Rocky Tutorial Guide

ANSYS, Inc. Release 2025 R1

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Table of Contents
1. Tutorial - Transfer Chute ........................................................................................................................ 23
1.1. Part A: Project Setup and Processing ................................................................................................ 23
1.1.1. OBJECTIVES ............................................................................................................................ 23
1.1.2. GEOMETRY INTRODUCTION .................................................................................................... 24
1.1.3. PROJECT CREATION ............................................................................................................... 24
1.1.4. ROCKY INTERFACE (UI) ........................................................................................................... 25
1.1.5. PROJECT SETUP DATA PANEL ITEMS ....................................................................................... 26
1.1.6. POST-PROCESSING DATA PANEL ITEMS .................................................................................. 28
1.1.7. PROJECT DETAILS .................................................................................................................. 29
1.1.8. PHYSICS DEFINITION ............................................................................................................. 30
1.1.9. GEOMETRY IMPORT ............................................................................................................... 32
1.1.10. PROJECT SAVING ................................................................................................................. 34
1.1.11. 3D VIEW .............................................................................................................................. 36
1.1.12. 3D VIEW CONTROL .............................................................................................................. 37
1.1.13. INLET DEFINITION ................................................................................................................ 37
1.1.14. GRAPHIC DISPLAY ................................................................................................................ 40
1.1.15. MOTION FRAMES ................................................................................................................. 42
1.1.16. MATERIAL DEFINITION ......................................................................................................... 50
1.1.17. INTERACTIONS BETWEEN MATERIALS ................................................................................... 52
1.1.18. PARTICLE GROUP DEFINITION .............................................................................................. 55
1.1.19. PARTICLE PREVIEW .............................................................................................................. 58
1.1.20. INLETS AND OUTLETS DEFINITION ........................................................................................ 58
1.1.21. SOLVER DEFINITION ............................................................................................................. 62
1.1.22. SIMULATION STATUS ............................................................................................................ 67
1.1.23. SIMULATION ........................................................................................................................ 68
1.1.24. HELP - USER MANUAL .......................................................................................................... 69
1.1.25. CONCLUSION ...................................................................................................................... 70
1.2. Part B: Post-Processing .................................................................................................................... 71
1.2.1. OBJECTIVES ........................................................................................................................... 71
1.2.2. OPEN PROJECT ....................................................................................................................... 71
1.2.3. MOVING TROUGH OUTPUTS .................................................................................................. 72
1.2.4. COLORING GEOMETRIES/PARTICLES ........................................................................................ 73
1.2.5. ANIMATION ............................................................................................................................ 74
1.2.6. ANIMATION PANEL ................................................................................................................. 75
1.2.7. CREATING AN ANIMATION ...................................................................................................... 76
1.2.8. TIME-DEPENDENT PLOTS ........................................................................................................ 77
1.2.9. MULTI TIME PLOT .................................................................................................................... 79
1.2.10. USER PROCESSES .................................................................................................................. 81
1.2.11. USER PROCESSES - CUBE ....................................................................................................... 82
1.2.12. USER PROCESSES - PLANE ..................................................................................................... 85
1.2.13. TIME PLOT ............................................................................................................................ 89
1.2.14. POST PROCESSING - USER PROCESSES .................................................................................. 91
1.2.15. POST PROCESSING - EXPORT IMAGES .................................................................................... 91
1.2.16. HELP - USER MANUAL .......................................................................................................... 92
1.2.17. CONCLUSION ....................................................................................................................... 93
2. Tutorial - Static Angle of Repose Test .................................................................................................... 95
2.1. Part A: Project Setup and Processing ................................................................................................ 95
2.1.1. OBJECTIVES ........................................................................................................................... 95
2.1.2. PREREQUISITES ...................................................................................................................... 95

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2.1.3. GEOMETRY ............................................................................................................................. 96

2.1.4. PROJECT CREATION ................................................................................................................ 96
2.1.5. PROJECT DETAILS ................................................................................................................... 97
2.1.6. PHYSICS DEFINITION .............................................................................................................. 98
2.1.7. GEOMETRY IMPORT .............................................................................................................. 100
2.1.8. VIEW GEOMETRY - CHANGE PROJECTION .............................................................................. 102
2.1.9. BOUNDARY MOVEMENT ....................................................................................................... 103
2.1.10. MOTION FRAME – TRANSLATION ......................................................................................... 103
2.1.11. MOTION FRAMES ................................................................................................................ 104
2.1.12. MOTION FRAMES – EDITING TIP .......................................................................................... 105
2.1.13. MOTION FRAME – CONTAINER CYLINDER ............................................................................ 107
2.1.14. MOTION FRAMES ................................................................................................................ 108
2.1.15. MOTION PREVIEW ............................................................................................................... 109
2.1.16. MATERIAL DEFINITIONS ...................................................................................................... 110
2.1.17. INTERACTIONS BETWEEN MATERIALS .................................................................................. 112
2.1.18. PARTICLE GROUP DEFINITION ............................................................................................. 114
2.1.19. PARTICLE INPUT – VOLUMETRIC INLET ................................................................................. 118
2.1.20. INLETS AND OUTLETS DEFINITION ...................................................................................... 119
2.1.21. SOLVER DEFINITION ............................................................................................................ 125
2.1.22. SIMULATION ....................................................................................................................... 127
2.1.23. HELP – USER MANUAL ........................................................................................................ 128
2.1.24. CONCLUSION ..................................................................................................................... 129
2.2. Part B: Post-Processing with Scripts ................................................................................................ 129
2.2.1. OBJECTIVES ......................................................................................................................... 129
2.2.2. OPEN PROJECT ..................................................................................................................... 130
2.2.3. POST-PROCESSING: MANUAL METHOD ................................................................................. 131
2.2.4. CROSS PLOT ......................................................................................................................... 131
2.2.5. PLOT SETTINGS .................................................................................................................... 132
2.2.6. AXES SETTINGS .................................................................................................................... 134
2.2.7. MEASURING RESULTS – MANUAL METHOD ........................................................................... 138
2.2.8. CALCULATIONS – MANUAL METHOD .................................................................................... 138
2.2.9. POST-PROCESSING: AUTOMATIC METHOD ............................................................................ 139
2.2.10. PREPOST SCRIPT PANEL ...................................................................................................... 139
2.2.11. SCRIPT RESULTS .................................................................................................................. 141
2.2.12. SCRIPT RESULTS .................................................................................................................. 142
2.2.13. SCRIPT RESULTS .................................................................................................................. 143
2.2.14. CALIBRATION SUITE AND MATERIAL WIZARD ....................................................................... 143
2.2.15. MODIFYING THE SCRIPT ...................................................................................................... 144
2.2.16. HELP – SCRIPTS MANUAL .................................................................................................... 146
2.2.17. HELP – PREPOST SCRIPTING MANUAL ................................................................................. 146
2.2.18. HELP – USER MANUAL ........................................................................................................ 147
2.2.19. CONCLUSION ..................................................................................................................... 148
2.3. Part C: Batch-Processing ................................................................................................................ 148
2.3.1. OBJECTIVES ......................................................................................................................... 148
2.3.2. PROJECT .............................................................................................................................. 149
2.3.3. SAVE COPIES WITHOUT RESULTS ........................................................................................... 149
2.3.4. INPUT VARIABLES ................................................................................................................. 151
2.3.5. INTERACTIONS BETWEEN MATERIALS .................................................................................... 152
2.3.6. SCHEDULED PREPOST SCRIPTS ............................................................................................. 155
2.3.7. PROJECT SCRIPTS ................................................................................................................. 156
2.3.8. POST SCRIPT ........................................................................................................................ 157

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2.3.9. SAVE COPIES WITHOUT RESULTS ........................................................................................... 158

2.3.10. ROCKY SCHEDULER ............................................................................................................ 160
2.3.11. RESULTS ............................................................................................................................. 166
2.3.12. HELP – USER MANUAL ........................................................................................................ 168
2.3.13. CONCLUSION ..................................................................................................................... 169
3. Tutorial - Vibrating Screen .................................................................................................................. 171
3.1. Part A: Project Setup and Processing .............................................................................................. 171
3.1.1. OBJECTIVES .......................................................................................................................... 171
3.1.2. PREREQUISITES .................................................................................................................... 171
3.1.3. GEOMETRY ........................................................................................................................... 172
3.1.4. PROJECT CREATION .............................................................................................................. 172
3.1.5. PROJECT DETAILS ................................................................................................................. 173
3.1.6. PHYSICS DEFINITION ............................................................................................................ 174
3.1.7. GEOMETRY IMPORT .............................................................................................................. 176
3.1.8. VIEW GEOMETRY .................................................................................................................. 178
3.1.9. INLET SURFACE DEFINITION ................................................................................................. 179
3.1.10. OUTLET SURFACE DEFINITION ............................................................................................. 179
3.1.11. BOUNDARY MOVEMENT ..................................................................................................... 180
3.1.12. MOTION FRAME – VIBRATION AND PENDULUM ................................................................... 181
3.1.13. PERIODIC MOTION – OSCILLATION ...................................................................................... 181
3.1.14. PERIODIC MOTION – INITIAL PHASE .................................................................................... 181
3.1.15. VIBRATION OSCILLATION .................................................................................................... 182
3.1.16. MOTION FRAME ................................................................................................................. 182
3.1.17. MATERIAL DEFINITION ........................................................................................................ 186
3.1.18. INTERACTIONS BETWEEN MATERIALS .................................................................................. 187
3.1.19. PARTICLE GROUP DEFINITION ............................................................................................. 189
3.1.20. PARTICLE SIZE DISTRIBUTION (PSD) ..................................................................................... 191
3.1.21. PARTICLE GROUP DEFINITION ............................................................................................. 191
3.1.22. MASS FLOW DEFINITION ..................................................................................................... 193
3.1.23. DOMAIN SETTINGS ............................................................................................................. 197
3.1.24. SOLVER DEFINITION ............................................................................................................ 199
3.1.25. SIMULATION ....................................................................................................................... 203
3.1.26. EXTEND SIMULATION DURATION ........................................................................................ 204
3.1.27. SOLVER DEFINITION ............................................................................................................ 206
3.1.28. SCREEN VERIFICATION ........................................................................................................ 206
3.1.29. HELP – USER MANUAL ........................................................................................................ 207
3.1.30. CONCLUSION ..................................................................................................................... 208
3.2. Part B: Post-Processing .................................................................................................................. 208
3.2.1. OBJECTIVES .......................................................................................................................... 208
3.2.2. PREREQUISITES .................................................................................................................... 209
3.2.3. OPEN PROJECT ..................................................................................................................... 209
3.2.4. POST PROCESSING – SCREEN EFFICIENCY .............................................................................. 209
3.2.5. USER PROCESS – CUBE ......................................................................................................... 211
3.2.6. USER PROCESS – FILTER ........................................................................................................ 213
3.2.7. INCLUDING REMOVED PARTICLES ......................................................................................... 216
3.2.8. CUSTOM CURVES ................................................................................................................. 216
3.2.9. TABLE VIEW .......................................................................................................................... 222
3.2.10. POST PROCESSING – SCREEN EFFICIENCY ............................................................................ 224
3.2.11. PARTICLES TIME SELECTION ................................................................................................ 225
3.2.12. HISTOGRAM ....................................................................................................................... 228
3.2.13. PSD HISTOGRAM ................................................................................................................ 230

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3.2.14. HELP – USER MANUAL ........................................................................................................ 231

3.2.15. CONCLUSIONS ................................................................................................................... 231
3.3. Part C: Post-Processing – Optimization .......................................................................................... 232
3.3.1. OBJECTIVES .......................................................................................................................... 232
3.3.2. PREREQUISITES .................................................................................................................... 232
3.3.3. PROJECT CREATION .............................................................................................................. 233
3.3.4. OPTIMIZATION SETUP – PARAMETRIZE INPUTS ...................................................................... 235
3.3.5. OPTIMIZATION SETUP – CRITERIA .......................................................................................... 237
3.3.6. OPTIMIZATION SETUP – OPTIMIZATION METHOD .................................................................. 238
3.3.7. OPTIMIZATION SETUP – RUN ................................................................................................. 241
3.3.8. OPTIMIZATION ANALYSIS – RESULTS ..................................................................................... 241
3.3.9. HELP – ANSYS LEARNING HUB .............................................................................................. 244
3.3.10. CONCLUSIONS ................................................................................................................... 244
4. Tutorial - SAG Mill ................................................................................................................................ 247
4.1. Part A: Project Setup and Processing .............................................................................................. 247
4.1.1. OBJECTIVES ......................................................................................................................... 247
4.1.2. PREREQUISITES .................................................................................................................... 248
4.1.3. GEOMETRY ........................................................................................................................... 249
4.1.4. PROJECT CREATION .............................................................................................................. 249
4.1.5. PROJECT DETAILS ................................................................................................................. 250
4.1.6. PHYSICS DEFINITION ............................................................................................................ 252
4.1.7. MODULES DEFINITION .......................................................................................................... 253
4.1.8. DEFAULT MODULES .............................................................................................................. 254
4.1.9. MODULES DEFINITION .......................................................................................................... 256
4.1.10. ENERGY SPECTRA ............................................................................................................... 260
4.1.11. MODULES DEFINITION ........................................................................................................ 261
4.1.12. MODULE-SPECIFIC PARAMETERS ......................................................................................... 263
4.1.13. GEOMETRY IMPORT ............................................................................................................ 264
4.1.14. VIEW GEOMETRY – CHANGE PROJECTION ........................................................................... 265
4.1.15. GEOMETRY BEST PRACTICE ................................................................................................. 266
4.1.16. MOTION FRAME ................................................................................................................. 267
4.1.17. MOTION FRAME – ROTATION (MILL START) .......................................................................... 269
4.1.18. MOTION FRAME – ROTATION (STEADY STATE) ...................................................................... 270
4.1.19. MOTION FRAME ................................................................................................................. 270
4.1.20. MOTION PREVIEW ............................................................................................................... 271
4.1.21. GEOMETRY DEFINITION – WEAR MODEL ............................................................................. 272
4.1.22. GEOMETRY DEFINITION – WEAR AND TRIANGLE SIZE .......................................................... 273
4.1.23. GEOMETRY DEFINITION – WEAR – MESHING ....................................................................... 274
4.1.24. CHANGE TRIANGLE SIZE ..................................................................................................... 275
4.1.25. REFERENCE GEOMETRY ....................................................................................................... 276
4.1.26. MATERIAL DEFINITION ........................................................................................................ 278
4.1.27. INTERACTION BETWEEN MATERIALS .................................................................................... 280
4.1.28. PARTICLE GROUP DEFINITION ............................................................................................. 282
4.1.29. PARTICLE INLET – VOLUMETRIC INLET .................................................................................. 286
4.1.30. INLET DEFINITION ............................................................................................................... 288
4.1.31. CONTACTS COLLECTION ..................................................................................................... 292
4.1.32. DOMAIN SETTINGS – PERIODIC ........................................................................................... 293
4.1.33. SOLVER DEFINITION ............................................................................................................ 296
4.1.34. SIMULATION ....................................................................................................................... 299
4.1.35. HELP – USER MANUAL ........................................................................................................ 300
4.1.36. CONCLUSION ..................................................................................................................... 301

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4.2. Part B: Post-Processing (Wear and Contacts Analyses) .................................................................... 301

4.2.1. OBJECTIVES ......................................................................................................................... 301
4.2.2. PREREQUISITES .................................................................................................................... 302
4.2.3. OPEN PROJECT ..................................................................................................................... 302
4.2.4. WEAR ANALYSIS – COMPARE PROFILES .................................................................................. 303
4.2.5. WEAR ANALYSIS – RADIAL DISPLACEMENT ............................................................................ 304
4.2.6. WEAR ANALYSIS – EXPORT WORN GEOMETRY ....................................................................... 309
4.2.7. POST PROCESSING – PARTICLES TRAJECTORY ........................................................................ 311
4.2.8. EULERIAN STATISTICS ........................................................................................................... 314
4.2.9. USER PROCESS – CYLINDER .................................................................................................. 315
4.2.10. EULERIAN STATISTICS .......................................................................................................... 316
4.2.11. VISUALIZE EULERIAN STATISTICS ......................................................................................... 319
4.2.12. PLOT EULERIAN STATISTICS ................................................................................................. 322
4.2.13. HELP – USER MANUAL ........................................................................................................ 323
4.2.14. CONCLUSION ..................................................................................................................... 324
4.3. Part C: Post-Processing (Energy Analyses) ....................................................................................... 324
4.3.1. OBJECTIVES ......................................................................................................................... 324
4.3.2. PREREQUISITES .................................................................................................................... 325
4.3.3. OPEN PROJECT ..................................................................................................................... 325
4.3.4. ENERGY SPECTRA ANALYSES ................................................................................................. 326
4.3.5. CONTACTS ENERGY SPECTRA ................................................................................................ 327
4.3.6. PARTICLES ENERGY SPECTRA ................................................................................................ 328
4.3.7. CONTACTS ENERGY SPECTRA ................................................................................................ 331
4.3.8. ENERGY BALANCE ANALYSES ................................................................................................ 333
4.3.9. ENERGY BALANCE – SUPPLIED POWER .................................................................................. 334
4.3.10. ENERGY BALANCE – MECHANICAL ENERGY ......................................................................... 335
4.3.11. ENERGY BALANCE – DISSIPATED POWER ............................................................................. 339
4.3.12. ENERGY BALANCE ANALYSES .............................................................................................. 345
4.3.13. HELP – USER MANUAL ........................................................................................................ 346
4.3.14. CONCLUSION ..................................................................................................................... 346
5. Tutorial - Drop Weight Test .................................................................................................................. 349
5.1. Part A: Project Setup and Processing .............................................................................................. 349
5.1.1. OBJECTIVE ........................................................................................................................... 349
5.1.2. PREREQUISITES .................................................................................................................... 349
5.1.3. GEOMETRY ........................................................................................................................... 350
5.1.4. INTRODUCTION .................................................................................................................... 351
5.1.5. PROJECT CREATION .............................................................................................................. 351
5.1.6. PROJECT DETAILS ................................................................................................................. 352
5.1.7. PHYSICS DEFINITION ............................................................................................................ 354
5.1.8. GEOMETRY IMPORT .............................................................................................................. 356
5.1.9. INLET SURFACE DEFINITION ................................................................................................. 357
5.1.10. BOUNDARY MOVEMENT ..................................................................................................... 358
5.1.11. MOTION FRAME ................................................................................................................. 358
5.1.12. MOTION FRAME – EXAMPLE 1 ............................................................................................. 359
5.1.13. MOTION FRAME – EXAMPLE 2 ............................................................................................. 360
5.1.14. MOTION FRAME – EXAMPLE 3 ............................................................................................. 361
5.1.15. MOTION FRAME ................................................................................................................. 362
5.1.16. BOUNDARY SETUP .............................................................................................................. 365
5.1.17. MOTION PREVIEW ............................................................................................................... 367
5.1.18. MATERIAL DEFINITION ........................................................................................................ 368
5.1.19. INTERACTION BETWEEN MATERIALS .................................................................................... 370

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5.1.20. PARTICLE GROUP DEFINITION ............................................................................................. 372

5.1.21. BREAKAGE MODEL ............................................................................................................. 374
5.1.22. PARTICLE GROUP DEFINITION ............................................................................................. 376
5.1.23. MASS FLOW DEFINITION ..................................................................................................... 377
5.1.24. SOLVER DEFINITION ............................................................................................................ 379
5.1.25. SOLVER DEFINITION ............................................................................................................ 381
5.1.26. SIMULATION ....................................................................................................................... 382
5.1.27. HELP – USER MANUAL ........................................................................................................ 383
5.1.28. CONCLUSION ..................................................................................................................... 384
5.2. Part B: Post-Processing .................................................................................................................. 385
5.2.1. OBJECTIVE ........................................................................................................................... 385
5.2.2. PREREQUISITES .................................................................................................................... 385
5.2.3. OPEN PROJECT ..................................................................................................................... 385
5.2.4. HISTOGRAM ......................................................................................................................... 386
5.2.5. BROKEN PARTICLES .............................................................................................................. 388
5.2.6. FREE BODY MOTION ANALYSIS .............................................................................................. 388
5.2.7. HELP – USER MANUAL .......................................................................................................... 390
5.2.8. CONCLUSION ....................................................................................................................... 390
6. Tutorial - High Pressure Grinding Roll (HPGR) .................................................................................... 391
6.1. Part A: Project Setup and Processing .............................................................................................. 391
6.1.1. OBJECTIVE ........................................................................................................................... 391
6.1.2. PREREQUISITES .................................................................................................................... 392
6.1.3. GEOMETRY ........................................................................................................................... 392
6.1.4. PROJECT CREATION .............................................................................................................. 393
6.1.5. MODULES DEFINITION .......................................................................................................... 393
6.1.6. GEOMETRIES ........................................................................................................................ 394
6.1.7. VISUALIZE GEOMETRIES ........................................................................................................ 395
6.1.8. BOUNDARY MOVEMENT ....................................................................................................... 396
6.1.9. MOTION FRAME – SPRING-DASHPOT FORCE/MOMENT .......................................................... 396
6.1.10. MOTION FRAMES ................................................................................................................ 397
6.1.11. BOUNDARY DEFINITION ..................................................................................................... 398
6.1.12. INTERACTION BETWEEN MATERIALS .................................................................................... 399
6.1.13. SOLVER DEFINITION ............................................................................................................ 400
6.1.14. SETUP CONFIRMATION ....................................................................................................... 401
6.1.15. SOLVER DEFINITION ............................................................................................................ 401
6.1.16. CONCLUSION ..................................................................................................................... 403
6.2. Part B: Post-Processing .................................................................................................................. 404
6.2.1. OBJECTIVE ........................................................................................................................... 404
6.2.2. PREREQUISITES .................................................................................................................... 404
6.2.3. OPEN PROJECT ..................................................................................................................... 404
6.2.4. ANALYZE BREAKAGE ............................................................................................................. 405
6.2.5. DISPLACEMENT .................................................................................................................... 407
6.2.6. DISPLACEMENT AREA ........................................................................................................... 408
6.2.7. WEAR VOLUME LOSS ............................................................................................................ 409
6.2.8. COLOR MAP OF SHEAR WEAR ............................................................................................... 412
6.2.9. POWER MEASURE ................................................................................................................. 413
6.2.10. CONCLUSION ..................................................................................................................... 414
7. Tutorial - Conical Dryer ........................................................................................................................ 417
7.1. Part A: Project Setup and Processing .............................................................................................. 417
7.1.1. OBJECTIVE ............................................................................................................................ 417
7.1.2. PREREQUISITES .................................................................................................................... 417

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7.1.3. GEOMETRY ........................................................................................................................... 418

