Traditional powder flow measurement devices, such as shear cells, operate in the quasi-static regime of shear strain rate. The FT4 powder rheometer of Freeman Technology, developed over the last two decades, has provided a clearer differentiation of powder flowability in some instances. This has been attributed to the instrument operating in the dynamic regime of shear strain rates, a feature that has yet to be established. We report an analysis of the dynamic behaviour of a bed of glass beads made cohesive by silanisation and subjected to standard FT4 testing procedure, where a rotating blade is driven into a cylindrical bed, using a combination of experimental measurements and numerical simulations by the Distinct Element Method (DEM). The DEM analysis underestimates the flow energy measured experimentally, although the agreement is improved when sliding friction is increased. The shear stress of the powder in front of the blade is shown to be roughly constant along the radial direction and increasing as the impeller penetrates the bed, suggesting that a characteristic shear stress can be determined for a powder under a given test condition in the FT4. For ease of simulations large beads were used (1.7–2.1mm). Future work will investigate the influence of particle properties and operational conditions on the prevailing stresses and strain rates

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.

Measurement of the adhesive force is of great interest in a large number of applications, such as powder coating and processing of cohesive powders. Established measurement methods such as Atomic Force Microscopy (AFM) and the centrifugal method are costly and time consuming. For engineering applications there is a need to develop a quick test method. The drop test method has been designed and developed for this purpose. In this test method particles that are adhered to a substrate are mounted on and are subjected to a tensile force by impacting the stub against a stopper ring by dropping it from a set height. From the balance of the detachment force and adhesive force for a critical particles size, above which particles are detached and below which they remain on the substrate, the interfacial specific energy is calculated. A model of adhesion is required to estimate the adhesive force between the particles and the surface, and in this work we use the JKR theory. The detachment force is estimated by Newton's second law of motion, using an estimated particle mass, based on its size and density and calculated particle acceleration. A number of materials such as silanised glass beads, Avicel, α-lactose monohydrate and starch have been tested and the adhesive force and energy between the particle and the substrate surface have been quantified. Consistent values of the interface energy with a narrow error band are obtained, independent of the impact velocity. As the latter is varied, different particle sizes detach; nevertheless similar values of the interface energy are obtained, an indication that the technique is robust, as it is in fact based on microscopic observations of many particles. The trends of the results obtained with the drop test method are similar to those shown in studies by other researchers using established methods like the AFM and the centrifuge method

Powder processing and manufacturing operations are rate processes for which the bottleneck is cohesive powder flow. Diversity of material properties, particulate form, and sensitivity to environmental conditions, such as humidity and tribo-electric charging, make its prediction very challenging. However, this is highly desirable particularly when addressing a powder material for which only a small quantity is available. Furthermore, in a number of applications powder flow testing at low stress levels is highly desirable.Characterisation of bulk powder failure for flow initiation (quasi-static) is well established. However, bulk flow parameters are all sensitive to strain rate with which the powder is sheared, but in contrast to quasi-static test methods, there is no shear cell for characterisation of the bulk parameters in the dynamic regime. There are only a handful of instruments available for powder rheometry, in which the bulk resistance to motion can be quantified as a function of the shear strain rate, but the challenge is relating the bulk behaviour to the physical and mechanical properties of constituting particles. A critique of the current state of the art in characterisation and analysis of cohesive powder flow is presented, addressing the effects of cohesion, strain rate, fluid medium drag and particle shape.