleration caused
by the trough motion exceed the acceleration of gravity.

The periodical particle motion can be divided into characteristic phases: sliding, flight, collision, rest as well as combined
phases. The start and end time of each characteristic point have to be calculated. For this, the equations of particle and
trough motion as well as the momentum equations of the particle-trough interaction have to be solved. A throw over the
whole period result in values Γ ≥ 3.3 . For each phase, a particle velocity is computed. The sum of all phases defines the
conveying speed. Hence, the basic formula for the determination of the average conveying speed is given by

g ⋅n2
v th = cot β with 0 ≤ n ≤ 1 (2)
2 ⋅ f dr

with
n - factor of throw time, it is a function of the throw number,

f dr - driving frequency.

The inverse relation of n and Γ is

2
 cos( 2πn ) + 2π 2 ⋅ n 2 − 1 
Γ =   +1
 (3)
 2 ⋅ π ⋅ n − sin( 2 ⋅ π ⋅ n ) 

The factor of the throw time indicates the relation of the pure throw time to the whole vibrating period.

The theoretical average conveying speed will not be achieved because the many unaccounted factors, influencing the bulk
solid motion. The real bulk solid properties and other parameters which influence the bulk solid motion are considered by
the use of correction coefficients:

v = v th ⋅ K1 ⋅ K 2 ⋅ K 3 ⋅ K 4 (4)

with
v - conveying speed achieved in practice.
v th - theoretical conveying speed,

K1 - coefficient due to bulk solid properties,

K2 - coefficient due to the percentage of fines in a bulk solid,

K3 - coefficient due to height of load,

K4 - coefficient due to trough inclination.

The product of all correcting coefficients can range between 0.05 and values over 1.0.

Numerous works in this field cover the definition of the influences of air permeability, friction, bulk solid reaction on the
trough motion, trough inclination and other factors. Despite many works which recommend improved calculation theories,
the basic formula for the average conveying speed is still used in practice.

3.2 Mechanical-rheological model of the bulk solid layer

A number of investigations base on the rheological model of a “bulk solid – trough” system. The model bases on a primary
assumption that the bulk solid can deform elastically and plastically during its motion on the trough. For example, a model
can consist out of discrete mass elements and damping effects, elastic and plastic deformation as well as other rheological,
mechanical or even electromechanical interactions. These works [4,5], done in the late 1970s and early 1980s show the
extensive search for an improved method which considers the real physical behaviour of a particular system. The usage of
this method was limited due to the complex non-linear equation system and the missing experimental validation.
 BulkEurope 2008

3.3 Discrete Element Models

The effects of the bulk solid reaction are difficult to analyse by experimental tests only. However, computer simulations
based on the Discrete Element Method (DEM) can help to increase the understanding of these processes. The DEM is based
on the solution of Newton’s equations for each particle. An overview about the DEM basics is given in [6].

The DEM allows the simulation of the particle interaction inside bulk solids and consider its influence on integral parameters
such as conveyer speed, required driving power, forces as well as the general material flow or eventual wear. The DEM can
be called as a new innovative method for the problem solving in the field of vibratory conveying as well as in the whole bulk
solid handling.

4 SIMULATIONS OF THE REACTIVE EFFECT

4.1 General DEM-model of a vibratory conveyor

For a planed simulation a model must be developed. On the one hand, the model of the vibratory conveyor must be close to
reality and reproduce the conveyor geometry, the bulk solid properties as well as the operating conditions. On the other
hand, a model must take account of the calculation time, which is the decisive parameter for any DEM simulation.

For the DEM simulation of a vibratory conveyor the following aspects can be considered:

− Modelling of the real trough geometry:

In general, any geometry can be modelled. Usually, the real trough length has to be reduced to limit the particle
amount. A quasi endless conveyor can be modelled using so-called periodic boundaries. This means that
particles, which leave the model at one other site, are re-generated on the opposite site with the same properties
(Fig.1).

Fig. 1: DEM simulation of a vibrating conveyor with some bulk material. Periodic boundaries are used in x-direction.
Particle colour: particle velocity in x-direction: <-0.1 >0.35 m/s

− Modelling of the bulk solid:

As a rule, certain bulk solid properties e.g. particle size and shape have to be idealised in the simulation. The real
particle size distribution can be usually applied only for ideal bulk solids (e.g. glass or steel beads). Usually the
fine particles have to be neglected to limit the calculation time. Strongly irregular particle shapes can be modelled
via clumps of ball segments. However, simple spherical particles are used mostly. The bulk solid properties can
be modelled via various contact models. The contact model defines the interaction of individual particles and
contains several contact laws and contact parameters (Fig 2). The above named idealisations in the simulation
model result in a particular system which shows significant differences to the real system. In order to achieve a
 real behaviour of the idealised system, a calibration of the contact model parameters is required. Hence, real bulk
solid parameters can not be used or can be used only partially. The calibration can be done by using different
laboratory tests e.g. shear tests and angle of repose tests. For further information see [6].