7.1.4. PROJECT CREATION .............................................................................................................. 419
7.1.5. PHYSICS DEFINITION ............................................................................................................ 419
7.1.6. PROJECT SETUP .................................................................................................................... 420
7.1.7. BOUNDARY MOVEMENT ....................................................................................................... 421
7.1.8. MOTION FRAME ................................................................................................................... 422
7.1.9. MOTION PREVIEW ................................................................................................................ 424
7.1.10. BOUNDARY DEFINITION – THERMAL BOUNDARY ................................................................. 425
7.1.11. MATERIAL DEFINITION ........................................................................................................ 426
7.1.12. COMPLETE PROJECT SETUP ................................................................................................ 427
7.1.13. SETUP CONFIRMATION ....................................................................................................... 427
7.1.14. SIMULATE PROJECT ............................................................................................................ 428
7.1.15. CONCLUSION ..................................................................................................................... 430
7.2. Part B: Post-Processing .................................................................................................................. 431
7.2.1. OBJECTIVE ............................................................................................................................ 431
7.2.2. PREREQUISITES .................................................................................................................... 431
7.2.3. OPEN PROJECT ..................................................................................................................... 432
7.2.4. SET AND REUSE EXACT VIEWS ............................................................................................... 432
7.2.5. EXPORT PROJECT CONTEXT .................................................................................................. 437
7.2.6. SET AND REUSE EXACT VIEWS ............................................................................................... 440
7.2.7. EVALUATING PARTICLE TEMPERATURE ................................................................................... 441
7.2.8. COLOR SCALE ...................................................................................................................... 443
7.2.9. EVALUATING PARTICLE TEMPERATURE ................................................................................... 444
7.2.10. TIME PLOT .......................................................................................................................... 444
7.2.11. CELL INSPECTOR ................................................................................................................. 445
7.2.12. TIME PLOT .......................................................................................................................... 449
7.2.13. CONCLUSION ..................................................................................................................... 450
8. Tutorial - Cone Crusher ........................................................................................................................ 451
8.1. Part A: Project Setup and Processing .............................................................................................. 451
8.1.1. OBJECTIVES ......................................................................................................................... 451
8.1.2. PREREQUISITES .................................................................................................................... 451
8.1.3. GEOMETRY ........................................................................................................................... 452
8.1.4. PROJECT CREATION .............................................................................................................. 452
8.1.5. PROJECT SETUP .................................................................................................................... 453
8.1.6. GEOMETRY IMPORT .............................................................................................................. 453
8.1.7. MOTION FRAME CONE CRUSHER ........................................................................................... 454
8.1.8. MATERIAL DEFINITION .......................................................................................................... 458
8.1.9. PARTICLE GROUP DEFINITION ............................................................................................... 459
8.1.10. RANDOM PARTICLE ORIENTATION ....................................................................................... 459
8.1.11. PARTICLE GROUP DEFINITION ............................................................................................. 461
8.1.12. TAVARES BREAKAGE MODEL ................................................................................................ 462
8.1.13. PARTICLE GROUP DEFINITION ............................................................................................. 462
8.1.14. MASS FLOW DEFINITION ..................................................................................................... 464
8.1.15. SETUP CONFIRMATION ....................................................................................................... 465
8.1.16. SIMULATE PROJECT ............................................................................................................ 465
8.1.17. CONCLUSION ..................................................................................................................... 467
8.2. Part B: Post-Processing .................................................................................................................. 468
8.2.1. OBJECTIVES ......................................................................................................................... 468
8.2.2. PREREQUISITES .................................................................................................................... 469
8.2.3. OPEN PROJECT ..................................................................................................................... 469
8.2.4. POST PROCESS PSD HISTOGRAM .......................................................................................... 469

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8.2.5. POST PROCESS - DIVISIONS TAGGING ................................................................................... 472

8.2.6. POST PROCESS - ISOLATE FRAGMENTS .................................................................................. 478
8.2.7. POST PROCESS - ISOLATE FRAGMENTS .................................................................................. 478
8.2.8. POST PROCESS - ISOLATE FRAGMENTS .................................................................................. 480
8.2.9. POST PROCESS - POWER DRAW ............................................................................................. 480
8.2.10. CONCLUSION ..................................................................................................................... 483
9. Tutorial - Tablet Coater ........................................................................................................................ 485
9.1. Part A: Project Setup and Processing .............................................................................................. 485
9.1.1. OBJECTIVE ........................................................................................................................... 485
9.1.2. PREREQUISITES .................................................................................................................... 485
9.1.3. GEOMETRY ........................................................................................................................... 486
9.1.4. PROJECT CREATION .............................................................................................................. 487
9.1.5. PROJECT SETUP .................................................................................................................... 487
9.1.6. PARTICLE GROUP DEFINITION ............................................................................................... 489
9.1.7. ORIGINAL SIZE SCALE ........................................................................................................... 490
9.1.8. PARTICLE GROUP DEFINITION ............................................................................................... 490
9.1.9. INLET SETUP ......................................................................................................................... 492
9.1.10. CONTACTS COLLECTION ..................................................................................................... 492
9.1.11. SOLVER DEFINITION ............................................................................................................ 493
9.1.12. SETUP CONFIRMATION ....................................................................................................... 493
9.1.13. SIMULATION SUMMARY ...................................................................................................... 494
9.1.14. CONCLUSION ..................................................................................................................... 496
9.1.15. APPENDIX: CONVEX AND CONCAVE DETECTION .................................................................. 496
9.2. Part B: Post-Processing .................................................................................................................. 497
9.2.1. OBJECTIVE ............................................................................................................................ 497
9.2.2. PREREQUISITES .................................................................................................................... 498
9.2.3. OPEN PROJECT ..................................................................................................................... 498
9.2.4. PARTICLE RESIDENCE TIME .................................................................................................... 499
9.2.5. USER PROCESS – POLYHEDRON 1 .......................................................................................... 500
9.2.6. USER PROCESS – POLYHEDRON 2 .......................................................................................... 502
9.2.7. POST PROCESSING – PARTICLE RESIDENCE TIME .................................................................... 504
9.2.8. POST PROCESSING – INTER TABLET VARIABILITY (COV) .......................................................... 506
9.2.9. TIME PLOT ............................................................................................................................ 506
9.2.10. POST PROCESSING – COV ................................................................................................... 509
9.2.11. EULERIAN STATISTICS .......................................................................................................... 512
9.2.12. USER PROCESS – CYLINDER ................................................................................................. 513
9.2.13. EULERIAN STATISTICS .......................................................................................................... 514
9.2.14. TIME STATISTICS PROPERTIES .............................................................................................. 515
9.2.15. INTRA-PARTICLE COLLISION STATISTICS ............................................................................... 518
9.2.16. INTER-PARTICLE COLLISION STATISTICS ............................................................................... 520
9.2.17. CONCLUSION ..................................................................................................................... 521
9.3. Part C: Spray Zone Evaluation ....................................................................................................... 521
9.3.1. OBJECTIVE ............................................................................................................................ 521
9.3.2. PREREQUISITES .................................................................................................................... 522
9.3.3. OPEN PROJECT ..................................................................................................................... 522
9.3.4. PARTICLE VISIBILITY .............................................................................................................. 523
9.3.5. COATING VISIBILITY WIZARD ................................................................................................. 525
9.3.6. COATING VISIBILITY WIZARD – INTER-TABLET VARIABILITY (CoV) ............................................ 534
9.3.7. POST PROCESSING – VISIBILITY ............................................................................................. 538
9.3.8. POST PROCESSING – PARTICLES VISIBILITY ............................................................................ 539
9.3.9. POST PROCESSING – TRIANGLE VISIBILITY ............................................................................. 540

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9.3.10. CONCLUSION ..................................................................................................................... 542

9.3.11. BIBLIOGRAPHY ................................................................................................................... 543
10. Tutorial - Bucket Conveyor ................................................................................................................ 545
10.1. Part A: Project Setup and Processing ............................................................................................ 545
10.1.1. OBJECTIVE ......................................................................................................................... 545
10.1.2. PREREQUISITES ................................................................................................................... 545
10.1.3. GEOMETRY ......................................................................................................................... 546
10.1.4. PROJECT CREATION ............................................................................................................ 547
10.1.5. GEOMETRY SETUP .............................................................................................................. 547
10.1.6. BOUNDARY MOVEMENT ..................................................................................................... 549
10.1.7. PERIODIC MOTION .............................................................................................................. 552
10.1.8. MOTION FRAME ................................................................................................................. 552
10.1.9. BOUNDARY DEFINITION – REPLICATION .............................................................................. 555
10.1.10. CONTINUE PROJECT SETUP ............................................................................................... 557
10.1.11. MASS FLOW DEFINITION – CONSTANT FEED ...................................................................... 558
10.1.12. PERIODIC INJECTION ......................................................................................................... 558
10.1.13. MASS FLOW DEFINITION – SURGE FEED ............................................................................. 559
10.1.14. SETUP CONFIRMATION ..................................................................................................... 560
10.1.15. SIMULATE PROJECT .......................................................................................................... 560
10.1.16. CONCLUSION ................................................................................................................... 562
10.2. Part B: Post-Processing ................................................................................................................ 563
10.2.1. OBJECTIVE ......................................................................................................................... 563
10.2.2. PREREQUISITES ................................................................................................................... 563
10.2.3. OPEN PROJECT ................................................................................................................... 563
10.2.4. VISUALIZE SEPARATE FEEDS ................................................................................................ 564
10.2.5. PLOT PARTICLE COUNT ....................................................................................................... 565
10.2.6. EVALUATING BUCKET MASS ................................................................................................ 568
10.2.7. TIME PLOT .......................................................................................................................... 569
10.2.8. PARTICLE TRAJECTORY ........................................................................................................ 572
10.2.9. POST PROCESSING – PARTICLE TRAJECTORY ........................................................................ 573
10.2.10. CONCLUSION ................................................................................................................... 573
11. Tutorial - Discharge Air Flow ............................................................................................................. 575
11.1. Part A: Project Setup and Processing ............................................................................................ 575
11.1.1. OBJECTIVE ......................................................................................................................... 575
11.1.2. PREREQUISITES ................................................................................................................... 575
11.1.3. GEOMETRY ......................................................................................................................... 576
11.1.4. PROJECT CREATION ............................................................................................................ 576
11.1.5. PROJECT SETUP .................................................................................................................. 577
11.1.6. AIR FLOW DEFINITION ........................................................................................................ 578
11.1.7. CONTINUE PROJECT SETUP ................................................................................................. 581
11.1.8. SETUP CONFIRMATION ....................................................................................................... 581
11.1.9. SIMULATE PROJECT ............................................................................................................ 582
11.1.10. CONCLUSION ................................................................................................................... 583
11.2. Part B: Post-Processing ................................................................................................................ 583
11.2.1. OBJECTIVE ......................................................................................................................... 583
11.2.2. PREREQUISITES ................................................................................................................... 584
11.2.3. OPEN PROJECT ................................................................................................................... 584
11.2.4. POST PROCESS – AIR FLOW ................................................................................................. 585
11.2.5. USER PROCESS – PLANE ...................................................................................................... 586
11.2.6. USER PROCESS – PROPERTY ................................................................................................ 588
11.2.7. CONCLUSION ..................................................................................................................... 589

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11.2.8. BIBLIOGRAPHY ................................................................................................................... 590

12. Tutorial - Static Structural ................................................................................................................. 591
12.1. Part A: Project Setup and Processing ............................................................................................ 591
12.1.1. OBJECTIVE ......................................................................................................................... 591
12.1.2. PREREQUISITES ................................................................................................................... 592
12.1.3. GEOMETRY ......................................................................................................................... 592
12.1.4. GEOMETRY PREPARATION ................................................................................................... 593
12.1.5. WORKBENCH SETUP ........................................................................................................... 594
12.1.6. PROJECT SETUP .................................................................................................................. 597
12.1.7. GEOMETRY MESH ............................................................................................................... 598
12.1.8. VISUALIZING THE GEOMETRY .............................................................................................. 599
12.1.9. EXTERNAL COUPLING ......................................................................................................... 601
12.1.10. FINISH PROJECT SETUP ..................................................................................................... 602
12.1.11. POST PROCESS – OUTPUT ................................................................................................. 605
12.1.12. COMPLETE PROJECT ......................................................................................................... 606
12.1.13. CONCLUSION ................................................................................................................... 606
12.2. Part B: Mechanical Coupling (Workbench) .................................................................................... 607
12.2.1. OBJECTIVE ......................................................................................................................... 607
12.2.2. PREREQUISITES ................................................................................................................... 607
12.2.3. WORKBENCH SETUP ........................................................................................................... 608
12.2.4. WORKBENCH – STATIC STRUCTURAL ANALYSIS .................................................................... 608
12.2.5. MECHANICAL – DEFINING THE STRUCTURAL ANALYSIS ........................................................ 609
12.2.6. MECHANICAL – POST-PROCESSING ..................................................................................... 618
12.2.7. WORKBENCH – RUNNING MULTIPLE SIMULATIONS .............................................................. 621
12.2.8. WORKBENCH – DESIGN EXPLORATION ................................................................................ 623
12.2.9. CONCLUSION ..................................................................................................................... 627
13. Tutorial - Windshifter ........................................................................................................................ 629
13.1. Part A: Fluent Case Setup (Workbench) ........................................................................................ 629
13.1.1. OBJECTIVE ......................................................................................................................... 629
13.1.2. PREREQUISITES ................................................................................................................... 629
13.1.3. ANSYS COMPONENT INSTALLATION IN ROCKY .................................................................... 630
13.1.4. GEOMETRY ......................................................................................................................... 633
13.1.5. GEOMETRY PREPARATION ................................................................................................... 633
13.1.6. WORKBENCH SETUP ........................................................................................................... 635
13.1.7. MESH ................................................................................................................................. 636
13.1.8. FLUENT SETUP .................................................................................................................... 641
13.1.9. MODELS ............................................................................................................................. 642
13.1.10. MATERIALS ....................................................................................................................... 644
13.1.11. BOUNDARY CONDITIONS .................................................................................................. 645
13.1.12. INITIALIZATION ................................................................................................................. 647
13.1.13. SOLUTION ........................................................................................................................ 647
13.1.14. RESULTS ........................................................................................................................... 649
13.1.15. HELP ................................................................................................................................ 652
13.1.16. CONCLUSION ................................................................................................................... 653
13.2. Part B: Rocky Project Setup (Workbench) ..................................................................................... 653
13.2.1. OBJECTIVE ......................................................................................................................... 653
13.2.2. PREREQUISITES ................................................................................................................... 654
13.2.3. GEOMETRY ......................................................................................................................... 655
13.2.4. WORKBENCH SETUP ........................................................................................................... 655
13.2.5. PROJECT SETUP .................................................................................................................. 657
13.2.6. RECEIVING CONVEYOR DEFINITION .................................................................................... 657

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13.2.7. MATERIAL AND SHAPE DEFINITIONS ................................................................................... 658

13.2.8. MATERIAL DEFINITION ........................................................................................................ 659
13.2.9. PARTICLE GROUP DEFINITION ............................................................................................. 660
13.2.10. MASS FLOW DEFINITION ................................................................................................... 662
13.2.11. FINISH PROJECT SETUP ..................................................................................................... 663
13.2.12. PROCESS SIMULATION ...................................................................................................... 663
13.2.13. POST PROCESSING ............................................................................................................ 665
13.2.14. CONCLUSIONS .................................................................................................................. 668
13.3. Part C: One-Way Coupling (Workbench) ....................................................................................... 668
13.3.1. OBJECTIVE ......................................................................................................................... 668
13.3.2. PREREQUISITES ................................................................................................................... 669
13.3.3. GEOMETRY ......................................................................................................................... 670
13.3.4. WORKBENCH SETUP ........................................................................................................... 671
13.3.5. CFD COUPLING ................................................................................................................... 672
13.3.6. CFD VISUALIZATION ............................................................................................................ 673
13.3.7. SOLVER DEFINITION ............................................................................................................ 675
13.3.8. PROCESS SIMULATION ........................................................................................................ 676
13.3.9. CFD COUPLING POST PROCESSING ..................................................................................... 678
13.3.10. EVALUATE DRAG FORCE .................................................................................................... 680
13.3.11. CFD COUPLING POST PROCESSING ................................................................................... 687
13.3.12. CONCLUSIONS .................................................................................................................. 690
14. Tutorial - Fluidized Bed ..................................................................................................................... 693
14.1. Part A: Fluent Case Setup ............................................................................................................. 693
14.1.1. OBJECTIVES ........................................................................................................................ 693
14.1.2. PREREQUISITES ................................................................................................................... 693
14.1.3. GEOMETRY INTRODUCTION ................................................................................................ 694
14.1.4. OPEN ANSYS FLUENT .......................................................................................................... 695
14.1.5. IMPORT MESH .................................................................................................................... 696
14.1.6. FLUID MESH SETUP ............................................................................................................. 696
14.1.7. SINGLE PHASE SETUP ......................................................................................................... 696
14.1.8. ENABLE ENERGY AND TURBULENCE .................................................................................... 697
14.1.9. MATERIALS AND BOUNDARY CONDITIONS .......................................................................... 697
14.1.10. METHODS ........................................................................................................................ 698
14.1.11. INITIALIZE AND CALCULATE .............................................................................................. 698
14.1.12. SAVE CASE ........................................................................................................................ 699
14.1.13. HELP ................................................................................................................................ 699
14.1.14. CONCLUSION ................................................................................................................... 700
14.2. Part B: Setup and Processing in Rocky .......................................................................................... 700
14.2.1. OBJECTIVES ........................................................................................................................ 700
14.2.2. PREREQUISITES ................................................................................................................... 701
14.2.3. GEOMETRY INTRODUCTION ................................................................................................ 702
14.2.4. PROJECT CREATION ............................................................................................................ 703
14.2.5. PROJECT SETUP .................................................................................................................. 703
14.2.6. VOLUMETRIC INLET ............................................................................................................. 704
14.2.7. CONTINUE PROJECT SETUP ................................................................................................. 705
14.2.8. VISUALIZE VOLUMETRIC INLET BOUNDS .............................................................................. 706
14.2.9. FINISH PROJECT SETUP ....................................................................................................... 707
14.2.10. SETUP CONFIRMATION ..................................................................................................... 707
14.2.11. SIMULATE PROJECT .......................................................................................................... 708
14.2.12. SIMULATION ..................................................................................................................... 710
14.2.13. SAVE FOR RESTART ........................................................................................................... 711

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14.2.14. IMPORTING CFD SOLUTION .............................................................................................. 713

14.2.15. REDEFINE SOLVER ............................................................................................................. 716
14.2.16. HELP ................................................................................................................................ 717
14.2.17. CONCLUSIONS .................................................................................................................. 717
14.3. Part C: Post-Processing in Rocky ................................................................................................... 718
14.3.1. OBJECTIVES ........................................................................................................................ 718
14.3.2. PREREQUISITES ................................................................................................................... 719
14.3.3. OPEN PROJECT ................................................................................................................... 719
14.3.4. ROCKY – POST-PROCESSING ............................................................................................... 719
14.3.5. ROCKY – POST-PROCESSING – DIVISIONS TAGGING ............................................................. 720
14.3.6. ROCKY – POST-PROCESSING – CREATING A NEW CUBE ........................................................ 722
14.3.7. ROCKY – POST-PROCESSING – CREATING A HISTOGRAM ...................................................... 723
14.3.8. ROCKY – POST-PROCESSING – CREATING A PROPERTY ........................................................ 725
14.3.9. ROCKY – POST-PROCESSING – CREATING A TIME PLOT ......................................................... 726
14.3.10. ROCKY – POST-PROCESSING – PARTICLE TEMPERATURE ..................................................... 727
14.3.11. ROCKY – POST-PROCESSING – PRESSURE DROP ................................................................. 730
14.3.12. ROCKY – POST-PROCESSING – SOLID VOLUME FRACTION .................................................. 733
14.3.13. ROCKY – POST-PROCESSING – FLUID VELOCITY ................................................................. 735
14.3.14. HELP – USER MANUAL ...................................................................................................... 738
14.3.15. CONCLUSIONS .................................................................................................................. 739
15. Tutorial - Transient Structural ........................................................................................................... 741
15.1. Part A: Rocky Setup and Processing (Workbench) ......................................................................... 741
15.1.1. OBJECTIVES ........................................................................................................................ 741
15.1.2. PREREQUISITES ................................................................................................................... 741
15.1.3. GEOMETRY ......................................................................................................................... 743
15.1.4. GEOMETRY PREPARATION ................................................................................................... 743
15.1.5. WORKBENCH SETUP ........................................................................................................... 745
15.1.6. VISUALIZING THE GEOMETRY .............................................................................................. 745
15.1.7. FEED CONVEYOR DEFINITION ............................................................................................. 746
15.1.8. FEED CONVEYOR – EXPRESSION/VARIABLES ....................................................................... 747
15.1.9. RECEIVING CONVEYOR DEFINITION .................................................................................... 749
15.1.10. PARTICLE AND MASS FLOW DEFINITION ............................................................................ 749
15.1.11. EXTERNAL COUPLING AND SOLVER ................................................................................... 750
15.1.12. SETUP CONFIRMATION ..................................................................................................... 750
15.1.13. SIMULATE PROJECT .......................................................................................................... 750
15.1.14. POST PROCESS – TIME PLOT .............................................................................................. 753
15.1.15. POST PROCESS – OUTPUT ................................................................................................. 753
15.1.16. CONCLUSION ................................................................................................................... 754
15.2. Part B: Mechanical Coupling (Workbench) .................................................................................... 754
15.2.1. OBJECTIVE ......................................................................................................................... 754
15.2.2. PREREQUISITES ................................................................................................................... 755
15.2.3. WORKBENCH SETUP ........................................................................................................... 755
15.2.4. DEFINING THE STRUCTURAL ANALYSIS ................................................................................ 756
15.2.5. POST-PROCESSING ............................................................................................................. 759
15.2.6. WORKBENCH – RUNNING MULTIPLE SIMULATIONS .............................................................. 761
15.2.7. CONCLUSION ..................................................................................................................... 764
16. Tutorial - Mixing Tank ........................................................................................................................ 765
16.1. Part A: Fluent Case Setup ............................................................................................................. 765
16.1.1. OBJECTIVES ........................................................................................................................ 765
16.1.2. PREREQUISITES ................................................................................................................... 765
16.1.3. GEOMETRY INTRODUCTION ................................................................................................ 766

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16.1.4. OPEN ANSYS FLUENT .......................................................................................................... 767

16.1.5. IMPORT CASE ..................................................................................................................... 767
16.1.6. FLUID MESH SETUP ............................................................................................................. 768
16.1.7. FLUID PHASES SETUP .......................................................................................................... 769
16.1.8. TURBULENCE DEFINITION ................................................................................................... 771
16.1.9. CELL ZONE CONDITIONS ..................................................................................................... 771
16.1.10. BOUNDARY CONDITIONS .................................................................................................. 772
16.1.11. METHODS ........................................................................................................................ 773
16.1.12. CONTROLS ....................................................................................................................... 774
16.1.13. INITIALIZATION ................................................................................................................. 774
16.1.14. CELL REGISTERS ................................................................................................................ 775
16.1.15. INITIALIZE AND PATCH ...................................................................................................... 775
16.1.16. CALCULATION SETUP ........................................................................................................ 776
16.1.17. SETUP CONFIRMATION ..................................................................................................... 776
16.1.18. CALCULATE PROJECT ........................................................................................................ 777
16.1.19. CONCLUSION ................................................................................................................... 778
16.2. Part B: Rocky Coupling Setup ....................................................................................................... 778
16.2.1. OBJECTIVES ........................................................................................................................ 778
16.2.2. PREREQUISITES ................................................................................................................... 778
16.2.3. GEOMETRY INTRODUCTION ................................................................................................ 780
16.2.4. PROJECT CREATION ............................................................................................................ 781
16.2.5. PROJECT SETUP .................................................................................................................. 781
16.2.6. GEOMETRY MOTION SYNC .................................................................................................. 782
16.2.7. PROJECT SETUP .................................................................................................................. 783
16.2.8. IMPORTING CFD SOLUTION ................................................................................................ 784
16.2.9. IMPORTED MOTION FRAME ................................................................................................ 786
16.2.10. ASSIGN IMPORTED MOTION FRAME .................................................................................. 787
16.2.11. FINISH PROJECT SETUP ..................................................................................................... 788
16.2.12. SETUP CONFIRMATION ..................................................................................................... 788
16.2.13. SIMULATE PROJECT .......................................................................................................... 789
16.2.14. SETUP CONFIRMATION ..................................................................................................... 790
16.2.15. POST-PROCESSING OPTIONS ............................................................................................. 791
16.2.16. CONCLUSIONS .................................................................................................................. 792
17. Tutorial - Mixing Tee .......................................................................................................................... 793
17.1. Part A: Project Setup and Processing ............................................................................................ 793
17.1.1. OBJECTIVES ....................................................................................................................... 793
17.1.2. PREREQUISITES ................................................................................................................... 794
17.1.3. GEOMETRY ......................................................................................................................... 794
17.1.4. (OPTIONAL) FLUENT CASE SETUP ........................................................................................ 795
17.1.5. (OPTIONAL) VERIFY EXPORT COMPONENT ........................................................................... 795
17.1.6. (OPTIONAL) FLUENT CASE PROCESSING .............................................................................. 796
17.1.7. ROCKY PROJECT CREATION ................................................................................................. 797
17.1.8. ROCKY PROJECT SETUP ....................................................................................................... 797
17.1.9. PHYSICS DEFINITION - COARSE-GRAINING ........................................................................... 797
17.1.10. PHYSICS DEFINITION - COARSE-GRAINING ......................................................................... 798
17.1.11. ROCKY PROJECT SETUP ..................................................................................................... 798
17.1.12. REMOVE GEOMETRIES ....................................................................................................... 799
17.1.13. ROCKY PROJECT SETUP ..................................................................................................... 799
17.1.14. PARTICLE GROUP DEFINITION ........................................................................................... 800
17.1.15. ROCKY PROJECT SETUP ..................................................................................................... 802
17.1.16. COARSE-GRAINING COMPARISON ..................................................................................... 802

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17.1.17. CFD COUPLING DEFINITION .............................................................................................. 805

