Estimate of Stress Induced During Filling and Discharge of Metallic Silos For Cement Storage

5/9/2016
EstimateofstressinducedDuringfillinganddischargeofmetallicsilosforcementstorage
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Dynarev.fac.nac.minasvol.82No.194Nov./DecMedellin.2015
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http://dx.doi.org/10.15446/dyna.v82n194.49731
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DOI:http://dx.doi.org/10.15446/dyna.v82n194.49731
EstimateofstressinducedDuringfillingand
dischargeofmetallicsilosforcementstorage
Estimationofinducedduringfillingandemptyingof
metalsilosforcementstorageefforts
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WilmerBayonneCarvajalto&JairoUsecheViverob
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Received:March19th,2015.Receivedinrevisedform:June1rd ,
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Abstract
ThepresentarticleshowthestructuralanalysisRealizedtometallicsiloforstorageofcementthroughthe
parametricmodeldevelopmentinthefiniteelementsoftwareASNYSAPDL,thefillanddischargePressureson
thesilowallappliedisdeterminedtoEurocodeWiththeEN19914normative.Themodelisdevelopmentwith
typeshellelementsAllowingThatthesilostructurefitstothecylindricalandconicalgeometricofthesilo.It
ExplainseachofthephasesHavingthedevelopmentofthemodelandismadeadetailedanalysisoftheresults
deliveredbythesoftwareEVALUATEDdifferentmodelsarechangingthesheetthicknessThemostAppropriate
forselect.AlsotheresultsareAnalyzedbechangingthetiltingWhenthehopperandisreviewedthebehaviorof
thesiloWhenisAnalyzedWithitsstructure.
Keywords:Cementsilos,structuralanalysis,finiteelement,parametricmodel,EurocodeEN19914,ANSYS
APDL,typeshellelements
Summary
Thisarticledescribesthestructuralanalysistoametalsilostoringcementthroughaparametricmodel
developedinthefiniteelementsoftwareANSYSAPDL,pressurefillingandemptyingthematerialexertsonthe
wallsofthesiloaredeterminedbasedintheregulationsofEurocodeEN19914.Themodelismadewithshell
elementstypesallowingitsstructurefitsthecylindricalandconicalsilogeometry.Eachofthephasesinvolved
inthedevelopmentofthemodelisexplainedandadetailedanalysisoftheresultsproducedbythesoftware
analysisisdone,differentmodelsareevaluatedbyvaryingthesheetthicknessinordertoselectthemost
appropriate.Theresultsarealsoanalyzedwhenthehoppersilochangesitsangleofinclinationandbehavior
thathasthesilowhenanalyzedinconjunctionwithitssupportstructureisreviewed.
http://www.scielo.org.co/scielo.php?script=sci_arttext&pid=S001273532015000600029
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Keywords:Siloofcement,structuralanalysis,finiteelementparametricmodel,EurocodeEN19914,ANSYS
APDL,typeshellelements.
1.Introduction
Thecementsiloisresponsibleforstoringthereadytopackanddelivertotheconsumermaterial,alsoserves
asareservetocushionproductionchangesandmaintenancedowntime,ensuringthatallthetimecementcan
bedeliveredtothecustomer.
Tomakethedesignofametalsiloefficiently,theyshouldtakeintoaccountdifferentvariablesthataffectthe
behaviorofthematerialwithinitisessentialtodeterminetheloadsthatdeterminethestructuralbehaviorof
thesilo.Initiallywemustbeclearthatthematerialstoredinthesiloplaysacriticalroleintheoutcomeof
structuralanalysistobeperformed,differentphysicalcharacteristicsofthematerialinfluencetheresultantof
theforcesgeneratedbythepressureonthesidesofthesilo[5,6].
