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ROCKY and ANSYS Integration

Mario Neira C.
FEA-DEM Application Specialist. ESSS-ANSYS
What is ROCKY?

Rocky is a new generation Discrete Element


Method (DEM) code to predict the behavior
of bulk solids.
Different Bulk Solids

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Image Jenike and Johnason

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Brief Description of Discrete Element Method

Discrete Element Method deals with flows of


granular media which is media consisting of
large number of solid particles (flows of sand,
ore, grain etc.)

Granular materials can behave like both fluids


and solids; derivation of continuous equations
of motion/state for this type of media is
extremely complicated* and these methods
only marginally applicable there

DEM is an attempt so solve this problem on Fluid-like Behavior

micro level without equations of state and


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motion by simulation the evolution of every Solid-like Behavior
particle in the system subject to contact forces

A. Goldshtein, V. Kamenetsky, A. V. Potapov, M. Shapiro, C. S. Campbell, and D. Degani; Hydrodynamics of rapid granular flow of inelastic particles
into vacuum; Granular Matter 4 (2002) 115-127.
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Brief Description of Discrete Element Method

Finite Volume Simulation Example DEM Simulation Example


(Continuum) (Discrete)

Airflow around conveyor frame Particles flow inside grinding


simulated with FLUENT CFD mill with grate simulated using
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package. Navier-Stokesto edit Master
Rockytitle
DEMstyle
package.
continuum equations are solved Parameters for each particle
on computational mesh (over million in this case) are
tracked at every time step.

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History of DEM

1960s: Existing continuum models have discontinuities introduced into


them
1971: First recognizable form of DEM for looking at rock mechanics
problems
1979: Extended to granular material (not just rock)
1992: DEM defined as any computer program that:
(i) Allows finite displacement, rotation, and detachment of discrete bodies
(ii) Recognizes new contacts as the calculation progresses
Throughout the late 90s and early 2000s, the number of publications
referencing DEM grows exponentially

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DEM Principles

DEM consists of:


Interaction of particles modeled through contacts with all contacts
considered
Movement of particles modeled by considering each particle individually
Explicit through time with a finite difference algorithm

Typically:
Particles can be any shape
Particles are elastic and do not suffer permanent deformation

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Structure of a DEM Program and Contact Forces

Particle Contact Forces


In a DEM program, particles are usually not
deformable but allowed a slight overlap.
The contact forces are calculated based on
values of this overlap.

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Contact Forces in Normal and Tangential
One must know how to calculate directions have to be defined via values of
particle contact and other forces overlap sn and tangential contact
(gravity, fluid etc) displacement from the contact initiation st

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Discrete Elements Method Material Handling

It models the dynamics of each


particle
It considers:
Mechanics and inertials
properties.
It consider the interactions with:
Other particles
Geometry (Equipment)
Other field forces (Gravity)
The behavior of the joint is calculated
from each particle physics

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Workflow

Model particle builder


Pre-processing Particle generation
CAD model geometry import

Contact mechanics
Change design or Solver
operating conditions Mechanical coupling: FEA

3D video and tracking


Post-processing Graphical analysis
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Data extraction and export

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Some Industrial applications of ROCKY

Shot Peening Fragmentation

Collection Piles
Chutes

ClickMill
to edit Master titleWear
style

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OVERVIEW

Why is ROCKY 3.0 unique?

ACCURATE, with real physical representation;

FAST, having an unprecedented solver performance;

CUSTOMIZED, tailored for equipment designers;

EASY TO USE, with a modern and customized GUI;

TIGHTLY INTEGRATED with ANSYS tools.


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ACCURATE, with real physical representation

Non-round Particles:

ROCKY enables you to create a nearly unlimited


array of particle shapes that compact, settle, and
behave just like real-world particles;

More realistic simulation results;

You can mix and match different shape, size, and


adhesion combinations to create a unique particle
set.

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Nearly limitless shapes


and size distributions.

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Spherical Particles v/s Nonspherical Particles on ROCKY

Spherical particles with rolling resistance Nonspherical particles


(Typical DEM simulation) (Aspects ratio 1 : 0.75 : 1.5 )
2 hours of CPU on an Intel I7 6 hours of CPU on an Intel I7

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The use of nonspherical particles allows to represent of the most real way the dynamics of
rotations and interlocking of particles.

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ACCURATE, with real physical representation

Non-round Particles (cont.):

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* Root picker simulation with variety of particles shapes.

