Finite element-based analysis of blasting rock fragmentation using a digital sieving algorithm

Abstract

Fragmentation serves as a critical blasting quality indicator in hydropower engineering, directly influencing rock extraction efficiency, operational quality, and economic costs. This study introduces a simulation method based on finite element digital sieving to address the limitations of traditional finite element methods (FEM) in predicting fragmentation. The method integrates finite element results with damage mechanics theory, employing a calibrated damage threshold (D₀₎ to differentiate high-damage element (HDE) from slow-damage element (SDE). Fragment size distribution is determined through damage-size correlation mapping and a maximum Feret diameter algorithm, establishing quantitative connections between numerical simulations and actual fragmentation patterns. Validation through Split Hopkinson Pressure Bar (SHPB) testing at Tongcheng Pumped Storage Power Station enabled precise calibration of critical simulation parameters. The results demonstrate reliable prediction of fragmentation distributions, providing an effective computational framework for practical engineering implementation. The conforming-to-dynamite mass ratio (CDR) metric demonstrates that insufficient decoupling coefficients compromise detonation efficiency, whereas excessive values promote oversized fragment generation, providing valuable insights for optimizing blasting design in practice.