17.1.18. CFD VISUALIZATION .......................................................................................................... 806
17.1.19. FINISH PROJECT SETUP ..................................................................................................... 807
17.1.20. SETUP CONFIRMATION ..................................................................................................... 807
17.1.21. SIMULATE PROJECT .......................................................................................................... 808
17.1.22. CONCLUSION ................................................................................................................... 809
17.2. Part B: Post-Processing ................................................................................................................ 810
17.2.1. OBJECTIVES ....................................................................................................................... 810
17.2.2. PREREQUISITES ................................................................................................................... 810
17.2.3. OPEN PROJECT ................................................................................................................... 811
17.2.4. STEADY STATE .................................................................................................................... 811
17.2.5. MASS FLOW CALCULATION ................................................................................................. 812
17.2.6. MASS FLOW CALCULATION ................................................................................................. 813
17.2.7. INTENSITY AND WEAR ........................................................................................................ 816
17.2.8. SHEAR WORK CALCULATION ............................................................................................... 816
17.2.9. CONCLUSION ..................................................................................................................... 821
18. Tutorial - Ribbon Blender .................................................................................................................. 823
18.1. Part A: Project Setup and Processing ............................................................................................ 823
18.1.1. OBJECTIVES ........................................................................................................................ 823
18.1.2. PREREQUISITES ................................................................................................................... 823
18.1.3. EXTERNAL MODULE ........................................................................................................... 824
18.1.4. GEOMETRIES ...................................................................................................................... 825
18.1.5. PROJECT CREATION ............................................................................................................ 825
18.1.6. MODULES DEFINITION ........................................................................................................ 826
18.1.7. LIQUID BRIDGE DEFINITION ................................................................................................ 826
18.1.8. PROJECT SETUP .................................................................................................................. 828
18.1.9. INTERACTION BETWEEN MATERIALS - LIQUID BRIDGE .......................................................... 829
18.1.10. PARTICLES AND INLETS DEFINITIONS ................................................................................. 831
18.1.11. SETUP CONFIRMATION ..................................................................................................... 834
18.1.12. SIMULATE PROJECT .......................................................................................................... 834
18.1.13. CONCLUSION ................................................................................................................... 836
18.2. Part B: Post-Processing (LMI Analysis) ........................................................................................... 837
18.2.1. OBJECTIVES ....................................................................................................................... 837
18.2.2. PREREQUISITES ................................................................................................................... 837
18.2.3. OPEN PROJECT ................................................................................................................... 838
18.2.4. POST-PROCESSING ............................................................................................................. 838
18.2.5. EVALUATION OF MIXING DEGREE ........................................................................................ 839
18.2.6. MIXING INDEX .................................................................................................................... 840
18.2.7. FILTERING ADDITIVE PARTICLES ........................................................................................... 841
18.2.8. TAGGING ADDITIVE PARTICLES ............................................................................................ 842
18.2.9. ADDITIVE MASS CALCULATION ........................................................................................... 842
18.2.10. SAMPLING ........................................................................................................................ 843
18.2.11. ADDITIVE MASS FRACTION ............................................................................................... 844
18.2.12. FILTERING ......................................................................................................................... 846
18.2.13. MIXING INDEX .................................................................................................................. 847
18.2.14. CONCLUSION ................................................................................................................... 851
18.3. Part C: Post-Processing (Liquid Distribution Analysis) .................................................................... 851
18.3.1. OBJECTIVES ....................................................................................................................... 851
18.3.2. PREREQUISITES ................................................................................................................... 852
18.3.3. OPEN PROJECT ................................................................................................................... 852
18.3.4. LIQUID DISTRIBUTION ......................................................................................................... 853

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18.3.5. LIQUID DISPERSION ............................................................................................................ 858

18.3.6. CONCLUSION ..................................................................................................................... 861
19. Tutorial - Backhoe Loader ................................................................................................................. 863
19.1. Part A: Ansys Motion Coupling Setup ........................................................................................... 863
19.1.1. OBJECTIVE .......................................................................................................................... 863
19.1.2. PREREQUISITES ................................................................................................................... 863
19.1.3. GEOMETRIES ...................................................................................................................... 864
19.1.4. MOTION COMPARISON ....................................................................................................... 865
19.1.5. FMU OVERVIEW .................................................................................................................. 865
19.1.6. INSTALL MODULES ............................................................................................................. 866
19.1.7. ANSYS MOTION SETUP - OPEN PROJECT .............................................................................. 868
19.1.8. ANSYS MOTION SETUP - PREPARE SUBSYSTEM .................................................................... 870
19.1.9. ANSYS MOTION SETUP - EXPORT FILES ................................................................................ 871
19.1.10. HELP ................................................................................................................................ 873
19.1.11. CONCLUSION ................................................................................................................... 873
19.2. Part B: Rocky Setup and Processing .............................................................................................. 873
19.2.1. OBJECTIVE ......................................................................................................................... 873
19.2.2. PREREQUISITES ................................................................................................................... 874
19.2.3. GEOMETRIES ...................................................................................................................... 875
19.2.4. PROJECT SETUP .................................................................................................................. 875
19.2.5. TURN ON MODULES ........................................................................................................... 876
19.2.6. IMPORT MOTIONS .............................................................................................................. 876
19.2.7. FMU GEOMETRY IMPORT .................................................................................................... 878
19.2.8. MATERIAL DEFINITION ........................................................................................................ 878
19.2.9. PARTICLE GROUP DEFINITION ............................................................................................. 879
19.2.10. SETUP CONFIRMATION ..................................................................................................... 880
19.2.11. SIMULATE PROJECT .......................................................................................................... 880
19.2.12. FORCE ANALYSIS - CURVES ................................................................................................ 881
19.2.13. EVALUATING BUCKET MASS .............................................................................................. 882
19.2.14. OUTPUT VALUE ................................................................................................................. 883
19.2.15. STRESS ANALYSIS .............................................................................................................. 884
19.2.16. HELP - SETUP GUIDE ......................................................................................................... 886
19.2.17. CONCLUSION ................................................................................................................... 887
20. Tutorial - Fertilizer Spreader ............................................................................................................. 889
20.1. Part A: Project Setup and Processing ............................................................................................ 889
20.1.1. OBJECTIVES ........................................................................................................................ 889
20.1.2. PREREQUISITES ................................................................................................................... 889
20.1.3. GEOMETRY ......................................................................................................................... 890
20.1.4. PROJECT CREATION ............................................................................................................ 890
20.1.5. CFD COUPLING - 1-WAY CONSTANT ..................................................................................... 892
20.1.6. CONTINUE PROJECT SETUP ................................................................................................. 895
20.1.7. SETUP CONFIRMATION ....................................................................................................... 895
20.1.8. SIMULATE PROJECT ............................................................................................................ 896
20.1.9. CONCLUSION ..................................................................................................................... 898
20.2. Part B: Post-Processing ................................................................................................................ 898
20.2.1. OBJECTIVES ........................................................................................................................ 898
20.2.2. PREREQUISITES ................................................................................................................... 899
20.2.3. OPEN PROJECT ................................................................................................................... 899
20.2.4. POST PROCESSING - CUMULATIVE MASS FIELD .................................................................... 900
20.2.5. POST PROCESSING - PERIOD SELECTION .............................................................................. 901
20.2.6. LAYER 1 - PARTICLES TIME SELECTION ................................................................................. 901

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20.2.7. LAYER 1 - PARTICLES TIME SELECTION ................................................................................. 902

20.2.8. LAYER 2 - CUBE ................................................................................................................... 904
20.2.9. LAYER 3 - EULERIAN STATISTICS ........................................................................................... 904
20.2.10. LAYER 4 - FILTER ................................................................................................................ 906
20.2.11. CUMULATIVE MASS FIELD - EXTENSIONS ........................................................................... 907
20.2.12. CONCLUSIONS .................................................................................................................. 907
21. Tutorial - Bottling Line ...................................................................................................................... 909
21.1. Part A: Project Setup and Processing ............................................................................................ 909
21.1.1. OBJECTIVES ........................................................................................................................ 909
21.1.2. PREREQUISITES ................................................................................................................... 909
21.1.3. GEOMETRIES ...................................................................................................................... 910
21.1.4. PROJECT CREATION ............................................................................................................ 910
21.1.5. MOTION FRAMES ................................................................................................................ 911
21.1.6. CONTINUE PROJECT SETUP ................................................................................................. 913
21.1.7. CONVEX AND CONCAVE DETECTION ................................................................................... 914
21.1.8. PARTICLE GROUP DEFINITION ............................................................................................. 914
21.1.9. PARTICLE CUSTOM INLET DEFINITION ................................................................................. 917
21.1.10. INPUT DEFINITION ............................................................................................................ 918
21.1.11. CONTINUE PROJECT SETUP ............................................................................................... 920
21.1.12. SETUP CONFIRMATION ..................................................................................................... 921
21.1.13. SIMULATE PROJECT .......................................................................................................... 922
21.1.14. CONCLUSION ................................................................................................................... 924
21.2. Part B: Post-Processing ................................................................................................................ 924
21.2.1. OBJECTIVES ....................................................................................................................... 924
21.2.2. PREREQUISITES ................................................................................................................... 925
21.2.3. OPEN PROJECT ................................................................................................................... 925
21.2.4. PARTICLES COUNT .............................................................................................................. 926
21.2.5. RESIDENCE TIME ................................................................................................................. 926
21.2.6. BOTTLE ORIENTATION ......................................................................................................... 927
21.2.7. BOTTLE IMPACT VELOCITY .................................................................................................. 929
21.2.8. CONCLUSION ..................................................................................................................... 931
22. Tutorial - Lawn Mower ....................................................................................................................... 933
22.1. Part A: Project Setup and Processing ............................................................................................ 933
22.1.1. OBJECTIVES ........................................................................................................................ 933
22.1.2. PREREQUISITES ................................................................................................................... 934
22.1.3. GEOMETRIES ...................................................................................................................... 934
22.1.4. PROJECT CREATION ............................................................................................................ 934
22.1.5. PARTICLE GROUP DEFINITION ............................................................................................. 936
22.1.6. PARTICLE SHAPE EXPORT .................................................................................................... 939
22.1.7. PARTICLE GROUP DEFINITION ............................................................................................. 940
22.1.8. INPUT DEFINITION .............................................................................................................. 943
22.1.9. SOLVER DEFINITION ............................................................................................................ 945
22.1.10. SETUP CONFIRMATION ..................................................................................................... 946
22.1.11. SIMULATE PROJECT .......................................................................................................... 946
22.1.12. CONCLUSION ................................................................................................................... 948
22.2. Part B: Post-Processing ................................................................................................................ 948
22.2.1. OBJECTIVES ....................................................................................................................... 948
22.2.2. PREREQUISITES ................................................................................................................... 948
22.2.3. OPEN PROJECT ................................................................................................................... 949
22.2.4. VIEW INDIVIDUAL ELEMENTS .............................................................................................. 949
22.2.5. TORQUE AND POWER ......................................................................................................... 951

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22.2.6. TORQUE AND POWER ......................................................................................................... 951

22.2.7. INTENSITY AND WEAR ........................................................................................................ 955
22.2.8. INTENSITY AND WEAR ........................................................................................................ 955
22.2.9. CONCLUSION ..................................................................................................................... 957
23. Tutorial - Solver SDK .......................................................................................................................... 959
23.1. Part A: Working Environment Setup ............................................................................................. 959
23.1.1. OBJECTIVE .......................................................................................................................... 959
23.1.2. PREREQUISITES ................................................................................................................... 959
23.1.3. INSTALLATION COMPONENTS ............................................................................................. 960
23.1.4. Working Environment Setup for Windows 10/11 64-bit ........................................................ 961
23.1.4.1. SOLVER SDK FILES SETUP (WINDOWS) ........................................................................ 961
23.1.4.2. SDK VARIABLE CREATION (WINDOWS) ........................................................................ 961
23.1.4.3. CUDA TOOLKIT SETUP (WINDOWS) ............................................................................ 962
23.1.4.4. ENSURE CUDA VARIABLE CREATION (WINDOWS) ........................................................ 962
23.1.4.5. BUILD TOOLS SETUP (WINDOWS) ............................................................................... 963
23.1.4.6. WORKING FOLDER SETUP (WINDOWS) ....................................................................... 963
23.1.4.7. PLUGIN VARIABLE SETUP (WINDOWS) ......................................................................... 964
23.1.5. Working Environment Setup for Linux 64-bit ....................................................................... 964
23.1.5.1. SDK FILES SETUP (LINUX) ........................................................................................... 964
23.1.5.2. SDK VARIABLE CREATION (LINUX) ............................................................................... 965
23.1.5.3. CUDA TOOLKIT SETUP (LINUX) ................................................................................... 966
23.1.5.4. BUILD TOOLS SETUP (LINUX) ...................................................................................... 966
23.1.5.5. WORKING FOLDER SETUP (LINUX) .............................................................................. 967
23.1.5.6. PLUGIN VARIABLE SETUP (LINUX) ................................................................................ 967
23.1.6. HELP - SOLVER SDK MANUAL .............................................................................................. 968
23.1.7. CONCLUSION ..................................................................................................................... 968
23.2. Part B: Building a Custom Module ................................................................................................ 968
23.2.1. OBJECTIVE ......................................................................................................................... 968
23.2.2. PREREQUISITES ................................................................................................................... 969
23.2.3. ROCKY SOLVER SDK OVERVIEW ........................................................................................... 969
23.2.4. EXAMPLE MODULE OVERVIEW ............................................................................................ 970
23.2.5. Get and Review Files that Define the Module ...................................................................... 970
23.2.5.1. FILES OVERVIEW ........................................................................................................ 970
23.2.5.2. STEP 1: GET FILES ....................................................................................................... 971
23.2.5.3. STEP 2: REVIEW INFO FILE ........................................................................................... 972
23.2.5.4. STEP 3: REVIEW PYTHON FILE ..................................................................................... 974
23.2.5.5. STEP 4: REVIEW CUDA FILE ......................................................................................... 977
23.2.5.6. STEP 5: REVIEW PDF FILE ............................................................................................ 982
23.2.5.7. STEP 6: REVIEW CMAKE FILE ....................................................................................... 983
23.2.5.8. STEP 6: REVIEW CMAKE FILE ....................................................................................... 983
23.2.6. ENABLE AUTO-COMPLETE FOR MODULES DEVELOPMENT (WINDOWS - OPTIONAL) ............. 984
23.2.7. COMPILATION OVERVIEW ................................................................................................... 985
23.2.8. STEP 1: EXECUTE BUILD COMMANDS (WINDOWS) ............................................................... 986
23.2.9. STEP 1: EXECUTE BUILD COMMANDS (LINUX) ...................................................................... 987
23.2.10. STEP 2: VERIFY COMPILED FILES ......................................................................................... 987
23.2.11. TEST THE MODULE ............................................................................................................ 988
23.2.11.1. OPEN ROCKY ........................................................................................................... 988
23.2.11.2. USE THE MODULE IN A PROJECT ............................................................................... 989
23.2.12. HELP - SOLVER SDK MANUAL ............................................................................................ 990
23.2.13. CONCLUSION ................................................................................................................... 991
24. Tutorial - Dam Break .......................................................................................................................... 993

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24.1. Part A: Project Setup and Processing ............................................................................................ 993

24.1.1. OBJECTIVES ........................................................................................................................ 993
24.1.2. PREREQUISITES ................................................................................................................... 993
24.1.3. GEOMETRY INTRODUCTION ................................................................................................ 994
24.1.4. PROJECT CREATION ............................................................................................................ 994
24.1.5. INITIAL SETUP ..................................................................................................................... 995
24.1.6. MOTION FRAMES ................................................................................................................ 995
24.1.7. FLUID DEFINITION .............................................................................................................. 997
24.1.8. SPH PARAMETERS ............................................................................................................... 997
24.1.9. INLET DEFINITION ............................................................................................................... 999
24.1.10. DOMAIN SETTINGS ......................................................................................................... 1000
24.1.11. DOMAIN AND SOLVER ..................................................................................................... 1000
24.1.12. SETUP CONFIRMATION .................................................................................................... 1001
24.1.13. SIMULATION SUMMARY .................................................................................................. 1001
24.1.14. CONCLUSION .................................................................................................................. 1002
24.2. Part B: Post-Processing .............................................................................................................. 1003
24.2.1. OBJECTIVES ...................................................................................................................... 1003
24.2.2. OPEN PROJECT ................................................................................................................. 1003
24.2.3. COLORING FLUID ELEMENTS ............................................................................................. 1004
24.2.4. EULERIAN SOLUTION VIEW ................................................................................................ 1004
24.2.5. DISCRETE AND CONTINUOUS FLUID VIEWS ....................................................................... 1005
24.2.6. WATER SURFACE - WEIGHT PROPERTY ............................................................................... 1007
24.2.7. WATER SURFACE ............................................................................................................... 1009
24.2.8. FLUID ANIMATION ............................................................................................................ 1010
24.2.9. FLUID FORCES .................................................................................................................. 1010
24.2.10. PROPERTY VISUALIZATION .............................................................................................. 1011
24.2.11. CONCLUSION .................................................................................................................. 1012
25. Tutorial - Slurry Mill ......................................................................................................................... 1015
25.1. Part A: Project Setup and Processing .......................................................................................... 1015
25.1.1. OBJECTIVES ...................................................................................................................... 1015
25.1.2. PREREQUISITES ................................................................................................................. 1015
25.1.3. GEOMETRY ....................................................................................................................... 1016
25.1.4. PROJECT CREATION .......................................................................................................... 1016
25.1.5. INITIAL SETUP ................................................................................................................... 1017
25.1.6. MOTION FRAMES .............................................................................................................. 1017
25.1.7. MILL SETUP ...................................................................................................................... 1018
25.1.8. MATERIALS ....................................................................................................................... 1019
25.1.9. PARTICLES ........................................................................................................................ 1019
25.1.10. SPH - FLUID SETUP .......................................................................................................... 1020
25.1.11. INLET DEFINITION ........................................................................................................... 1021
25.1.12. DOMAIN AND SOLVER ..................................................................................................... 1023
25.1.13. SETUP CONFIRMATION .................................................................................................... 1024
25.1.14. SIMULATION SUMMARY .................................................................................................. 1024
25.1.15. HELP - USER MANUAL ..................................................................................................... 1026
25.2. Part B: Post-Processing .............................................................................................................. 1026
25.2.1. OBJECTIVES ...................................................................................................................... 1026
25.2.2. PREREQUISITES ................................................................................................................. 1027
25.2.3. OPEN PROJECT ................................................................................................................. 1027
25.2.4. SLURRY FILLING ................................................................................................................ 1028
25.2.5. SLURRY FILLING CALCULATION ......................................................................................... 1029
25.2.6. SLURRY FILLING - RESULT .................................................................................................. 1030

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 Rocky Tutorial Guide

25.2.7. POWER ANALYSIS ............................................................................................................. 1031

25.2.8. SLURRY FILLING - RESULT .................................................................................................. 1031
25.2.9. POWER ANALYSIS ............................................................................................................. 1032
25.2.10. POWER ANALYSIS - POOLING .......................................................................................... 1033
25.2.11. SLURRY BEHAVIOR .......................................................................................................... 1034
25.2.12. POWER ANALYSIS ........................................................................................................... 1035
25.2.13. CONCLUSION .................................................................................................................. 1036
25.2.14. BIBLIOGRAPHY ............................................................................................................... 1036

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Chapter 1: Tutorial - Transfer Chute
1.1. Part A: Project Setup and Processing
Introduce the Rocky user interface, go over the various parameters, and outline the basic steps for setting
up and processing a Rocky project.

1.1.1. OBJECTIVES
The purpose of this tutorial is to introduce the Rocky user interface, go over the various parameters,
and outline the basic steps for setting up a Rocky project.

The scenario considered is analyzing the performance of a transfer chute with one feed and two re-
ceiving conveyors.

You will learn how to:

• Import Geometries

• Create Motion Frames and define geometry movements

• Configure Material properties and interactions

• Create sets of Particles and define Mass Flow Rates

• Process (run) the simulation

And you will use these features:

• Archive Project

• Translation motion type

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Tutorial - Transfer Chute

1.1.2. GEOMETRY INTRODUCTION

The geometry in this tutorial is composed of:

• (1) Feed Conveyor;

• (2) Skirt;

• (3) Pulley;

• (4) Chute;

• (5) Receiving Conveyors.

The complete geometry is subdivided into several parts in order to apply different movements to
each one. In the tutorial files folder (presented below), each .stl file can be found.

1.1.3. PROJECT CREATION

To begin the steps for this tutorial, do the following:

• Download the dem_tut01_files.zip file .

• Unzip dem_tut01_files.zip to your working directory.

• Open Rocky 2025 R1 (look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut).

• From the Rocky program, click the New Project button, or from the File menu, click New
Project (Ctrl+N).

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 Part A: Project Setup and Processing

1.1.4. ROCKY INTERFACE (UI)

The Rocky user interface (UI) is customizable, you can add/remove/reposition any window or panel
available. To change back to the default, select View from the main Toolbar, and then click Reset
layout.

The default layout contains the following components:

• (1) Menu and Toolbar: Contains the main program menus, shortcuts, camera options, time
step controls, and display tools.

• (2) Workspace: Displays the available windows that have been opened for the project (3D
Views, Motion and Particle Previews, and Plots and Histograms).

• (3) Data Panel: Displays the project tree through which the setup parameters are defined.

• (4) Data Editors Panel: Displays the details of the item that is selected in the Data panel.

• (5) Progress Panel: Shows the processing tasks currently being performed.

• (6) Status Panel: Shows any warnings or errors regarding the current project.

• (7) Simulation Log Panel: Lists any Solver warnings or errors.

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Tutorial - Transfer Chute

1.1.5. PROJECT SETUP DATA PANEL ITEMS

To set up any Rocky simulation, from the Data panel under Study, follow the items listed top-down
and one-by-one:

• Study: Change the study name from the default (Study) and add a description.

– Study also enables the activation of two other entities that are hidden by default:

→ Regions of Interest: (For certain external Modules only.) Create a Cube or Cylinder region
where custom calculations can be performed.

→ Point Clouds: (For certain external Modules only.) Import field data that is defined in a
text file.

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 Part A: Project Setup and Processing

– Aternatively, Regions of Interest and Point Clouds are also enabled from the main Study
menu:

• Modules: Enable additional models and data collection options.

• Physics: Set physical conditions (Gravity, Momentum, Coarse-Graining, and Thermal models).

• Materials: Define materials and set densities and other properties.

• Motion Frames: Add and preview movement to the simulation components (Geometries).

• Geometries: Import, add, and edit geometry components.

• Particles: Create particles, set size distributions and preview particle shapes.

• Joints: Enable the collection of joints data.

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Tutorial - Transfer Chute

• Contacts: Enable the collection of contact data.

• SPH: Define fluid (SPH elements) parameters and boundary conditions.

• Inlets and Outlets: Define particle and fluid inlets and/or outlets and release locations.

1.1.6. POST-PROCESSING DATA PANEL ITEMS

The remaining items at the bottom of the Data panel are for post-processing:

• CFD Coupling: Set up LBM air flow, or define One-Way or Two-Way coupling with Ansys Fluent
fluid dynamics solver.

• Domain Settings: Define the domain behavior and periodic boundaries.

• Solver: Define how the solver processes the simulation and collects data.

• Calculations: Displays user-defined particle or SPH properties, such as particle tagging.

• User Processes: Displays user-defined processes, such as analysis cubes and planes.

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 Part A: Project Setup and Processing

• Color Scales: Shows display details of all plotted properties.

Note:

These items will be covered in more detail in later tutorials.

1.1.7. PROJECT DETAILS

The Study entity covers the first step of the simulation setup. The purpose is to define any useful
information for the project.

1. From the Data panel, click Study.

2. From the Data Editors panel, enter the project information (as shown).

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Tutorial - Transfer Chute

1.1.8. PHYSICS DEFINITION

In the Physics step, the Gravity, Momentum, Thermal, and Coarse-Graining tabs are used to en-
able/disable the various models used in the solver.

1. From the Data panel, select Physics.

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 Part A: Project Setup and Processing

2. From the Data Editors panel, on the Momentum tab, set the Rolling Resistance Model.

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Tutorial - Transfer Chute

1.1.9. GEOMETRY IMPORT

The Geometries step enables you to add default geometries, such as conveyors or surfaces, or import
your own custom geometries (walls or surfaces).

For this case we will import geometry files in .stl format.

