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双齿辊破碎机的破碎力离散元模拟研究

Research on discrete element method simulation of crushing force for double-toothed roller crusher

  • 摘要: 基于离散单元法理论,对分析过程中的颗粒接触模型、颗粒接触搜索算法和迭代时间步长算法进行了改进,分析破碎过程中齿辊的受力以保证其满足强度和寿命要求。改进后的离散单元法对该型双齿辊破碎机的一级粗破碎段的破碎过程进行了数值仿真。首先应用离散单元法模拟双齿辊破碎机对煤炭颗粒的破碎过程,获取双齿辊破碎机在破碎时所受的破碎力,并将该结果与使用传统经验公式计算得出的解进行对比。
    分析不同参数下仿真结果变化,研究了双齿辊破碎机的齿辊转速、颗粒直径对破碎力的影响规律。结合Hertz-Mindlin无滑动接触模型与Hertz-Mindlin黏结接触模型,将颗粒接触模型简化为振动运动模型并分别推导各分力的计算公式,在EDEM软件的基础上进行了二次开发,使用API插件构建与2种模型相结合的煤炭颗粒接触模型。煤炭颗粒在进入破碎腔前将其转化为若干小颗粒紧凑在一起的集合,小颗粒之间施加黏结接触,当任意2个小颗粒间所受外力小于绑定约束的约束力时,忽略小颗粒间的相对位移,使颗粒集合仍然以一个整体的形态运动;当某2个小颗粒间所受外力大于绑定约束力时,取消这2个小颗粒间的绑定约束,使小颗粒从颗粒集合体中分离。
    以该方法建立的煤炭颗粒接触模型能够有效地仿真煤炭颗粒的完整破碎过程,并且在仿真时节约计算时间和资源。最后,通过对比分析得出了对双齿辊破碎机进行数值模拟时所用到的接触检索网格尺寸的最优取值。以最新设计制造的YLWP+S1000-1500WX双齿辊式破碎机为例进行影响规律研究,应用上述理论方法对燃煤颗粒的破碎过程进行仿真,提取破碎齿在破碎过程中的受力变化曲线。获得一级粗破碎辊上的单排破碎齿在破碎正常煤颗粒过程中承受的最大破碎力载荷和平均破碎力载荷,得到了颗粒直径与齿辊转速的变化对破碎齿受力的影响规律。以上研究结果可为破碎机设计及破碎能力的预估提供参考。

     

    Abstract: Based on the theory of discrete element method,the particle contact model,the particle contact search algorithm and the iteration time step algorithm in the analysis process are improved,and the force of the tooth roll in the crushing process is analyzed to ensure that the strength and life requirements are met.The improved discrete element method is used to simulate the crushing process of the first rough crushing section of the double-tooth roller crusher.Firstly,the discrete element method is used to simulate the crushing process of coal particles by the double-tooth roller crusher,and the crushing force of the double-tooth roller crusher is obtained.The results are compared with the solution calculated by the traditional empirical formula.The simulation results under different parameters were analyzed,and the influence of the speed and particle diameter of the tooth roll on the crushing force was studied.Then,combined with Hertz-Mindlin non-sliding contact model and Hertz-Mindlin bonding contact model,the particle contact model is simplified to vibration motion model and the calculation formulas of each component force are derived respectively.On the basis of EDEM software,the second development was carried out,and the coal particle contact model combined with the two models was constructed by API plug-in.Before entering the crushing chamber,coal particles are transformed into compact aggregates of several small particles,and bonding contacts are exerted between the small particles.When the external force between any two small particles is less than the binding constraint force,the relative displacement between the small particles is neglected,so that the particle set still moves in a whole shape.When the external force between two small particles is greater than the binding force,the binding constraint between the two small particles is cancelled to separate the small particles from the aggregate.The contact model of coal particles established by this method can effectively simulate the complete crushing process of coal particles,and save computing time and resources.Finally,through comparative analysis,the optimal value of contact retrieval mesh size used in numerical simulation of double tooth roll crusher is obtained.Taking YLWP+S1000-1500WX double-toothed roller crusher newly designed and manufactured as an example,the influence law is studied.The crushing process of coal-fired particles is simulated by the above-mentioned theoretical method,and the force change curve of crushing teeth in the crushing process is extracted.The maximum crushing force load and average crushing force load of single row crushing teeth on the first rough crushing roll in the process of crushing normal coal particle are obtained,and the influence law of particle diameter and rotational speed of gear roll on the force of crushing teeth is obtained.It provides a reference for the design of crusher and the prediction of crushing capacity.

     

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