ROCKY Particle Calibration Supplement PDF

ROCKY Particle Calibration Supplement
220-031213
LAB: Determining Particle Flow Calibrations
Calibrating particles is the method by which you determine what ROCKY settings will best replicate your realworld particles. Use the following images and ROCKY settings to get a rough guideline for how to calibrate
particles using ROCKY.
The basic calibration process is as follows:
1. Using real-world particles, determine:

the various shapes and size ranges within the particle set

the tonnage, density, and friction values

the stockpile and withdrawal angles of repose
Note: This information is typically gathered by using established
industry methods, such as observing existing stockpiles. It is not
necessary to recreate in real life the lab geometries described below;
though for smaller particles (for example, less than 6 mm) this is
feasible if desired. See image at right for an example.
2. Using ROCKY and the examples that follow, set up simulation
labs using particles of similar shape, size, tonnage, density, and
friction values as your real particles.
3. As you run your labs, adjust the following values until your angles
of repose in ROCKY matches that of your real-world particles:

Rolling Resistance

Static Friction

Adhesive Properties
Note: It can take several separate simulations to properly calibrate
your particles. Especially if you are using non-round particle shapes,
plan for this time accordingly before project onset.
Figure 1: Example of a real-world
angle of repose tester built by GDI.
Useful for testing small particles (less
than 6 mm).
Page 1 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
This section contains the following topics:

Lab 1: 37/60 “Typical” Scenario

Lab 2: 40/50 “Slot” Scenario

Lab 3: 35/63 “No Rolling Resistance” Scenario

Lab 4: 42/72 “Higher Rolling Resistance and Static Friction” Scenario
Page 2 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 1: 37/60 “Typical” Scenario
Description:
Reclaim opening – hole configuration
using non-round particles that results
in a “typical” 37 degree stockpile and
a 60 degree withdrawal angle.
Labs 3 and 4 will be variations of this
lab.
Key Boundary Settings:
Hole Size: 70 mm diameter
Key Particle Settings:
Shape: Rounded Polyhedron
Size: 0.011 @ 100%
Rolling Resistance: 0.05
(surface asperity)
Figure A: Stockpile Angles of Repose
Static Friction: 0.5
Boundary Adhesive Fraction:
0.015
Particle Adhesive Fraction: 0.015
Figure B: Withdrawal Angles of Repose
Page 3 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 1: ROCKY settings for duplicating Figures A-B.
File: RP-240-650-660-70-440-R02.rcy
Particle Group Settings
Solids Fraction for Bulk Density Calculations:
0.6 (default)
Name: Particle Group 01
Number of Processors: 24
Release Point: Inlet 01
Over the Network (Y/N): Y (default)
Rotations: Checked (default)
Start Time: 4/28/2011 12:58 PM
Density: 1650
End Time: 4/29/2011 9:58 AM
Bulk Density: Unchecked
Total Processing Time: 21 hours 0 Minutes
Restitution: 0.3 (default)
Static Friction: 0.5
Simulation Summary
Dynamic Friction: 0.5
Total Number of Particles: 21221
Tonnage (mt/h): 22
Total Number of Enabled Air Nodes: 0
Total Number of Boundary Triangles: 3068
Loading Stiffness per Size: 100000000
(default)
Area of Broken Particle Surfaces: 0
Material Size: 0.011 = 100%
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z0.335,0.335
Shape: Rounded Polyhedron
Time Step: 3.28749e-006
Horizontal Aspect Ratio: 0.8
Vertical Aspect Ratio: 1.6
Smoothness: 0.25
Simulation Settings
Simulation Title: RP-240-650-660-70-440-R02
Rolling Resistance (Round): 0.05
(surface asperity)
Customer Name: CDI
Side Angle: (disabled)
Duration: 20 (default)
Number of Corners: 10
Output Frequency: 0.05 (default)
Superquadric Degree: 2
Statistics Start Time: 10 (default)
Breakage Properties: Not used.
Loading N-Steps (10-30): 8
Boundary Adhesive Distance: 0.0001 (default)
Boundary Component Settings
Boundary Adhesive Fraction: 0.015
Static Friction (for all): 0.3 (default)
Particles Adhesive Distance: 0.0001 (default)
Dynamic Friction (for all): 0.3 (default)
Particle Adhesive Fraction: 0.015
Cylinder Size: 240 mm Diameter x 650 mm
Height
Simulation Description
Upper Plate Size: 660 mm Diameter
Overall Time Duration: 20.0 seconds
Hole Size: 70 mm Diameter
Cylinder fills for 3.0 seconds
Lower Plate Size: 440 mm Diameter
Cylinder moves on the Y axis from 3.0 to 9.5
seconds at 0.05 meters per second
Gate moves on the X axis from 9.5 to 9.51 at 7.0
meters per second
Case stopped at: 12.350 seconds
Page 4 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 2: 40/50 “Slot” Scenario
Description:
Reclaim opening – slot configuration
using round particles that results in
a 40 degree stockpile and a 50
degree withdrawal angle.
Key Boundary Settings:
Hole Size: 60 mm x 300 mm Slot
Key Particle Settings:
Shape: Spheres
Size: 0.01 @ 100%
Rolling Resistance: 0.16
Static Friction: 0.5
Boundary Adhesive Fraction:
0.015
Figure C: Slot Configuration (Head-On)
Particle Adhesive Fraction:
0.015
Figure D: Slot Configuration (Side View)
Page 5 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Figure E: Looking Across the Smallest Side of the Slot
Figure F: Looking Across the Longest Side of the Slot
Page 6 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 2: ROCKY settings for duplicating Figures C-F.
File: S-240x650-600-60x300-440-R00.rcy
Particle Group Settings
Solids Fraction for Bulk Density Calculations: 0.6
(default)
Name: 10 mm Spheres
Number of Processors: 24 (hyperthreads-12 cores)
Over the Network (Y/N): Y (default)
Start Time: 4/28/2011 8:34 AM
End Time: 4/28/2011 10:32 AM
Total Processing Time: 1 hour 58 minutes
Simulation Summary
Total Number of Particles: 21221
Total Number of Enabled Air Nodes: 0
Total Number of Boundary Triangles: 2780
Area of Broken Particle Surfaces: 0
Mass of Broken Particles: 0
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z0.335,0.335
Time Step: 3.46276e-006
Simulation Settings
Simulation Title: S-240x650-600-60x300-440-R00
Customer Name: CDI
Duration: 30
Output Frequency: 0.05 (default)
Statistics Start Time: 10 (default)
Loading N-Steps (10-30): 15 (default)
Boundary Adhesive Distance: 0.0001 (default)
Boundary Adhesive Fraction: 0.015
Particles Adhesive Distance: 0.0001 (default)
Particle Adhesive Fraction: 0.015
Release Point: Inlet 01
Rotations: Checked (default)
Density: 1650
Bulk Density: Unchecked
Restitution: 0.3 (default)
Static Friction: 0.5
Dynamic Friction: 0.5
Tonnage (mt/h): 22
Loading Stiffness per Size: 100000000 (default)
Material Size: 0.01 = 100%
Shape: Spherical (default)
Vertical Aspect Ratio: (disabled)
Horizontal Aspect Ratio: (disabled)
Smoothness: (disabled)
Rolling Resistance (Round): 0.16
Side Angle: (disabled)
Number of Corners: (disabled)
Superquadric Degree: (disabled)
Breakage Properties: Not used.
Boundary Component Settings
Static Friction (for all): 0.3 (default)
Dynamic Friction (for all): 0.3 (default)
Cylinder Size: 240 mm Diameter x 650 mm Height
Upper Plate Size: 660 mm Diameter
Hole Size: 60 mm x 300 mm Slot
Lower Plate Size: 440 mm Diameter
Simulation Description
Overall Time Duration: 30.0 seconds
Cylinder fills for 3.0 seconds
Cylinder moves on the Y axis from 3.0 to 7.0 seconds at 0.05 meters per second
Gate moves on the X axis from 7.0 to 7.1 at 6.0 meters per second