1. From the Data panel, right-click Geometries, and then click Import Wall.

The following geometry formats can be imported into Rocky:

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 Part A: Project Setup and Processing

2. From the Select file to import dialog, navigate to the tutorial_01_input_files folder that you
previously downloaded, find the geometry folder, and then while pressing either the Ctrl or Shift
key, multi-select all of the following files:

3. Click Open.

4. If you haven't saved your project yet, a Save File dialog will appear. Select a folder location, enter
a File name, and then click Save.

After saving the project, a Rocky dialog is displayed, where geometry limits (in X, Y and Z directions)
are shown.

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Tutorial - Transfer Chute

Import Unit defines the unit with which the geometry was saved previously.

5. For this tutorial, all geometries are in "mm" so make this change to the Import Unit, as shown.

6. Review the Geometry Limits to ensure the unit you selected is correct.

7. Click OK to add the new parts into the simulation project.

Tip: .stl files are not saved with an embedded unit so ensure you select the correct unit during geometry
import.

1.1.10. PROJECT SAVING

Rocky always saves your project in 2 parts:

• (Project_name).rocky: This is the Project file, which includes the simulation setup values.

• (Project_name).rocky.files: This is the Project folder, which contains all the generated configurations,
logs and calculated timesteps.

To share your project, it is very important to always send both parts. Rocky provides an easy way to
do this:

• From the File menu, select Archive project. Rocky will create a file called (Pro-
ject_name).rocky_archive, which is a compressed file, containing both parts.

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 Part A: Project Setup and Processing

• To open it, just click the File menu, and then select Restore archived project.

After you process your simulation, three other options for saving the project are displayed when you
select Save project as. . . from the File menu, as follows:

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Tutorial - Transfer Chute

These additional saving options will be covered in later tutorials.

1.1.11. 3D VIEW
To visualize the freshly imported geometries, do the following:

1. From the Data panel, click and hold the Geometries entity.

2. Drop it on top of the Workspace. The workspace will then be filled with a 3D View window of the
geometries.

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 Part A: Project Setup and Processing

1.1.12. 3D VIEW CONTROL

In the 3D View window, you can use the following controls and shortcuts to modify the view:

1.1.13. INLET DEFINITION

After the geometries are imported, a Surface must be defined to use it later as an Inlet to release
particles inside the domain.

Note: Except for Volumetric and Custom Inlets, an Inlet or Outlet must be associated with a Surface.

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Tutorial - Transfer Chute

1. From the Data panel, right-click Geometries, and then click Create Rectangular Surface. A new
entry will be added under Geometries called Rectangular Surface <01>.

2. From the Data panel, select Rectangular Surface <01>, and from the Data Editors panel, define
the Name, Center Coordinates, Length, Width, Angle and Vector.

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 Part A: Project Setup and Processing

The surface will be automatically shown as a red box in the 3D View after its creation (as shown below).

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1.1.14. GRAPHIC DISPLAY

A 3D View window can be changed by right-clicking anywhere in the background (outside the geo-
metries parts). Some configuration options include:

• Grids: Allows you to change faces and edges colors for the geometries, as well as the display
method.

• Background and Font color: Change the color of the 3D View background and the text displayed
in the window.

• Auto Update: Enable/disable update of the graphical 3D View regarding any modification in the
Data panel.

• Bounding Box: Enable/disable visualization of the geometry limit coordinates on each axis.

• Synchronized Time: When disabled, allows you to display multiple 3D Views at different times or
lock them to the same time step when enabled.

• Copy and Save Image: Copy the window and/or save it as a .png, .bmp or .jpg file.

The color, transparency, and visibility of each part of the geometries can be changed from the Color-
ings tab.

For example, you can make the geometries transparent by doing the following:

1. From the Data panel, under Geometries, multi-select (press the CTRL or SHIFT key while clicking)
all six of the imported walls.

2. From the Data Editors panel, select the Colorings tab and then enable the Transparency checkbox
(as shown).

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 Part A: Project Setup and Processing

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1.1.15. MOTION FRAMES

After importing/creating all the necessary geometries, movements can be added using the Motion
Frames tool, which is located in the Data panel.

In order to set up a new motion, you will use the following steps:

1. Create a new Frame: You can define a new Frame either setting the position and orientation using
the global reference Frame or using a previously created Frame (nested Motion Frame).

2. Define the Frame's motion: Every Frame can have multiple motions defined, which can include:

• Translation and Rotation

• Periodic Translation and Rotation (Vibration and Pendulum)

• Free Body Translation and Free Body Rotation

• Additional Forces and Moments (only for Free Body Motions)

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 Part A: Project Setup and Processing

• Spring-Dashpot Forces and Moments

• Linear Time Variable Forces and Moments

• Time Series (customized) Translation and Rotation

3. Associate the geometry with a Motion Frame: For every moving boundary, select one Motion
Frame to be associated with that boundary. To apply a nested set of Motion Frames, assign only the
lowest level child Frame.

4. Preview the motion: Use the Motion Preview tool to ensure that the movement for all the
boundaries is as desired.

Note: Motion Frames can be associated with some User Processes. This will be covered in later tutorials.

For this tutorial, two separate Translation movements will be created.

Both movements will use the Keep in Place: Global option. This means the particles in contact with
the geometry will have the prescribed velocity but the geometry itself will not move.

• The Global and Local distinctions are necessary only for complex nested motions, which we will
cover in later tutorials (Tutorial 07 - Conical Dryer).

• For standard motions like the ones we will create in this tutorial, choosing either option will have
the same effect upon the simulation.

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Note: Since there is no geometry displacement in this tutorial, we will cover the Motion Preview window
in later tutorials.

To set a Translation motion, you must either align the Frame with the movement direction, or provide
the velocity components.

Both methods are covered in this tutorial:

• Feed Conveyor: Translation without displacement

Velocity = 2.5 m/s

Method: Aligned Frame

• Receiving Conveyor 1: Translation without displacement

Velocity = 2 m/s

Method: Velocity Components

To add a new Motion Frame to your project, do the following:

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 Part A: Project Setup and Processing

1. From the Data panel, right-click Motion Frames, and then select Create Motion Frame.

A new Frame <01> entry appears in the Data panel.

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From the Data panel, select Frame <01> and then from the Data Editors panel, define (as shown):

• Name: Feed Conveyor Motion

• Relative Position (Frame origin coordinate)

• Angle

• Vector (indicates the rotation direction with the defined Angle)

• Keep in Place: Global

3. To create a new motion using this Frame, click the green plus button (Add Motion). A Translation
motion is added by default.

4. Define the Velocity (as shown).

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 Part A: Project Setup and Processing

Create a second Motion Frame by doing the following:

1. From the Motion Frames entity, create another new Frame and then define (as shown):

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• Name: Receiving Conveyor Motion

• Keep in Place: Global

This motion will be defined using the velocity components based on the global reference Frame so
the Relative Position, Relative Rotation Vector, and Rotation Angle must not be changed.

2. To create a new motion using this Frame, click the green plus button (Add Motion).

3. Define the Velocity (as shown).

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 Part A: Project Setup and Processing

Once both the Motion Frames have been created, they can be assigned to their respective geometries.

1. From the Data panel under Geometries, select feed conveyor.

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2. From the Data Editors panel, on the Wall tab, select Feed Conveyor Motion from the Motion
Frame drop-down list (as shown).

3. Repeat the same steps for the receiving conveyor 1 geometry, using the Receiving Conveyor
Motion Frame (as shown).

1.1.16. MATERIAL DEFINITION

The Materials step allows you to define the density, Young's Modulus, and other values you want
assigned to your particles, belts, geometries and fluid (for SPH simulations).

Note:

SPH simulations wil be covered later in Tutorials 24 and 25.

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For this tutorial, default values for the three default Solid Materials will be used.

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Once all the Materials have been defined, they must be assigned to the walls and particles.

By default, Rocky always assigns the material Default Boundary to any imported wall. Because three
of our imported walls are actually conveyor belts, we want to be sure to change the materials for
those components.

1. From the Data panel, under Geometries, select feed conveyor.

2. From the Data Editors panel, on the Wall tab, select Default Belt from the Material drop-down
list (as shown).

3. Repeat these steps for the receiving conveyor 1 and receiving conveyor 2 geometries.

1.1.17. INTERACTIONS BETWEEN MATERIALS

Materials Interactions define adhesion and other properties for materials interactions.

In this simulation we have 3 solid materials: one for particles, one for belts, and another for walls.

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 Part A: Project Setup and Processing

For every pair of materials in contact, a set of material interaction properties must be defined.

Since only particles will interact with each material, we need to define 3 pairs of interactions:

• Particle x Particle

• Particle x Belt

• Particle x Boundary

To set the interaction properties, do the following:

1. From the Data panel, click Materials. The Data Editors panel then displays the editable parameters
under the Materials Interactions tab.

2. From the left drop-down list, select Default Particles, and from the right drop-down list, select
one of its pairs: Default Particles, Default Boundary, or Default Belt.

3. Adjust the parameters for each pair combination (as shown).

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1.1.18. PARTICLE GROUP DEFINITION

The Particles step is where you define particle shapes, sizes, and other attributes.

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To create a new particle group, do the following:

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 Part A: Project Setup and Processing

1. From the Data panel, right-click Particles and then select Create Particle. With this, a new Particle
<01> entity will appear.

2. Select this new entity from the Data panel.

3. From the Data Editors panel, on the Size sub-tab, define Size.

4. From the Movement sub-tab, define the Rolling Resistance.

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5. To visualize the newly created particle, click the View button.

1.1.19. PARTICLE PREVIEW

A new Particles Details window appears showing the (transparent) particle, its geometric center
(yellow dot) and its center of mass (blue dot).

Note: The geometric center and center of mass coincide for homogeneous particle, and only the first one
can be seen (as shown).

You can close or minimize this window to get back to the 3D View 01 window.

1.1.20. INLETS AND OUTLETS DEFINITION

The Inlets and Outlets step allows you to define how particles and fluid enter and exit the simulation.
In this version of Rocky, there are five options:

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• Particle Inlet: Releases particles in a continuous stream from the surface (or Feed Conveyor) that
you select. It is also possible to inject fluid (SPH elements).

• Particle Custom Inlet: Releases particles in user defined positions, sizes, times, velocities, temper-
atures and orientations through a .csv, .xls, .xlsx, .xlsm or .odf file.

• Fluid Inlet: Similar to Particle Inlet but for SPH elements instead of Particles.

• Volumetric Inlet: Fills a spherical region with closely packed particles or a prismatic region with
SPH elements.

• Outlet: Defines an Exit Point for fluid or particles to get out of the simulation and allows to define
prescribed pressure.

To create a new particle mass flow, do the following:

1. Right-click Inlets and Outlets in the Data panel and then select Create Particle Inlet.

With this, a new Particle Inlet <01> entity appears.

2. From the Data panel, select this new entity.

3. From the Data Editors panel, select Inlet Surface from the Entry Point drop-down list.

4. From the Particles sub-tab, click the Add button to add a new particle mass flow rate row and
then from the Particle drop-down list, select Particle 01.

5. Define the Mass Flow Rate.

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 Part A: Project Setup and Processing

6. From the Time sub-tab, define the Stop time.

Prior to processing your simulation, you can use the Inlets and Outlets Info tab to review how many
particles Rocky expects to simulate*.

When viewed from the main Inlets and Outlets entity, you can see an estimate for the entire simu-
lation.

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When viewed from an individual Inlet, you can see an estimate for only that entity's particle contri-
bution.

*These estimates take into account the release times defined for each Input and the Simulation Duration
defined in the Solver step, which is shown on the next slide.

1.1.21. SOLVER DEFINITION

The Solver step is where you define processing time and stability details, and finally Start processing
your simulation.

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Specifically, the Solver | Time tab is where you define:

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• Simulation Duration: The total amount of real time that you want the simulation to run.

• Output Settings | Time Interval: Time intervals during which you want your output files to be
saved.

• Output Settings | Resume Data Frequency: Frequency of the data you want to save that allows
you to resume the simulation from.

• Output Settings | Solver Curves Frequency: Number of results for Curves in each output.

• Breakage | Start: Time delay before starting to calculate particle breakage.

• Breakage | Delay After Release: Time delay after a particle has been released before starting to
calculate particle breakage.

• Wear | Start: Time delay before starting to calculate geometry wear.

• Wear | Geometry Update Interval: Amount of time between wear geometry updates.

1. From the Data panel, click Solver, and then from the Data Editors panel, select the Solver | Time
tab. Define Simulation Duration.

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 Part A: Project Setup and Processing

2. From the General sub-tab, select what you want (CPU or GPU(s)) for Simulation Target, and then
the Number of Processors (or Target GPU(s)). For this tutorial, CPU will be faster due to the low
particle count.

3. Click the Start button to begin processing.

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Note: After defining Solver options, it is also possible to begin processing using the button from the
Simulation Toolbar.

Once you click Start, the Simulation Summary window will appear. It shows the geometry bounds,
enabled models (wear, breakage, non-round particles), number of particles and triangles, and the
calculated Timestep Duration.

This window will disappear on its own, then processing begins.

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 Part A: Project Setup and Processing

1.1.22. SIMULATION STATUS

While the simulation processes, the program's title bar shows the number of saved timesteps (Output),
the simulated solved time, the real solver time (Elapsed), and the estimated time to finish (ETA).

At the bottom of the screen, you can see the progress bar, the Stop button (to stop the solver), the
Refresh button (to visualize the results up to the last solved output), and the Auto Refresh option
(to automatically update the 3D View for every newly saved output).

To view the Particle states in real time, do the following:

1. Either click the Refresh button or select the Auto Refresh checkbox.

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1.1.23. SIMULATION
Through a 3D View window, particle states can be viewed in real time.

The speed of the simulation depends upon various factors such as:

• Number of mesh elements used to define the geometry

• Number of contacts in the simulation domain at any time

• Smallest particle size and material stiffness

• The particle shape and the number of vertices used to define the shape

• Frequency of file output

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 Part A: Project Setup and Processing

1.1.24. HELP - USER MANUAL

This completes Part A of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

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To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

You can use the Search field to quickly find the topic you are interested in:

1.1.25. CONCLUSION
Rocky was used to set up and process a transfer chute simulation.

During this tutorial, it was possible to:

• Understand the basics of the Rocky user interface

• Import sample geometries

• Define basic parameters

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 Part B: Post-Processing

• Process the simulation

What's Next?

• Now that you understand the basics of setting up and running a Rocky project, you are ready to
move on to Part B and post-process this project.

1.2. Part B: Post-Processing

Introduce some basic methods for analyzing a simulation after it has been processed.

1.2.1. OBJECTIVES
The purpose of this tutorial is to introduce some basic methods for analyzing a simulation after you
have processed it. We will continue from where we left off in Part A.

You will learn how to:

• Create an Animation

• Visualize Properties in a 3D View Window

• Create Graphs and Plots

• Filter Data with User Processes

• Export results

And you will use these features:

• Animation panel (videos)

• Time toolbar

• Multi Time plot

• Time plot

• User Process - Cube

• User Process - Plane

1.2.2. OPEN PROJECT

• If you completed Part A of this tutorial, ensure that Rocky project is open (Part B will continue
from where Part A left off ).

• Download the dem_tut01_files.zip file .

• Unzip dem_tut01_files.zip to your working directory.

• Open Rocky 2025 R1 (Look for Rocky 2025 R1 in the Program Menu or use the desktop shortcut).

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• From the Rocky program, click the Open Project button, find the tutorial_01_input_files folder,
and then from the tutorial_01_A_pre-processing folder, open the tutorial_01_pre-pro-
cessing.rocky file.

• Process the simulation. (From the Simulation toolbar, click the Start button.)

1.2.3. MOVING TROUGH OUTPUTS

Now that the project has completed processing, we can begin to analyze it. For example, you can
use the Time toolbar in the following ways:

(1) Select a specific output/time from the drop-down list.

(2) Use the arrow buttons (from left-to-right) to:

• Go to first output

• Step back one output

• Step forward one output

• Go to last output

(3) Play the animation.

(4) Slide to the output you want using the slider bar.

(5) Use the Timeset Filter to display only a specified time range.

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 Part B: Post-Processing

1.2.4. COLORING GEOMETRIES/PARTICLES

There are 3 different ways to color the geometries and/or the particles:

Use the Coloring service toolbar to color all the geometries/particles by a property:

Use the Coloring tab by doing the following:

• From the Data panel, select either a wall under Geometries or the main Particles entity.

• From the Data Editors panel, select the Coloring tab, expand Faces (for boundaries) or Nodes
(for particles) and then select the desired property to color. This way, only the selected item will
be colored (not all of them as with the other options).

Use the Properties tab by dragging and dropping the desired property over a 3D View window.

For this tutorial, we want to color our particles by velocity.

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1. From the Data panel, select Particles and then from the Data Editors panel, select the Properties
tab.

2. Select Absolute Translational Velocity and then drag and drop it onto the 3D View window.

3. You can then use your mouse to zoom and pan, and use your mouse or the options on the Fit
toolbar (as shown) to change the orientation.

1.2.5. ANIMATION
To create an animation (video) in Rocky, you set key frames of a particular 3D View window at specified
outputs.

Rocky will interpolate between the created key frames using the available outputs saved during the
simulation.

1. To show the Animation panel, from the Tools menu, select Animation.

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1.2.6. ANIMATION PANEL

(1) Frames per Second (FPS) will change the playback speed of the animation. At least 30 FPS is re-
commended. To create a smooth animation, the Time Interval should not be greater than 1/FPS.

(2) Key Frames list.

(3) Select a specific moment in the animation.

(4) Add Key Frame / Remove Key Frame / Update Current Key Frame / Remove All Key Frames / Play
/ Stop / Export (video or images).

(5) Number of frames between the selected Key Frame and the next one. The Number of Frames di-
vided by the FPS gives the real animation time. This value can be changed to display the animation
in real time.

(6) Duplicate the selected Key Frame.

(7) Move the selected Key Frame Up or Down to change the order.

(8) Camera Interpolation method.

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(9) Name of 3D View window that is currently selected.

1.2.7. CREATING AN ANIMATION

For this tutorial, a simple animation using only 2 Key Frames in real time will be created (13s).

1. We will start by removing the Bounding Box from the 3D View, so it won't appear in the animation.
Right-click the 3D View and disable Bounding Box.

2. Since we use an Time Interval of 0.05 s, we should use an FPS of 20 or less (FPS should be less
or equal 1/Time Interval). Use FPS equal to 20.

3. Select the 3D View you set up earlier. Then, using the Time toolbar, change the output to 0 s.

4. Add the first Key Frame by clicking the Add Key Frame (green plus) button.

5. Select the new frame and then from the Frame tab, change the Number of Frames to 260 (as
shown). Since there are 260 output files in this simulation, and our FPS is 20, this will give us the
full 13 seconds between our first and second frames. (260 / 20 = 13)

6. Use the Time toolbar to change the time to the last output, and add a second Key Frame.

7. Your Total Time should be 00:13 (real time).

8. Click Play to preview the movie in the 3D View window.

9. Click Export Animation to save the movie to an AVI file.

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1.2.8. TIME-DEPENDENT PLOTS

All the Properties are calculated for every timestep and every Triangle (geometry mesh) or Particle.

In order to create a Time Plot or a Multi Time Plot, you must select one of the following operations
to transform the Properties into a single time-dependent curve:

• Minimum: Lowest value among all particles/triangles

• Maximum: Highest value among all particles/triangles

• Average: Mean value among all particles/triangles

• Sum: Sum of all values among all particles/triangles

• Sum Squared: Sum of the squared values among all particles/triangles

• Variance: Squared deviation of a value from its mean

• Standard Deviation: Squared root of the variance

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Particles and Solver each contain a Curves tab, which includes several pre-defined curves that can
be plotted without applying any additional operations.

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1.2.9. MULTI TIME PLOT

The Multi Time Plot is a useful tool to compare different curves at the same time, but are plotted
either on the same grid, or on a separate one (subplot).

In this tutorial we will compare the amount of particles that entered the domain (Particles In Count),
left the domain (Particles Out Count), and the total amount of particles inside the domain (Particle
Count) at each output.

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To create a Multi Time Plot, do the following:

1. From the Windows panel (if not visible, point to View, and click on Windows), select New Multi
Time Plot, or use the shortcut Ctrl+M (as shown).

2. From the Data panel, select Particles and then from the Data Editors panel, select the Curves
tab.

3. From the Curves tab, drag and drop Particles In Count over the plot window. Repeat the same
procedure for Particles Out Count.

4. To plot the total number of particles in a separate subplot, click and hold Particles Count, and
then with the Ctrl key pressed, drag and drop the curve over the plot.

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 Part B: Post-Processing

5. In the top left corner of the plot, you can select Configure Window to edit text display, colors,
axes limits, units and other related options.

1.2.10. USER PROCESSES

For some DEM analyses the data must be restricted to a particular region, or a particular subset of
material.

Rocky User Processes are used to divide and analyze Particles, Geometries, and Fluids and include
the following types:

• Cube: Create a subset of data based upon a box region.

• Cylinder: Create a subset of data based upon a cylinder region.

• Plane: Create a subset of data based upon a plane.

• Polyhedron (Envelope): Create a subset of data based upon a custom shape region that you import
via .stl file.

• Property: Create a subset of particles/geometry based upon a particular property value or range.

• Cell Inspector: Select a single, individual particle or triangle (geometry).

• Particles Trajectory: Create the particles` path lines for a specified time range.

• Particle Time Selection: Create a subset of particles based upon a time filter.

• Eulerian Statistics: Transform the discrete properties into continuous values by averaging the
values over discretized regions.

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To illustrate the use of these tools, a Cube and a Plane User Process will be used to analyze the
mass unbalance on the receiving conveyor.

One Cube and two Planes will be used: the Cube to isolate the receiving conveyor and the Planes
to divide those particles into two subsets: left (orange) and right (green).

1.2.11. USER PROCESSES - CUBE

The first User Process will be the Cube. To create it, do the following:

1. From the Data panel, right-click Particles, point to Processes, and then select Cube.

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 Part B: Post-Processing

2. From the Data Editors panel, in the Cube tab, use the values shown in the image for Center,
Magnitude, Method, and Rotation.

3. From the Windows panel, select the 3D View <01> window.

4. From the Coloring tab, select Solid Color as Nodes | Property, and ensure the Node color is set
to red and the Visible checkbox is selected.

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Note: User Processes can be manually changed using the 3D View, or adjusted using the parameters
displayed in the Data Editors panel. For this tutorial, we defined exact parameters in the Data Editors
panel.

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 Part B: Post-Processing

Once the cube has been created, the subset of particles inside this region can be used to create
specific plots, new properties and also to create new subsets derived from it.

In this tutorial, we want to divide only the particles on the conveyor (envolved by Cube <01>), into
two sets: left and right. In order to do that, two Planes will be created based upon the Cube sub-
selection of Particles.

1.2.12. USER PROCESSES - PLANE

To create the first plane, do the following:

1. Right-click Cube <01>, point to Processes, and then select Plane.

2. From the Data Editors panel, select the Plane tab and then define the Name, Plane Origin and
Orientation values (as shown).

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3. From the Coloring tab, set also the Node color to orange.

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 Part B: Post-Processing

When a User Process is selected in the Data panel, Rocky highlights the association between it and
other User Processes by displaying the parent User Process name in Bold.

For example, when you select Cube <01>, Particles will be displayed in bold letters. And when you
select the Left plane, Cube <01> will be bold.

The second Plane is exactly the opposite of the previous, so we will create a copy of it:

1. From the Data panel, right-click Left and then select Duplicate.

2. From the Data Editors panel, select the Plane tab and then modify the Name and Plane Orientation
| Angle value.

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3. From the Coloring tab, set also the Node color to green.

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 Part B: Post-Processing

Tip: You can visualize the planes in the 3D View window by ensuring that the eye icons for Left and Right
are turned on.

The next step is to create a Time Plot comparing the unbalance between both sides of the conveyor.

1. Similar to the Multi Time Plot, create a Time Plot by selecting New Time Plot from the Windows
panel, or by using the shortcut Ctrl+T.

1.2.13. TIME PLOT

2. From the Data panel, under User Processes, multi-select both the Left and Right planes.

3. From the Data Editors panel, select the Properties tab, and then drag and drop Particle Mass
over the plot.

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Note: Properties will either be Instantaneous or will have resulted from a Statistical analysis. This cat-
egorization will be shown in the Evaluation column.

