QUSIMAV – Quantitative Simulation Method for the Prediction of Abrasive Wear

• Applicant: Professor Dr.-Ing. Andrè Katterfeld
• Subject Area: Mechanical Process Engineering ; Engineering Design, Machine Elements, Product Development ; Traffic and Transport Systems, Intelligent and Automated Traffic
• Term: from 2018 to 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 415862397

The main objective of the research project is the development of a standardized method for the validated quantitative prediction of sliding and impact wear in the field of material handling and construction machines using the Discrete Element Method (DEM). The simulation approach allows for the first time the consideration of,- complex component and plant geometries,- different bulk material properties that significantly influence the flow and flow behavior of the bulk material and thus the bulk material-component interaction,- realistic operative boundary conditions (mass flow rates, motion of machine components).The results of the research project would provide a great deal of added value for predicting wear in the bulk material handling and processing industry and would allow economic and resource efficient use of high quality wear protection materials. Since the existing wear models in DEM have limitations in the assessment of wear, it is necessary to further develop them and develop appropriate validation and calibration strategies to ensure realistic results.For calibration, the real mass loss of specific wear protection materials resulting from the bulk material interaction should be determined with the help of wear test stands which independently consider sliding and impact wear cases. The experimental data will be compared with the results of the idealized DEM simulations.To calibrate the sliding wear, a wear test rig (already been financed and constructed from appellants' appeals) will be used. For the calibration of the impact wear, however, the development and the construction of a new test stand are necessary.Finally, for validation, experiments are carried out on the modified impact wear test stand, in which a flow of bulk material acts on a component with complex geometry. Hence, both wear types, abrasive sliding and impact wear occur at the same time. The functionality of the calibration procedure is to be validated by comparison with analogous DEM simulations of these validation tests using the previously calibrated wear model parameters.

• DFG Programme: Research Grants