Innovative Approaches to Wear Reduction in Horizontal Powder Screw Conveyors: A Design of Experiments-Guided Numerical Study

Abstract

Numerical simulations play a vital role in the modern engineering industry, especially when faced with interconnected challenges such as particle interactions and the structural integrity of conveyor systems. This article focuses on the handling of materials and emphasizes the importance of using parametric numerical analysis to improve efficiency, reduce wear, and enhance the structural integrity of horizontal screw conveyors. Through the utilization of the Design of Experiments, we systematically investigated critical parameters such as screw pitch, clearance, wear, rotational velocity, and additional structural factors. This examination was carried out within a well-defined parametric framework, utilizing a combination of software tools provided by the Ansys suite and Minitab. The findings demonstrate the effectiveness of the Design of Experiments analysis in achieving improved performance and provide valuable insights for engineers and researchers involved in the design of conveyor systems. Furthermore, this comprehensive approach clarifies how conveyor systems respond to changes in parameters and highlights the complex interaction between transported particles and the conveyor system. We present a detailed analysis that clarifies the complex relationships and dependencies among different parameters, providing engineers and researchers with valuable insights. By understanding the interactions of these factors, the methodology provides not only results but also a strategic framework for advancing conveyor system design and engineering practices.