Currentlytherearedifferentregulationswithwhichonecandeterminethepressureonthewallsofthesilos,
howeverEurocodeEN19914hasgainedprominencebecauseofitslargeapplicationworldwideandwith
satisfactoryresultsinthedesigns[1].Basedonthismethodologyaspreadsheetinvolvingeachofthevariables
presentinthecalculationofthepressuresanddevelopedwithstandardregulationsstudieditdevelops.To
determinesomevariablessiloisnecessarythatitsgeometrydefined,sothatthespreadsheetmusthaveas
inputsthedimensionsofthesiloplusthematerialcharacteristicsstored.Withthesevaluesandtheinformation
containedtherein,theyareobtainedasaresultofcalculatingthepressuresbothfillingandemptyingintothe
cylindricalportionandthesilohopper.
Withcertainpressurescanperformfiniteelementstructuralanalysis,notwithoutfirstseekingthemostsuitable
torepresentthemetalelementgeometryofthesilo.Shellelementstypesormorecommonlyknownasshell
typeelementsaredescribedinthedevelopmentofthisworkanditistheseelementsthatthesilomodels[4,7].
Structuralanalysisofthesilobymeansofafiniteelementcomputermodeltodeterminethesuitablewall
thicknessshouldhavethesilo.InitiallytwocodesANSYSAPDLcommandsaregeneratedintwotabsofthe
spreadsheetoneforthemodelfillingpressuresandtheotherwithdrainpressure.Eachcodetakesasinputall
variablesinthesiloforparameterizinganydesiredgeometry.Additionally,inthisfileyoucanchangethe
characteristicsofthescreentoselectthetype,quantityandsizeofelementsthatitshouldhave.Thecodeis
linkedtotheresultsofthepressuresoffillingandemptyingobtainedwiththesameworksheet.Bytwolinks
youhavethespreadsheetcanbegeneratedtextfilesintxtformat,containingthecodethatisinsertedintothe
commandlineANSYSAPDL,theretheprogramresultsrunandevaluatedandanalyzedtogetpropersilodesign
[2,12].
variationofeffortshasthesilowhentheinclinationangleofthehopperchangesitsbehaviorandfinallythesilo
isevaluatedwhenanalyzedinconjunctionwithastructurethatsupports[13]isalsoanalyzed.
Withamodelthatcanvarythepropertiesofthestoredmaterialandadjustthegeometriccharacteristicsofthe
silo,thedesignerwillbeabletoassessthebestconditionforagivenscenario,resultinginasuitabledesign
thatmeetsthespecificneedsofacase.
2.Methodology
Todeterminethestressesandstrainsinthesiloafirstpartdeterminingworkingpressuresbothfillingand
emptyingthecylinderandthehopperandasecondpartwhichisthemodelwithfiniteelementANSYSAPDL.
2.1.CalculationofpressurebasedontheregulationsofEurocodeEN19914
2.1.1.geometricspecificationssilo
TheFig.1showsthegeometryofthesilowiththevariablesaffectingthepressurecurveandwhichareinputfor
calculatingthesilo[3,10].
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Where
d c=diametersilo
h b=theheightthathasthematerial
h c=heightofthematerialinthecylindricalportion
h h=Itistheheightthathasthehopper
h s=heightoftheupperconeformingmaterial
b=anglebetweenthewallofthehopper
and i=Eccentricityfilling
and or=emptyingrunout
2.1.2.Propertiesofthegranularmaterialsinthecalculationofthesilo
Thepropertiesofthematerialthatiscontainedinthesiloandwhicharenecessaryforthecalculationofthe
pressureonthewallsofthisare:
Specificmaterialweightg
Angleofreposewiththehorizontalf r
effectiveinternalfrictionanglef i
llateralpressureratio
angleofwallfrictionf w
ThepropertiesfordifferentgranularmaterialscanbefoundintheEurocodeEN19914AnnexE[3,10].
2.1.3.Calculatingfillingpressuresinthecylinderandhopper
InFig.3pathshownzypressuresareinvolvedinfillingthesiloinitscylindricalpart[3.10].
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Where:
With:
A=areaofthecrosssectionofthesilo.
U=circumferenceofthecircularsectionofthesilo.
R=Radiusofthesilo.
Z=Traversingthecylinderpressure=specificweightmaterial.=Ratiooflateralpressure.