− The dynamic behaviour of the trough (sinusoidal vibrations) is defined by the frequency, the amplitude and the
vibration angle, which have to be similar to the reality.

− The simulations can be analysed via different measurable parameters (particle velocity, emergent contact forces
and other parameters). The general bulk solid motion can be observed via pictures sequences.

Fig. 2: Visualisation of a DEM contact model: Springs = elastic deformation law, dash pots = viscose damping law,
parallel lines = Coulomb’s friction and meniscus = attractive laws (cohesion). [6]

4.2 Programming of the reactive effect

In pure DEM-computations the constructional details of the trough are considered as walls with infinitely great mass and a
given wall velocities. Hence, the wall motion can not be directly influenced by the bulk load. Therefore, the reactive effects
must be indirectly described and implemented into the simulation model. The consideration of the reactive effect can be
realised by the use of an extra algorithm. In this procedure, all particle forces influencing the trough are summed. From this
total force, a new trough velocity is calculated considering the real trough mass, inertia and the parameter of the springs.

The equation of trough motion can be written as:

m t &s&t = ∑ Fi = Fd + Fdr + Fe + Fr (5)

with
Fd - total damping force of the springs,

Fdr - driving force ( Fdr = F0 cos Ω ⋅ t ),

Fe - total elastic force of the springs,

Fi - particle contact force on the wall

Fr - force of the bulk solid reaction

f dr - driving frequency

mt - trough mass

&s&t - trough acceleration

The parameters of vibrating, damping and elastic forces are given and calculated depending on the current time, trough
velocity and acceleration. The particle contact forces on the trough contain the already described components of the reactive
effect: the mass coupling force and the material damping force. It can be measured in each calculation cycle, so a new trough

velocity is calculated from the sum of contact forces ∑ Fi . The equation for the new trough velocity is given by:
 BulkEurope 2008

s& t j+1 =
∆t
mt
(
Fr + ρ sd s& t j + cs t j + F0 cos Ω ⋅ t ) (6)

with

j - index of the computing cycle,

ρ sd - total damping constant of the springs

c - total elasticity constant of the springs,

The necessary simulation parameters can be summarised as follows:

− trough geometrics (trough dimensions, angle of inclination),

− bulk solid parameters (contact model laws und parameters, material and bulk density, grain size distribution, mass
flow rate = bulk solid height on the trough),
− dynamic parameters (frequency, amplitude, vibration angle, driving force, trough mass, spring constant and spring
damping constant).

In the first step of the studies the simulation model must be generally verified. This means some preliminary simulations
must be curried out. Then, the reactive effect must be implemented into the model and the main simulations follow after that.
In the phase of testing the preliminary simulation model, a qualitative verification is sufficient.

Already in the first preliminary simulations of a free mass vibratory conveyor (Fig.1), 5% difference between the theoretical
and simulated conveying speeds could be recognised.

4.3 Simulation of the vertical component of the reactive effect

An analysis of the bulk solid parameters, which influence the reactive effect, is the main focus of the investigations. From the
previous works it is known, that the vertical component of reactive effect dominates for the usually used throw number
values ( Γ = 2,0...3,3 ). Therefore, the simulations and the verification work are concentrated on this component.

The horizontal component is caused by a friction between the lowest bulk material layer and the trough surface. Coulomb
friction assumed, this component can be described by the vertical component of the reactive effect (= normal force), the
inclination angle of the conveyor, the vibration angle and the wall friction coefficient. Hence, the horizontal component can
be calculated out of the vertical component.

For the studies of the vertical component of the reactive effect, it seems to be sufficient to consider vertical vibration only.
This simplification allows an easier analysis of the processes in the bulk solid. Furthermore, it allows a better and more
detailed verification of the simulation results because all processes can be traced back to a single cause. Due to this
simplification a new DEM model has been developed. It is a vertical vibrating plate (Fig. 3) that is subjected to the bulk load
reaction.
Fig. 3: DEM simulation of a vertical vibrating plate with some bulk material. Periodic boundaries are used in x- and y-
direction. Particle colour: particle velocity in y-direction: <-0.35 >0.35 m/s

In the simulation the influence of variable parameters like exciter frequency, throw number, bulk solid properties and bulk
load height are analysed. The results of simulations have to be compared with the results of experimental investigation.

