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Computers and Electronics in Agriculture 118 (2015) 281289
Original papers
a r t i c l e i n f o a b s t r a c t
Article history: Silos are structures widely used in the industrial and agricultural sectors. Despite the advances in
Received 6 July 2015 research during the last century, many uncertainties still remain. Some of the still unresolved questions
Received in revised form 7 September 2015 in silos are the knowledge about the laws which control the behavior of materials stored in silos or the
Accepted 11 September 2015
phenomena produced during the discharge process, when the highest thrust forces exerted by the stored
Available online 25 September 2015
materials on the walls appear.
Numerical methods have been extensively employed for the understanding of these complex
Keywords:
structures. Among them, the Finite Element Method is a suitable technique to determine the stresses
Silos
Finite Element Model
and displacements appeared on the walls or the bulk solid both for filling and discharge of the silo.
Experimental tests However, numerical models must be validated by experimental assays. Due to the high investment
Normal pressures required, there are very few experimental installations in the world with full-scale silos for determining
Discharge the actions produced by the stored materials. Therefore, very few assays can be found in the literature.
In this article, it has been accomplished a comparison of the results obtained in several assays con-
ducted using an experimental cylindrical silo with those calculated using a Finite Element Model
(FEM) developed by using ANSYS software package. A mid-scale test silo was used to carry out the assays,
which is equipped to measure the normal wall pressures and the friction forces. The numerical pressures
predicted by the FEM are quite close of those experimentally obtained, both for filling and discharge. In
addition, the mean vertical pressure obtained at transition is the same for both sets of results during the
filling process. Some differences appear during the initial instants of the discharge, when the numerical
model predicts higher mean vertical pressures at transition than those experimentally measured. The
FEM predicts higher peak pressures than the experimental ones measured, and at a location closer to
the transition than the real position of the sensor placed in the hopper to detect this peak.
2015 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.compag.2015.09.014
0168-1699/ 2015 Elsevier B.V. All rights reserved.
282 E. Gallego et al. / Computers and Electronics in Agriculture 118 (2015) 281289
F
F
STORAGE
TEST SILO SILO 2
D
3
F D
F D
2 F D
D 1 F
1 D
F 3
Fig. 1. Experimental facilities. 1: Slide gate; 2: screw conveyor; 3: AC motor; F: filling; D: discharge.
E. Gallego et al. / Computers and Electronics in Agriculture 118 (2015) 281289 283
m K=1 K 1
The value of the grain specific weight was calculated when the
silo was completely filled, during the static condition derived from
the repose state. The silo volume was known and the slope angle of
the stored material was also measured. So, the specific weight of
the stored material was obtained from vertical load cell readings
from level L0 using Eq. (2).
F L0A F L0B F L0C WT
d 2
Vc Vh Vc Vh
Vertical load cells can register at any moment the total vertical
loads caused by the bulk solid. However, it was not possible to
measure the change in volume of the bulk solid during the filling
or discharge processes. Thus, it was not possible to experimentally
obtain the variation of the bulk density during filling or discharge.
The values obtained are shown in Table 1.
z 3.1. Geometry
dc=1000
150 ANSYS software package (ANSYS, 2012) was used to develop the
GA7 3-D numerical model that accurately reproduces the dimensions
and shape of the test silo, thus considering the real binhopper
250 geometry existing. It is important to bear in mind that the diffi-
GA6 culty of simulating this type of junction may lead to unexpected
pressures, especially for discharge analysis (Keiter and Rombach,
250 2001). Because of this, a finer mesh was used for the transition.
GA5
An element size of 0.10 m was used for the entire silo, excepting
250 hc=2000 for the transition between the hopper and the bin, where an ele-
ph GA4 ment size of 0.025 m was employed. In addition, the numerical
model developed also took into account the real thickness of the
250 silo wall (0.03 m).
