Development of a Non-Spherical Polymeric Particles Calibration Procedure for Numerical Simulations Based on the Discrete Element Method

The manufacturing industry, in general, and the plastic industry, in particular, have been developing new materials and process methods that need a correct study and optimization. Nowadays, the main approach to optimize these processes is using numerical methods and, in the case of particulate materials, the Discrete Elements Method to estimate the particles interactions. But those mathematical models use some parameters that depend on the material and must be calibrated, thus requiring an important computational and experimental cost. In this study, we integrate different speed-up procedures and present a general calibration method of Low-Density Polyethylene particles, to obtain the calibrated solid density and Poisson’s ratio of the material, the restitution, static and rolling friction factors in the particle-to-particle and particle-to-wall interactions, and the contact model variables (damping factor, stiffness factor, and energy density). For this calibration, four different tests were carried out, both experimentally and with simulations, obtaining the bulk density, the repose and shear angles, and the dropped powder. All these response variables were compared between simulations and experimental tests, and using genetic algorithms, the input parameters (design variables) were calibrated after 85 iterations, obtaining a Mean Absolute Percentage Error of the response variables lower than 2% compared to the experimental results.