Workshop 06 – High Pressure

Grinding Roll (Wear and

Breakage)

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 OBJECTIVE

The two main purposes of this workshop are to set up a High Pressure
Grinding Roll (HPGR) simulation, and to calculate and view surface
wear modification upon the Deflector geometry during post -processing.

You will learn how to:
Add and Define a Feed Conveyor
Create a Free Body Rotation with an
Additional Moment
Measure and Visualize Surface
Displacement
Calculate and Compare Power Draw
And you will use these features:
Motion Frames
Surface Wear Modification Model
Ab-T10 Breakage Model
Property User Process
Time Plot

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 PREREQUISITES

This workshop assumes that you are already familiar with the Rocky
user interface (UI) and with the project workflow.
If this is not the case, please refer to Workshop 01 – Transfer Chute
for a basic introduction about Rocky usage before beginning this
workshop.

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 AGENDA
Part 1: Project Setup and
Processing
Geometry Introduction and Project
Creation
Project Details and Physics Setup
Geometry Import and Feed Conveyor
Definition
Defining Motion Frames for the Rolls
and Deflector Geometries
Activating the Surface Wear
Modification Model
Materials Definitions and Interactions
Particle Groups, Breakage, and Inputs
Solver Setup and Processing
Part 2: Post-Processing
Defining a Property User Processes
Using the Coloring Tab to Visualize
Displacement
Using a Time Plot to Graph the
Displacement Area
Use a Time Plot to Compare Power for
Both Roll Geometries
Accessing the User Manual
Conclusion
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PART 1: PROJECT SETUP
AND PROCESSING

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 GEOMETRY

(1) The geometries in this tutorial

are composed of:
1) Feed Conveyor
2) Hopper
3) Deflector
4) Roll 1
5) Roll 2
(3) (2)

In the workshop directory the

*.stl files can be found.

(4)

(5)

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 PROJECT CREATION

Ensure you have downloaded and extracted the WS 06 – Input Files

zip folder that was provided along with this PDF.
Open Rocky 4. Look for Rocky 4 in Program Menu or use the desktop
shortcut. Click the New Project button, or from the File menu, click
New Project (Ctrl+N).

New Project Save Project

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PROJECT DETAILS

The first step of the setup is to define any

useful information of the project.
From the Data panel, click Study 01 and
then edit the parameters in the Data
Editors panel (as shown).

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PHYSICS DEFINITION

For this workshop, the Numerical

Softening Factor will be lowered to
reduce the simulation time.
From the Data panel, select Physics.
From the Data Editors panel, select
the Momentum sub-tab, and then
change the Numerical Softening
Factor (as shown.)

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GEOMETRY IMPORT
For this case, we will both create and import
geometries. Four of the geometries will be
imported as *.stl formats.
From the Data panel, right-click Geometries,
point to Import, and then click Custom
Geometry.

Select the following files:

Hopper.stl
Deflector.stl
Roll 1.stl
Roll 2.stl
These parts will be imported using “mm” as
Import Unit and with the option Convert Y
and Z Axes kept unchecked.

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 FEED CONVEYOR DEFINITION

The fifth geometry will be created from a default geometry.

Rocky not only allows Custom geometry import but also provides some
default geometries, such as a Feed Conveyor and a Receiving
Conveyor, that you can add to your projects.
For this workshop, a Feed Conveyor will be added, which will input the
material without the need of a separate inlet.
From the Data panel, right-click Geometries, point to Create, and then
click Feed Conveyor.

Under Geometries, select the new Feed Conveyor <01> component.

From the Data Editors panel, select the Feed Conveyor tab, and then
change the parameters on each sub-tab according to the following
slides.

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 FEED CONVEYOR DEFINITION
Geometry:
Transition Length: 3 m
Loading length: 3 m
Belt Width: 1.5 m
Triangle Size: 0.1 m
Belt Thickness: 0.025 m
Orientation:
Alignment Angle: 0º
Belt Incline Angle: 10º
Vertical Offset: 3 m
Horizontal Offset: -1 m
Out-of-Plane Offset: 1 m
Return Belt Angle: 0º
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Skirtboard:
Material: Default Boundary
Width: 0.7 m
Length: 4.5 m
Skirtboard Height: 0 m
Length Offset: 1.5 m
Height Offset: 0 m
Feeder Box:
Front Plate Offset: 1 m
Drop Box Length: 1.5 m
Drop Box Width: 1.5 m
Drop Box Height: 0.5 m
Wall Thickness: 0.025 m
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 FEED CONVEYOR DEFINITION

Head Pulley: Belt Motion:

Face Width: 1.2 m Belt Speed: 3 m/s
Diameter: 0.5 m Beginning Start Time: 0 s
Offset to Idlers: 0 m Beginning Stop Time: 1000 s
Acceleration Period: 0 s
Belt Profile: Deceleration Period: 0 s

Material: Belt Default

Belt Profile: Three Rolls
Use 0.371 ratio for Center Roll
Length: Checked
Troughing Angle: 35º
Lower Corner Radius: 0.15 m

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BOUNDARY MOVEMENT

Free
Rotational
Both rolls have rotational
Motion
movements in opposite
directions.
The left roll rotates in a clockwise
direction, and the right roll rotates
in counter-clockwise direction.

