Investigating mixing and segregation using discrete element modelling (DEM) in the Freeman FT4 rheometer

Mixing and segregation in a Freeman FT4 powder rheometer, using binary mixtures with varied particle size ratio and volume fraction, were studied using the Discrete Element Method (DEM). As the blade moves within the particle bed, size induced segregations can occur via a sifting mechanism. A larger particle size ratio and/or a larger volume fraction of large particles lead to a quicker segregation process. A higher particle velocity magnitude can promote the segregation process and the rate for the segregation index increases in the radial direction: from the centre towards the outer layer. In the current DEM simulations, it is shown that the change in flow energy associated with segregation and mixing depends on the choice of frictional input parameters. FT4 is proposed as a potential tool to compare and rank the segregation tendency for particulate materials with distinct differences in flow energy of each component. This is achieved by measuring the flow energy gradient after a number of test cycles for mixing powders with different flow properties. Employing the FT4 dynamic powder characterisation can be advantageous to establish blending performances in an industrial context.