Particulate Composite Mixing Processes

ABSTRACT: Global Engineering and Materials, Inc. (GEM) along with Columbia University propose to develop a simulation tool for modeling mixing process of multi-particle composite systems and generating the ultimate microstructure. A combined theoretical, numerical, and experimental approach will be developed to create a high fidelity software product with a reduced order modeling capability for an optimal exploration of a full scale mixing process. Our innovative approach consists of a novel combined local and global homogeneity identification metrics, an advanced multi-scale model for large scale mixing simulations, a high fidelity DEM/SPH coupling module for high shear mixing of suspensions, a two-scale simulation framework to bridging the continuum and discrete description of an interactive solid particle and fluid system, a parallelized code base that enables both GPU and CPU computing, and customized case study wizard within a GUI to streamline the model generation and solution process for both experienced and inexperienced users. The resulting Particle Dynamics Parallel Simulator (PDPS) toolkit will be validated using test data of multi-particle systems with different solid loads and fluid contents. The validated toolkit will be used to establish a design table for users to describe the trade space as a function of system properties and mixing parameters.; BENEFIT: The results from this research will have significant benefits and broad commercial applications in the Air Force, DoD labs, food, pharmaceutical, catalysis, mineral and other related industries. The results from Phase II will result in an enhanced and fully validated software package for a more heterogeneous system with up to six particle types under realistic mixing scenarios. The proposed DEM/SPH, two-scale solution algorithm and the parallelized software package will provide customers with the key functionality and performance to realize maximum productivity benefits, from engineering simulation to product design. By incorporating the proposed computational algorithms and the high fidelity software product into the design workflow, industries may reduce testing costs significantly while increase the productivity and reliability of the equipment and processes. The finalized software will have an easy-to-use GUI and case wizard that simplify model setup and speeds up simulation set-up time.