Case stopped at: 10.950 seconds
Page 7 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 3: 35/63 “No Rolling Resistance” Scenario
Description:
Reclaim opening – hole
configuration using non-round
particles that results in a 35 degree
stockpile and 63 degree withdrawal
angle.
This lab uses the same setup as
Lab 1, but has no rolling
resistance.
Key Boundary Settings:
Hole Size: 70 mm Diameter
Key Particle Settings:
Shape: Rounded Polyhedron
Size: 0.0111 @ 100%
Figure G: Stockpile Angle
Rolling Resistance: 0
(no asperity)
Static Friction: 0.5
Boundary Adhesive Fraction:
0.015
Particle Adhesive Fraction:
0.015
Figure E: Withdrawal Angle
Page 8 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 3: ROCKY settings for duplicating Figures G-H.
Particle Group Settings
File: RP-240-650-660-70-440-R03.rcy
Solids Fraction for Bulk Density Calculations:
0.6 (default)
Number of Processors: 16
Over the Network (Y/N): Y (default)
Start Time: 4/27/2011 1:29 PM (from 3 seconds)
End Time: 4/29/2011 12:57 PM (to 7.35 seconds)
Total Processing Time: 23 hours 32 minutes
Simulation Summary
Total Number of Particles: 21221
Total Number of Enabled Air Nodes: 0
Total Number of Boundary Triangles: 3068
Area of Broken Particle Surfaces: 0
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z0.335,0.335
Name: Particle Group 01
Release Point: Inlet 01
Rotations: Checked (default)
Density: 1650
Bulk Density: Unchecked
Restitution: 0.3 (default)
Static Friction: 0.5
Dynamic Friction: 0.5
Tonnage (mt/h): 22
Loading Stiffness per Size: 100000000 (default)
Material Size: 0.0111 = 100% (default)
Shape: Rounded Polyhedron
Vertical Aspect Ratio: 1.6
Time Step: 3.28749e-006
Horizontal Aspect Ratio: 0.8
Simulation Settings
Rolling Resistance (Round): 0.0
Simulation Title: RP-240-650-660-70-440-R03
Customer Name: CDI
Duration: 20 (default)
Output Frequency: 0.05 (default)
Smoothness: 0.25
Side Angle: (disabled)
Number of Corners: 10
Superquadric Degree: 2
Breakage Properties: Not used.
Statistics Start Time: 10 (default)
Loading N-Steps (10-30): 8
Boundary Adhesive Distance: 0.0001 (default)
Boundary Adhesive Fraction: 0.015
Particles Adhesive Distance: 0.0001 (default)
Particle Adhesive Fraction: 0.015
Boundary Component Settings
Static Friction (for all): 0.3 (default)
Dynamic Friction (for all): 0.3 (default)
Cylinder Size: 240 mm Diameter x 650 mm
Height
Upper Plate Size: 660 mm Diameter
Hole Size: 70 mm Diameter
Lower Plate Size: 440 mm Diameter
Simulation Description
Overall Time Duration: 20.0 seconds
Cylinder fills for 3.0 seconds
Cylinder moves on the Y axis from 3.0 to 9.5 seconds at 0.05 meters per second
Gate moves on the X axis from 6.5 to 6.51 at 7.0 meters per second
Case stopped at: 11.150 seconds
Page 9 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 4: 42/72 “Higher Rolling Resistance and Static
Friction” Scenario
Description:
Reclaim opening – hole configuration
using non-round particles that results in
a 42 degree stockpile and a 72 degree
withdrawal angles.
This lab uses the same setup as lab 1
except that it has higher Rolling
Resistance and Static Friction values.
Key Boundary Settings:
Hole Size: 70 mm Diameter
Key Particle Settings:
Shape: Rounded Polyhedron
Size: 0.0111 @ 100%
Figure I: Stockpile Angle
Rolling Resistance: 0.15
Static Friction: 1.0
Boundary Adhesive Fraction: 0.015
Particle Adhesive Fraction: 0.015
Figure J: Withdrawal Angle
Page 10 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.
ROCKY Particle Calibration Supplement
220-031213
Lab 4: ROCKY settings for duplicating Figures I-J.
File: RP-240-650-660-70-440-R00.rcy
Particle Group Settings
Solids Fraction for Bulk Density Calculations: 0.6
(default)
Name: Particle Group 01
Release Point: Inlet 01
Number of Processors: 64 (hyperthreads-32 cores)
Rotations: Checked (default)
Over the Network (Y/N): Y (default)
Density: 1650
Start Time: 4/27/2011 9:05 AM
Bulk Density: Unchecked
End Time: 4/28/2011 8:24 AM
Restitution: 0.3 (default)
Total Processing Time: 11 hours 19 minutes
Static Friction: 1.0
Dynamic Friction: 0.5
Simulation Summary
Tonnage (mt/h): 22
Total Number of Particles: 21221
Loading Stiffness per Size: 100000000 (default)
Total Number of Enabled Air Nodes: 0
Material Size: 0.111 = 100% (default)
Total Number of Boundary Triangles: 3068
Shape: Rounded Polyhedron
Area of Broken Particle Surfaces: 0
Vertical Aspect Ratio: 1.6
Boundary Limits X-0.335,0.335; Y-0.255,0.65; Z0.335,0.335
Horizontal Aspect Ratio: 0.8
Time Step: 3.28749e-006
Rolling Resistance (Round): 0.15
Simulation Settings
Simulation Title: (default)
Customer Name: (default)
Duration: 20 (default)
Output Frequency: 0.05 (default)
Statistics Start Time: 10 (default)
Loading N-Steps (10-30): 8
Boundary Adhesive Distance: 0.0001 (default)
Boundary Adhesive Fraction: 0.015
Smoothness: 0.25
Side Angle: (disabled)
Number of Corners: 10
Superquadric Degree: 2
Breakage Properties: Not used.
Boundary Component Settings
Static Friction (for all): 0.3 (default)
Dynamic Friction (for all): 0.3 (default)
Particles Adhesive Distance: 0.0001 (default)
Cylinder Size: 240 mm Diameter x 650 mm
Height
Particle Adhesive Fraction: 0.015
Upper Plate Size: 660 mm Diameter
Hole Size: 70 mm Diameter
Lower Plate Size: 440 mm Diameter
Simulation Description
Overall Time Duration: 20.0 seconds
Cylinder fills for 3.0 seconds
Cylinder moves on the Y axis from 3.0 to 9.5 seconds at 0.05 meters per second
Gate moves on the X axis from 9.5 to 9.51 at 7.0 meters per second
Case stopped at: 11.150 seconds
Page 11 of 11 | Copyright © 2013 Granular Dynamics International, LLC. All rights reserved.

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