The Deflector has a free

rotational motion around its
axis with a counter constant
moment applied.

Prescribed
Rotational Motions

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MOTION FRAME

To add a new Motion Frame, from the Data

panel, right-click Motion Frames and then
select Create Motion Frame.

To visualize the newly created Frame, click

Motion Frames and then click Preview.
A new window will appear showing the
geometries and the created Frame.
Adjust the Frame axis size by changing the
Default axis size parameter.

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 MOTION FRAME –
ROTATION – ROLL 1

From the Data panel, select

the new Frame 01 entry.
From the Data Editors panel,
select the Frame tab and then
define (as shown):
Name: Roll 1 Motion
To create a new motion using
this Frame, click the green
plus button (Add Motion).
Define (as shown):
Type
Initial Angular Velocity

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 MOTION FRAME –
ROTATION – ROLL 2

Create another new Motion

Frame.
Select the new Frame 01 entry,
and then define (as shown):
Name: Roll 2 Motion
Relative Position
To create a new motion using
this Frame, click the green plus
button (Add Motion).
Define (as shown):
Type
Initial Angular Velocity

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 MOTION FRAME –
FREE BODY MOTION

Create a third new Motion

Frame.
Select the new Frame 01 entry,
and then define (as shown):
Name: Deflector Motion
Relative Position
To create a new motion using
this frame, click the green plus
button (Add Motion).
Define (as shown):
Start Time
Type
Free Motion Direction

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 MOTION FRAME – ADDITIONAL PRESCRIBED MOMENT

For the exact same Motion

Frame, an additional
prescribed moment will be
applied together with the Free
Body Motion you already
defined.
Add a second motion by
clicking the green plus button
(Add Motion).
Define (as shown):
Start Time
Type
Moment Value

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 MOTION FRAME – ADDITIONAL PRESCRIBED
FORCE/MOMENT

When the motion Type of Additional Force or Additional Moment is

selected, the only option available is the Force Value or Moment Value
respectively.
These Values specify the components of the constant external force or
moment applied to the geometry to which the Motion Frame is
assigned.

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 MOTION FRAME

Once all the Motion Frames have been created, they can be assigned
to the geometries.
From the Data panel under Geometries, select Deflector <01>, and
then in the Custom Boundary tab, select Deflector Motion from the
Motion Frame drop-down list (as shown).

Repeat this step for the Roll 1<01> and Roll 2<01> geometries,
assigning the Roll 1 Motion and Roll 2 Motion frames respectively.
Note that the Feed Conveyor doesn’t need a Motion Frame since its
movement is already predefined in the default geometry settings.
Also note that the Free Body Motion will not be displayed in the Motion
Preview window since it is calculated based upon particle interactions.

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 BOUNDARY DEFINITION – WEAR
For this workshop, the Wear model will be activated on the Deflector
geometry, which enables you to evaluate how the geometry surface is
modified as a result of particle interaction.
To enable this model, from the Data panel under Geometries, select
Deflector <01>, and then from the Data Editors panel, select the Custom
Boundary tab.
From the Wear sub-tab, enable the Use Wear option and then define the
Volume/Shear Work Ratio (as shown).
From the Geometry sub-tab, define the Triangle Size (as shown).

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 BOUNDARY DEFINITION – MASS

Since the Deflector has a

free body motion, it is
important to correctly define
the Mass, Gravity Center
and Moment of Inertia
properties. This enables
Rocky to properly calculate
the resulting accelerations.
From the Mass sub-tab,
define the properties (as
shown).
These values can be extracted
from your CAD software
program or from the equipment
vendor.

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MATERIAL DEFINITION

For this
workshop,
default values
for the three
materials will
be used.

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INTERACTION BETWEEN MATERIALS

To set the interaction properties, click

Materials Interaction in the Data panel.
From the left drop-down list (as shown),
select Default Particles, and from the
right drop-down list, select, in order:
Default Boundary, Default Belt, and
Default Particles.

Adjust the parameters for each

combination pair according to the values
shown on the next slide.

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 INTERACTION BETWEEN MATERIALS

Static Friction: 0.6

Dynamic Friction: 0.6
Tangential Stiffness Ratio: 1
Adhesive Distance: 0.0001 Default
Force Fraction: 0 Belt
Restitution Coefficient: 0.3

Static Friction: 0.5

Dynamic Friction: 0.5
Default Tangential Stiffness Ratio: 1 Default
Particles Adhesive Distance: 0.0001 Boundary
Force Fraction: 0
Restitution Coefficient: 0.3

Static Friction: 0.7

Dynamic Friction: 0.5 Default
Tangential Stiffness Ratio: 1 Particles
Adhesive Distance: 0.0001
Force Fraction: 0
Restitution Coefficient: 0.3

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PARTICLE GROUP DEFINITION

To create a new particle group, from the

Data panel, right-click Particles and then
select Create Particle.

