Stress and input energy analyses of shearing a particle bed under a centrifugal field

Effective shearing of fine powders for surface modification and dry coating requires a compressed powder bed to prevent aeration. A device known as Mechanofusion® provides the necessary conditions using a centrifugal field, under which submicron particles are coated onto coarser host particles by shearing under great compressive forces at very high strain rates. This creates composite powders with enhanced properties, such as good flowability, surface functional effects, etc. Understanding the dynamics of particle motion, required level of shear stresses and input energy is a prerequisite for process optimisation. Here, numerical simulation by the Discrete Element Method is carried out, analysing features which are otherwise difficult to obtain by experimental work, e.g. the determination of the thickness of the zone in which particles experience shearing strains, as necessary for functional effect, compressive forces on particles, and input energy. Correlations are proposed for the energy input requirement and stresses experienced by the device as a function of rotational speed.