Numerical Modeling for Simulation of Compaction of Refractory Materials for Secondary Steelmaking

Abstract

The purpose of this work is to simulate the powder compaction of refractory materials, using the discrete element method (DEM). The capability of two cohesive contact models, implemented in different DEM packages, to simulate the compaction of a mixture of two refractory materials (dead burnt magnesia (MgO) and calcined alumina (Al2O3)) was analyzed, and the simulation results were compared with experimental data. The maximum force applied by the punch and the porosity and final shape quality of the compact were examined. As a starting point, the influence of Young’s modulus (E), the cohesion energy density (CED), and the diameter of the Al2O3 particles (D) on the results was analyzed. This analysis allowed to distinguish that E and CED were the most influential factors. Therefore, a more extensive examination of these two factors was performed afterward, using a fixed value of D. The analysis of the combined effect of these factors made it possible to calibrate the DEM models, and consequently, after this calibration, the compacts had an adequate final shape quality and the maximum force applied in the simulations matched with the experimental one. However, the porosity of the simulated compacts was higher than that of the real ones. To reduce the porosity of the compacts, lower values of D were also modeled. Consequently, the relative deviation of the porosity was reduced from 40–50% to 20%, using a value of D equal to 0.15 mm.

Modelling of the Fine-Grained Materials Briquetting Process in a Roller Press with the Discrete Element Method

“…That is why this method was chosen to perform research in the article. In order to conduct research on the fine-fraction materials compaction processes, the Altair ® EDEM™ (Discrete Element Method (DEM) Software) was selected, which is widely used to model physical processes using discrete elements [ 47 , 48 , 49 , 50 ].…”

Microstructure-based discrete simulations of the compaction of refractory powder composites

“…The major part of the numerical and experimental studies concerning the powder compaction is related to composites made of metal-ceramic materials for the powder-metallurgy process. DEM simulations of the compaction of homogeneous refractory materials (alumina, magnesia) have been reported with various sizes of particles [20,21]. However, as far as we know, no study has been reported yet in the literature regarding compaction simulations using DEM to model refractory composites on a mixture of hard particles and a soft binder.…”

Discrete Element Framework for Determination of Sintering and Postsintering Residual Stresses of Particle Reinforced Composites

“…Generally, the DEM was introduced for modeling granular materials in the pioneering works by Cundall [ 24 , 25 ] and Walton [ 26 ]. Recently, special DEM models are developed for powder metallurgy processes [ 27 , 28 , 29 , 30 , 31 , 32 , 33 , 34 , 35 ]. Most of the DEM applications for powder metallurgy have considered one-phase powder; there are very few works dealing with two-phase powders [ 36 , 37 , 38 , 39 ].…”