A new particle group is created under

Particles.
Select the newly created Particle <01> entry
to begin editing its parameters.

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 PARTICLE GROUP DEFINITION

From the Data Editors panel, select the Particle tab, and then define
the Shape (as shown).
From the Shape sub-tab, define the Horizontal Aspect Ratio and
Number of Corners (as shown).
To visualize the new created particle, click Preview.
A new window will appear showing the particle geometry (as shown).

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 PARTICLE GROUP DEFINITION

From the Size sub-tab, click

the Add button (green plus)
until you have three size
definition rows.
For each row, define the
Size and Cumulative %
values (as shown).

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 PARTICLE GROUP DEFINITION

From the Breakage sub-tab,

define the Model (as shown).
From the Parameters sub-
sub-tab, define (as shown):
Reference Size
Minimum Specific Energy
Selection Function Coefficient

From the Fragment

distribution sub-sub-tab,
define Minimum Size (as
shown).

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MASS FLOW DEFINITION

To create a new particle mass flow, from the

Data panel, right-click Input and then click
Create Particle Input.

A new entry is created under Input.

Select the newly created Particle Input <1>
and then from the Data Editors panel,
modify the parameters as specified on the
following slide.

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 MASS FLOW DEFINITION

From the Entry Point drop-down list, select Feed Conveyor <01> (as
shown).
To add a new particle mass flow, click the green plus button.
From the Particle column, select the Particle <01> from the drop-down
list and then define the Tonnage (as shown).

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 SOLVER DEFINITION
From the Data panel, click Solver and then from the Data Editors panel,
ensure that the Solver tab is selected.
From the Time sub-tab, define the Statistics/Wear/Breakage Start, and
Statistics/Attrition/Breakage Delay after Release (as shown).
From the General sub-tab, select CPU (or GPU/Multi GPU) as Simulation
Target, and then set the Number of Processors (or Target GPU(s)).
For this workshop, CPU will be fastest due to the low particle count.
Click Start.

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 SIMULATION SUMMARY

The Simulation Summary screen appears.

Click OK to have Rocky begin processing.

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 SIMULATION

From the Windows menu, click New 3D View.

Click the Refresh button (or use the Auto Refresh checkbox) to see
the results during processing.
Particle states can be viewed in real time as the
simulation progresses.
The speed of the simulation depends upon
various factors such as:
Number of mesh elements
used to define the geometry
Number of contacts in the
simulation domain at any
one time
Smallest particle size and
material stiffness
The particle shape and the
number of vertices used to
define the shape
Frequency of file output
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PART 2: POST-PROCESSING

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 DISPLACEMENT

To evaluate wear, the geometry modification can be analyzed using the

Property User Process, and then defining Displacement as the
Property to analyze. This shows the distance each vertex was moved.
From the Data panel, right-click Deflector, point to Process, and then
select Property.
From the Data Editors panel, ensure the Property tab is selected, and
then define Property, Mode, Type, Minimum value and Maximum
value (as shown).

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 DISPLACEMENT

The display options can be changed on the Coloring tab.

Here, the Property <01> Face color is changed to Dark Red with a
Transparency of 10, and the Edge color is changed to Red (as
shown).

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 DISPLACEMENT AREA

The worn area on the surface of the Deflector geometry can be

evaluated using a Time Plot of the <Property 01> User Process you
just created.
From the Window menu, click New Time Plot (Ctrl+T).
From the Data panel, under User Process, select Property <01>, and
then from the Data Editors panel, select the Properties tab.
Drag and drop Area over the new Time Plot window.
From the Select The Statistic to Plot dialog that appears, select only
Sum, and then click OK.
The resulting plot is shown on the next slide.

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DISPLACEMENT AREA

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 POWER MEASURE

It takes a certain amount of power for the two Roll geometries to

successfully comminute the material. This power draw can be measured
directly from the geometries.
From the Window menu, click New Time Plot (Ctrl+T).
From the Data panel, under Geometries, select Roll 1 <01>.
From the Data Editors panel, select the Curves tab, and then drag and
drop Power over the Time Plot window you just created.
Repeat the same procedure for Roll 2 <01>.
The results are shown on the next slide. This is a useful way to
compare the results with real data and to calibrate the material
properties correctly.

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POWER MEASURE

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 HELP – USER MANUAL

For further information on any topic presented, we suggest searching

the User Manual, which provides in-depth descriptions of the tools and
parameters.
To access it, from the main Toolbar click Help, point to Manuals, and
then click User Manual.

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 HELP – USER MANUAL

In the User Manual, use the Search tab to quickly find the topic you are
interested in:

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 CONCLUSION

Rocky was used to study wear and power draw in an HPGR.

During this workshop, it was possible to:

Set up Motion Frames using free body rotations and additional moments.
Model Ab-T10 Breakage parameters.
Calculate Surface Wear Modifications.
Use a Property User Process to visualize the surface area displacement.
Use Time Plots and Curves to compare power draw.

What’s Next?
If you completed this workshop successfully, then you are ready to move on to
Workshop 07 – Conical Dryer (Thermal Modeling).

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