Numerical Study on Material Removal of a Convex Pattern Surface Interacting with Non-Spherical Particles

A convex pattern surface is proposed and optimized to mitigate the sliding wear of bulk handling equipment caused by interaction with bulk solids. This work investigates the effectiveness of the convex pattern surface on wear reduction during interactions with non-spherical particles. Multiple representative particles, obtained through a sampling method, are reconstructed using a photogrammetry technique. Two contact parameters between particles are calibrated through shear box and drawdown tests to ensure flow behavior similar to the real material. The numerical results indicate that the convex pattern surface can effectively reduce wear compared to a plain sample when involving both spherical and non-spherical particles. For a plain sample, the wear volume remains independent of particle shapes and increases linearly with numerical revolutions. For the convex pattern surface, the wear volume demonstrates a quadratic relationship with the test revolutions as the deformation of convex elements weakens the effectiveness of the sample on wear reduction. The particle flow behavior analysis reveals that the convex pattern surface experiences the lowest wear volume when in contact with non-spherical particles. This can be attributed to the non-spherical particles sliding shorter distances and rotating with higher angular velocities on the convex pattern surface.