In the seed processing industry, rotary batch seed coaters are widely used for providing a protective coating layer (consisting of various ingredients including fertilisers and crop protection chemicals) on the seeds. Seed motion and mixing are important in ensuring uniform coating. In the batch seed coater, the base of a cylindrical vessel rotates, whilst the cylindrical wall is stationary and two baffles turn the bed over for mixing. In the present study, the Discrete Element Method (DEM) is used to simulate the effect of particle shape on motion and mixing in this device. Corn seed is used as a model material and the effect of its shape on motion is analysed by considering two approaches: (1) manipulation of rolling friction to account for shape as it is commonly used in the field; (2) approximation of the actual shape by a number of overlapping spheres of various sizes. The geometry of corn seeds is captured using X-Ray micro tomography and then the ASG2013 software (Cogency, South Africa) is used to generate and optimise the arrangement of the overlapping spheres. A comparison is made of the predicted tangential and radial velocity distributions of the particles from DEM and those measured experimentally. It is concluded that for rapid shearing systems with short collisional contacts a small number of clumped spheres suffices to provide a reasonable agreement with experimental results. Equally well, manipulating the rolling friction coefficient can provide results that match experiments but its most suitable value is unknown a priori, hence the approach is empirical rather than predictive

Rigorous non-linear models of elasto-plastic contact deformation are time-consuming in numerical calculations for the distinct element method (DEM) and quite often unnecessary to represent the actual contact deformation of common particulate systems. In this work a simple linear elasto-plastic and adhesive contact model for spherical particles is proposed. Plastic deformation of contacts during loading and elastic unloading, accompanied by adhesion are considered, for which the pull-off force increases with plastic deformation. Considering the collision of a spherical cohesive body with a rigid flat target, the critical sticking velocity and coefficient of restitution in the proposed model are found to be very similar to those of Thornton and Ning’s model. Sensitivity analyses of the model parameters such as plastic, elastic, plastic-adhesive stiffnesses and pull-off force on work of compaction are carried out. It is found that by increasing the ratio of elastic to plastic stiffness, the plastic component of the total work increases and the elastic component decreases. By increasing the interface energy, the plastic work increases, but the elastic work does not change. The model can be used to efficiently represent the force-displacement of a wide range of particles, thus enabling fast numerical simulations of particle assemblies by the DEM.