Investigation of Mixing of Solid Particles in a Plowshare Mixer Using Discrete Element Method (DEM)

The mixing process of powder materials determines the final quality of industrial products. This study employs the Discrete Element Method (DEM) to numerically characterize the effects of particle shape and mixer structure on mixing performance. Using the superquadratic equation, nine types of particles with regular shape variations are constructed, and mixing models are further simulated. The feasibility of superquadratic-generated particles is validated through a classic drum calibration experiment. To investigate the intrinsic mechanisms of particle shape effects, the motion and contact behaviors of particles are quantified by the diffusion index, proportion of rotational kinetic energy, interparticle compressive force, and contact number. Meanwhile, to examine geometry effects, three supplementary mixing simulations are conducted by varying the plow angle and deactivating the choppers. The results show that Cubic particles exhibited poor mixing performance, while disk-shaped particles outperformed cylindrical ones; Increasing the plow blade inclination angle enhanced particle convection and diffusion, whereas excessively small angles may fail to achieve homogeneous mixing; The auxiliary shear of chopper blades promoted particle diffusion, effectively overcoming dead zones between plow blade intervals.