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ACCURATE, with real physical representation

Breakage: High Pressure Grinding Roll validation

2.4m x 1.65 m High Pressure Grinding


Simulation Parameters:
Roll with 500,000 particles

Roll Speed: 1.4 m/s


Roll Gap: 61 mm
Roll Specific Force: 1.6 N/mm2
Specific Power Draw: 0.98 kWh/t
Material Ab: 30 ton/Kwt-hour
Material T10: 24.8%

*Studs geometry/spacing was not available


and was re-created from a photo.
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ACCURATE, with real physical representation

Breakage: High Pressure Grinding Roll validation (cont.)


Specific Force Specific Power Draw
for Different Material Stiffness: for Different Material Stiffness:
6 4
Specific Force, N/mm^2

Specific Power, Kwatt-


5
100 Mpa 3 100 Mpa
4

hour/ton
3 200 Mpa 2 200 Mpa
2 500 Mpa 500 Mpa
1
1
1000 Mpa 1000 Mpa
0 0
0 1 2 3 4 5 Measured 0 1 2 3 4 5 Measured
-1
Time, sec Time, sec

Product Size Distribution High Pressure Grinding Roll


(for 2.0x108 Pa Stiffness): is a displacement device and results
100 Click to edit do depend
Master on particle stiffness.
title style
Cumulative % Finer

50 Measured

0
Simulated Stiffness of 2x108 Pa produces results
10 100 Feed on power draw, specific force and
Size, mm
product size distribution that are
extremely close to experimental.

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FAST, having an unprecedented solver performance

Shared-Parallel Memory for both GPU and CPU Processing:


Relative Speed-Up of GPU
Compared to CPU Simulations

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One million particles passing through a transfer chute system over 10 seconds;
Particles including spheres and rounded polygons with three, five, and seven corners.

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CUSTOMIZED, tailored for equipment designers

See How Liners will Wear Down Over Time:

3D wear calculations are based upon:

Volume/Shear Work Ratio and


Boundary Triangle Size.

3D wear changes
the physical
appearance of
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as the simulation
progresses.

Start of simulation End of simulation

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CUSTOMIZED, tailored for equipment designers

Mill Liner 3D Surface Wear Modification:

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CUSTOMIZED, tailored for equipment designers

Airflow around chutes:

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1-way CFD coupling:
DEM - Lattice-Boltzmann built-in particles/gas flow coupled solver;

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CUSTOMIZED, tailored for equipment designers

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EASY TO USE, with a modern and customizable GUI

Main Interface:
Multiple windows;
Materials/interactions;
Materials catalogue;
Animations:
Key frame animations;
Coloring parameters;
Videos;
3D;

Local data:
Probing;
Statistics;
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Results:
Simultaneous results;
Time graphs, histograms, etc.
Analyze different structures;
Export results in .csv.
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EASY TO USE, with a modern and customizable GUI

ROCKYs API:
High level; User Interface
All application features are available:
- Visualization windows;
Calculator
- Model data;
Access to simulation curves and surface properties;
Manipulation of data from different simulations. Extend
+
Automate
Scripting:
Extend/Modify the applications behavior;
Interface with third-party
Clickscientific
to edit packages;
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Create data reports:
(e.g. Word, Excel, PowerPoint).
Complex Scripts
Data Reports
Additional Data

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ROCKY DEM Simulator

Visualize, Manipulate

3D Visualization
XY Plots Structural Analysis
User Interface Histograms Random Vibration
Fatigue

Calculator

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DEM CFD
Complex Scripts
Coupling
Data Reports
Dense Particle
Extend, Automate Additional Data
/Fluid Simulation

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TIGHTLY INTEGRATED with ANSYS tools

ROCKY as an ANSYS Workbench component:

3.6 Version (May. 2015):


Schematic Workbench integration;
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Geometry parameterization;
Optimization loops using ANSYS DX;
ROCKY parameters exposed into ANSYS Workbench environment.