=coefficientoffrictionwiththewall.
Thecalculationisperformedfreepressurebyincreasingthehorizontalpressurebythefollowingrelation:
Where:
and i=eccentricityfilling.
Thetotalhorizontalpressureisthesumofthetwohorizontalpressuresdeterminedpreviouslyfixedpressure
andpressurefree.
Thehorizontalfillingpressureisgivenby:
Andthehorizontalpressure:
TheFig.4describesthetrajectoryxypressuresareinvolvedinfillingthesiloinitsconicalpart[3.10].
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Where:
With:
Where:
=specificweightofthematerial.
h h=heightofthehopper,fromthetipoftheconetothejunctionwiththecylinder.
x=Traversingthepressureinthehopper.h=coefficientoffrictionwiththewallofthehopper.
=angleofthehopper.
P vft=verticalpressureofthecylindricalsection.
a=0.8forfillingpressures.
2.1.4.Calculationofpressureinthecylinderandemptyinghopper
TheFig.5showsthepressuresinvolvedinemptyingthesiloinitscylindricalpart.Thenequations[3,10].
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TheFig.6showsthepressuresinvolvedinemptyingthesiloinitsconicalpart.Thenequations.
Where
s=coefficientoffrictionofhopperwall
wh=angleofwallfrictionofthehopper
i=effectiveangleofinternalfrictionofsolidmaterial
2.2.FiniteelementmodelinANSYSAPDL
ForthisprojectplatformMechanicalAPDL(languageparametricdesign)itwaschosenbecauseitallowsto
developacodecommandswhicharestructuredeachofthephasesofstructuralanalysisandwhichcanbe
parameterizedgeometricinputs,materialcharacteristics,typeandsizeelementtobeused,anddetailed
meshingcharacteristicsoftheloadsonthemodel,themodelalsoallowstoprovideacurveofpressure,ifitis
notpossibleinWorckbenchasthisallowsonlyhydrostatic[2,12]pressures.
2.2.1.Methodforgeneratingmeshingsilo
Beforeperformingthemeshingvariablesgeometricsiloarenamedforthemodelareparametric,thispartalso
namedtheelementtypetouse(shell281,tobebettercurvaturessilosetting),sizeelementandmaterial
propertiesofthesilo.TheFig.7showsthesevariables.
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Oncevariablesgeometrysilodefinedproceedstolocatestrategicpointsinspace(keypont)inordertodrawthe
geometryofthesilo,withkeypontlinesaregeneratedandwhentheyrotateontheaxisofthesilotheselines
silosurfacesareobtained,theFig.8showsthisresult.
Formeshingthedifferentsurfacesofthesiloisselectedandassignedthephysicalpropertiesofthematerial,
thethicknessandsizeoftheelementinFig.9youcanseethemesh.
2.2.2.Loadallocationmodel
TheequationsusedinSection2.1.3and2.1.4areenteredintoaspreadsheetwherepressuresaredetermined
fillingandemptyingthecylinderandhoppersilo,hencetheconstantcurveofthethirdorderaredeterminedto
showthepressurecurvesandcanbeseeninFig.10.Withtheseconstantsandrelatingtheareawhereitis
appliedpressureloadstothemodelnodesareassignedbytwoequationsthatvarywithheightoneforthe
cylindricalpartandoneforthetaperedportion.TheFig.11representstheallocationofloadsinthecylinder.
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Finallytheyareassignedboundaryconditionstothenodesrepresentingthebaseofthesilosupportpreventing
itsmovementineitherdirection.OncethiscodeiscopiedtothecommandlineANSYSandSOLVEistyped,so
theprogramcalculatesthestressesandstrainsofthesilo.
3.Results
3.1.Esfuerzo.sydeformationssilostudied
TheFigs.12and13showtheeffortVonMisesproducedbythecastingpressure,itisevidentthatthemaximum
valueof0.166Mpaislocatedinreinforcementsbelt,thatislogicalbearinginmindthatthesupportofthesilois
locatedinthispartandtheresupportsallcargo
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RegardingthedeformationsofFigs.14and15showthatthemaximumvalueof8.29mmispresentinthe
hopperjustbelowthebeltreinforcements,phenomenonthatoccursduetotherestrictionofmovementis
supported.
