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This article presents a novel approach to calibrating the digital twin of a laboratory mill used for copper ore milling. By integrating computer vision techniques for real-time data extraction and employing DualSPHysics simulations for various milling scenarios, including balls only, balls with ore, and balls with slurry, we achieve a high degree of accuracy in matching the digital twin's behavior with actual mill operations. The calibration process is detailed for mills with three different diameters, highlighting the adjustments in simulation parameters necessary to account for the absence of ore. Understanding the dynamics between the suspension within the mill and the operation of the grinders is crucial for the future improvement of the grinding process. This knowledge paves the way for optimizing the process, not only in terms of the quality of the end product but primarily in terms of energy efficiency. A profound understanding of these interactions will enable engineers and technologists to design mills and grinding processes in a way that maximizes efficiency while minimizing energy consumption. [ABSTRACT FROM AUTHOR]

Powder deaggregation in Dry Powder Inhalers (DPI) with carrier-based formulations is a key process for the effectiveness of drug administration. Carrier-wall collisions are one of the recognised mechanisms responsible for active pharmaceutical ingredient (API) aerosolisation, and DPI geometries are designed to maximise their efficacy. The detachment of fine and cohesive API particles is investigated at a fundamental level by simulating with DEM the normal collision of a carrier sphere with an API particle attached. The impact velocity at which detachment occurs (escape velocity) is determined as a function of key parameters, such as cohesiveness, coefficient of restitution, static and rolling friction. An analytical model for the escape velocity is then derived, examining the role of the initial position of the particle, cohesion model and particle size. Finally, the results are framed in the context of DPI inhalers, comparing the results obtained with impact velocities typically recorded in commercial devices. [ABSTRACT FROM AUTHOR]

Many reptiles, known as 'sand swimmers', adapt to their specific environments by vibrating or rotating their body. To understand these type of interactions of active objects with granular media, we study a simplified model of a self-excited spherical object (SO) immersed in the granular bed, using three-dimensional discrete element method (DEM) simulations. Modelling the vibration by an oscillatory motion, we simulate the longitudinal locomotion of the SO in three modes: transverse vibration, rotation around different axes, and a combination of both. We find that the mode of oscillation in y direction coupled with rotation around x-axis is optimal in the sense that the SO rises fastest, with periodic oscillations, in the z direction while remaining stable at the initial x position. We analyze the physical mechanisms governing the meandering up or down and show that the large oscillations are caused by an asynchronous changes between the directions of oscillation and rotation. We also observed that the SO's rising rate is sensitive to three parameters: the oscillation amplitude, the oscillation frequency, f, and the rotation angular velocity, Ω. We report the following results. 1. When the frequencies of the rotation and transverse motion are synchronised, SO rises when Ω < 0 and sinks when Ω > 0 ; the average rising/sinking rate is proportional to | Ω | . 2. The rising rate increases linearly with the oscillation amplitude. 3. There exists a critical oscillation frequency, above and below which the rising mechanisms are different. Our study reveals the range of parameters that idealized 'swimmers' need to use to optimize performance in granular environments. [ABSTRACT FROM AUTHOR]

Featured Application: Nanoparticle suspensions are used in a variety of applications involving the transport of reagents and products to and from structured material surfaces. The more efficient alignment of particle layers adjacent to, and in contact with, a reactive surface, such as found in a fuel cell, bio-medical and electrochemical device, is often reliant upon the effective control of the dynamics of particle assembly in narrow conduits. One such control is possible by spectral thermal pulsing to generate a controlled Brownian motion of particles. This is demonstrated by numerical simulation here to be highly effective when particles are conveyed in viscous fluids close to a neutrally buoyant condition. Inter-particle and particle-wall connectivity in suspension flow has profound effects on thermal and electrical conductivity. The spectral impulse generation and the imparting of kinetic energy on the particles is shown through a mathematical analysis to be effective as a means of achieving an approximate equivalent of a Langevin thermostat. However, with dilute suspensions, the quadratic form of the thermal pulse spectra is modified with a damping coefficient to achieve the desired Langevin value. With the dense suspension system, the relaxation time is calculated from the non-linear differential equation, and the fluid properties were supported by the viscosity coefficient. A "smoothed" pulse is used for each time-step of the flow simulation to take care of the near-neighbor interactions of the adjacent particles. An approximate optimal thermostat is achieved when the number of extra pulses introduced within each time step is found to be nearly equal to the co-ordination number of each particle within the assembly. Furthermore, the ratio of the particle kinetic energy and the thermal energy imparted is found to be never quite equal to unity, as they both depend upon the finite values of the pulse duration and the relaxation time. [ABSTRACT FROM AUTHOR]