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Rocky and ANSYS Workbench Coupling

Transient Data to Output Array


External Load Mapping ANSYS Mechanical
Max, Min, Average, Sum, Sum Squared,
Variance, Standard Deviation

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Rocky and ANSYS Workbench Coupling

Direct Geometry Transfer (SpaceClaim Direct Link)


Parametric Future: wear bi-directional coupling
CAD Independent through faceted geometry

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Rocky and ANSYS Workbench Coupling

Direct Geometry Transfer (SpaceClaim Direct Link)

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Rocky and ANSYS Workbench Coupling

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Rocky and ANSYS Mechanical Coupling

Rocky ANSYS Coupling


Static Analysis
Harmonic Analysis
Fatigue Analysis
Dynamic Analysis

Export Particle Mass


Added mass

Parametric Analysis
Click to edit Master title styleExploration
Design
Parameters Correlation
Response Surface
Optimization

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Rocky and ANSYS Mechanical Coupling

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Rocky and ANSYS Mechanical Coupling

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ROCKY SIMULATION
Rocky and ANSYS Mechanical Coupling

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STATIC STRUCTURAL ANALYSIS
Rocky and ANSYS Mechanical Coupling

Structural Analysis in ANSYS Mechanical


Result of the analysis in ANSYS Mechanical with the equivalent stress

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Rocky
ROCKY
STATIC and ANSYS
ANSYS Coupling
STRUCTURAL Mechanical Coupling
ANALYSIS

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Rocky
Other and ANSYS
Possible AnalysisMechanical Coupling

Total Force X (N)


6000.00
FFT Magnitude X
450000
4000.00 3.3984
400000
350000
2000.00
300000
0.00 250000
0.00 5.00 10.00 15.00 20.00 25.00 30.00
200000
-2000.00
150000
3.2031
-4000.00
100000
50000
-6000.00 0
0 1 2 3 4 5
-8000.00

Total Force Y (N)


20000.00
FFT Magnitude Y
800000
15000.00 3.3984
700000
10000.00 600000
3.2031
500000
5000.00
400000
0.00 300000
0.00 5.00 10.00 15.00 20.00 25.00 30.00
200000
-5000.00 3.5938
100000
-10000.00 0
0 1 2 3 4 5
-15000.00

Total Force Z (N)


FFT Magnitude Z
20000.00

0.00
0.00 5.00
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10.00 15.00 20.00 25.00 30.00
5000000
4500000
4000000 3.203125
-20000.00
3500000
-40000.00
3000000
-60000.00
2500000
2000000
-80000.00 1500000
1000000 3.359375
-100000.00
500000
-120000.00 0
0 1 2 3 4 5
-140000.00

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Rocky and ANSYS DesignXplorer Coupling

Automated project-level
update mechanism

Pervasive parameter
management

Integrated optimization
tools

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Bidirectional parametric
CAD connectivity
(future)

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Rocky and ANSYS DesignXplorer Coupling

Design of Experiments
Using both ROCKY Input and
Output Parameters
ANSYS Mechanical Coupling
Parametric CAD

Enabled / Disabled
Parameters
Extension for Parametric
Analysis
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Rocky and ANSYS DesignXplorer Coupling

Tradeoff Chart
Sensitivity Analysis
Response Surfaces
Goal-driven Optimization

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Rocky and ANSYS FLUENT Coupling

Fluent Interface: 1-way coupling


Export Solution to Rocky option on menu File->Export

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Rocky and ANSYS FLUENT Coupling

Fluent Interface: 1-way coupling


Data export message and TUI log (from the UDF)

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Rocky and ANSYS FLUENT Coupling

Rocky Interface: 1-way coupling


CFD coupling options

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Rocky and ANSYS FLUENT Coupling

Rocky Interface: 1-way coupling


Fluent one way steady state + selection of drag laws

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Rocky and ANSYS FLUENT Coupling

Rocky Interface: 1-way coupling


Both solid and fluid phases visualized

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Rocky and ANSYS FLUENT Coupling

Rocky Interface: 1-way coupling


Standard simulation execution

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Rocky and ANSYS FLUENT Coupling

Test case #1 Windshifter (1-way coupling)


Typically used in industrial waste processes
to separate light from heavy particles;

Basically consists of a vertical shaft in which


an air stream flows upwards;

Particles are dropped into the shaft and,


depending on their sizes, shapes and
densities, will rise up (light fraction) or settle
down (heavy fraction);

Motivation: Click to edit Master title style

Investigate the influence of different drag


laws on the particles behavior in the
windshifter.