3.2.Selectingthemostsuitablemodel
6modelssilossamegeometrybutdifferentthicknessesanalyzeswereperformedinordertoevaluatewhich
offersbettersafetyfactorandislessheavy,thisinordertoreducemanufacturingcostsandassembly.Isthat
theModel5isrightbecauseitthrowssafetyfactorsof1.51forfillingandemptyingand1.37forweightis
40256kg.TheTable1showstheresults.
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3.3.Analysisofaneffortinasilowithdifferentinclinationhoppers
TakingthesilomodelMay2analyzesareperformedbychangingtheinclinationangleofthehopper(valueA1
ofTable1=60degrees),case1forhopper70degreesand50degrees2case.
TheFigs.16and17showtheVonMisesstressgeneratedbythefillingpressureinthecase1and2respectively
andinFigs.18and19foremptyingloads.
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Notethatforcase1VonMiseseffortisgreaterforemptying(0.146GPavs0.100GPa),thisoccursbecausethe
hopperismoreinclinedandverticalforcesareminor,oppositecaseoccursincase2wheretheeffortvonMises
is0.197GPaforemptying0.213GPaforfilling.
3.4.Analysisofasilostructure
Asseeninpreviousanalyzesthesiloshowedtheirutmosteffortsinbeltandthemaximumstrainsinthe
hopper,whichiswhyananalysisofthesiloisdonecontemplatingasupportstructure10metershigh,size
commonlyusedforthistypesilosinthecementpackingprocess.ItisusedasabasecodeANSYSmodel5
adicionndolethegeometryofthecolumnsandbeamsofthestructure.
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TheFigs.20and21representtheVonMisesstressforfillinganddischargepressuresrespectivelyandFigures
22and23deformationsinthesamecases.
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Fromtheresultsitcanbededucedthateffortsinthesiloarelowerwhenanalyzedinconjunctionwithits
structure,thisisduetothefactthatthetwodifferentboundaryconditionsofeachmodelisinduced.
Whenthesiloisonlyanalyzestheirfulcrumshavenodegreeoffreedom,whileinthecasesilostructurethese
samepointshavedegreesoffreedomanditsmovementitdependsontherigidityofthestructure.
4.Conclusions
TheparametricmodeldevelopedwithacodeandthefiniteelementsoftwareASNYSAPDLallowsthecalculation
ofasilowithanygeometry,size,sheetthicknessandtypeofmaterial,sizeandtypeoffiniteelementtouse.
Thismodelcanbemanipulatedthicknessesofdifferentsectionsofthesiloforcomparativeanalysisand
evaluatethesuitabilityofoneoranotherdesign,allowingthecalculistadevelopasuitablemodelthatmeetsthe
conditionsofmanufactureandassemblyofthesilo.
Indeterminingthepressuresexertedbythematerialandareappliedonthewallsofthesilo,initscylindrical
partandtheconicalpartisthattherearetwotypesofbehaviorinrelationtothepressureintheconicalpart,
findingthatforhopperswithhighpressuredraininclinationsarenotoriouslyhigherthanfillingotherwiseit
occursinthehopperswithasmallslopewherethepressuresoffillingandemptyingaresimilar.
Graphicalenvironments,whicharequitefriendlybutlittlemanipulated,majorfiniteelementsoftwaredonot
havetheoptiontoenterthemodelpressureswithvariationfromaheight,theclosesttheyofferisapplication
ofhydrostaticpressurewhichislinear.Asthepressurecurvesweredeterminedarethirdorder,itbecomes
necessarytoreplaceacodethatpressureforroutineapplicationofequivalentforcesonthenodesineacharea,
cylindricalportionandconicalportion.ThisisanotherreasonwhyAPDLANSYSwaschosenasthesoftwarefor
finiteelementanalysis,theplatformallowsanytypeofloadapplication.
