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International Journal of
Rock Mechanics & Mining Sciences
journal homepage: www.elsevier.com/locate/ijrmms
a r t i c l e i n f o
abstract
Article history:
Received 21 November 2011
Received in revised form
6 August 2012
Accepted 28 December 2012
Available online 1 February 2013
Comminution processes are not fully understood today and more research is necessary towards the
improvement of existing comminution equipment. Presently, the best suited modeling technique is the
Discrete Element Method (DEM) but in its conventional form it is not suitable for simulating industrial
comminution processes where size reduction is an important issue, if not the main issue, such as in
crushers. Attempts for simulating such mining equipment with DEM have been carried out previously
applying empirical models for rock rupture. The foundations of the Discrete Crack Model (DCM) are
presented here as a new method for efciently modeling rock fracture within a DEM work frame. In
DCM, random cracks seeds are generated inside the rock specimens and the stress eld in the vicinity of
the cracks is calculated by the Convex Polygons Stress Approximation (CPSA), the basis of DCM.
A rupture criterion is then applied to determine if or when the rock splits. Resulting CPSA stress elds
are compared here to those obtained by a more precise but much slower Finite Element Method (FEM)
solution. Next, to validate DCM methodology, three illustrative loading cases are analyzed comparatively. It is shown that the failure mechanism predicted by the DCM methodology agrees to similar
documented cases in the literature. The proposed approach is applicable both in 2D and 3D.
& 2013 Elsevier Ltd. All rights reserved.
Keywords:
Discrete Element Method
Comminution
Rock fracture
1. Introduction
Simulation of comminution process is still not well understood
and although much effort has been made in the past, many
aspects of the process still remain poorly understood. Authors
such as Powell and Morrison [1] identify essentially four
approaches to study comminution processes. The rst approach
is Power based models, for example the Bond index [2,3]
provides a good correlation for controlled laboratory work in ball
mills. However, an abuse of Bonds excellent work is often made
by trying to cover most comminution machinery with little
consideration of the limitations of the original work. Improvements have been made to cover todays machines, but as in all
empirical relationships its strength relies on the experimental
database, and accurate extrapolation to different machines, ores,
or production rates is not guaranteed.
The second approach is Population balance-based model,
which is good at predicting size reduction, production rates, and
power drawn. The problem with these kinds of models is that
they do not describe the breakage process, and only keep track of
the output. It is also difcult to obtain some ore-specic parameters needed for simulation.
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D.A. Estay, L.E. Chiang / International Journal of Rock Mechanics & Mining Sciences 60 (2013) 125133
127
sxy ZC 0 msy
srr
2C 1 cos y 2C 3 sin y
,
r
r
sry 0, syy 0,
F2
where F1 and F2 are the applied forces, and a and b are the wedge
angles shown in Fig. 1.
This analytical solution is used to determine the stress eld in
a disk as in the case of the conventional Brazilian test for example.
As depicted in Fig. 2, it can be shown that a solution can be
obtained by applying the Flamant solution for each force. This will
create a compressive stress state at the perimeter of the disk,
adding a constant radial traction force at circumference of the
disk, the perimeter becomes stress free and it looks as below:
X F
si,j x,y
si,ji x,ysTi,j x,y
4
Fig. 1. Angles and forces for Flamant linear elastic wedge solution.
128
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where si,j x,y is the stress in the disk, sFi,ji x,y is the stress
predicted by Flamant solution, and sTi,j x,y is the stress generated
by the traction force at the perimeter
Timoshenko and Goodier [20] analized more complicated load
conguration. The solution has a similar form, which is to apply
the Flamant solution for each force and apply a radial tension
solution.
3.2.2. Convex Polygons Stress Approximation (CPSA)
When we change from a disk to a more complex shape like
polygons the same principle can be applied, for each force we use
the Flamant solution. This will generate a compressive stress at
the boundary, the only difference is that the applied force at the
perimeter to eliminate the compressive stress is not constant and
because of this the stress distribution sTi,j x,y generated inside
the rock is not easily found:
sTi,j x,y
nT
X
wi x,ysG x,y
i1
where sTi,j x,y is the stress caused by the tension solution on the
perimeter, wi x,y is the weight function, and sG xi ,yi is the stress
in the ith point of the perimeter.
It is not necessary to use all the nT points in the perimeter, a
subset with the n closest points can be used with good results.
