Category: Classes

ME 49800 (Fa19) Project (3 credit hours)
Contact: Prof. Wassgren (wassgren@purdue.edu)

Project Title: Optimizing Particle Shape For Flow and Packing

Project Description
The objective of this project is to determine what particle shapes result in good bulk flow behavior, but dense packings when flow ceases. This information is useful in the design of particles for use in powder bed fusion 3D-printing applications. In powder-based 3D printing, particles will ideally flow well in order to form a uniform powder base layer, but pack densely and uniformly so that fused powder parts have uniform, dense microstructures.

Project Responsibilities:

1. Produce superellipsoid shapes using Mathematica, MATLAB, or Maple and export in a CAD file format.
2. Train to use the Rocky DEM software package.
3. Develop a shear cell simulation in Rocky. The simulation will be used to predict the shear stress required to shear a particle bed subject to a prescribed normal stress. The solid fraction during and after shearing will also be predicted. Lastly, gather statistics on the contact area between particles using the simulation.
4. Develop a vibrating cylindrical container packing simulation in Rocky. The simulation will be used to predict the poured and tapped bulk solid fraction of particles as well as particle contact areas.
5. Perform parametric studies using the simulations developed in #3 and #4 and the particle shapes developed in #1.
6. Examine the data generated from the parametric studies to determine relationships between the bulk friction coefficient, ratio of tapped to poured bulk solid fractions, contact areas, and particle shape. Attempt to determine what particle shape(s) result in good flow and dense packings.
7. Report your progress in weekly research group meetings. (1 hr/wk)
   A. These will be ~15 minute updates.
   B. The objectives of these meetings are: (a) to give you presentation practice, (b) keep others in the group up-to-date about the work you’re doing, and (c) get help and advice from the group on your work.
8. Help in the preparation of a journal article describing the work.

Grading Criteria
• A: Satisfactory completion of all items.
• B: Satisfactory completion of all items, except for item #6.
• C: Satisfactory completion of all items, except for items #5 and #6.
• D: Satisfactory completion of all items, except for items #3 or #4, and items #5 and #6.
• F: Otherwise

Applicant Requirements
• Junior or senior standing
• GPA greater than or equal to 3.0
• Sufficient time to devote ~9 – 12 hrs/wk to the project, on average

References
Purdue Center for Particulate Products and Processes (CP3):
https://engineering.purdue.edu/CP3
Superellipsoids:
https://en.wikipedia.org/wiki/Superellipsoid
http://mathworld.wolfram.com/Superellipsoid.html
https://cse.buffalo.edu/~jryde/cse673/files/superquadrics.pdf
Rocky DEM:
https://rocky.esss.co/
Powder fusion 3D printing (these can be provided upon request):
Haeri, S., Wang, Y., Ghita, O., and Sun, J., 2016, “Discrete element simulation and
experimental study of powder spreading process in additive manufacturing”, Powder
Technology, Vol. 306, pp. 45 – 54.
Herbold, E.B., Walton, O., and Homel, M.A., 2015, “Simulation of powder layer deposition in
additive manufacturing processes using the discrete element method”, Lawrence
Livermore National Laboratory Report #LLNL-TR-678550.
Parteli, E.J.R. and Poschel, T., 2016, “Particle-based simulation of powder application in
additive manufacturing”, Powder Technology, Vol. 288, pp. 96 – 102.
Parteli, E.J.R., 2013, “DEM simulation of particles of complex shapes using the multisphere
method: application for additive manufacturing”, Powders and Grains 2013, AIP Conf.
Proc. 1542, pp. 185 – 188.
Xiang, Z., Yin, M., Deng, Z., Mei, X., and Yin, G., 2016, “Simulation of forming process of powder
bed for additive manufacturing”, Journal of Manufacturing Science and Engineering, Vol.
138, Article 081002.
Zhou, J., Zhang, Y., and Chen, J.K., 2009, “Numerical simulation of random packing of
spherical particles for powder-based additive manufacturing”, Journal of Manufacturing
Science and Engineering, Vol. 131, Article 031004.