Performedthestructuralanalysiswasfoundtonotnecessarilypressuresdraincancausefailuresinasilo,is
easyskewthisinformationaspressurecastingarealwayshigherinthesilo,caninthehopperdescribedabove
provisoisgiven,butthetotalsiloisalwayshigher.Thespecificeventoccursinoneoftheimportantpartsof
thesiloandoftenrelegatesbeltisinchargeofattachingthesilostructure.Itwasfoundthatvaluestheefforts
weregreaterwhenthefillwasapplied,thisisbecausethereisabalancebetweentheloadsofthehopperand
thecylinderjustatthatpoint,ifthecylinderislowerthehopperbegintosagbutthisarea,makinggreater
effortsatthispoint.Isimportanttonotethattheeffortsinthebodyofthesiloifolderthanemptyingfilling.
Todescribethebehaviorofcurvedsilosurfacesmodeldevelopsmostknowntypeshellelementsas"shell"as
thesesimultaneouslydisplaysbendingstressesandmembranestresses,thefirstcorrespondingtothebending
stressesofaplateproducingmomentsbendingandtorsionalmomentsandthelattercorrespondtoeffortsplane
stressproblem,whichacttangentiallytothemiddlesurfaceandtangentsproduceforcesinthemembrane.
References
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[4]Cook,R.,Malkus,D.,Plesla,M.andWitt,R.,Conceptsandapplicationsoffiniteelementanalysis,
UniversityofWisconsin,Madison,2001.[Links]
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[8]Jrgen,T.AssessmentofMechanicalpropertiesofcohesiveparticulatesolidsPart2.ParticulateScience
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elements.DYNAMagazine,82(189),pp.3038,2015.DOI:10.15446/dyna.v82n189.41872[Links]
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[11]Ulrich,H.andJosef,E.,Numericalinvestigationsondischargingsilos.JournalofEngineeringMechanics,
110,pp.957971,1984.DOI:10.1061/(ASCE)07339399(1984)110:6(957)[Links]
[12]UniversityofAlbertaANSYStutorials.Canada.[Online]Availableat:
http://www.mece.ualberta.ca/tutorials/ansys/[Links]
[13]Yanes,to.,Fernndez,M.andLopez,P.,Analysisofthedistributionofstaticpressuresinsiloswith
eccentriccylindricalhopperbyMEFinfluenceofeccentricityandcomparisonwithEurocode1.Reportsof
Construction,52,2001,472P.[Links]
Bayonne,W.,receivedhisBSc.inElectromechanicalEngineeringin2004atthePedagogicalandTechnological
UniversityofColombia,formorethan10yearshehasworkedintheareaofmechanicaldesigndeveloped
conceptual,basicanddetailofdifferentplantsintheenergy,metalworking,steel,cementsectorengineering
andPetroleum.researchareasofinterest:stressandstrainanalysisbythefiniteelementmethod,studythe
behavioroffluidsandpowderedmaterialsthroughcomputationalfluodinmica,designofsilos,tanksand
pressurevessels.ORCID:0000000157995246
Useche,J.,isaprofessorofmechanicalengineeringattheTechnologicalUniversityofBolvar(UTB),
Colombia,iscoordinatoroftheResearchGroupofMaterialsandStructuresContinuousUTB.IsPhDin
MechanicalEngineeringfromtheStateUniversityofCampinas,Brazil.HereceivedhisBScinMechanical
EngineeringattheTechnologicalUniversityofBolivar,ColombiaandMSc.inMechanicalEngineeringfromthe
UniversityoftheAndes,Colombia.researchareasofinterest:finiteelementmethod,boundaryelementmethod
andmeshfreemethodsforanalysisofstressandstrain,mechanicaldamageandresiduallifeassessment.
ORCID:0000000297612067
NationalUniversityofColombiaatMedellin
Street59ANo6320
Block42cenpubli@unalmed.edu.co
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Estimate of Stress Induced During Filling and Discharge of Metallic Silos For Cement Storage

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