Numerical investigation on the effect of roller screen operating parameters on the mechanical behavior of its rolls in classification of green iron ore pellets through coupled DEM-FEM simulation

The operational parameters of the roller screen substantially affect the efficiency and mechanical performance of its components, particularly those of the rolls. This study presents, for the first time, extensive coupled simulations employing the discrete element method-finite element method (DEM-FEM) to examine the effects of operating parameters on the mechanical behavior of rolls. This is achieved through the utilization of a realistic geometric model of the green pellets in conjunction with a hysteretic spring elastic-plastic contact model. The investigation revealed that decreasing the undersize gap from ۹.۷۵ mm to ۹ mm led to increases of ۲۰.۲۷%, ۲۹.۷۱%, and ۱۰۲.۹۱% in the average force, total deformation, and equivalent stress exerted on the rolls, respectively. Furthermore, coupled DEM-FEM simulation tests of an industrial-scale roller screen were conducted for the first time, and the results obtained were compared with those from laboratory tests. The average force acting on the rolls of the laboratory roller screen was measured at ۲.۴۳ N. In contrast, simulations of a full-scale roller screen operating at capacities of ۱۲۰ t/h and ۲۰۰ t/h revealed average forces of ۳۴.۴۶ N and ۵۴.۰۶ N, respectively. The average total deformation observed in the rolls of the laboratory roller screen was measured at ۴.۲۷E-۰۵ mm. In contrast, under industrial conditions, this deformation increased significantly to ۱.۸۹E-۰۲ mm at a processing capacity of ۱۲۰ t/h, and further escalated to ۲.۹۵E-۰۲ mm at a capacity of ۲۰۰ t/h

کلیدواژه ها:

Coupled DEM-FEM simulation ، Equivalent Stress ، Green pellets ، Industrial-scale roller screen ، Total deformation