The internal processes, causing the damping and mass coupling, can be observed and analysed in the simulation. From the
analysis of the “thrown” bulk solid, it was discovered, that not only the dynamic parameters of the trough, but also the mode
of bulk solid layers interaction have a great influence on the trough motion as well as on the general behaviour.

The exciter impulses diminish layer by layer throughout the bulk solid bed. The attenuation intensity of the impulses
depends on the bulk solid properties as well as on the mode and value of trough vibration. The kinetic energy of the trough is
consumed for the bulk solid acceleration and the compensation of losses in the irreversible and elastic deformation. These
effects can be interpreted as bulk solid damping. The simulation makes it possible to measure a damping ratio of pure bulk
solid damping without consideration of the spring damping.

The simulations indicate, that a phase displacement in the motion of the bulk solid bed and trough can be observed at large
load heights. This phase displacement causes a loss of kinetic energy because certain layers move against each other. From
the simulations it can be observed that the bulk solid layers can be in three different general states during the material
motion. These are compaction, displacement and loosening. These behaviours define the throw and the handling process.

5 PLANED EXPERIMENTAL INVESTIGATIONS

For the purpose of DEM verification new experimental equipment is being built at the ILM of University Magdeburg
(Fig.4). The vibratory test rig is a one-mass vibrating system with double unbalance motors as free oscillator which operates
above the resonance state. Pure vertical vibration can be studied with this equipment. The measurement facilities can record
the trough displacement, the trough acceleration and the reactive forces acting on the trough. The general program of
experimental investigations is shown in table 2. In order to document the bulk solid influence, the behaviour of the test rig
has to be determined in no-load operating conditions. Due to the use of a transparent tube, the bulk solid behaviour during
the operation can be documented via videos.
 BulkEurope 2008

Fig. 4: 3D-model of the vibratory test rig: 1- glass tube (that is filled by bulk solid); 2 – unbalance motors; 3 – force
sensors; 4 – supporting springs; 5 – linear guiding

Table 2: General experimental and measuring program

bulk solid load height parameter measured

no-load operation required power, W

spherical particles
load height, mm
under 100 mm trough acceleration, m/s2
(glass - und steel balls,
trough displacement, mm
mustard seeds, etc.)
under 300 mm driving force, N

6 CONCLUSION

An optimal selection of the dynamic parameters of a vibratory conveyor is only possible by considering the real behaviour of
the bulk solid. This is important for the handling stability, the achievement of maximal conveying speed and the energy loss
minimisation. The regularities that are the basis for this selection are being investigated by the DEM and will be presented in
the next papers.

The targets of the investigation are the prediction of volume and mass flow, the selection of optimal parameters for the
handling and an improvement of the conveyor capacity as well as the creation of a model as a tool for the design of vibratory
conveyors.

The DEM-simulation allows a new analysis strategy in the field of vibratory conveyors. It is an efficient tool. With its use,
many theoretical problems can be solved. The DEM application promises the improvement of the calculation theory for the
design of vibrating conveyors as well as the development of a tool for the direct determination of the transport velocity, the
volumetric flow and the drive power.
REFERENCES

[1] Hoormann, W., Über den Einfluss des Fördergutes auf das Betriebsverhalten von Schwingförderrinne,
Dissertation TH Hannover, 1967

[2] Steinbruck, K Zur Fördergutrückwirkung auf Schwingrinnen, Dissertation TH Hannover, 1981

[3] Böttcher, S., Beitrag zur Klärung der Gutbewegung auf Schwingrinnen. Diss. TH Hannover (1957) und Fördern
und Heben 8 (1958) S. 127/31, S. 235/40, S. 307/15

[4] Gončarevič I.F., Teorija vibracijonnoj techniki i technologii. Moskva, Nauka, 1981

[5] Spivakovskij A.O., Vibracionnye i volnovye transportirujuščie mašiny. Moskva, Nauka, 1983

[6] Gröger, T. and A. Katterfeld: Application of the Discrete Element Method in Materials Handling: Basics and
Calibration; Bulk Solids Handling Vol. 27 (2007) Nr. 1