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Computers and Electronics in Agriculture 88 (2012) 111–119

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Computers and Electronics in Agriculture


journal homepage: www.elsevier.com/locate/compag

CFD–DEM simulation of material motion in air-and-screen cleaning device


Hongchang Li a,b,⇑, Yaoming Li b, Fang Gao a, Zhan Zhao b, Lizhang Xu b
a
Department of Automobile Engineering, Changzhou Institute of Mechatronic Technology, Changzhou, Jiangsu 213164, China
b
Key Laboratory of Modern Agricultural Equipment and Technology, Ministry of Education & Jiangsu Province, Jiangsu University, Zhenjiang, Jiangsu 212013, China

a r t i c l e i n f o a b s t r a c t

Article history: In this work, a numerical study of the gas–solid flow in an air-and-screen cleaning shoe is carried out by
Received 1 July 2011 use of the combined Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD) model
Received in revised form 14 July 2012 where the motion of discrete particles phase is obtained by DEM which applies EDEM software and
Accepted 16 July 2012
the flow of continuum fluid by the traditional CFD which solves the Navier–Stokes equations at a com-
putational cell scale. The effect of inlet airflow velocity is studied and analyzed in terms of grains and
short straws’ longitudinal velocity and vertical height, and cleaning loss. Simulation results showed that,
Keywords:
in a certain range, different inlet airflow velocity only affects the magnitude of airflow velocity in the
Combine harvester
Air-and-screen cleaning device
cleaning shoe, but does not affect the distribution regularity of flow field in the cleaning shoe. With
CFD–DEM simulation the inlet airflow velocity increase, vibrating screen processing power improves, while grain losses
Material motion increase. Grains mainly concentrate on 4–12 sections under the screen surface. Comparison of numerical
simulation results with experiments has demonstrated adequate agreement. It showed that numerical
simulation of material motion on vibrating screen of air-and-screen cleaning device based on CFD–
DEM is feasible. The results provide a basis for improving the design on air-and-screen cleaning device
of combine harvester.
Ó 2012 Elsevier B.V. All rights reserved.

1. Introduction a cross-flow opening on the performance of the fan using three


fans of similar geometries but different in their cross-flow opening.
Cleaning device is an important part of combine harvesters, its Numerical simulation based on the so-called Discrete Element
superior or inferior performance directly affects the whole combine Method (DEM) (Cundall and Strack, 1979) is an effective way to
harvester performance. High efficiency, high performance combine study on screening process. This method has been applied to the
harvester makes new demands for the cleaning device. Previous re- study of particle flow in various industrial processes and shown to
search investigated the influence of the different cleaning device be very useful in understanding the fundamentals (Yu, 2003). How-
settings like fan speed, screen lip angle, oscillation frequency and ever, its application to screening operation is rather preliminary. Li
amplitude on the transportation of grain and chaff along with the et al. (2003) presented a mathematical investigation of particulate
cleaning screen by experiment on test bed (Simpson, 1966; German motion on an inclined screening chute using the Discrete Element
and Lee, 1967; Lee and Winfield, 1969; Bo }ttinger and Kutzbach, Method (DEM). Cleary (2000) used the Discrete Element Method
1987; Cheng and Wang, 1999; Xu et al., 2007; Chen et al., 2009). (DEM) to simulate a full industrial scale double deck banana screen
But experiment on test bed is with high cost and strong seasonality. for a range of accelerations. Hongguang et al. (2008) developed a
With the development of Computational Fluid Dynamics (CFD) two-dimensional DEM emulator named SieveDEM by a VC++.NET,
technology, it has been able to implement complex geometry area and investigated three typical penetrating behaviors in screen pro-
numerical simulation of fluid flows, quantitative description of cess by the emulator. Zhao et al. (2010) simulated the screening pro-
temporal and spatial change characteristics of the flow field, more cess of particles flow on the vibrating plate based on the dry contact
profoundly revealed the mechanism of fluid. CFD continues to ex- model of soft-ball, and analyzed the motion state and change of
pand the scope of application and offers new ways to solve practi- screening efficiency of coal particles flow, and discussed the effect
cal engineering problems (Karim and Nolan, 2011; Ahuja and of particles size distribution on screening efficiency.
Patwardhan, 2008; Blocken et al., 2009; Hanna et al., 2009). Gebre- On the other hand, in recent years, the so-called combined ap-
hiwot et al. (2010) applied CFD to study the effect of the addition of proach of Discrete Element Method (DEM) and CFD (CFD–DEM)
has been developed (Tsuji et al., 1992; Xu and Yu, 1997; Zhou
et al., 2010) and accounts for both particle–particle and particle–fluid
⇑ Corresponding author at: Department of Automobile Engineering, Changzhou
Institute of Mechatronic Technology, Changzhou, Jiangsu 213164, China. Tel./fax:
interactions. The CFD–DEM approach has been proved to be effective
+86 (0)15051981238. in modeling various particle–fluid flow systems (Li et al., 1999; Xu
E-mail address: sxlhch@163.com (H. Li). et al., 2000; Rhodes et al., 2001; Kafui et al., 2002; Yu and Xu,