4. A new dialog will be displayed asking which operation you want to apply to the properties to turn
it into a curve. Select only Sum, and then click OK.

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 Part B: Post-Processing

1.2.14. POST PROCESSING - USER PROCESSES

The Time Plot that appears shows that there is a balance difference between the two sides of the
conveyor, which can cause operational problems and lead to additional wear on the belt surface.

1.2.15. POST PROCESSING - EXPORT IMAGES

It is possible to Export Rocky plots and Save 3D views as images.

1. To export an image of the plot, right-click an empty area within it, point to Export, and then click
Image.

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2. From the Image dialog, choose the Snapshot Size, and then click OK.

3. From the Snapshot dialog, set a File name, Save as type image extension, and location for your
file, and then click Save.

1.2.16. HELP - USER MANUAL

This completes Part B of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click the User
Manual.

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 Part B: Post-Processing

1.2.17. CONCLUSION
Rocky was used to study a transfer chute design.

During this tutorial, it was possible to:

• Create an animation of your simulation

• Visualize Properties in a 3D View window

• Plot Properties and Curves

• Filter data using User Processes

• Use post-processing tools to analyze and export the results

What's Next?

Now that you understand the basics of setting up and running a Rocky project, you are ready to
move on to next tutorials.

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Chapter 2: Tutorial - Static Angle of Repose Test
• (Part A) Set up and run a SAOR test case using a cylinder and tray.

• (Part B) Calculate the resulting SAOR using two methods: manually using Cross Plots and automatically
using a Python script.

• (Part C) Study how the SAOR behaves with different particle-to-particle static and dynamic friction
values by running multiple cases in the Rocky Scheduler.

2.1. Part A: Project Setup and Processing

2.1.1. OBJECTIVES
The purpose of this tutorial is to run a Static Angle of Repose (SAOR) test case with different material
and interaction parameters in order to validate the DEM coefficients for future simulations.

You will learn how to:

• Set up an adhesion model

• Change material values

• Inject particles by Volumetric Inlet

And you will use these features:

• Materials and Materials Interactions

• Volumetric Inlet

Important:

Even though this tutorial involves running only one SAOR test, other simulations must be
done in order to calibrate the particle model in full.

2.1.2. PREREQUISITES
• This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

• If this is not the case, please refer to Tutorial 01 - Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

• This tutorial uses SI Units as default units.

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2.1.3. GEOMETRY

The geometry in this tutorial is composed of:

• (1) Container cylinder

• (2) Upper Tray

In the tutorial directory each .stl file can be found.

2.1.4. PROJECT CREATION

To start the tutorial, let's create a new project:

• Download the dem_tut02_files.zip file .

• Unzip dem_tut02_files.zip to your working directory.

• Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop shortcut.)

• From the Rocky program, click the New Project button, or from the File menu, click New Project
(Ctrl+N).

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 Part A: Project Setup and Processing

2.1.5. PROJECT DETAILS

The Study entity covers the first step of the simulation setup. The purpose is to define any useful
information for the project.

1. From the Data panel, click Study.

2. From the Data Editors panel, enter the project information.

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2.1.6. PHYSICS DEFINITION

For the Physics step, we will be adding a rolling resistance model and an adhesive force and will be
lowering the softening factor to reduce the simulation time.

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 Part A: Project Setup and Processing

1. From the Data panel, select Physics.

2. From the Data Editors panel, select the Momentum sub-tab, and then define all of the following:

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Important:

Lowering the softening factor may cause excessive overlaps between particles and
between particles and boundaries.

2.1.7. GEOMETRY IMPORT

For the Geometries step, we will import geometry files in .stl format.

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 Part A: Project Setup and Processing

1. From the Data panel, right-click Geometries and then click Import Wall.

2. From the Select file to import dialog, navigate to the dem_tut02_files folder that you previously
downloaded, find the geometry folder, and then while pressing either the Ctrl or Shift key, multi-
select all of the following files, and then click Open:

• Container_Cylinder.stl

• Upper_Tray.stl

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3. (Save your project now if you have not already done so.)

4. From the Import File Info dialog, select "mm" as Import Unit, ensure that the option Convert Y
and Z axes is cleared (unchecked), and then click OK (as shown).

2.1.8. VIEW GEOMETRY - CHANGE PROJECTION

After the geometry is imported, you can view the results in a 3D View window:

1. Drag and drop the Geometries entity from the Data panel onto the Workspace. A new 3D View
window appears showing the geometries that you imported.

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 Part A: Project Setup and Processing

2.1.9. BOUNDARY MOVEMENT

In this tutorial, after the cylinder container has been filled with particles, it slowly moves up and away
from the tray, which allows the particles to spread out and form a pile.

2.1.10. MOTION FRAME – TRANSLATION

To compute the boundary movement, a motion frame of the type Translation needs to be selected.

After selecting Translation, the following options will be available:

• Fixed Velocity: Constant velocity will be defined in the local coordinates.

• Initial and Final Velocity: The velocity at the Start Time and at the Stop Time will be defined in
the local coordinates and the Acceleration will be calculated.

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• Initial Velocity and Acceleration: With the Stop Time fixed, the velocity at the Start Time and
the Acceleration will be defined in the local coordinates and the velocity at the Final Velocity will
be calculated.

Note:

The following procedures include step-by-step directions on how to create the motion
frame.

2.1.11. MOTION FRAMES

To add a new Motion Frame, do the following:

1. From the Data panel, right-click Motion Frames, and then select Create Motion Frame.

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 Part A: Project Setup and Processing

2. From the Data panel, under Motion Frames, select the newly added Frame <01> entry.

3. From the Data Editors panel, on the Frame tab, define the parameters as shown on the next
section.

2.1.12. MOTION FRAMES – EDITING TIP

At this point, you may not be able to see the entire Data Editors panel by default (as shown).

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Tip:

To display more of the panel, you can drag and drop it by its header, double click it or
click the blue button to make it float. This can facilitate the visualization of the fields.

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 Part A: Project Setup and Processing

2.1.13. MOTION FRAME – CONTAINER CYLINDER

1. Define the Name: Container Cylinder Motion

2. To create a new motion for this Frame, do the following:

• Click the green plus button (Add motion).

• Set the Type as Translation motion (default).

• In order to settle the particles inside the cylinder before it rises, we want this motion to have
a slight delay. So define the Start Time, Stop Time and Velocity.

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2.1.14. MOTION FRAMES

Once the Motion Frame has been created, it can be assigned to the Cylinder geometry:

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 Part A: Project Setup and Processing

1. From the Data panel, under Geometries, select Container_Cylinder.

2. From the Data Editors panel, on the Wall tab, from the Motion Frame drop-down list, select
Container Cylinder Motion (as shown).

2.1.15. MOTION PREVIEW

For this tutorial, since the geometry has a motion with displacement assigned, the movement can
be previewed using the Motion Preview window.

1. From the Data panel, select Motion Frames.

2. From the Data Editors panel, click Preview (as shown). A new window will appear showing the
geometry and the created Frame.

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Tip:

You can define the axes size for better visualization with the Default axes size parameter.

The Time toolbar can be used to play the preview. The yellow color of the slider indicates that the
simulation has not yet been processed.

2.1.16. MATERIAL DEFINITIONS

For the Materials step, only two materials will be used: one for all the geometry parts (Default
Boundary) and another for the particles (Default Particle).

Modify these two Materials as follows:

1. From the Data panel, under Materials select Default Boundary and then from the Data Editors
panel, change the following: Density and Young's Modulus.

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 Part A: Project Setup and Processing

2. From the Data panel, under Materials select Default Particles and then from the Data Editors
panel, change the following: Bulk Density.

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2.1.17. INTERACTIONS BETWEEN MATERIALS

Now let's set the interaction properties for the materials:

1. Select Materials Interactions from the Data panel. The Data Editors panel then displays the
editable parameters.

2. From the left drop-down list, select Default Particles, and from the right drop-down list, select
one of these pairs: Default Boundary or Default Particles.

3. Adjust the parameters for each pair combination according to the values shown as follows:

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 Part A: Project Setup and Processing

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2.1.18. PARTICLE GROUP DEFINITION

For the Particles step, we will create a new sphere-shaped particle group with some added rolling
resistance.

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1. From the Data panel, right-click Particles and then select Create Particle. A new particle group
is created under Particles.

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2. Select the newly created Particle <01> entry, and then from the Data Editors panel, modify the
parameters as specified on the following steps.

3. From the Size sub-tab, define Size (in m).

4. From the Movement sub-tab, define Rolling Resistance.

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 Part A: Project Setup and Processing

5. To visualize the new particle, click View. A new Particle Details window will appear showing you
the (transparent) particle geometry, its geometric center (yellow dot), and its center of mass (blue
dot).

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Note:

The geometric center and center of mass coincide when the density is uniform
throughout the particle (as shown).

2.1.19. PARTICLE INPUT – VOLUMETRIC INLET

For the Inlets and Outlets step, we will create a Volumetric Inlet input, which enables us to inject
a sphere-like ball of closely packed particles into the simulation all at one time.

When compared with the original Particle Inlet method (used in Tutorial 01), using Volumetric Inlet
has the primary benefit of ensuring that the particle bed will already be formed in the cylinder at the
start of the simulation.

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 Part A: Project Setup and Processing

When defining a Volumetric Inlet input, it is important to understand the following components:

• Seed Coordinate: Location of a point around which layers of particles are built.

• Gap Scale Factor: How closely the particles are to each other when they build around the Seed
Coordinate.

• Mass: The target mass of particles that you want to be built around the Seed Coordinate.

• Bounds : Defines the physical limits by which the particle layers will be constrained. Specifically:

– The limits must include Box Bounds, which can be defined manually using coordinates, or can
be automatically calculated by Rocky using the limits of one or more Geometries that you select.

– The limits may also include the walls of one or more Geometries within your simulation.

• Time: The Time sub-tab contains optional time settings for Volumetric Inlets that can improve your
simulation project:

– Injection Time: Set the simulation time at which the particle injection occurs.

– Periodic: When enabled, Periodic allows for a periodic injection of particles into the simula-
tion. Period Time defines the period duration and Stop Time defines the simulation time
when periodic injection stops.

2.1.20. INLETS AND OUTLETS DEFINITION

For this tutorial, we'll create a Volumetric Inlet constrained only by the Cylinder Wall.

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1. From the Data panel, right-click Inlets and Outlets and then select Create Volumetric Inlet. A
new Volumetric Inlet <01> entry is created under Inlets and Outlets.

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 Part A: Project Setup and Processing

2. Select the newly created Volumetric Inlet <01> entry, and then from the Data Editors panel,
modify the parameters as specified below:

• From the Particles sub-tab, click the Add button (green plus) to create an entry row.

• Select the Particle <01> group name from the drop down list and then define the Mass in
kilograms (as shown).

• Leave the Gap Scale Factor as 1 (default) so that the particles are injected as closely together
as possible.

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3. From the Region sub-tab, define the Seed Coordinates.

4. From the Geometries box, enable the Container_Cylinder checkbox.

5. Enable the Use Geometries to Compute checkbox.

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 Part A: Project Setup and Processing

You can visualize the Seed Point you configured in the previous step in a 3D View window.

Since the Seed Coordinates were set to be inside the cylinder, we first have to enable its Transparency
to be able to see the Seed Point.

1. From the Workspace, select a 3D View window (or create a new one).

2. From the Data panel, select the Container_Cylinder geometry.

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3. From the Data Editors panel, select the Coloring tab and then enable the Transparency checkbox.

4. From the Data panel, hide Particles and reselect the Volumetric Inlet <01>.

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 Part A: Project Setup and Processing

You can now visualize the Seed Point (blue dot) and geometry bounds (white box) in the 3D View
window.

2.1.21. SOLVER DEFINITION

Now let's set the Solver parameters:

1. From the Data panel, click Solver and then from the Data Editors panel, ensure that the Solver
tab is selected.

2. From the Time sub-tab, define the Simulation Duration.

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3. From the General sub-tab, select CPU (or GPU/Multi GPU) as Simulation Target, and then set
the Number of Processors (or Target GPU(s)). For this tutorial, CPU will be faster due to the low
particle count.

4. Click the Start button to begin processing.

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 Part A: Project Setup and Processing

Once you click Start, the Simulation Summary window will be displayed.

This window will disappear on its own, then processing begins.

Tip:

You can also review this information from the Solver | Summary tab.

2.1.22. SIMULATION
To visualize the simulation as it's processing:

1. From the Window menu, click New 3D View.

2. Click the Refresh button (or use the Auto Refresh checkbox).

The speed of the simulation depends upon various factors such as:

• The particle shape and the number of vertices used to define the shape

• Number of contacts in the simulation domain at any time

• Number of mesh elements used to define the geometry

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• Smallest particle size and material stiffness

• Frequency of file output

2.1.23. HELP – USER MANUAL

This completes Part A of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

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 Part B: Post-Processing with Scripts

2.1.24. CONCLUSION
Rocky was used to set up and process a simulation of a static angle of repose (SAOR) test.

Note:

Even though this tutorial involves running only one SAOR test, other simulations must be
done in order to calibrate the particle model in full.

During this tutorial, it was possible to:

• Set up a constant adhesion model

• Change materials and interactions values

• Define a Volumetric Inlet Input

• Process the simulation

What's Next?

• Now that you have set up and processed this simulation, you are ready to move on to Part B and
post-process this project.

2.2. Part B: Post-Processing with Scripts

2.2.1. OBJECTIVES
The purpose of this tutorial is to calculate the Static Angle of Repose (SAOR) using two methods:
manually using Cross Plots and automatically using a Python script.

• We will continue from where we left off in Part A.

You will learn how to:

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• Use a cross plot to measure the SAOR

• Open the PrePost Script panel

• Import and run a saved Python script

• Interpret the results from the executed script

• Modify the Python script

And you will use these features:

• Cross Plot window

• PrePost Script panel

• PrePost Scripting Manual

Important:

Even though this tutorial involves running only one SAOR test, other simulations must be
done in order to calibrate the particle model in full.

2.2.2. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that the Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut02_files.zip file .

b. Unzip dem_tut02_files.zip to your working directory.

c. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut.)

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut02_files folder,
then from the tutorial_02_pre-processing folder, open the tutorial_02_pre-processing.rocky
file.

e. Process the simulation. (From the Simulation toolbar, click the Start button.)

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 Part B: Post-Processing with Scripts

2.2.3. POST-PROCESSING: MANUAL METHOD

Now that the project has completed processing, we can begin to analyze it. Let's start with the
manual method first.

In this method, the Static Repose Angles (green lines) will be calculated manually by following these
steps:

• Generation of a plot with the particle distribution along X and Y directions

• Measurement of the length and height using the chart scale

• Calculation of the angles using trigonometric relationships

2.2.4. CROSS PLOT

The Cross Plot is used to create a scatter plot, which allows you to compare two properties of the
Particles/Geometry one on the X-axis and another on the Y-axis for a given Output.

In this tutorial, we will use a Cross Plot to see the projection of the particles pile in the XY plane. In
order to do that, the Particle Y-Coordinate will be plotted against the Particle X-Coordinate.

To create the Cross Plot, do all of the following:

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1. From the Window menu, click New Cross Plot, or use the shortcut Ctrl+R.

2. From the Data panel, select Particles and then from the Data Editors panel, select the Properties
tab.

3. Click and drag Coordinate: Y over the plot window and then release.

4. From the Select Source Curves window that appears, select Coordinate: X from the Domain
drop-down list, and then click OK.

Unlike the (Multi) Time Plot, which shows a single value per output for all the Particles, the Cross
Plot shows all the Particles' values, but for only a single Output.

You can choose what instant to analyze using the Time toolbar.

Select the Time at 4.6 s to measure the Static Repose Angles.

The result is shown below.

2.2.5. PLOT SETTINGS

Rocky plots can be edited by right-clicking anywhere on the plot grid.

Cross Plot

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Multi Time Plot

• Export and Copy: Copy the plot or data; save the plot as a .png, .bmp or .jpg image file; or save
a .csv data file.

• Title Format: Display/hide the plot title, and edit it.

• Legend Format: Display/hide the curves legend, and edit it.

• Canvas Background: Change the plot area color and display/hide grid lines.

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• Curve Colors: Select curves coloring method: one color for each curve (Unique), identical colors
for the same curves in the same or different entities (Particles/Geometries/Processes) (Property
Based), or identical colors for the same or different curves in the same entities (Entity Based).

• Axes Colors: Enable/disable the axis coloring according to the curve color.

• Axes Layout: Toggle between independent axes for each curve (By Property), or a single axis for
the same units (By Quantity).

• Time Mark: Enable/disable the vertical dotted line synchronized with the selected instant in the
Time toolbar.

• Annotations: Add a custom text over the plot at any XY point.

• Settings: Open the Windows Editor panel for additional controls.

2.2.6. AXES SETTINGS

Now, let's modify and re-scale the plot:

1. Right-click the cross plot view and then select Settings. (Or in the top left corner of the plot, select
the Configure Window icon.)

2. In the Window Editors panel, select the Axes tab, and then under Axis, multi-select both proper-
ties.

3. Under Values, change the Limits option to User Defined.

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4. Set the value for Min, Max and Step for the two separate axes as shown below.

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2.2.7. MEASURING RESULTS – MANUAL METHOD

• SAOR (1): Δx= 0.220 m; Δy= 0.155 m

• SAOR (2): Δx= 0.160 m; Δy= 0.150 m

Note:

The values you end up with in your project may vary slightly from the ones shown in this
tutorial.

2.2.8. CALCULATIONS – MANUAL METHOD

Once the values are measured, simple calculations can be done outside of Rocky using a spreadsheet
or calculator:

• SAOR(1): Δx= 0.220 m; Δy= 0.155 m

– SAOR=atan(0.155/0.220) ~ 35.2°

• SAOR (2): Δx= 0.160 m; Δy= 0.150 m

– SAOR=atan(0.150/0.160) ~ 43.1°

Although these values were measured using the cross plot's axis scale, they can be measured using
the mouse. To do that, hold the Shift key and then click the plot to show the cursor's value.

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2.2.9. POST-PROCESSING: AUTOMATIC METHOD

You can also post-process your results automatically by using a Python script.

Important:

The provided script was designed for cases with higher particle counts than what was
simplified for this tutorial. As a result, tutorial results may vary significantly.

In this method, the Static Angle of Repose (SAOR) will be calculated using the following steps:

• At a given output, a parallelepiped slice is divided into N vertical cells and placed at the pile center
(as shown).

• In each of these cells, the maximum particle height is collected.

• Then, the parallelepiped slice is rotated 10 degrees around the vertical axis (Y-direction), and the
maximum height of each cell is collected again. This step is repeated 36 times.

• Using the average of the collected maximum heights for each cell, a regression line is created and
the Static Angle of Repose is calculated.

2.2.10. PREPOST SCRIPT PANEL

In Rocky, you can automate frequent tasks in one of two ways:

• Within Rocky, you can record Scripts of the exact steps you take in the user interface.

• Outside of Rocky, you can write Scripts using the Python programming language that makes use
of the PrePost Scripting.

Although they are generated in different ways, both methods can be played (executed) in the PrePost
Script panel.

For this tutorial, we will focus on using a previously created script.

1. To start, show the PrePost Script panel by selecting it from the Tools menu.

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• (1) Scripts shared across projects: Lists the scripts that can be used for any Rocky project.

• (2) Project scripts: Lists the scripts that can be used for this project only.

• (3) Lists all available scripts that are saved in the default folder for the selected tab.

• (4) Record Script: Creates a script by recording the commands you execute manually in the user
interface.

• (5) Playback PrePost Script: Executes the selected script.

• (6) Open PrePost Scripts Directory: Based upon the selected tab, opens the default folder where
scripts are saved.

• (7) Reload PrePost Scripts from the Filesystem: Refreshes the available scripts list based upon
the default folder for the selected tab.

• (8) Help: Displays some PrePost Script assistance content.

Tip:

More PrePost Script panel content is available in the User Manual. (From the Help menu,
point to Manuals, and then click User Manual.)

The Scripts shared across projects tab of the PrePost Script panel will show all the scripts you have
saved in Rocky's default folder: %HOMEPATH%DocumentsRockyScripts.

Now, let's add the provided script to this panel and run it:

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1. Ensure the Scripts shared across projects tab is selected.

2. Click the Open Scripts Directory button. This should take you to the Scripts folder listed above.

3. From dem_tut02_files folder you downloaded earlier, find the script folder and then copy and
paste the provided script script_calibration_SAOR.py to the folder you just opened.

Note:

The Static Angle of Repose script available in this Rocky Tutorial is only an example.
To see all necessary information about the Calibration Suite and the SAOR script: from
the Ansys Rocky Software, click Help, point to Ready-to-use Scripts and click Scripts
Manual.

4. The new script will appear in the PrePost Scripts panel on the Scripts shared across projects
tab (as shown).

5. With this new script selected, click the Playback Script button (as shown).

2.2.11. SCRIPT RESULTS

After the script finishes the calculation, the resulting plot will be displayed:

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The dashed regression lines are used to compute the SAOR of the pile.

The black dots represent the average of the maximum heights for each vertical cell.

The dark red area represents the minimum of the maximum heights for each vertical cell.

The light red area represents the maximum of the maximum heights for each vertical cell.

Note:

This script was designed for cases with higher particle counts than what was simplified for
this tutorial. As a result, your tutorial results may vary significantly.

2.2.12. SCRIPT RESULTS

In addition, a Results folder is created in the same place as the Rocky project.

This folder contains the following files:

• Experiment_saor.png: The output image of the script.

• experiment_data_points.csv: File containing the points used for fitting the lines.

• angles.json: Text file containing the calculated angles.

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2.2.13. SCRIPT RESULTS

The provided script is based on Calibration 1: Static Angle of Repose test of the Rocky Calibration
Suite.

• Further information about this calibration test or other available calibration tests can be found in
the Rocky Calibration Suite page.

As previously shown, the SAOR is calculated from the result of two linear regressions, one starting
from the bottom of the pile and another one starting from the top of the pile.

Both linear regressions are performed initially with minimum number of points. Then, more points
are iteratively added to the regressions until certain conditions are fulfilled. Such details are explained
in the Calibration 1: Static Angle of Repose documentation.

The more particles you have, the better your results will be and the closer will be the SAOR calculated
From Top to the one calculated From Bottom.

Tip:

A smaller Particle Size or a larger Cylinder will increase particle count.

2.2.14. CALIBRATION SUITE AND MATERIAL WIZARD

For additional particle calibration tests, consider making use of the following resources, both of which
are available on the Customer Portal.

The Rocky Calibration Suite contains:

• Eight pre-made Rocky projects representing common bench tests

• Simplified project setup using pre-processing scripts

• Automatic post-processing reports

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The Material Wizard can be used as a time-saving starting point for your calibration process. For
more details access the Material Wizard Page.

2.2.15. MODIFYING THE SCRIPT

You can change some parameters within the script to have a better resolution of your repose angles
calculations.

Note:

The Static Angle of Repose script available for download and the workflow presented to
modify the script in this Rocky Tutorial are only examples. All information about the Rocky
Calibration Suite and its decks, including the SAOR script, are available in the Scripts
Manual. From the Ansys Rocky Software, click Help, point to Ready-to-use Scripts and
click Scripts Manual.

The main parameters are:

• N_DIVISIONS_FACTOR (line 31):

– Controls the cell size, which is defined by N_DIVISIONS_FACTOR Particle Size. As a consequence,
the higher the factor, the bigger the cell size.

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– The default value is 1.5.

• N_SAMPLES (line 33):

– For each SAOR calculation, this defines the number of times the parallelepiped rotates and collects
the maximum height.

– The default value is 36, which rotates the parallelepiped 10 degrees for each collection.

– Increasing this number (thereby reducing the angle of rotation) will give you more points to
average.

• LIN_REG_INI (line 35):

– Initial number of points for the linear regressions.

– The default value is 3.

To modify the script, do the following:

1. From the PrePost Script panel, from the Scripts shared across projects tab, click the Open
PrePost Scripts Directory button.

2. From the directory dialog, right-click the script file you want to edit, and then open it with your
favorite Python editor. (For example, Visual Studio Code.)

3. Modify it as desired, and then save the file as a .py extension.

Important:

In order for Rocky to recognize it, the script file name must begin with script_.

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2.2.16. HELP – SCRIPTS MANUAL

For further information about the Rocky Calibration Suite, we suggest searching the Rocky Scripts
Manual.

To access it, from the Rocky Help menu, point to Ready-to-use Scripts, and then click Scripts
Manual.