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Rocky and ANSYS FLUENT Coupling

Geometry Mesh

Fluid domain
(Fluent mesh)

1m

225
Particles
inlet in
Rocky

2m
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= 0.5 m

Air inlet (20 m/s)


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Rocky and ANSYS FLUENT Coupling

Windshifter - Material properties

Injection Material Shape Diameter [mm] Density [kg/m3] Mass flow rate [kg/h] Volume flow rate [m3/h]
20

Paper Flat 50 800 1000 1,25

80

20

Stone Sphere 50 3000 3750 1,25

80

20

Metal Rod 50 8000 10000 1,25

80
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Wood Briquette 50 900 1125 1,25
80

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Rocky and ANSYS FLUENT Coupling

Windshifter - Paper settling velocity


Estimated terminal velocity

Paper particle sphericity () = 0.434

Gas inlet velocity = 20 m/s

Paper particles Terminal velocity [m/s]

Equivalent diameter Schiller & Naumann Ganser


[mm]
2.0 Click to edit
19.69 Master
(rise) title style
7.71 (rise)

5.0 31.13 (settle) 12.31 (rise)


8.0 39.38 (settle) 15.66 (rise)

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Rocky and ANSYS FLUENT Coupling

CFD Results: cnverged steady-state solution

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Rocky and ANSYS FLUENT Coupling

Windshifter - Schiller & Naumann Drag Law

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Rocky and ANSYS FLUENT Coupling

Windshifter - Ganser Drag Law

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Rocky and ANSYS FLUENT Coupling

Schiller & Naumann drag law did not take in account for the non-sphericity,
predicting higher terminal velocity than Ganser, so that the bigger paper particles fall
down.

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Ganser drag law reproduces particle behavior more accurately.

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Rocky and ANSYS FLUENT Coupling

Test case# 2: VOF Channel (1-way coupling)


Predict particle behavior in an expanding open channel.
Two different types of particles:
lighter particle density: 995 kg/m3
heavier particle density: 1005 kg/m3
fluid density: 1000 kg/m3
Separation occurs by density difference when the flow slows down along the channel

wall
outlet
air
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symmetr
inlet y
air-water
water interface

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Rocky and ANSYS FLUENT Coupling

CFD simulation results - pressure and velocity

pressure increases

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Rocky and ANSYS FLUENT Coupling

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Rocky and ANSYS FLUENT Coupling

DEM-CFD 2-way coupling: What is unique in Rocky


Multiphase modeling - N particle phases and M fluid phases
The interaction forces are calculated in Rocky and transferred to Fluent in an
implicit fashion, allowing both solvers to run simultaneously.
Additional drag laws implemented to consider high solids volume fraction on the
multiphase flow:
Di Felice, Wen & Yu, Gidaspow, Huilin & Gidaspow

Rocky Fluent

Nith particle phases velocities


ith Click to edit
N particle volume fraction
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Mith fluid velocities
Shared pressure
Interaction forces

parallel run (GPU or CPU) parallel run ( CPU)

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Rocky and ANSYS FLUENT Coupling

Test case #4 - Fluidized bed


Gas or liquid flows through bulk solid material:

Used in various industrial processes due to high


heat and mass transfer rates;

The modelling, characterisation and understanding


of such multiphase flow present a major
challenge;

Nowadays are mostly based on experimental


studies.

Motivation: Click to edit Master title style


* Falah Alobaid and Bernd Epple (2013). Improvement,
validation and application of CFD/DEM model to dense
Validation study to assess the results obtained gas-solid flow in a fluidized bed. Particuology, 11, 514-
526.
from the CFD/DEM coupling method using
experimental data from a quasi-2D spouted-
fluidized bed *.

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Rocky and ANSYS FLUENT Coupling

Outlet

Parameters

Height [cm] 100.0

Width [cm] 15.0

Walls Depth [cm] 2.0


Gas density [kg/m3] 1.2

Gas Viscosity [kg/m s] 1.8 x 10-5

Gas inlet velocity [m/s] 20.0

ClickGas
tomass
editflow rate
[kg/s]
Master 0.0055
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Particle density [kg/m3] 2500.0
Inlet Particle diameter [mm] 2.5

Number of particles [ ] 36500


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Rocky and ANSYS FLUENT Coupling

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1- way coupling does not predict flow well!

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Rocky and ANSYS FLUENT Coupling

Rocky results - Fluidized bed (2-way coupling)

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Rocky and ANSYS FLUENT Coupling

Fluent results - Fluidized bed (2-way coupling)

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OPEN DISCUSSION rocky-dem-simulator

Mario Neira /RockyDEMSimulator

Mario.neira@esss.com.br /RockyDEMSimulator

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