0168-1699/$ - see front matter Ó 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.compag.2012.07.006
112 H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119

Fig. 4. 3D model of materials.

Table 1
Summary of modeling conditions.

Material Grain Short Screen


Fig. 1. Model of contact forces. properties straw (wall)
Density (kg/m3) 1380 100 7800
Poisson’s ratio 0.3 0.4 0.3
Shear modulus 2.6 1 700
(MPa)

Collision Grain–grain Grain– Grain– Short straw–


properties short screen screen (wall)
straw (wall)
Coefficient of 0.2 0.2 0.5 0.1
restitutions
Coefficient of 1 0.8 0.58 0.8
static friction
Coefficient of 0.01 0.01 0.01 0.01
rolling
friction

Vibrating screen Motion Amplitude Frequency Vibrating


form direction angle
Sinusoidal 20 mm 4.5 Hz 30°
translation
Test case Case 1 Case 2 Case 3 Case 4
Inlet airflow 5 7.5 10 12.5
Fig. 2. The process flow for EDEM–CFD coupling. velocity (m/s)
Inlet direction 20 20 20 20
angle (°)

2003; Limtrakul et al., 2004; Di Renzo and Di Maio, 2007; Tsuji, 2007;
Kuang et al., 2008). In particular, efforts have been made to extend
the CFD–DEM approach to study complex particle–fluid flow sys-
tems (Kawaguchi et al., 1998; Rong and Horio, 2001; Ibsen et al.,
2004; Chu and Yu, 2008; Chu et al., 2009a,b). To date, to the authors’
knowledge, few studies have been made on the gas–solid flow in
air-and-screen cleaning device by means of CFD–DEM approach.
In the air-and-screen cleaning device, there are interactions of
particle–particle and particle–fluid. So it is a complex gas–solid
two-phase flow. Therefore, we use Computational Fluid Dynamics
(CFD) and particle discrete element (DEM) to simulate the screen-
ing process of air-and-screen cleaning device. The effect of inlet
airflow velocity is studied and analyzed in terms of grains and
short straws’ longitudinal velocity and vertical height, and cleaning
loss. Theoretical basis for improving the design on air-and-screen
cleaning device of combine harvester was proposed in this paper.

2. Mathematical model

2.1. Equations of gas phase

The CFD portion of the coupling model uses the existing Euleri-
Fig. 3. Three-dimensional (3D) model of the cleaning device. an–Eulerian model in FLUENT. In the Eulerian model, an additional
H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119 113

Fig. 5. Overview of vibration screening at Case 3.

volume fraction term, ef, is added to the conservation equations to The continuity equation for the fluid phase is (Anderson and
take into account the solid phase. In the coupling module, although Jackson, 1967; Zhou et al., 2010):
two phases are created in FLUENT, the conservation equations for
@ðef qf Þ
the solid phase in the original Eulerian–Eulerian model are not þ r  ðef qf uf Þ ¼ 0 ð1Þ
solved. @t
114 H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119

Fig. 6. Velocity vector diagram of airflow field at different inlet airflow velocity.

