Particulate Composite Mixing Processes

ABSTRACT: Global Engineering and Materials, Inc. (GEM) along with its team member 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 the mixing process. Our innovative approach consists of Discrete Element Method (DEM) and Dissipative Particle Dynamic (DPD) coupled algorithms, reliable experimental and numerical measurement methods for validation of the proposed algorithms, a multiscale modeling/characterization approach to an objective homogeneity metrics, and a viable scale-up technique for quantifying the mixing results in the industry-scale from the laboratory-scale system. Quantitative understanding of mixing process will be achieved by using novel numerical algorithms and experimental studies for on-line control and optimization of mixing performance. The outcomes of the proposed research and development include numerical models for two or more types of particles mixing in a viscous fluid, experimental validation of the proof of concept models, standardized homogeneity metrics for quantification of mixing processes, and a reliable and efficient software package providing instant modeling/simulation for insights into the physical mixing process. BENEFIT: The results from this research will have significant benefits and broad commercial application in the Air Force, DoD labs, food, pharmaceutical, catalysis, mineral and other related industries. The results from Phase I will provide the framework to develop an enhanced and fully validated software package for a more heterogeneous system with up to six particle types under realistic mixing scenarios. Once the proposed DEM/DPD coupled algorithm and the software package are developed, it will provide customers with the key functionality and performance to realize maximum productivity benefits from engineering simulation to product design. With integration of the proposed computational algorithms and the high fidelity software product into the design workflow, industries can significantly reduce testing costs and increase the productivity and reliability of the equipment and processes. The finalized software will have an easy-to-use GUI that speeds simulation set-up time with tools to quickly create a particle-scale parameterized model of a bulk granular solids system. By integrating its reduced order model with an optimizer, we can look for a cost effective solution without performing an exhaustive testing.