A novel method for full-body modelling of grinding charges in tumbling mills

The smoothed particle hydrodynamic (SPH) method is used to model a ball charge and its interaction with the mill structure, while the flexible rubber lifter and the lining are modelled with the finite element method (FEM). The adaptive nature of the SPH-method together with the non-connectivity between the particles results in a method that is able to handle very large deformations. This computational model makes it possible to predict the deflection and stresses of the lining in a pilot ball mill and the mechanical waves travelling in the mill system. It also makes it possible to predict e.g. charge pressure and von Mises’ stress within the charge and the contact forces between the charge and lining. The deflection profile of the lifters obtained from SPH–FEM simulation shows a reasonably good correspondence to pilot mill measurements as measured by an embedded strain gauge sensor.

Graphical abstractFigure optionsDownload full-size imageDownload as PowerPoint slideHighlights► Combined SPH–FEM mill model. ► Predicts mechanical responses for the whole mill. ► Direct coupling between force, stress and deflection for the whole mill system. ► Predict stresses travelling in the lining and in the charge.