GA3
pw 3.2. Elements used and contact simulation
250
pv GA2
The element type used in ANSYS to represent the grain is an
250 eight node isoparametric element (SOLID185), which is of
GA1
Lagrangian type and it can support important features, e.g., large
zt deformations, birth and death options or plasticity. The nodal
pn GA0 degrees of freedom for this element are only translations. The silo
wall has been modeled by using SHELL281element, which has
ht =480 eight nodes with six degrees of freedom at each node: translations
=34.3
e0=0 h =738 in the x, y, and z axes, and rotations about the x, y, and z-axes. This
h
element is suitable for analyzing linear, large rotation, or large
strain nonlinear applications, and the MindlinReissner shell
x
theory is formulated, thus considering the effects arisen from the
real wall thickness. The element formulation is based on
logarithmic strain and true stress measures.
dh=350 The Coulombs friction model was used to describe the interac-
tion between the silo wall and the bulk solid. Thus, the grain to
Fig. 2. Dimensions of the test silo and position of the panels for measuring the
wall friction coefficient is the only parameter required to simulate
normal wall pressures.
this interaction, since the adherence between the wheat grains and
the smooth steel silo wall was considered negligible because the
R2 variety, with a minimum purity of 98%. The mechanical proper- material was dried before testing. A surface-to-surface contact
ties of this material were previously determined experimentally in algorithm was used in ANSYS to simulate this interaction, by using
the School of Agricultural Engineering of the University of Leon the four node isoparametric element types CONTA173 and
(Couto et al., 2013), laboratories in accordance with test methods TARGET170 that overlap the boundary surface of the bulk solid
proposed in Annex C of Eurocode EN 1991-4 (2006). and the inner surface of the silo wall, respectively. A further
As explained by Moya et al. (2006), the Poissons coefficient, m, description of grain wall contact simulation in silos can be found
for the bulk solid was deduced from the experimental tests con- in Gallego et al. (2010).
ducted by using the relation shown in Eq. (1), where K is the lateral
pressure ratio. The values for the lateral pressure ratio were 3.3. Loads and constrains
obtained from the experimental tests conducted, leading to values
for the Poissons coefficient of 0.25 for the filling process, and 0.42 The only load considered in the analysis was the full weight of
for the discharge process. the bulk material wheat, whose specific weight (8.397 kN/m3) was
284 E. Gallego et al. / Computers and Electronics in Agriculture 118 (2015) 281289
Fig. 3. Measurement of normal cylinder wall pressures (a) and vertical forces (b).
to prevent vibrations caused by rotation of the screw conveyor 5. Results and discussion
device from being transmitted to the test silo.
Values for normal wall pressures are obtained directly from Fig. 5 shows the comparison of wall normal pressures of the fill-
readings provided by the load cells located at the cylinder and hop- ing process experimentally measured, those obtained with the FE
per generatrix, by dividing the force value obtained by each cell by model and those calculated using Eurocode 1, Part 4 (EN 1991-4,
the panel surface. For example, to obtain the cylinder wall pressure 2006). It can be seen that the experimental normal pressures are
at the point where double bending beam load cell 1 is located (cell slightly greater than those predicted by the FE model. In addition,
GA1), at instant t, Eq. (3) is used. the normal pressures predicted by Eurocode are only slightly
greater than the experimental values for the bin part.
F GA1;t
phGA1;t 3
SG
The mean vertical pressure of the cylinder (measured in the
silohopper transition) by unit of length at each instant t, was
obtained by dividing the forces provided by the three tension/com-
pression load cells located at low part of the vertical cylinder by
the perimeter of its plan-cross section (Eq. (4)).
pw;t
lm 6
Phm;t
The lateral pressure ratio K (ratio of mean horizontal to mean
vertical pressure) was obtained (Eq. (7)) by dividing the mean
value of normal cylinder wall pressure by the vertical stress in
the stored material, taking both values at the silohopper union.
phct;t
Kt 7
pv t;t
Fig. 7. Comparison of vertical pressures just above the bin hopper transition.
