Hopper flow of irregularly shaped particles (non-convex polyhedra): GPU-based DEM simulation and experimental validation

Contact networks and force transmission in aggregates of hexapod-shaped particles

Hexapods, consisting of three mutually orthogonal arms, have been utilized as a representative nonconvex shape to demonstrate the impact of interlocking on the strength properties of granular materials. Nevertheless, the microstructural characteristics of hexapod packings, which underlie their strength, have remained insufficiently characterized. We use particle dynamics simulations to build isotropically-packed aggregates of hexapods and we analyze the effects of aspect ratio and interparticle friction on the microstructure and force transmission. We find that the packing fraction is an unmonotonic function of aspect ratio due to competition between steric exclusions and interlocking. Interestingly, the contact coordination number declines considerably with friction coefficient, showing the stronger effect of friction on the stability of hexapod packings as compared with sphere packings. The pair distribution functions show that local ordering due to steric exclusions disappears beyond the aspect ratio 3 and the hexapods touch their second neighbors. Remarkably, hexapods of aspect ratio 3 tend to align with their neighbors and form locally ordered structures, implying a contact coordination number which is highly sensitive to the confining pressure. We also show that the probability density function of forces between hexapods is similar to that of sphere packings but with broadening exponential fall-off of strong forces as aspect ratio increases. Finally, the elastic bulk modulus of the aggregates is found to increase considerably with aspect ratio as a consequence of the rapid increase of contact density and the number of contacts with second neighbors.

The effect of particle shape on discharge and clogging

Granular flow is common across different fields from energy resource recovery and mineral processing to grain transport and traffic flow. Migrating particles may jam and form arches that span constrictions and hinder particle flow. Most studies have investigated the migration and clogging of spherical particles, however, natural particles are rarely spherical, but exhibit eccentricity, angularity and roughness. New experiments explore the discharge of cubes, 2D crosses, 3D crosses and spheres under dry conditions and during particle-laden fluid flow. Variables include orifice-to-particle size ratio and solidity. Cubes and 3D crosses are the most prone to clogging because of their ability to interlock or the development of face-to-face contacts that can resist torque and enhance bridging. Spheres arriving to the orifice must be correctly positioned to create stable bridges, while flat 2D crosses orient their longest axes in the direction of flowlines across the orifice and favor flow. Intermittent clogging causes kinetic retardation in particle-laden flow even in the absence of inertial effects; the gradual increase in the local particle solidity above the constriction enhances particle interactions and the probability of clogging. The discharge volume before clogging is a Poisson process for small orifice-to-particle size ratio; however, the clogging probability becomes history-dependent for non-spherical particles at large orifice-to-particle size ratio and high solidities, i.e., when particle–particle interactions and interlocking gain significance.

Application of the Discrete Element Method for Manufacturing Process Simulation in the Pharmaceutical Industry

Process simulation using mathematical modeling tools is becoming more common in the pharmaceutical industry. A mechanistic model is a mathematical modeling tool that can enhance process understanding, reduce experimentation cost and improve product quality. A commonly used mechanistic modeling approach for powder is the discrete element method (DEM). Most pharmaceutical materials have powder or granular material. Therefore, DEM might be widely applied in the pharmaceutical industry. This review focused on the basic elements of DEM and its implementations in pharmaceutical manufacturing simulation. Contact models and input parameters are essential elements in DEM simulation. Contact models computed contact forces acting on the particle-particle and particle-geometry interactions. Input parameters were divided into two types-material properties and interaction parameters. Various calibration methods were presented to define the interaction parameters of pharmaceutical materials. Several applications of DEM simulation in pharmaceutical manufacturing processes, such as milling, blending, granulation and coating, were categorized and summarized. Based on this review, DEM simulation might provide a systematic process understanding and process control to ensure the quality of a drug product.

Study of the capsule-filling dosator process via calibrated DEM simulations

Capsule filling is frequently accomplished via the dosator process. Controlling the main quality attributes, i.e., the fill weight and the fill weight variability, requires excellent process understanding. For the investigation of critical process parameters of low-dose capsule filling, DEM simulations were used. Two contact models (Hertz model and Luding model) were calibrated and validated to represent the lactose powder Lactohale 100. Both models gave good results, yet the Luding model resulted in better predictions. Since the dosator process is a volume-based approach, the dosator geometry is an important factor. We provide evidence that not only the volume, but also the proportions of the dosator affect the capsule fill weight. Slim nozzle chambers cause lower mass due to increased wall friction impact. The process is not volumetric, as a fill weight to volume correlation does not exist. Furthermore, the fill weight increases with higher powder beds and smaller gaps between the nozzle tip and the container bottom due to higher densification of the powder. Fill weight variations due to bed inhomogeneity were investigated by varying the bulk density of the initial powder bed.