From the Rocky Scripts Manual you can find information about the Coating Visibility Wizard, Ma-
terial Wizard, General Scripts, and the focus of this Tutorial, the Calibration Suite.

2.2.17. HELP – PREPOST SCRIPTING MANUAL

For further information about Rocky scripting, we suggest searching the Rocky PrePost Scripting
Manual.

To access it, from the Rocky Help menu, point to Manuals, and then click PrePost Scripting
Manual.

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To see the list of classes and methods available for scripting, navigate through the Class Reference
section.

Tip:

Additional classes and methods for scripting are available in the Rocky code. To access
these, from the Rocky Tools menu, enable the Python Shell panel.

2.2.18. HELP – USER MANUAL

This completes Part B of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access these options, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

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2.2.19. CONCLUSION
Rocky was used to verify the repose profile of particles in order to calculate the Static Angle of Repose.

Note:

Even though this tutorial involves running only one SAOR test, other simulations must be
done in order to calibrate the particle model in full.

During this tutorial, it was possible to:

• Use a Cross Plot to manually measure the angles

• Use the PrePost Script panel to run a Python script that measured the angles automatically

• Find and make use of the PrePost Scripting Manual for modifying Python scripts

What's Next?

• Now that you understand the basics on how to set up a script, you are ready to move on to Part
C and learn about PrePost Scripts and the Rocky Scheduler.

2.3. Part C: Batch-Processing

2.3.1. OBJECTIVES
The purpose of this tutorial is to study how the Static Angle of Repose (SAOR) behaves using different
Static and Dynamic Frictions for the particle-particle interactions.

Note:

This tutorial can be continued from either Part A or Part B.

You will learn how to:

• Save the project setup parameters without the simulation results

• Use input variables to parameterize materials interactions properties

• Schedule scripts to run automatically before and after the simulation

• Use the Rocky Scheduler to run multiple Rocky projects in sequence

And you will use these features:

• Input Variables

• PrePost Scripts

• Materials Interactions

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 Part C: Batch-Processing

• Rocky Scheduler program

2.3.2. PROJECT
1. If you completed either Part A or Part B of this tutorial, ensure that one of those Rocky projects
are open. (Part C can continue from where either of these parts left off.)

2. If you did not complete Part A nor Part B, ensure that you have downloaded and extracted the
dem_tut02_files folder, and then open the tutorial_02_pre-processing.rocky project.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or later.
If you have an earlier version of Rocky, please upgrade Rocky to the latest version, or
complete the setup portion of Part A from scratch.

Note:

You do not need to process the simulation for this particular tutorial.

2.3.3. SAVE COPIES WITHOUT RESULTS

In this tutorial, we want to vary the Static and Dynamic Friction coefficients of the particle-particle
interactions and see how that changes the particle behavior.

To do this without losing the prior simulation's results, we will create multiple, similar projects and
change only the two friction values in the new ones.

To avoid recreating these new projects from scratch, we will create a copy of the current project's
setup parameters, and specifically NOT copy its results.

1. From the File menu, click Save project as....

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2. From the Save Options dialog, click Save as a New Project WITHOUT copying Simulation
Results, and then click OK.

We want to save the project in another folder so the current Results folder won't be rewritten by
the newly created project results.

We also want to name this new file in a specific way so that it is easier to track multiple copies later.

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To accomplish these tasks, do the following:

1. From the Save File window, create a new folder named friction_03 in the same location as the
original project (as shown).

2. Double-click the new folder to open it.

3. Enter tutorial_02_friction_03.rocky for the File name, and then click Save.

2.3.4. INPUT VARIABLES

For this tutorial, a single Input Variable will be set up for both Static Friction and Dynamic Friction.

For Input variables, you can enter into the parameter text fields a variable name on its own.

In this way, you can create dynamic relationships between parameters, and then change and update
placeholder values quickly.

1. First, enable the Expressions/Variables panel by selecting it from the Tools menu.

2. From the Expressions/Variables panel, ensure the Input tab is selected, and then click the Add
button.

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3. From the Variable Name dialog, set the Variable Name as ff (as shown), and then click OK.

4. From the entry row that was added, double-click the Value, and then set it to 0.3 (as shown).

2.3.5. INTERACTIONS BETWEEN MATERIALS

To assign the variable to the interaction properties, do the following:

1. From the Data panel, click Materials. From the Data Editors panel, select Materials Interactions
tab. The editable parameters are displayed.

2. From the left drop-down list, select Default Particles, and from the right drop-down list, select
Default Particles.

3. Type ff in the Static Friction text box.

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When you click away from this field, the Static Friction field will show the value you set for the
ff variable (as shown).

4. Repeat for the Dynamic Friction.

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Whenever you use an Input Variable to define a parameter, the Expressions/Variables panel lists
which variables were used for which parameters (as shown).

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2.3.6. SCHEDULED PREPOST SCRIPTS

Next, we want the script we used in Part B to automatically run and save the output files right after
the simulation is processed.

To do so, we must save it in the Project scripts tab, and then define it as a Post Script:

• Scripts saved to the Project scripts tab are eligible for running automatically in two ways:

– Right BEFORE the simulation starts processing (Pre Script)

– Right AFTER the simulation is done processing (Post Script)

• This is done through the PrePost Script sub-entity on the Data panel under the Solver entity (as
shown).

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In this way, you can further automate your setup and post-processing tasks, especially when running
many similar kinds of cases.

2.3.7. PROJECT SCRIPTS

Now, we will set this script to automatically run right after the simulation completes.

1. Ensure the PrePost Scripts panel is still shown. (From the Tools menu, select PrePost Scripts.)

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 Part C: Batch-Processing

2. From the PrePost Scripts panel, select the Project scripts tab and then click the Open Scripts
Directory button (as shown).

3. From the dem_tut02_files folder you downloaded earlier, find the script folder, and then copy
and paste the provided script script_calibration_SAOR.py into the directory you just opened.

The new script will appear in the PrePost Script panel on the Project scripts tab (as shown).

2.3.8. POST SCRIPT

Now, we will set this script to automatically run right after the simulation completes.

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1. From the Data panel, expand the Solver entity and then select PrePost Scripts.

2. From the Data Editors panel, within the Run after simulation list, enable the Calibration 1:
SAOR checkbox (as shown).

3. Save the project.

2.3.9. SAVE COPIES WITHOUT RESULTS

For this tutorial, we will run three cases in addition to the original case that we analyzed in Part B.

We already have the first copy defined (tutorial_02_friction_03.rocky), so let's now use it to create
two more project copies.

1. In the same root folder where you saved your original project, create another new folder named
friction_05.

2. In Rocky, from the File menu, click Save project as....

3. From the Save File dialog, find and open the new folder you just created, enter the File name
as tutorial_02_friction_05.rocky, and then click Save.

4. From within this new copy, change Input Variable ff to 0.5 (as shown).

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 Part C: Batch-Processing

5. From the File menu, click Save project.

6. Repeat this process to create another folder called Friction_09 containing another project copy
named tutorial_02_friction_09.rockywith both friction values (ff) changed to 0.9. (Remember
to save your changes.)

• You should now have the following three additional cases saved:

– tutorial_02_friction_03.rocky: both frictions equal to 0.3

– tutorial_02_friction_05.rocky: both frictions equal to 0.5

– tutorial_02_friction_09.rocky: both frictions equal to 0.9

7. Once these cases are created, you can close Rocky.

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We will now evaluate how the Angles of Repose behave in these cases.

• For the original case we analyzed in Part B, we already have the Angles of Repose results.

– If you did not complete Part B, you can review the results in the original_case_results folder,
inside the dem_tut02_files you extracted previously.

• We will get the results for these three new cases by running them through the Rocky Scheduler.

1. Open Rocky Scheduler 2025 R1.

2.3.10. ROCKY SCHEDULER

Rocky Scheduler is a separate program that allows multiple simulation projects (Jobs) to be processed
on specific hardware configurations (Resources) sequentially (one after the other) without having to
use the Rocky User Interface (UI).

In this way, several cases can be run automatically without your constant involvement.

Each Job requires at least one Resource to be assigned to it.

Each Resource used will require one instance of the Rocky solver for processing.

Therefore, you are limited by your Rocky license as to how many Jobs you can process at once.

• Most users have a single-instance Rocky license and can therefore process only one job at a time.

• Only those users with unnumbered Rocky licenses can process many jobs at the same time.

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For this tutorial, we will add only one CPU resource and run the jobs sequentially.

1. To set up the Scheduler, from the Resources section, click the Add Resource (green plus) button.

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• The Add Resource dialog appears with a Resource Type list that shows all the resources
available on your computer (as shown).

2. From the Add Resource dialog, set the Resource Type to CPU, enter the Caption and Number
of Processors (as shown), and then click OK.

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The resource you defined now appears on the Resources list.

Next, we will add our three projects to the Jobs queue:

1. From the Jobs section, click the Add Job (green plus) button (as shown).

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2. From the Choose Rocky project files dialog, select the tutorial_02_friction_03.rocky project
we created previously, and then click Open.

3. Repeat this process for the tutorial_02_friction_05.rocky and tutorial_02_friction_09.rocky

files. The three new jobs appear in the queue (as shown).

To assign the same Resource to all three jobs, do the following:

1. Multi-select all three jobs. (Hold the Shift or Ctrl key and then click each job to select it).

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 Part C: Batch-Processing

2. While holding the Shift key, double-click the last selected of the three Click to assign resources
bars (as shown).

3. From the Assign Resources dialog, enable the Main Resource checkbox, and then click OK (as
shown).

All three jobs should now list the same Resource (as shown).

Now, let's start the simulations:

1. Click the Start Scheduler button (as shown).

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The first job in the list begins processing. You can view the Progress column to see the processing
status and percentage complete.

• RUNNING shows when the file is currently being processed (as shown).

• QUEUED shows if the file is not currently processing but will once the resource is available.

• PAUSED shows when the file has been partially run but isn't processing currently.

• FINISHED shows when processing is complete.

• ERROR shows when processing can't continue due to errors.

Tip:

To filter the Jobs list by progress type, click the button you want from the Show list (as
shown). To turn off a filter, click the same button again.

2.3.11. RESULTS
After all three jobs are done processing, all three Progress columns show FINISHED 100% and you
will see that the Results folders were created inside of each of the created project folders.

Inside each folder there will be two files: angles.json and experiment_data_points.csv.

The angles.json files are shown below.

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 Part C: Batch-Processing

Note:

When using the Scheduler, the figures are not generated. If you want to generate the figures,
you must open each project in Rocky and run the script again.

From the values provided in the four .json files, a graph can be built outside of Rocky (as shown).

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Note:

• For sake of simplicity, the particle count of this tutorial was reduced.

• Thus, the angle values you end up with in your real-world projects may vary significantly
from the ones shown in this tutorial.

• This is because the angles of repose calculations are very sensitive to the system resolu-
tion (proportion between the particle size and the cylinder size).

• In order to achieve more accurate results you should increase particle count (reduce the
particle size or increase the cylinder size).

2.3.12. HELP – USER MANUAL

This completes Part C of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click the User
Manual.

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 Part C: Batch-Processing

2.3.13. CONCLUSION
The Rocky Scheduler was used to run multiple projects and analyze how the SAOR values vary when
different particle-particle Dynamic and Static Frictions are used.

Note:

Other simulations must be completed in order to calibrate the particle model in full.

During this tutorial, it was possible to:

• Save the project without results to create a copy of just the setup parameters.

• Use Input Variables to parameterize materials interactions properties.

• Add a Project Script and then use PrePost Scripts to run it automatically after processing completes.

• Use the Rocky Scheduler to run multiple projects sequentially.

What's Next?

• If you completed this tutorial successfully, then you are ready to move onto the next tutorial.

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Chapter 3: Tutorial - Vibrating Screen
(Part A) Learn how to define vibration motions for a vibrating screen.

(Part B) Analyze the screening efficiency of a vibrating screen using User Processes, custom Curves, and
Time Plot functions.

(Part C) Learn how to make optimization analysis via optiSLang for the screening efficiency of a vibrating
screen.

3.1. Part A: Project Setup and Processing

3.1.1. OBJECTIVES
The main purpose of this tutorial is to learn how to define vibration motions for a vibrating screen.

You will learn how to:

• Define a vibration motion

• Define a particle size distribution (PSD)

• Set custom domain limits

• Extend the simulation duration

And you will use these features:

• Motion Frames

3.1.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

• If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

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3.1.3. GEOMETRY

The geometry in this tutorial is composed of:

• Vibrating Screen

In the tutorial directory, the .stl file can be found.

3.1.4. PROJECT CREATION

To begin the steps for this tutorial, do the following:

1. Download the dem_tut03_files.zip file .

2. Unzip dem_tut03_files.zip to your working directory.

3. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in your Program Menu or use the desktop shortcut.)

4. From the Rocky program, click the New Project button, or from the File menu, click New Project
(Ctrl+N).

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 Part A: Project Setup and Processing

3.1.5. PROJECT DETAILS

The Study entity covers the first step of the simulation setup. The purpose is to define any useful
information for the project.

1. From the Data panel, click Study.

2. From the Data Editors panel, edit the parameters (as shown).

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3.1.6. PHYSICS DEFINITION

For the Physics step, we will set the model for rolling resistance and then lower the numerical
softening factor to reduce the simulation time.

Important:

Lowering the numerical softening factor may cause excessive overlaps between particles
and between particles and boundaries.

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 Part A: Project Setup and Processing

1. From the Data panel, select Physics.

2. From the Data Editors panel, select the Momentum sub-tab, and then set the Rolling Resistance
Model and the Numerical Softening Factor.

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3.1.7. GEOMETRY IMPORT

For the Geometries step, we will import a Wall geometry file in .stl format, and then add a Surface
to associate later with an Inlet and release particles into the domain.

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 Part A: Project Setup and Processing

1. From the Data panel, right-click Geometries and then click Import Wall.

2. From the Select file to import dialog, navigate to the dem_tut03_files folder that you previously
downloaded, find the geometry folder, select the following file, and then click Open:

• screen.stl

3. (Save your project now if you have not already done so).

4. From the Import File Info dialog, select "mm" as Import Unit, ensure that the option Convert Y
and Z axes is cleared, and then click OK.

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3.1.8. VIEW GEOMETRY

After importing the geometry, you can visualize it in a new 3D View window. To do this:

1. Drag and drop the Geometries entity from the Data panel onto the Workspace. A new 3D View
window appears showing the geometries that you imported (as shown).

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 Part A: Project Setup and Processing

3.1.9. INLET SURFACE DEFINITION

Now let's define the inlet Surface:

1. From the Data panel, right-click Geometries and then click Create Rectangular Surface.

2. Under Geometries, select the newly created Rectangular Surface <01> entry.

3. From the Data Editors panel, on the Rectangular Surface sub-tab, define: Center Coordinates
and Width (as shown).

3.1.10. OUTLET SURFACE DEFINITION

Let's define the outlet Surface:

1. From the Data panel, right-click Geometries and then click Create Rectangular Surface.

2. Under Geometries, select the newly created Rectangular Surface <02> entry.

3. From the Data Editors panel, on the Rectangular Surface sub-tab, define: Center Coordinates
and Width (as shown).

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3.1.11. BOUNDARY MOVEMENT

For the Motion Frames step, a single-axis Periodic Translation (Vibration) movement (shown in
yellow) will be defined within a Motion Frame and then applied to the screen geometry.

In order to evaluate the separation efficiency of the screen, the following items will be compared:

• Feed Material: Particle mass that was originally injected.

• Screen Overflow: Particle mass that doesn't make it through the vibrating screen.

• Screen Underflow: Particle mass that makes it through the vibrating screen.

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 Part A: Project Setup and Processing

3.1.12. MOTION FRAME – VIBRATION AND PENDULUM

As their names suggest, Periodic Translation (Vibration) and Periodic Rotation (Pendulum) motions
are periodic versions of the Translation and Rotation motions, respectively.

When either of these Type of motions are selected, the following options are available:

• Initial Frequency: The number of oscillations per second at the Start Time.

• Initial Amplitude: The maximum displacement in the specified Direction at the Start Time.

• Direction: The vibration orientation along the Frame's local axis.

• Initial Phase: The point at which the motion begins along the sine wave.

• Frequency Variation: Frequency's rate of change.

• Amplitude Variation: Amplitude's rate of change.

These last three items define the oscillation of the periodic motion, as explained below.

3.1.13. PERIODIC MOTION – OSCILLATION

For periodic motion types like Vibration and Pendulum, oscillation is defined by specifying the
Amplitude, Frequency, and Initial Phase values for a sine wave.

• The Amplitude defines how far the displacement will be, with reference to the original point.

• The Frequency defines how many complete cycles will occur per second.

• The point at which the motion begins along the sine wave is defined by the Initial Phase value.

To help illustrate how these settings work in practice, let's look at some Initial Phase examples.

3.1.14. PERIODIC MOTION – INITIAL PHASE

An Initial Phase value of zero degrees (default) causes the sine wave to start at the center point of
the motion.

For a simple linear oscillation, the frame would move in the following manner:

1. Frame movement starts at the defined position

2. Frame moves in the specified direction until it reaches the maximum amplitude

3. Frame reverses the direction past the starting position and continues until it reaches the minimum
amplitude

4. Frame completes the cycle by reversing direction again back to the original position

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Changing the Initial Phase will change the motion start position. A value of 90 degrees moves the
starting point of the sine wave to the maximum amplitude.

In the simple linear oscillation example:

1. Frame movement starts its motion at the maximum amplitude along the specified direction

2. Frame reverses the direction, past the starting position and continues until it reaches the minimum
amplitude

3. Frame reverses again to end its cycle at the maximum amplitude position

3.1.15. VIBRATION OSCILLATION

For this tutorial, we want the vibration motion to have its sine wave start at the center point of the
motion (Initial Phase = 0).

We also want a constant oscillation so will be setting both our Frequency and Amplitude Variation
to 0.

3.1.16. MOTION FRAME

Follow the directions to define this motion in a new Motion Frame.

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 Part A: Project Setup and Processing

1. To add a new Motion Frame, from the Data panel, right-click Motion Frames, and then select
Create Motion Frame.

2. To visualize the newly created Frame, click Motion Frames and then in the Data Editors panel,
click Preview. A new window will appear showing the geometry and the created Frame.

You can adjust the Frame axes size by changing the Default axes size parameter.

3. From the Data panel, select the new Frame <01> entry.

4. From the Data Editors panel, select the Frame tab and then define:

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• Name: Vibration Motion

• Relative Orientation | Angle and Vector

5. To create a new motion using this Frame, click the green plus button (Add Motion).

6. Define Type and Direction.

7. Set Initial Frequency and Initial Amplitude as variables for further optimization analysis (Part
C).

Tip:

In Rocky, parameters can be set as variables by typing names instead of numerical

values in parameters value fields. In this case, a dialog box for setting up variable

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 Part A: Project Setup and Processing

Initial Value automatically shows up. Then, you can check (and edit) your variables
values on the Expressions/Variables panel through Input tab.

• Define Initial Frequency as Frequency, click outside the field, and define Initial Value as 15
Hz

• Define Initial Amplitude as Amplitude, with Initial Value of 0.02 m

• From Menu | Tools, enable the Expressions/Variables panel and check your Variables values
in the Input tab

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Once the Motion Frame has been created, it must be assigned to the screen.

1. From the Data panel under Geometries, select screen.

2. From the Data Editors panel, on the Wall tab, select Vibration Motion from the Motion Frame
drop-down list (as shown).

For this tutorial, since the geometry has a motion with displacement assigned, the movement can
be previewed using the Motion Preview window.

The Time toolbar can be used to play the preview. The yellow color of the slider indicates that the
simulation has not yet been processed.

3.1.17. MATERIAL DEFINITION

For the Materials step, only two materials will be used: one for all the geometry parts (Default
Boundary) and another for the particles (Default Particle).

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 Part A: Project Setup and Processing

For this tutorial, keep all the values as default for these Materials.

3.1.18. INTERACTIONS BETWEEN MATERIALS

To set the interaction properties, do the following:

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1. From the Data panel, select Materials. From the Data Editors panel, select the Materials Inter-
actions tab.

2. From the Data Editors panel, from the left drop-down list, select Default Particles, and from the
right drop-down list, select one of its pairs: Default Particles or Default Boundary.

3. Leave all values as they were set by default, according to the combinations shown below.

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 Part A: Project Setup and Processing

3.1.19. PARTICLE GROUP DEFINITION

For the Particles step, we will create a new sphere-shaped particle group that includes a range of
different sizes, and some added rolling resistance.

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1. From the Data panel, right-click Particles, and then select Create Particle.

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 Part A: Project Setup and Processing

A new particle group is created under Particles.

2. Select the newly created Particle <01> entry to edit its parameters.

3.1.20. PARTICLE SIZE DISTRIBUTION (PSD)

In Rocky, you are able to set a Particle Size Distribution (PSD) for your particles, instead of a single
constant value.

Based on sieve analysis, Rocky uses discrete Size ranges and Cumulative % mass of the particles
smaller than the specified size.

For this tutorial, the PSD shown below is used, where the smallest particle is 0.1 m, and the largest
particle 0.5 m.

From the PSD provided, 50% of the sample mass is below 0.15 m.

3.1.21. PARTICLE GROUP DEFINITION

To set up the particles for this simulation, follow these steps:

1. From the Data Editors panel, in the Size sub-tab, click the Add button (green plus) until you
have five size definition rows.

2. For each row, define Size and Cumulative % (as shown).

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3. From the Movement sub-tab, define Rolling Resistance (as shown).

4. To visualize the newly created particle, click View. A new Particles Details window will appear
showing the (transparent) particle geometry, its geometric center (yellow dot), and its center of
mass (blue dot).

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 Part A: Project Setup and Processing

Note:

The geometric center and center of mass coincide when the density is uniform
throughout the particle.

3.1.22. MASS FLOW DEFINITION

For the Inlets and Outlets step, we will create a Particle Inlet and Outlet, then associate them to the
Surfaces we created before.

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1. From the Data panel, right-click Inlets and Outlets and then select Create Particle Inlet.

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 Part A: Project Setup and Processing

A new entry is created under Inlets and Outlets.

2. Select the newly created Particle Inlet <01> entry and then from the Data Editors panel, modify
the parameters as specified below.

3. From the main Particle Inlet tab, select Rectangular Surface <01> from the Entry Point drop-
down list (as shown).

4. From the Particles sub-tab, do the following:

a. Click the green plus button to add a new particle mass flow rate row.

b. From the Particle column, select the Particle <01> from the drop-down list and then define
the Mass Flow Rate in t/h (as shown).

5. From the Time sub-tab, define the Stop time (as shown).

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6. From the Data panel, right-click Inlets and Outlets and then select Create Outlet.

A new entry is created under Inlets and Outlets.

7. Select the newly created Outlet <01> entry and then from the Data Editors panel, modify the
parameters as specified below.

8. From the main Outlet tab, select Rectangular Surface <02> from the Exit Point drop-down list
(as shown).

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 Part A: Project Setup and Processing

3.1.23. DOMAIN SETTINGS

For the Domain Settings step, we will define a custom boundary box that exceeds the limits of our
geometry.

Doing this will allow Rocky to compute the particles in the Overflow region.

• By default, Rocky automatically creates a domain box based upon the boundary limits of the Geo-
metries.

• Any particle that leaves those limits is eliminated from the simulation (as shown).

• These default settings would not work for the vibrating screen as the particles would be eliminated
before they reached the Overflow area.

To set the boundary limits:

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1. From the Data panel, click Domain Settings.

2. From the Data Editors panel, clear the Use Boundary Limits checkbox, and then define the Min
and Max Values (as shown).

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 Part A: Project Setup and Processing

3.1.24. SOLVER DEFINITION

Now let's set up the solver:

1. From the Data panel, click Solver and then from the Data Editors panel, select the Solver tab.

2. From the Time sub-tab, define the: Simulation Duration, and Output Settings: Time Interval.

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Tip:

Saving the outputs more frequently will provide a better view of the vibrations.

3. From the General sub-tab, set the Simulation Target and the Number of Processors (as shown).

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 Part A: Project Setup and Processing

Note:

For this tutorial in particular, ensure that you set the Number of Processors to 1. This
will ensure the simulation results are consistent for later post-processing.

4. Click Start.

The Simulation Summary screen appears. This window will disappear on its own, then processing
begins.

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Tip:

You can also review this information from the Solver | Summary tab.