E. Gallego et al. / Computers and Electronics in Agriculture 118 (2015) 281289 287
Fig. 8. Comparison of vertical pressures obtained with the FE model at different heights above outlet for the filling process.
Fig. 9. Comparison of vertical pressures obtained with the FE model at different heights above outlet for the initial phase of the discharge process.
more pronounced because the arch endings are located in a zone In this case, vertical pressures are greater at the silo center, and a
where the material changes the sliding direction, hindering its decrease of vertical pressures is observed when approaching to
movement and increasing the supported loads. the silo wall hopper. In addition, vertical pressures also decrease
The mean value of the vertical pressures predicted by the FE at the hopper if the distance to the transition increases.
model (12.0 kPa) for filling analysis is almost the same than the The formation of arching distributions in the bin part of the silo
experimental value (12.3 kPa). However, the FE model predicts induces a reduction of vertical pressures at silo heights placed at
an increase of vertical pressures during the first stages of the dis- the hopper.
charge process that is not experimentally detected. Thus, FE results Fig. 9 shows the evolution suffered by the vertical pressures at
predict an increase of vertical pressures up to 25% during discharge different silo heights for the beginning of the discharge process. It
(mean value of 15 kPa), while the vertical pressure experimentally can be observed that the greater changes in the values or distribu-
measured remains nearly constant for the initial steps of discharge. tions of the vertical pressures occur for those locations closer to the
Fig. 8 shows the vertical pressure distribution through a silo binhopper transition.
diameter obtained for the filling process with the FE model. Verti-
cal pressures remain nearly constant in the silo bin for silo heights 6. Conclusions
far from the binhopper transition, while arching distributions
tend to form at silo heights closer to the transition. As it could be An experimental setup has been developed for a silo with 2.5 m
expected, lower vertical pressures are predicted for greater silo in height to determine the lateral pressures exerted by the stored
heights above the outlet. The peak vertical pressure predicted is material. Thus, a Finite Element Model has been developed to
at the binhopper transition, when this arching effect caused by simulate the conditions of the experimental setup by employing
the settlement of bulk solid against the walls is maximized. the commercial software package ANSYS.
If the vertical pressure distribution is observed at locations The normal pressures predicted by the Finite Element Model are
placed at the silo hopper, then a reversed pattern can be observed. very close to the experimental values registered, both for filling
288 E. Gallego et al. / Computers and Electronics in Agriculture 118 (2015) 281289
and discharge processes. The lateral pressures experimentally WT total weight of the stored material
measured at the silo bin are slightly greater than the predicted f grain flow during discharge (kg/s)
numerical values during the filling process, while lower values U perimeter of the plan-cross section of the vertical
are reported for the silo discharge. walled segment
The predictions made by Eurocode match quite well the exper- SG cylinder wall surface acting on each load cell (m2)
imental and numerical results for the filling process. Eurocode SG0 hopper wall surface acting on each load cell (m2)
overestimate normal pressures throughout the silo wall for the dis- nzSk;t mean value of vertical stress per perimeter unit at the
charge process, but the peak pressure predicted is close to the one silohopper transition at instant t (kN/m)
experimentally measured and slightly lower than the value F GA1;t value of the force recorded by load cell GA1 at instant
obtained with the FE model. t (kN)
The results obtained with the numerical model show that the F L0X;t vertical force exerted on the load cells located at level
peak pressure is located just below the transition, and above the L0 at each instant t (kN)
location of sensor GA0. Thus, this implies that the peak of lateral F L1X;t vertical force exerted on the load cells located at level
pressures provided by sensor GA0 could have been underesti- L1 at each instant t (kN)
mated, especially for the filling process. However, there is not a Sc;t cylinder surface in contact with stored material at
significant difference between the peak lateral pressure experi- instant t (m2)
mentally measured and the one predicted by the Finite Element phm;t mean value of normal cylinder wall pressure at
Model. instant t (kN/m2)
The Finite Element Model predicts an increase of vertical pres-
sures during the initial steps of discharge. This effect has not been
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