Table 2 2.2. Particles contact model


Average longitudinal velocity of material.

Test case 1 2 3 4
This concept, contact mechanics can be considered as a ‘spring-
dashpot’ configuration, as shown in Fig. 1. The contact model is the
Velocity of the grains (m/s) 0.158 0.162 0.198 0.224
Velocity of the short straws (m/s) 0.173 0.225 0.331 0.483
default model used in EDEM software for its accurate and efficient
force calculation. The model is based on the work of Mindlin (Cun-
dall and Strack, 1979; Di Renzo and Maio, 2004).
The normal force, Fn, is given by
where qf is the fluid density, t is time and uf is the fluid velocity.
A similar equation exists for the conservation of momentum: 4  1=2 3=2
Fn ¼ E R dn ð5Þ
3
@ðef qf uf Þ
þ r  ðef qf uf uf Þ ¼ rp þ r  ðlf ef ruf Þ  ef qf g  S ð2Þ where E is the equivalent Young’s Modulus, R the equivalent ra-
@t dius and dn the normal overlap. Additionally there is a damping
Here, P is the pressure, g is the gravity force vector, gf denotes the force, Fdn , given by
viscosity and S is the momentum sink. The coupling between the rffiffiffi
two phases is then achieved through the calculation of the momen- 5 pffiffiffiffiffiffiffiffiffiffiffi rel
Fdn ¼ 2 b Sn m v n ð6Þ
tum sink of the drag force that arises due to the relatively velocity 6
between the phases. Therefore, the momentum sink S is calculated
where m is the equivalent mass, v reln is the normal component of
by
the relative velocity and b and Sn (the normal stiffness) are given by
1 Xn
ln e
s¼ FD;i ð3Þ b ¼ pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi ð7Þ
DV i¼1 2
ln e þ p2
pffiffiffiffiffiffiffiffiffi

where DV = DxDyDz, Dx, Dy and Dz is control volume length, FD,i is Sn ¼ 2E R d n ð8Þ
fluid viscous resistance. FD,i is calculated by (Yu et al., 2008)
where e is the coefficient of restitution.
ðvþ1Þ The tangential force, Ft, depends on the tangential overlap dt
FD;i ¼ 0:5C D qf Ap ðuf  up Þjuf  up jef ð4Þ
and the tangential stiffness Sn.
h i
ð1:5log10 ReÞ2 Ft ¼ St dt ð9Þ
where v ¼ 3:7  0:65 exp 2
; C D ¼ ð0:63 þ 4:8=Re0:5 Þ2 ;
e q d ju u j With
Re ¼ f f pl f p , CD is fluid resistance coefficient, Re is Reynolds
number.
f
pffiffiffiffiffiffiffiffiffi

St ¼ 8G R d n ð10Þ
Standard k–e turbulence model and wall function are applied to
calculate the airflow. Additionally there is a tangential damping force, Fdt , given by
H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119 115

Fig. 7. Variation of the mean materials longitudinal velocity with time.

rffiffiffi
d 5 pffiffiffiffiffiffiffiffiffiffi rel Particle–wall interaction can also be calculated according to the
Ft ¼ 2 b St m v t ð11Þ above equations, which is treated as a contact between a particle
6
and a finite polygon surface whose radius and mass is infinity.
Fig. 2 illustrates the process flow for EDEM–FLUENT coupling.
where v rel
t , is the relative tangential velocity. The tangential force is
limited by Coulomb friction, lsFn, where ls is the coefficient of sta-
tic friction. 3. Simulation conditions
For simulations in which rolling friction is important, this is ac-
counted for by applying a torque to the contacting surfaces. Because actual air-and-screen cleaning device is too large and
complex, mesh and calculation is limited by computer conditions,
we simplify the structure of the cleaning device, and its three-
si ¼ lr F n Ri xi ð12Þ
dimensional (3D) model is shown in Fig. 3. The width of cleaning
device was reduced from 1000 mm to 100 mm; length and height
with lr the coefficient of rolling friction, Ri the distance of the con- are consistent with the real elements. The structure of vibrating
tact point from the center of mass for object i and xi the unit angu- screen is not simplified. The structure of the vibrating screen is
lar velocity vector of object i at the contact point. wire woven screen which is 650 mm long, 100 mm wide and has
116 H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119