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 Part A: Project Setup and Processing

3.1.25. SIMULATION

To visualize the simulation as it's processing:

1. From the Window menu, click New 3D View.

2. Click the Refresh button (or use the Auto Refresh checkbox) to see the results during processing.

Particle states can be viewed in real time as the simulation progresses.

The speed of the simulation depends upon various factors such as:

• The particle shape and the number of vertices used to define the shape

• Number of contacts in the simulation domain at any time

• Number of mesh elements used to define the geometry

• Smallest particle size and material stiffness

• Frequency of file output

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3.1.26. EXTEND SIMULATION DURATION

After the simulation is finished processing, it will be clear that the original 10 s Simulation Duration
was not long enough for this analysis.

• This can be seen by observing that many particles did not leave the domain at the end of the
simulation.

1. In order to extend the simulation without losing the results, from the Solver tab, click Extend.

2. From the Extend Simulation window, define the Extend by value (as shown), and then click OK.

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 Part A: Project Setup and Processing

3. On the Data Editors panel, from the Solver | Time tab, note that the Simulation Duration has
been updated to show the new total time of 25 s.

4. Click Resume to continue processing.

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3.1.27. SOLVER DEFINITION

The Simulation Summary screen appears again. This will disappear on its own, then processing re-
sumes.

3.1.28. SCREEN VERIFICATION

At the end of the newly extended simulation (25 s), no particles are left on the screen (as shown).

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 Part A: Project Setup and Processing

This means that we are ready to analyze the results of the simulation.

3.1.29. HELP – USER MANUAL

This completes Part A of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

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3.1.30. CONCLUSION
Rocky was used to set up and process a vibrating screen simulation.

During this tutorial, it was possible to:

• Use Motion Frames to set up a vibration motion

• Define a particle size distribution (PSD)

• Set custom domain limits

• Extend the simulation duration

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

3.2. Part B: Post-Processing

3.2.1. OBJECTIVES
The main purpose of this tutorial is to learn how to analyze the screening efficiency of a vibrating
screen using User Processes, custom Curves, and Time Plot functions. We will continue from where
we left off in Part A.

You will learn how to:

• Employ User Processes to define different analysis areas

• Create a custom Curve

• Create a Time Plot table view and add custom functions

• View and customize a Histogram

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 Part B: Post-Processing

And you will use these features:

• User Processes, including:

– Cube

– Property

– Particles Time Selection

• Curves

• Time Plot

• Histogram

3.2.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

• If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

3.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that project is open in Rocky. (Part B will continue
from where Part A left off.)

2. If you did not complete the project from Part A, do all of the following:

a. Download the dem_tut03_files.zip file .

b. Unzip dem_tut03_files.zip to your working directory.

c. Open Rocky 2025 R1.

d. From the Rocky program, click the Open Project button, find the tutorial_03_input_files
folder, then from the tutorial_03_A_pre-processing folder, open the tutorial_03_A_pre-
processing.rocky file.

From the Rocky program, click the Open Project button, find the dem_tut03_files folder,
then from the tutorial_03_A_pre-processing folder, open the tutorial_03_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Simulation toolbar, click the Start button.)

3. Once the simulation is finished processing, you are ready to start Part B.

3.2.4. POST PROCESSING – SCREEN EFFICIENCY

In this tutorial, the Screen Efficiency will be calculated. As the sieve size of the screen mesh is 180
mm:

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• Particles with diameter >180 mm will be considered Oversized Particles

• Particles with diameter <180 mm will be considered Undersized Particles

Screen Efficiency based on Oversized:

(3.1)

Screen Efficiency based on Undersized:

(3.2)

Total Screen Efficiency:

(3.3)

To calculate the necessary variables, the particles must be sampled using the following User Processes:

• Cubes: One to account for the particles that went through the screen (Underflow) and a second
to account for the particles that did not go through the screen (Overflow).

• Filters: Three, to filter the particles by size in separate locations.

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3.2.5. USER PROCESS – CUBE

The first User Process will be a Cube. To create it, follow these steps:

1. From the Data panel, right-click Particles, point to Processes, and then select Cube.

2. From the Data Editors panel, ensure that the Cube tab is selected and then change the Name
to Underflow and use the values shown in the image below to define the Center, Magnitude,
Orientation | Method and Rotation.

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To create the second Cube, do the following:

1. From the Data panel, under User Processes right-click the Underflow User Process, and then
select Duplicate.

2. A new Underflow <01> entry appears with the same values you entered earlier.

3. For this new Cube entry, change the Name to Overflow and use the values shown in the image
for Center and Magnitude (as shown).

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 Part B: Post-Processing

At this point in the tutorial, when you select one of the Cubes in the Data panel, the 3D View should
show the cubes in blue.

3.2.6. USER PROCESS – FILTER

To finish the sample creation, both the particles that are fed and the ones that end up in the Overflow
cube must be divided based upon the size. (This is not necessary for particles in the Undersized cube
since all sieved particles are below 180 mm.)

To create these size filters, the Filter User Process will be used with the following three processes:

• Undersized in Feed: Created from Particles with a Particle Size filter smaller than 180 mm.

• Oversized in Feed: Created from Particles with a Particle Size filter larger than 180 mm.

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• Oversized in Overflow: Created from Overflow with a Particle Size filter larger than 180 mm.

To set up the Filter User Processes:

1. Right-click Particles, point to Processes, and then select Filter.

A new Filter <01> entry is created beneath Underflow.

2. For this new entry, change the Name to Undersized in Feed and use the values shown in the
image for Property, Type and Maximum value.

3. For the second Filter, right-click Undersized in Feed in Data panel, and then select Duplicate.
A new Undersized in Feed <01> entry appears with the same values you set earlier.

4. For this new process, change the Name to Oversized in Feed and use the values shown in the
image for Minimum value and Maximum value.

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 Part B: Post-Processing

5. For the third Filter, right-click Overflow (Cube), point to Processes, and then select Filter. A new
Filter <01> entry appears.

6. For this one, change the Name to Oversized in Overflow and use the values shown in the image
for Filter, Type, Minimum value, and Maximum value.

Please take a moment to verify that each of the three Filter User Processes matches the settings in
the images below.

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3.2.7. INCLUDING REMOVED PARTICLES

To correctly evaluate the screen efficiency, all the mass that passed through the screen and the mass
that remained above the screen need to be accounted for.

Rocky has two different ways to include the particles that crossed the boundary limits:

• Custom Curves: Curves can be customized in Rocky to include time functions and advanced curves
based upon multiple Properties.

• Particles Time Selection: A time filter can be used to include all the particles that were present
in a specific sample for a given time frame.

For this tutorial, the Custom Curves will be used to calculate the screen efficiency and the Particles
Time Selection will be used to compare the PSD in the Feed and in the Overflow areas.

3.2.8. CUSTOM CURVES

A Custom Curve created for either the Particles or Geometries will be available for all the associated
User Processes within this project and for any future Rocky projects done on this computer as well.

To create a custom curve for this tutorial:

1. From the Data panel, select Particles.

2. From the Data Editors panel, on the Curves tab, select the Add new custom curve icon (as
shown).

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 Part B: Post-Processing

3. From the Add new window that appears, enter the Name and Output unit (as shown).

4. Under Inputs, you must select all the curves that will be used to define the new Custom Curve.
In this case, select Particles Mass Flow In, which accounts the mass flow that enters a region at
a given time.

5. Click OK.

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The Custom Curves window appears with the new Curve selected.

The function we will use for this Total Mass In curve is the cumsum(), which returns the cumulative
sum of the selected variable over time.

The available Variables are listed below Expression, along with their Association and Unit.

Continue defining the Curve as follows:

1. In the Expression field, enter the shown expression to calculate the sum of the mass of particles
that got into the domain in the desired unit (kg).

2. Click OK.

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 Part B: Post-Processing

The new Total Mass In (Custom) Curve is now available in the Curves tab, under custom.

Tip:

If your Curve does not appear in the Curves tab immediately, select another item in the
Data panel and then come back to this tab to refresh it.

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Note that this custom curve will be available for any other User Process that was created based upon
the Particles entity. It will also be available for any future Rocky projects that you run on this computer.

To visualize the curves, we'll now create a Time Plot:

1. From the Window menu, click New Time Plot (or click Ctrl + T)

2. From the Data panel, under User Processes, select Underflow.

3. From the Data Editors panel, on the Curves tab, drag and drop the Total Mass In (Custom)
curve over the grid.

Note:

Due to the calculations involved, it may take a few minutes for the data to display.

Tip:

To ensure that the curves appear in the right order, it is best to wait for one curve to
finish processing before adding the next one.

4. One-by-one, also drag-and-drop the Total Mass In (Custom) curve from the Curves tab for each
of the following User Processes:

Note:

It is important to follow this order.

a. Oversized in Overflow

b. Undersized in Feed

c. Oversized in Feed

The Time Plot should now show four data sets (as shown).

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 Part B: Post-Processing

Note:

The order that you add the curves affects the column order of the Table tab (shown
below).

5. For further optimization analysis (Part C), select the Output tab of Expressions/Variables panel
(enabled in Part A), and drag and drop the same four curves (Total Mass In (Custom) for Under-
flow, Oversized in Overflow, Undersized in Feed and Oversized in Feed User Processes) into
the Output Variables field.

6. Note that for every Output Variable, the default settings consider the maximum values for the
curves, that match the last output values.

7. One by one, Edit the Output Variables (click ) and define the Name for each one accordingly:

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Tip:

The steps 5 to 7 allow and facilitate optimization analysis using optiSLang (Part
C).

3.2.9. TABLE VIEW

Rocky allows you to use a Table view to create Formulas in the Time Plot.

1. To switch to this view, from the top left of the Time Plot window, click the Table tab.

Please take a moment to ensure that data in the Element row matches the column order of the
screenshot. The three efficiencies will be calculated based upon this order.

1. To define each formula, click Add Formula, and then from the Add Expression window, fill in
the Curve Caption and Curve Expression values as shown below.

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 Part B: Post-Processing

2. In the Add Expression window, define all three equations as shown below. Keep in mind that
the column order matters, so ensure the EU and EO are correctly defined in the order specified.

(3.4)

(3.5)

(3.6)

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3.2.10. POST PROCESSING – SCREEN EFFICIENCY

From the Table tab, it is possible to evaluate the screening efficiency by viewing the data at the very
end of the table:

• EU = 0.690725

• EO = 1

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 Part B: Post-Processing

• E = EU * EO = 0.690725

Note:

The values you end up with in your project may vary slightly from the ones shown in this
Tutorial.

Achieving 1 (max value) on the undersized efficiency (Eu) means that every undersized particle inputted
went through the sieve as desired.

• In this case, EU = 0.690725, which means that not all of the Undersized particles passed through
the screen. Looking at the 3D View, we can see that many smaller particles exited with the bigger
particles in the Overflow area.

• An adjustment in vibration may improve the screening efficiency, as may a screen redesign.

Achieving 1 (max value) on the oversized efficiency (Eo) means that all the oversized particles inputted
moved over the Screen and into the Overflow area as desired (this case).

3.2.11. PARTICLES TIME SELECTION

The Particles Time Selection is a powerful tool to sample the particles based upon the simulation
time.

The first Particles Time Selection will be created for the whole domain, so this should be created
for the Particles entity.

1. From the Data panel, right-click Particles, point to Processes, and then select Particles Time
Selection. A new Particles Time Selection <01> entity appears.

2. From the Data Editors panel, select the Time Selection tab.

3. Change the Name to PSD_Feed and to include the entire time range, from the Domain Range
drop-down list, select All.

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Repeat the same procedure for the Overflow Cube.

1. From the Data panel, right-click Overflow, point to Processes, and then select Particles Time
Selection.

2. From the Data Editors panel, select the Time Selection tab, and then change the Name to
PSD_Overflow.

3. From the Domain Range drop-down list, select All (as shown).

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 Part B: Post-Processing

Please take a moment to verify that both Particles Time Selections match the settings in the images.

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3.2.12. HISTOGRAM
Histograms are used to create bar plots showing Properties values and their distribution among
the selected samples in a given Output.

In this tutorial we will use a Histogram to compare the PSD of the Feed with the PSD of the Overflow.

1. To create a Histogram, from the Window menu, select New Histogram (or use the shortcut
Ctrl+H).

2. From the Data panel, select PSD_Feed.

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 Part B: Post-Processing

3. From the Data Editors panel, select the Properties tab, and then drag and drop Particle Size
onto the Histogram window.

4. Repeat this process to include on the Histogram the Particle Size property for the PSD_Overflow
process.

The results are shown below.

1. The default settings provide a plot that is difficult to analyze. To improve the analysis, click the
Configure histogram icon at the top left of the Histogram window.

The Configure Histogram window appears.

The cumulative PSD distribution plot is linear with the mass plotted between the specified sizes.

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1. To reproduce this plot, select the distribution Weight, increase the Number of Bins, and activate
both Cumulative Bins and Percent Values (as shown).

2. The axes limits can be specified by selecting Particle Size (under Properties) and then changing
the Limits to User Defined (as shown).

3. Specify the Min and Max values (as shown), and then click OK.

3.2.13. PSD HISTOGRAM

Compared to the default settings, the reconfigured Histogram better illustrates how different the
PSDs are before and after the sieve.

The PSD from Feed (green bars) shows a higher percentage of mass in the smaller sizes.

It can also be seen that particles smaller than the screen aperture have left the screen from the
Overflow area.

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3.2.14. HELP – USER MANUAL

This completes Part B of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this option, from the main Toolbar click Help, point to Manuals, and then click the User
Manual option.

3.2.15. CONCLUSIONS
Rocky was used to analyze the screening efficiency of the vibrating screen simulation we created in
Part A.

During this tutorial, it was possible to:

• Use the Cube, Filter, and Particles Time Selection User Processes to calculate particle screening
efficiencies

• Create a custom Curve

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• Plot data in a Time Plot and use the Table view to add custom functions

• Use a Histogram to plot and compare the efficiency results

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part C
and optimize this project with optiSLang.

3.3. Part C: Post-Processing – Optimization

3.3.1. OBJECTIVES
The main purpose of this tutorial is to learn how to make optimization analysis via optiSLang for the
screening efficiency of a vibrating screen. We will continue from where we left off in Part B.

You will learn how to:

• Set up an optiSLang project for optimization of a Rocky project

• Define criteria variables

• Set parameter ranges

And you will use this feature:

• optiSLang Optimization wizard

3.3.2. PREREQUISITES
To complete this tutorial, you are required to have on your machine both of the following:

• (1) A license of Ansys optiSLang 2025 R1.

• (2) A license of Rocky 2025 R1 or later.

• (3) Tutorial 03 project folder with Part A and B data already processed.

Important:

If you skipped Part A and used the already set up tutorial_03_A_pre-pro-

cessing.rocky project file for going through Part B, you will have to follow step 7
from Section 3.1.15 (Part A) in order to create Rocky Inputs for optimization analyses.
If you went through Part A step by step, you are ready to start Part C.

Important:

This tutorial assumes that you are already familiar with the following programs and re-
sources:

• The Ansys optiSLang platform.

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 Part C: Post-Processing – Optimization

• Rocky user interface (UI) and project workflow.

– If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic intro-
duction about Rocky usage before beginning this tutorial.

3.3.3. PROJECT CREATION

When running any analysis in optiSLang, some files are created inside the project folder. As a good
practice, you might have a folder containing only your Tutorial 03 Rocky files (.rocky file and .rocky.files
folder) as your project directory to start with the optiSLang project creation.

To begin the steps for the optiSLang project creation, do the following:

1. Open optiSLang 2025 R1.

2. From the optiSLang New Project field, select Guided to start the project setup.

3. From the Solver Wizard window, select Ansys Rocky.

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Tutorial - Vibrating Screen

4. From the Select project file dialog, go to your project directory and select your Tutorial 03 project
file.

After selecting the Rocky project, a new window will show up to select a python script (automat-
ically created by optiSLang) to export Rocky results.

5. From the Choose Rocky script to export results., select the brand new export_rocky_outputs.py
that is in your project directory and click Open.

Rocky opens with the selected project loaded and will save a copy without results, asking if you
want to delete the results.

6. Click Yes to complete the Wizard setup (project closes).

7. From the optiSLang menu, click Save current project button , and from the Save Project
dialog, select your project directory, define the File name as tutorial_03_optimization and click
Save.

Your project Schematic in optiSLang should now look like the image:

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 Part C: Post-Processing – Optimization

And your project directory should look similar to the image below.

3.3.4. OPTIMIZATION SETUP – PARAMETRIZE INPUTS

Many analyses can be done in optiSLang through its Wizards, which guide the user in order to facil-
itate the project setup. In this tutorial, we are going to use the Optimization wizard to start our
Rocky project optimization setup.

Tip:

You can access the Wizards panel through the optiSLang user interface, in the top
right corner of the window.

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Follow the steps below to configure optimization settings.

1. From the Wizards panel, drag and drop the Optimization wizard onto the Parametric solver
system box in the project Schematic.

The Optimization Wizard dialog box shows up to Parametrize Inputs.

Note:

optiSLang loads Rocky inputs that we defined as variables in Part A of this tutorial.

2. Set the Range for both parameters according to the following image and click Next >:

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 Part C: Post-Processing – Optimization

Note that optiSLang considers the inputs limit values to define the design points that will be processed
posteriorly in Rocky. In this case, Frequency will be varied from 10 Hz to 20 Hz, and Amplitude will
vary from 0.014 m to 0.026 m, for example.

3.3.5. OPTIMIZATION SETUP – CRITERIA

In the Criteria step of the wizard, you can define new variables using Rocky inputs and outputs, and
even performing mathematical operations between them. In this step you can also define an Objective
to optimize the response you want from your Rocky simulation.

For this step, we want to define the screen efficiency (defined in Rocky in Part B) as a Variable in
optiSLang and set an Objective for it. For this, follow the steps and the image shown.

1. On the Criteria | Create new field, click three times in the Variable button and one time in
Objective button.

2. Define the Name and Expression for each new Variable.

Note:

This process is similar to the one done in the Table of the Time Plot in Rocky,
in Part B.

3. Define the Expression and Criterion for the objective in order to maximize the screen effi-
ciency.

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4. Click Next > to continue setting your optimization project.

3.3.6. OPTIMIZATION SETUP – OPTIMIZATION METHOD

In the Optimization method step, you can set parameters to define how optiSLang will process the
simulations with the evaluated design points. To get specific information about these calculations,
check the optiSLang documentation.

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 Part C: Post-Processing – Optimization

For this tutorial, we will define the maximum number of simulations to be processed and let the
other parameters as default.

1. Define the Maximum number of design evaluations and click Next >.

2. On Additional options, you can choose to visualize the postprocessing during the optimization
processing or when it finishes. For this tutorial purposes, we only need to visualize it on ter-
mination, so you might let the settings as default and click Finish.

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Your project Schematic should now look similar to the image below.

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 Part C: Post-Processing – Optimization

3.3.7. OPTIMIZATION SETUP – RUN

After passing through every section of the wizard, we are ready to run the optimization case.

1. In the top left corner of the optiSLang user interface, click the Run button to run the
optimization analysis.

Note:

For each design point evaluated, Rocky opens to set the Amplitude and Fre-
quency values and process the simulation.

You can check the progress of your analysis in optiSLang user interface.

When the algorithm finishes running the analysis, a post-processing window opens automatically. If
you reopen your project, you can access the same data by double-clicking Postprocessing in the
project Schematic.

3.3.8. OPTIMIZATION ANALYSIS – RESULTS

By default, optiSLang shows four post-processing result panels (as shown): History, Response values,
Design parameter and Criteria data.

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Each one of these panels will be detailed below.

1. History

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 Part C: Post-Processing – Optimization

This panel shows the evolution of the objective through different combinations of Amplitude and
Frequency (design points). It also indicates in which design point the solution obtains the best
results.

Note:

You can click on each (design) point in the plot and see its results in the other
panels. By default, the selected one is the best for optimization purposes.

2. Response values

This panel shows the resulting values of each Rocky Output Variable for the selected design point
in the first panel.

3. Design parameter

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This panel shows the values of Rocky Input Variables (Amplitude and Frequecy) for the selected
design point.

4. Criteria data

This panel shows the numerical values of the variables defined in the Criteria step of the Optim-
ization wizard for the selected design point.

Note:

The optimization project brought an improvement in screen efficiency if compared

to what was observed in Part B, from 0.69 to 0.98.

Note:

Your results may vary slightly from the ones presented in this tutorial.

3.3.9. HELP – ANSYS LEARNING HUB

This completes Part C of this tutorial.

For further information on any topic presented, we suggest completing the optiSLang courses available
at Ansys Innovation Space (AIS) and Ansys Learning Hub (ALH).

3.3.10. CONCLUSIONS
Ansys optiSLang was used to optimize the screening efficiency of the vibrating screen simulation we
created in Part A and post-processed in Part B.

During this tutorial, it was possible to:

• Create a coupled project using Rocky and optiSLang

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 Part C: Post-Processing – Optimization

• Use the Optimization wizard

• Parametrize and define range of analysis for Rocky variables

• Define and analyze an Objective to guide optimization process

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 4: Tutorial - SAG Mill
(Part A) Learn how to set up and process a simulation that modifies the surface of geometries to show
the effects of wear.

(Part B) Learn how to visualize the wear modification to the surface of the geometry, add particle tra-
jectories, and analyze properties derived from contacts.

(Part C) Learn how to analyze the energy balance of the system by using particle energies and particle
energy spectra data.

4.1. Part A: Project Setup and Processing

4.1.1. OBJECTIVES
The main purposes of this tutorial are to:

• Learn how to set up and process a simulation that modifies the surface of geometries to show the
effects of wear (Parts A and B).

• Learn how to analyze the energy balance of the system (Part C).

The scenario considered is that of a semi-autogenous grinding (SAG) mill, which is a rotating machine
that contains steel balls and ore.

• SAG mills are used in the mining industry to grind ore particles into smaller pieces. To save pro-
cessing time, only a slice of the mill will be simulated.

You will learn how to:

• Collect collision statistics, particle energies, and energy spectra data

• Define a rotation motion

• Model surface wear, and properly mesh geometries

• Add a custom Material type

• Define a Volumetric Inlet for particles

• Turn on the collection of Contacts data

• Define periodic domains

And you will use these features:

• Modules

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• Motion Frames

• Surface Wear Modification Model

• Cartesian Periodic Domains

4.1.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

• If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

Tip:

If you are unsure which version of Rocky you have, ask your IT department, or contact
Rocky Support for assistance.

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 Part A: Project Setup and Processing

4.1.3. GEOMETRY

The geometry in this tutorial is composed of:

• Mill slice

In the tutorial directory the .stl file can be found.

4.1.4. PROJECT CREATION

To start the tutorial, you have to create a new project:

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1. Download the dem_tut04_files.zip file .

2. Unzip dem_tut04_files.zip to your working directory.

3. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop shortcut.)

4. From the Rocky program, click the New Project button, or from the File menu, click New Project
(Ctrl+N).

4.1.5. PROJECT DETAILS

The Study entity covers the first step of the simulation setup. The purpose is to define any useful
information for the project.

1. From the Data panel, click Study 01.

2. From the Data Editors panel, enter the project information.

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 Part A: Project Setup and Processing

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4.1.6. PHYSICS DEFINITION

For the Physics step, we will be lowering the softening factor to reduce simulation time, and will also
set a rolling resistance model.

Important:

Lowering the softening factor may cause excessive overlaps between particles and between
particles and boundaries.

1. From the Data panel, select Physics.

2. From the Data Editors panel, select the Momentum sub-tab, and then set the Rolling Resistance
Model and change the Numerical Softening Factor.

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 Part A: Project Setup and Processing

4.1.7. MODULES DEFINITION

For the Modules step, we will be turning on the collection of some additional data.

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But before we take these steps, it is necessary to understand more about Modules:

• In Rocky, Modules refer to separate pieces of code that add in discrete features or functionality
within your project.

• By having the state of (most of ) these Modules be off by default, calculations that you may not
require are avoided, which saves processing time and reduces file size.

• But it also means that if you want to use of a Module, you must remember to turn it on during
your simulation setup.

• In addition, some Modules add new options within other parts of the Rocky setup so it is important
that you turn on your Modules before setting up the rest of your project.

It is also important to understand that some Module settings will override similar default settings
in the Rocky UI.

Tip:

To find out what models or settings are affected by a Module, you can view the Affected
Simulation Entities information on the Module's Info tab.

There are several Modules provided by default in Rocky. (Listed on next slides.)

You may also have access to other custom Modules that are not included with Rocky by default.