The weighting function used depends on the distance from the
crack seed point to the boundary point and it is represented by
Qn q
xj x2 yj y2
j1
q
wi x,y
8
xj x2 yj y2
where x,y is the crack seed coordinates, and xj ,yj is the point at
the perimeter.
syy
D.A. Estay, L.E. Chiang / International Journal of Rock Mechanics & Mining Sciences 60 (2013) 125133
9sFEM sDCM 9
sFEM
10
129
Fig. 3. Loading cases examined: (a) point to point loading; (b) point to plane
loading; and (c) plane to plane loading.
Fig. 4. Stress eld for a diamond shaped rock: (a) Von Misses stress, solved by the CPSA method in point to point loading case; and (b) relative error between FEM and
CPSA solutions for point to point loading case.
Fig. 5. Stress eld for a triangle shaped rock: (a) Von Misses stress, solved by the CPSA method in point to plane loading case; and (b) relative error between FEM and CPSA
solutions for point to plane loading case.
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Fig. 6. Stress eld for a square shaped rock: (a) Von Misses stress, solved by the CPSA method in plane to plane loading case; and (b) relative error between FEM and CPSA
solutions for plane to plane loading case.
Fig. 7. Activated cracks seeds in fracture process for the three analized loading cases: (a) point to point loading; (b) point to plane loading; and (c) plane to plane loading,
green cracks seeds are activated by shear and red by tensile failure, red arrow represents the propagation direction of tensile cracks. (For interpretation of the references to
color in this gure legend, the reader is referred to the web version of this article.)
more shear failure points occurs near the loading points, and
nally tensile cracks appear at the center of the rock. The red line
indicates the direction in which the crack should propagate, so in
this case clearly the rock will be divided in two main parts. This
behavior is similar to the Brazilian test where a disk is loaded
with opposite point forces. Khanal et al. [24] studied breakage in
the Brazilian test and reported that failure is by axial splitting.
It is also possible to say that the area near the loading point is
damaged due to contact and the multiple cracks activated by
shear are proof of this.
It is important to compare Fig. 7a with Fig. 4b. We can clearly
see that all activated crack fall in a zone with a low stress error
between FEM and CPSA, so the approximation for the stress eld
using CPSA is really helpful given the simulation time reduction
achieved.
4.2. Case 2: point to plane loading
Fig. 7b shows activated cracks in plane-to-plane loading at the
nal stage of loading. When load is small, shear failure occurs at
the point force application point. The cracks grow quickly as the
load increases. When breakage condition is achieved tensile
cracks appear, and given the crack propagation direction it can
be concluded that the cracks will propagate in an inclined
direction towards the loading point. Similar to point to point
loading (Case 1), it can be concluded that contact damage will
occur at the top.
As in point to point loading, we can identify the zone of
activated cracks. From Fig. 5b it is important to note that all
activated cracks are found in a zone with low error between CPSA
and FEM.
4.3. Case 3: plane to plane load
Fig. 7c shows activated cracks in plane-to-plane loading. Since
no point forces exist, no stress concentration points or shear
D.A. Estay, L.E. Chiang / International Journal of Rock Mechanics & Mining Sciences 60 (2013) 125133
131
Fig. 8. Fracture pattern for the three different loading cases examined: (a) point to point loading, the rock is subdivided in two major parts by tensile failure, shear
activated cracks at the contact points are proof of contact damage; (b) point to plane loading, shear fractures are generated at the contact point and tensile cracks are
generated towards the loading point; and (c) plane to plane loading, a shear crack propagates at the center of the rock, only a few cracks seeds present shear failure at the
contact surface so no damage is assumed.
Fig. 9. DCM simulation of a disk Brazilian Test: (a) loading principle of Brazilian test in a cylindrical shaped rock; (bd) Von Mises stress before and after breakage;
and (e) rock fragments at the nal time step.
Table 1
DCM simulation parameters for Brazilian test
Parameter
Value
2.5 10 3
0.01
129.5
13
50
4.23
36
50
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D.A. Estay, L.E. Chiang / International Journal of Rock Mechanics & Mining Sciences 60 (2013) 125133
st
Fig. 10. Convergence behavior of tensile strength when the number of crack seeds
changes in a Brazilian test simulation.
2P
pLD
11
6. Conclusions
Fig. 11. Loaddisplacement curve for a Disk Brazilian test simulation. Note that
loading platen was not in contact with the disk at start.
D.A. Estay, L.E. Chiang / International Journal of Rock Mechanics & Mining Sciences 60 (2013) 125133
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