Assessing the Effects of Material Properties on Load Behavior in Dry Ball Mills Using DEM

Understanding how the mill load behaves is crucial for enhancing ball mill effectiveness. This study aimed to create a discrete element method (DEM) model to simulate the motion charge in ball mills and to analyze how the simulation material properties affected the load behavior. The steel balls were modelled as a collection of distinct particles, each of which was subject to Newton’s laws of motion and tracked in a Lagrangian manner. Hertzian contact law was used to describe inter-particle collisions. Then, this numerical model was coded using the open-source C++ program LAMMPS Improved for General Granular and Granular Heat Transfer Simulation (LIGGGHTS) to mimic laboratory and pilot-scale ball mills. The load positions measured from the DEM simulations were compared to the published experimental data and empirical models of comparable laboratory and pilot-scale experiments to validate the findings. The angular shoulder position ranged between 137° to 154° for the range of Young’s modulus of 0.5 to 1000 MN/mm2. Angular shoulder and toe positions had a variation of less than 10% from the laboratory and pilot-scale experimental data. The outcomes demonstrated a significant relationship between load position and material characteristics such as Young's modulus in DEM simulation. This preliminary model can be used for choosing the appropriate material parameters for ball mills both with DEM and coupled CFD–DEM multiphase simulations. This assessment concluded that material properties affect the load behavior in computer simulations of ball mills.