Fig. 8. Variation of the mean materials vertical height with time.

a 4° declination. The screen mesh is considered to be a square aper- 320 short straws/s) with initial velocity v0 = 0 m/s at the point
ture 10 mm  10 mm formed from u = 2 mm steel wires. Materials where they enter into the calculation domain. The other simulation
are fed onto the front-top section of the vibrating screen by gravity conditions are summarized in Table 1. Data are from the pre-test
via a particle factory. Because the structure of cleaning device is results which are the mean number of repeated test results (rice
simplified, the periodic boundary condition is used for the sidewall varieties: Wu japonica rice 13) and related literature (Yang et al.,
that it can be closer to the actual situation. For gas, the gas velocity 2009; Li et al., 2008; Qiao, 1992; Zhang et al., 2006).
of the sidewall is given to the other. For particles, when a particle
leaves from the sidewall, it will enter into the domain via the other.
We take the rice grains and short straws for screening object. The 4. Simulations and discussions
rice grain is spheroid which is 6 mm long with 1.6 mm radius of
rotation. The short straw is a cylinder 30 mm long by 4 mm diam- A time step of 10–6 s was used for a total simulation time of
eter. Their 3D models are shown in Fig. 4. Materials are loaded 2.84 s in EDEM. Case 3 is discussed in this part. Fig. 5 shows an
from the particle factory at a fixed rate (6000 grains/s and overview of vibration screening at various time instants from 0 s
H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119 117

the screen surface. The grains and short straws move backward
and bounce under the combined action of vibrating screen and
wind. All materials are processed complete at t = 2.82 s.

4.1. Airflow field

The airflow velocity vector field at different inlet airflow veloc-


ity is shown in Fig. 6. It can be concluded that inlet airflow velocity
only affects the magnitude of the airflow velocity, not the distribu-
tion regularity of airflow field in the cleaning shoe. There is a local
eddy above the oscillating pan. Above and near the screen surface,
airflow velocity in the front is higher than the middle, the rear is
highest.

4.2. Materials motion on the vibrating screen

Materials motion velocity is decomposed along the length of


screen surface velocity and vertical the screen surface velocity.
The velocity along the length of screen surface is longitudinal
velocity, which is transportation velocity of the vibrating screen,
Fig. 9. Grains distribution of different inlet airflow velocity. and its magnitude determines processing power of cleaning device
(In this paper, the processing power is defined as, under a certain
structural parameters of the screen, the total mass of processed
Table 3
materials within 1 m2 area per hour.) The higher longitudinal
The number of short straws passing through the screen.
velocity, the less residence time of the materials on the screen sur-
Test case 1 2 3 4 face it will take, and the greater the processing power of the clean-
The number of the short straws 42 34 30 25 ing device will be. In order to make the figure clearer, we specially
The number of the grain loss 0 0 0 11 select a period of time to make simulation data mapping. Table 2
shows the longitudinal average velocity of the materials. The lon-
gitudinal velocity of the grains and the short straws is shown in
Fig. 7. Fig. 7 and Table 2 show that, with the inlet airflow velocity
to 2.82 s. The section on the screen displays the number of materi- increases, the average longitudinal velocity of grains and short
als on the screen in real-time; another section in rear of the screen straws have increased, and the rate of change of the short straws
counts the total number of cleaning loss; then the section below is particularly evident. The end of the simulations, the section on
the screen was divided into 20 parts to analyze the relation be- the screen surface displays the number of the materials on the
tween the screen length and the distribution of the grains. Differ- screen surface which is 137, 117, 0 and 0, respectively. Therefore,
ent colors represent different speeds of the materials. It can be from the above relationships we can draw a conclusion that, with
concluded that the materials generated by the particle factory the increase of inlet airflow velocity, vibrating screen processing
reach the screen surface when t = 0.19 s. Some grains penetrate power improves. Fig. 8 shows variation of the mean materials ver-
the screen directly. At t = 1.00 s, the particle factory has completed tical height with time. From the analysis of Fig. 8 we can see, inlet
generating materials and the materials have scattered in front of airflow velocity has little influence on the vertical height of the
the screen surface. The total number of grains penetrating the grains; the vertical height of the short straws increase slightly as
screen has increased. At the same time, some short straws are the inlet airflow velocity increases. This course is beneficial to
blown out of the calculation domain. After t = 1.15 s, the materials the stratification and screen-penetrating of the materials. As the
all fall to the screen surface. At t = 2.58 s, all the grains penetrate time goes by, the grains continually penetrate the screen, and at

