Simulation of a High-Pressure Grinding Roll using ANSYS Rocky
In this video, we will simulate a high-pressure grinder roll using ANSYS Rocky. We will cover wear, particle breakage, and analyze results with counter plots, time plots, and histograms. Let's get started.
Project Setup
- Create a new project and save it appropriately. It's a good practice to include setup details for a quick overview of the model. Make sure to add all relevant information.
- Go to the physics section to adjust the numerical softening factor. Note that a smaller value results in a larger simulation time step.
- Enable the boundary conditions and the Boundary Condition Statistics module. Activate the Intensities option within it.
Geometry and Motion Setup
- Start with an existing conveyor. Define the belt's width and orientation, and set up the feeder box.
- Import remaining geometries as STL files by dragging them into the workspace.
- Use mouse controls to rotate, pan, and zoom as needed. Optionally, change the background and text colors.
Motion Definition
- Create the motion for the model, including two rolls and a deflector.
- For the first roll, set a rotating motion about its axis with a rotational speed of 50 radians per second (477 RPMs). Repeat for the second roll in the opposite direction. Note that this value can be parameterized for optimization studies.
- For the deflector, define the center of rotation using coordinates from your CAD software or a technical drawing. Set the motion as a free body rotation in the Z direction.
- Add the spring and dashpot coefficients for a realistic response of the deflector.
Wear and Material Setup
- Assign motions to each geometry and adjust the triangle size for the surface mesh to perform wear calculations.
- Include the deflector's mass and moments of inertia, obtainable from CAD software or another technical source.
- Enable the wear model and set up the volume share work parameter. Use default material properties, adjusting coefficients for material interactions as needed.
Particle Definition
- Create the particle and define its properties. Use a polyhedron with 15 sides for this demonstration.
- Set up the particle size distribution and specify the minimum size of the particle and fragments.
- Include factors for the ABT10 breakage model.
Simulation Setup
- Define the inlet section using a predefined conveyor as the entry point. Add polyhedron particles and specify the mass flow rate.
- Set up the solver, adjusting the initial time to activate the wear and breakage models. Use 10 CPU cores for a runtime of approximately 37 minutes.
Post-Processing Tasks
- Create a region at the outlet between the rolls, typing the coordinates of the center and the size for each direction. Use this region to visualize results in graphs.
- Create a histogram and select variables for the x and y axes, adjusting options like the number of bins and range.
- Plot the cumulative wear volume loss over time by requesting a time plot and navigating to the property object for the deflector. Drag and drop the wear volume loss parameter to observe changes during the simulation.
- Use the volume region at the outlet to compute and plot data, such as the mass of the particle distribution. Create a histogram following the same procedure as before.
- Include a time plot for particle size as a function of time.
That's all for today. See you in the next video. Thanks for watching.
Hi everyone, in this video we will simulate a high-pressure grinding roll using ANSYS Rocky. We will cover wear, particle breakage, and analyze results with counter plots, time plots, and histograms. Let's get started. 1. Create a new project and save it appropriately.
Include setup details for a quick overview of the model. 2. Go to the physics section to only adjust the numerical softening factor. A smaller value results in a larger simulation time step. 3. Enable the boundary conditions.
Enable the Boundary Condition Statistics module and within it activate the Intensities option. 4. For the geometry, start with an existing conveyor. Define the belt's width and orientation and set up the feeder box.
The remaining geometries are imported STL files. 5. Create the motion to the left of the model. 6. Create the motions for the two rolls and the deflector. The first roll will have a rotating motion about its axis with a rotational speed of 50 radians per second or 477 RPMs.
Repeat the same process for the second roll but with the opposite direction. The deflector setup is different because it is defined using two components. Start by defining the center of rotation. The second step is to define the center of rotation.
The first step then is to select the motion as a free body rotation in the Z direction. Next, add the spring and damping coefficient to achieve a more realistic response for the deflector.
Once the motions are defined, assign them to each geometry. 7. Enable the wear model and set up the volume share work parameter. 8. Create the particle and define its properties.
For this demonstration, we will use a polyhedron with 15 sides. 9. Set up the particle size distribution and specify the minimum size of the particle. 10. Set the minimum absolute size expected for the fragments. 11. Include the factors shown for the ABT10 breakage model. 12. Now let's define the inlet section.
Select the predefined conveyor as the entry point. Then, add the polyhedron particles and specify the mass flow rate. 13. Set up the solver. Adjust the initial time to activate the wear and breakage models.
For this simulation, I'm using 10 CPU cores, and the runtime is close to 37 minutes. 14. Once the simulation is complete, click the play button to view the animation. 15. Create a region at the outlet, between the rolls.
Use this region to visualize some results in graphs at the end. 16. Create a histogram and select the variable in the x-axis. Click on the icon to select the variable for the y-axis, and more options for the histogram like the number of bins and the range. 17. Create a theorem for the calibration.
Click on the icon to find a parameter with a diaspora each time. Use the diagram to limit sir for the time to that axis, and recommend the estimator function. 18. Enter a place for the time size limit para per each time on the parameter. 19. Plot the cumulative wear volume loss over time.
To do this, request a time plot and navigate to the property object created for the deflector. 20. Use the volume region at the outlet to compute and plot data, for instance, the mass of the particle distribution. 21. Observe how the histogram changes over time, so you can export the data you need for your analysis.
I also want a time plot here. It will be for the particle size as a function of time. And that's all for today. See you in the next video. Thanks for watching.