Fig. 10. Structure schematic drawing of the air-and-screen cleaning device.


118 H. Li et al. / Computers and Electronics in Agriculture 88 (2012) 111–119

we can see that the results of simulation agree well with that of
experiments. It showed that numerical simulation of material mo-
tion on vibrating screen of air-and-screen cleaning device based on
CFD–DEM is feasible.

6. Concluding remarks

CFD–DEM simulations are carried out to study the effect of inlet


airflow velocity in terms of grains and short straws’ longitudinal
velocity and vertical height, and cleaning loss. Hertz–Mindlin con-
tact model has been used to simulate particle–particle and parti-
cle–screen (wall) collisions. CFD–DEM coupling model can well
describe the movement of particles on the screen surface in the
air–screen cleaning, leading to the following conclusions:
Fig. 11. Grains distribution of different inlet airflow velocity (experiment).
 Inlet airflow velocity has more influence on the longitudinal
velocity of short straws than that of grains. Inlet airflow velocity
Table 4 has little effect on vertical height of materials. Accordingly, the
Cleaning loss and the impurity rate. higher the inlet airflow velocity, the faster the backward veloc-
ity of the materials on the screen surface, and the more the
Experiment case 1 2 3 4
cleaning loss.
The impurity rate (%) 0.5 0.42 0.32 0.26
 The number of the grains in the back of the screen increases
The cleaning loss (%) 0 0 0.05 0.18
slightly as the inlet airflow velocity increases. After 15 sections
the number of grains is very small. So if material-other-than-
grain (MOG) is not much, we can shorten the length of the
the same time, the short straws is continually blown out of the cal- screen.
culation domain, the less total material, the greater the influence of  The experiment results show that the method is feasible and
the inlet airflow velocity on longitudinal velocity of the materials. effective. Numerical simulation of material motion based on
CFD–DEM, which can provide initial condition and parameter
4.3. Distribution of the grains configuration to the air-and-screen cleaning device of combine
harvester.
Fig. 9 shows the grains distribution curve of different inlet air-
flow velocity. It can be seen that the grains mainly concentrate
on 1–10 sections under the screen surface. There is the greatest Acknowledgments
number of the grains in section 4. The higher the inlet airflow
velocity, the higher the longitudinal velocity of the grains and This work is supported by the National Natural Science Founda-
the farther the movement distances. So, with the inlet airflow tion of China (50875113 and 50805068) and the National High
velocity increasing, the grains under the screen are slightly increas- Technology Development 863 Program of China (2010AA101402)
ing in the back of the cleaning shoe. After section 15, the grains be- and the Graduate Innovation Project of Jiangsu University
come very small. This is consistent with the longitudinal velocity of (CX09B_06XZ). Thanks for all your support.
the grains.
Make use of the section under the screen, we can also get the
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