• Custom Modules are installed via zip file from the Ready-to-use Modules page.

• After installation, they will appear in Rocky on the Data Editors panel for Modules.

Tip:

You can make your own custom Modules by using Rocky's Solver SDK functionality. (See
the Rocky Solver SDK Manual and the Tutorial 23 for details.)

When working with Modules, it is important to realize that:

• Default Modules are defined in the User and Technical Manuals, which can be found from the Rocky
Help | Manuals menu.

• Custom Modules have their own documentation that can be found in the Rocky Module Manual.

4.1.8. DEFAULT MODULES

The following fourteen Modules are available by default in Rocky:

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• Boundary Collision Statistics: Enables the collection of boundary-related collision (with particles)
data, such as collision frequency, intensities, and impact velocities.

Note:

We will enable this module within this tutorial.

• CFD Coupling Particle Statistics: Enables the collection of particle-fluid interactions, such as drag,
lift, and virtual mass forces.

• Contacts Energy Spectra: Enables the collection of collision-based energy values during the simu-
lation and the resulting data is categorized by the contact pair (particle group and/or geometry).

Note:

We will enable this module within this tutorial.

• Contacts Overlap Monitor: Checks each contact pair (particle-particle or particle-boundary) for
the amount that they overlapped the percentage of which is determined by the size of the smallest
particle in the contact pair and raises a message in the Simulation Log panel if an overlap exceeds
any of the three warning levels you define.

Note:

By default, this module is always enabled.

• Inter-group Collision Statistics: Enables the collection of energy dissipation data for each particle-
particle and particle-boundary pair.

Note:

We will enable this module within this tutorial.

• Inter-particle Collision Statistics: Enables the collection of particle-related collision data between
all particles in the simulation.

Note:

We will enable this module within this tutorial.

• Intra-particle Collision Statistics: Enables the particle-related collision data affecting the surfaces
of a particular particle set.

• Joint Statistics: Enables the collection of data for Joints when present in the simulation.

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• Move CFD Cells (Beta): Enables the use of larger CFD timesteps, resulting in improved performance
and a stable solution.

• Particle Instantaneous Energies: Enables the calculation of the kinetic and potential energies of
each individual particle in the simulation.

• Note:

We will enable this module within this tutorial.

• Particles Energy Spectra: Enables the collection of energy values during the simulation that are
related only to particles, and the resulting data is classified by size and particle group.

Note:

We will enable this module within this tutorial.

• SPH Boundary Interaction Statistics: Enables the collection of boundary-related collision (with
fluid) data, such as forces, torque and power.

• SPH Density Monitor: Monitors the density values associated to the SPH elements during a simu-
lation and issues possible related warnings.

Note:

By default, this module is always enabled.

• SPH Freeze Outside Region: Enables you to save calculation resources and drastically speed up
processing as a result by freezing the SPH elements that are outside from all the Regions of inIterest
and then disabling them from contact calculation.

• SPH HTC Calculator: Enables the estimation of heat transfer coefficient.

• SPH Mass Flow Rate: Enables the measure of fluid flow rate through a surface.

• SPH-DEM Interaction Statistics: Enables the collection of fluid-particle interaction data, such as
forces, torque and heat transfer.

4.1.9. MODULES DEFINITION

To enable the modules for this tutorial, do the following:

1. From the Data panel, select Modules.

2. From the Data Editors panel, under Modules enable the following checkboxes:

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For this tutorial, we are primarily interested in the power- and energy-related data that will be col-
lected by these Modules.

To save processing power and space, we can limit our collections to only the kinds of data we need.

Note:

This applies only to the five Collision Statistics and Energy Spectra modules we enabled;
it is not possible to limit the data collection for Particle Instantaneous Energies.

Let's start by defining what data we want for Boundary Collision Statistics:

1. From the Data panel, under Modules, select Boundary Collision Statistics.

2. From the Data Editors panel, enable the Intensities checkbox (as shown).

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Note:

With Intensities enabled, Rocky will collect the average dissipation and impact power
values measured by each individual geometry triangle. This can be useful for analyzing
impact wear or power draw.

Continue with the remaining two statistics modules:

1. From the Data panel, under Modules, select Inter-group Collision Statistics.

2. From the Data Editors panel, enable the Energy Dissipation checkbox (as shown).

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Note:

With Energy Dissipation enabled, Rocky will collect the energy dissipation values of
the collisions recorded for each particle-particle and particle-boundary pair in the sim-
ulation.

3. From the Data panel, under Modules, select Inter-particle Collision Statistics.

4. From the Data Editors panel, enable the Power checkbox (as shown).

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Note:

With Power enabled, Rocky will collect the dissipation, impact and shear power values
resulting from the collisions recorded for each individual whole particle or fragment,
during an output timestep.

4.1.10. ENERGY SPECTRA

In Rocky, you can use a Breakage Model to simulate the breakage behavior of your particles. For our
SAG Mill case, this would be useful information to analyze.

However, breakage models can increase both the computational cost and the processing length of
your simulation.

With this in mind, Rocky offers a less costly and faster way to analyze breakage called Energy Spectra,
which has the following features:

• Collects energy statistics based upon the following two gathering methods:

– Particle based: Energy is gathered per particle type and size.

– Contact based: Energy is gathered per contact pair (particle and/or geometry) and size.

• Enables you to limit your data collection in the following ways:

– By the type of energy you want to collect: Dissipation, Impact, and/or Shear.

– By the particle groups and/or geometries you want to participate in the collection.

Collecting these kinds of energy statistics can help with the prediction of breakage and attrition rates
for continuous processes such as grinding mills.

In Rocky, energy spectra is defined via two separate modules.

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For each module, you can set the following:

• What type of Energy collection you want.

• Number of Bins: Defines the resolution of the resulting energy curves. The higher the number of
bins, the better the resolution.

• Minimum and Maximum Energy (or Specific Energy): Defines the left and right limits of the res-
ulting Curves Energy (or Specific Energy) axis.

• Start Time and Time Delay After Release: Defines at what point in the simulation the data is
collected.

After defining the parameter on the module itself, there are module-specific parameters enabled on
the particle group and/or geometries involved in the simulation.

These additional parameters define the entity as participating in the energy spectra collection or not.

4.1.11. MODULES DEFINITION

Let's continue to set up our modules by defining Contacts Energy Spectra:

1. From the Data panel, under Modules, select Contacts Energy Spectra.

2. From the Data Editors panel, enable all three Energy checkboxes (as shown), and then define all
of the following (as shown):

a. Start Time

b. Time Delay After Release

c. Number of Bins

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Repeat similar steps for the Particles Energy Spectra module:

1. From the Data panel, under Modules, select Particles Energy Spectra.

2. From the Data Editors panel, enable all three Energy checkboxes (as shown), and then define all
of the following (as shown):

a. Start Time

b. Time Delay After Release

c. Number Of Bins

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4.1.12. MODULE-SPECIFIC PARAMETERS

Both of the Energy Spectra modules and the Inter-group Collisions Statistics module enable addi-
tional parameters in other parts of the UI.

For each item listed below, you can determine whether it will participate in the type of collection
specified:

• Each wall component.

• Each particle group.

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Note:

Geometry and particle group setup will be covered later in this tutorial. However, as these
module-specific settings are all enabled by default, we will leave them as-is for this tutorial
unless specified.

4.1.13. GEOMETRY IMPORT

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For the Geometries step, we will import the geometry file in .stl format:

1. From the Data panel, right-click Geometries and then click Import Wall.

2. From the Select file to import dialog, navigate to the dem_tut04_files folder that you previously
downloaded, find the geometry folder, and then select the following file:

• Mill.stl

3. Click Open.

4. (Save your project now if you have not already done so.)

5. From the Import File Info dialog, select "mm" as Import Unit, ensure that the option Convert Y
and Z axes is cleared (unchecked), and then click OK.

4.1.14. VIEW GEOMETRY – CHANGE PROJECTION

After the geometry is imported, you can view the results in a 3D View window:

1. Clicking and drag the Geometries entity from the Data panel to the Workspace. A new 3D View
window appears showing the geometries that you imported.

Tip:

Because this geometry is aligned with the global Z-direction (no surfaces on the XY
plane), it can be hard to see in the 3D View window if your projection is set to Ortho-
gonal instead of perspective.

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2. Change the projection shown in the 3D View window by doing the following:

a. Select the 3D View window.

b. From the Camera Visualization toolbar, click the Change projection:Default/Orthogonal

button until it shows the Default (perspective) projection.

Your geometry should appear clearly now.

4.1.15. GEOMETRY BEST PRACTICE

You may notice that we have imported only the internal surface of the 3D geometry.

This method is a best practice for mill slice simulations where you are also calculating surface wear
modification.

Doing so helps you avoid any potential wear issues that can occur to triangles (shown in green) that
are parallel and coincident to the plane used by the periodic domain.

Important:

If you do choose to include these triangles, Rocky will disable them by default. However,
this disabling can itself lead to other wear calculation instabilities. Therefore, it is best to
just avoid including these triangles in the first place.

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4.1.16. MOTION FRAME

For the Motion Frames step, we will create two separate Rotation motions within the same Frame,
and will then apply this Motion Frame to the mill slice geometry.

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The two separate motions represent the following actions:

• Mill start: This includes 3 s of constant Angular Acceleration.

• Steady state rotation: Starting from 3 s onward, a constant Angular Velocity will be applied,
which allows the mill to reach a steady state by 5 s.

When the motion Type of Rotation is selected, the following options are available:

• Initial Angular Velocity: The angular velocity at the Start Time.

• Angular Acceleration: The rate of change of the angular velocity.

To add a new Motion Frame, do the following:

1. From the Data panel, right-click Motion Frames and then select Create Motion Frame.

2. From the Data panel, under Motion Frames, select the newly added Frame <01> entry.

3. From the Data Editors panel, on the Frame tab, define the parameters as shown next.

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4.1.17. MOTION FRAME – ROTATION (MILL START)

To define the first motion frame:

1. Set the Name: Rotation Motion.

2. To create a new motion using this Frame, click the green plus button (Add motion).

3. Define the Stop Time, Type and Angular Acceleration (and units).

Tip:

Because Rocky will automatically translate an entered value based upon the unit you select,
it is best to select the unit first before you enter the value.

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4.1.18. MOTION FRAME – ROTATION (STEADY STATE)

Now let's create a second motion within the same Frame:

1. Click the green plus button (Add motion) once more.

2. Define Start Time, Type and Initial Angular Velocity (and units).

4.1.19. MOTION FRAME

Once the Motion Frame has been created, it must be assigned to the geometry.

1. From the Data panel under Geometries, select Mill.

2. From the Data Editors panel, on the Wall tab, select Rotation Motion from the Motion Frame
drop-down list (as shown).

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4.1.20. MOTION PREVIEW

For this tutorial, since the geometry has a motion with displacement assigned, the movement can
be previewed using the Motion Preview window.

1. From the Data panel, select Motion Frames.

2. From the Data Editors panel, click Preview. A new window will appear showing the geometry
and the created Frame.

Tip:

To better see the frame axes, change the Default axes size parameter (as shown).

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The Time toolbar can be used to play the preview. The yellow color of the slider indicates that the
simulation has not yet been processed.

4.1.21. GEOMETRY DEFINITION – WEAR MODEL

For this tutorial, we will activate the Shear Work Proportionality (Archard's Law) wear model on
the Mill slice.

• This will enable us to visually evaluate the changes to the surface of the geometry due to the pre-
dicted particle contact.

To enable this model, do all of the following:

1. From the Data panel, under Geometries, select the Mill component.

2. From the Data Editors panel, select the Wall | Wear tab, and then define both the Wear Model
and Volume/Shear Work Ratio options.

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4.1.22. GEOMETRY DEFINITION – WEAR AND TRIANGLE SIZE

When analyzing wear, it is very important to set the geometry parameters correctly, especially the
Triangle Size option.

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The number of triangles defines how refined the mesh will be when computing wear (and other
geometry results).

4.1.23. GEOMETRY DEFINITION – WEAR – MESHING

Tips for proper meshing:

• Keep the mesh refined enough to analyze the wear but not so fine that it excessively increases the
computational time.

• Avoid very fine triangles near the lifter tips as this can make the wear unstable.

• To help avoid instabilities, consider doing the following in your CAD program before you import
geometries into Rocky:

– Remove small details and curvatures.

– Fill in any small gaps between components. (For example, make use of the Shrinkwrap feature
in Ansys SpaceClaim.)

• You may also want to mesh your geometries in a program outside of Rocky, and then import the
results.

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4.1.24. CHANGE TRIANGLE SIZE

For this tutorial, we will decrease the triangle size in Rocky to create a more refined mesh.

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To change this value, do the following:

1. Select Mill from the Data panel, and on the Data Editors, from the main Wall tab, select the
Transform sub-tab and then define Triangle Size (as shown).

4.1.25. REFERENCE GEOMETRY

Since the original geometry will be modified by the wear model, we will create a reference geometry
for comparison purposes.

1. From the Data panel, right-click Mill and then select Duplicate. The duplicate will appear as a
new Mill <01> item.

2. Select this new item and then from the Data Editors panel, change the Name to Mill Reference.

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3. Also, increase the Enable Time value. This way, the geometry will be visible during the simulation
but not included in calculations.

4. Finally, from the Modules sub-tab, clear both the checkboxes.

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4.1.26. MATERIAL DEFINITION

For the Materials step, we will create two new Materials:

• One for the ore (Rock Material)

• Another for the grinding media (Steel Material)

The Default Boundary Material will be used for the mill slice geometry.

Note:

The values for this Material will be left as default.

The other two default Materials (Default Particles and Default Belt) will not be used in this tutorial.

To create the new Materials, complete the following instructions:

1. From the Data panel, right-click Materials, and then select Create Solid Material.

2. Repeat this step once more so that you have two new entries. Material <04> and Material <05>
are created under Materials.

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3. Select one of the new Materials and then from the Data Editors panel, change the Name and
Density values. Repeat this step for the second new Material.

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4.1.27. INTERACTION BETWEEN MATERIALS

Now let's set the interaction properties for the materials:

1. Select Materials Interactions in the Data panel.

2. Adjust the parameters for each combination, according to the values shown below.

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3. Let the values as default for the other combinations.

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4.1.28. PARTICLE GROUP DEFINITION

For the Particles step, we will create two new sphere-shaped particle groups with some added rolling
resistance. These will represent the ore and grinding media.

To create the Rock particle group, do the following:

1. From the Data panel, right-click Particles and then select Create Particle. A new particle group
is created under Particles.

2. Select the newly created Particle <01> entry and then from the Data Editors panel, on the main
Particle tab, modify the Name and Material.

3. From the Size sub-tab, click the green plus button (Add) until you have three size distribution
rows. For each row, define the Size (in m) and Cumulative %.

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4. From the Movement sub-tab, define Rolling Resistance.

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5. To visualize the newly created particle, the click the View button. A new Particles Details window
will appear showing the particle geometry.

For the Steel Particles, do the following:

1. Create a second new Particle set by right-clicking Particles and selecting Create Particle.

2. Select this new Particle set, and then from the Data Editors panel, do the following:

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a. On the main Particle tab, define the Name and Material.

b. From the Size sub-tab, define Size.

c. From the Movement sub-tab, define Rolling Resistance.

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4.1.29. PARTICLE INLET – VOLUMETRIC INLET

For the Inlets and Outlets step, we will create a Volumetric Inlet, which enables us to fill a spherical
region with closely packed particles into the simulation all at one time.

When compared with the traditional Particle Inlet method, using Volumetric Inlet has the primary
benefit of ensuring that the particle bed will already be formed in the mill at the start of the simulation.

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When defining a Volumetric Inlet, it is important to understand the following components:

• Seed Coordinate: Location of a point around which layers of particles are built.

• Mass: The target mass of particles that you want built around the Seed Coordinate.

• Bounds: Defines the physical limits by which the particle layers will be constrained.

• The limits must include Box Bounds, which can be defined manually using coordinates, or can be
automatically calculated by Rocky using the limits of one or more imported Geometries that you
select.

• The limits may also include the walls of one or more Geometries within your simulation.

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4.1.30. INLET DEFINITION

For this tutorial, we'll create a Volumetric Inlet constrained only by the mill geometry.

1. From the Data panel, right-click Inlets and Outlets and then select Create Volumetric Inlet.

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A new entry will be created under Inlets and Outlets.

2. Select the newly created Volumetric Inlet <01> entry, and then from the Data Editors panel, on
the Particles sub-tab, click the Add button (green plus) twice to create two entry rows.

3. For each row, select the Particle group name from the drop down list and then define the Mass
in t.

From the Region sub-tab, do the following:

1. Define the Seed Coordinates.

2. From the Geometries list, enable the Mill checkbox.

3. Enable the Use Geometries to Compute checkbox.

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Tip:

You can visualize the Seed Point (blue dot) and geometry bounds (white box) in a 3D
View window.

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4.1.31. CONTACTS COLLECTION

A Contact in Rocky refers to a specific location on a geometry or particle that has experienced a
collision with another particle during the simulation.

Always during processing, Rocky calculates and makes use of Contacts data. But to save file space,
you can choose whether or not to keep it.

For this tutorial, we will enable the collection of the Contacts data so that we can post-process it
later.

1. From the Data panel, select Contacts and then from the Data Editors panel, select the Contacts
tab.

2. Enable the Collect Contacts Data checkbox.

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4.1.32. DOMAIN SETTINGS – PERIODIC

For the Domain Settings step, we will define a Cartesian Periodic Domain to recycle particles that
leave one side of the mill slice back into the simulation from the opposite side.

• By default, Periodic Domain is turned off and Rocky automatically creates a domain box based
upon the Geometries boundary limits.

• Any particle that leaves those limits is eliminated from the simulation.

• These domain settings would not work for the mill slice as all particles would quickly be eliminated
through the open ends of the geometry (as shown).

For this case, we need Rocky to put any particles that leave the mill slice back into the mill slice.

To do this, we will define a Cartesian Periodic Domain at the extreme ends of the mill slice geometry.

By doing so, any particles that leave one side of the mill slice are introduced back into the simulation
from the other side (as shown).

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To define this domain, do to the following:

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1. From the Data panel, click Domain Settings.

2. From the Data Editors panel, set the Periodic Domain Type and the Periodic Direction.

3. Also, ensure the Periodic at Geometry Limits checkbox is enabled.

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Tip:

In order for a periodic Cartesian domain to be representative, the distance between the
Min Coordinate and Max Coordinate values must be at least 2.5 times the width of the
largest particle size.

4.1.33. SOLVER DEFINITION

From the Solver | Time tab, do the following:

1. Define the Simulation Duration.

2. Under Output Frequencies, define Simulation (as shown).

3. Under Wear, set the Start time (as shown).

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1. From the General sub-tab, under Execution, do the following:

a. Select CPU (or GPU/Multi GPU) as Simulation Target.

b. Set the Number of Processors (or Target GPU(s)).

Note:

For this tutorial, CPU will be faster due to the low particle count.

2. Click the Start button.

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Once you click Start, the Simulation Summary window will be displayed.

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Once initialization is complete, this screen will close automatically and Rocky will process your simu-
lation.

Tip:

You can find this information later on the Solver | Summary tab on the Data Editors
panel.

4.1.34. SIMULATION
Click the Refresh button (or use the Auto Refresh checkbox) to see the results in a 3D View window
during processing.

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Particle states can be viewed in real time as the simulation progresses.

The speed of the simulation depends on various factors such as:

• Number of mesh elements used to define the geometry

• Number of contacts in the simulation domain at any time

• Smallest particle size and material stiffness

• The particle shape and the number of vertices used to define the shape

• Frequency of file output

4.1.35. HELP – USER MANUAL

This completes Part A of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

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4.1.36. CONCLUSION
Rocky was used to set up and process a SAG Mill slice simulation that models wear and collects energy
spectra data.

During this tutorial, it was possible to:

• Use Modules to collect collision statistics, particle energies, and energy spectra data.

• Use Motion Frames to set up a rotation motion.

• Define basic surface Wear modification parameters.

• Define a Volumetric Inlet.

• Set Contacts data to be collected during processing.

• Set up a Cartesian Periodic Domain for a mill slice geometry.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

4.2. Part B: Post-Processing (Wear and Contacts Analyses)

4.2.1. OBJECTIVES
The main purposes of this tutorial are to use the results from the mill slice simulation we created in
Part A to learn how to:

• Visualize the wear modification to the surface of the geometry.

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• Visualize particle trajectories and properties derived from contacts.

Note:

We will analyze the particle energies and particle energy spectra data later in Part C.

You will learn how to:

• View Wear modification results

• Export a worn geometry profile to an .stl file

• Display particle trajectories

• Visualize Contacts data

• Define Eulerian Statistics

And you will use these features:

• Rendered Geometry Export

• Custom Properties

• User Processes, including:

– Plane

– Particles Trajectories

– Eulerian Statistics

– Cylinder

4.2.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

• If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

• If you are not sure which Rocky license you have, contact your IT Administrator or Rocky Support
for assistance.

4.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut04_files.zip file .

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b. Unzip dem_tut04_files.zip to your working directory.

c. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut.)

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut04_files folder,
then from the tutorial_04_A_pre-processing folder, open the tutorial_04_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Simulation toolbar, click the Start button.)

4.2.4. WEAR ANALYSIS – COMPARE PROFILES

After processing is complete, the geometry surface will appear to be worn away due to shear contact
with the particles.

Comparing the profiles of the worn geometry with the reference geometry you duplicated in Part A
(as shown) can help you better identify what changed.

Tip:

• To see the reference, rotate the view slightly with your mouse. (In this case, the ortho-
gonal view in the Z-direction is parallel to the reference surface so the reference won't
be visible by default.)

• To hide the particles from the 3D View window, click the eye icon to the right of
Particles in the Data panel.

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4.2.5. WEAR ANALYSIS – RADIAL DISPLACEMENT

Besides comparing the profiles, another way to analyze the effects of wear is by quantifying the radial
displacement of the geometry nodes.

For example, to identify the regions in which the surface wear was most severe, do the following:

1. From the Data panel, select the Mill geometry.

2. From the Data Editors panel, select the Properties tab and then from the upper right corner,
click the Add new custom property button.

3. From the Add new dialog, define the Name and Output unit; from the Inputs box, enable the
checkboxes for Displacement : X and Displacement : Y; and then click OK.

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4. From the Custom Property dialog, enter the Expression (as shown), and then click OK.

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5. From the Properties tab for the Mill geometry, drag-and-drop the newly created Radial Displace-
ment (Custom) property onto the 3D View.

Tip:

Use the Data panel eye icon to hide the Mill Reference geometry from the view.

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You can also analyze the Radial Displacement on a cut plane of the liner profile.

1. From the Data panel, under Geometries, right-click Mill, point to Processes, and then click Plane.

2. From the Data panel, under User Processes, select the new Plane <01> entry.

3. From the Data Editors panel, on the main Plane tab, define the Plane Origin and Orientation
| Angle and Vector (as shown).

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4. From the Coloring tab, expand the Edges section, and then define the Property and Width values
(as shown).

You can view the results in a 3D View window (as shown).

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Tip:

You may need to use the Data panel eye icon to hide the Mill and Mill Reference geo-
metries from the view.

4.2.6. WEAR ANALYSIS – EXPORT WORN GEOMETRY

One final way you can analyze your worn geometry is by exporting it out of Rocky and viewing it in
CAD or other 3D graphics program.

1. From the Time toolbar, select the output for which you want to export worn geometries (as
shown).

2. From the Data panel, under Geometries, right-click Mill, point to Export, and then click Rendered
Geometry (as shown).

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3. From the Select output unit dialog, define the Output Unit (as shown), and then click OK.

4. From the Select target STL file dialog, enter a File name and choose a location to save your file,
and then click Save.

You can now open your saved .stl file in a CAD program, such as Ansys SpaceClaim.

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4.2.7. POST PROCESSING – PARTICLES TRAJECTORY

To analyze the path of the particles, follow these steps:

1. From the Data panel, right-click Particles, point to Processes, and then select Particles Trajectory.

2. From the Data Editors panel, select the Particle Trajectory tab.

3. Define the Number of Intervals.

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4. Set the value for the Starting Timestep by doing the following:

a. From the Time toolbar, select the Output from which you want to begin particle trajectories
(as shown).

b. From the Particle Trajectory tab, click the Update Particles Selection button.

The Timestep you choose now appears in the Starting Timestep field (as shown).

Number of Timesteps: Defines how many future timesteps for which you want to track the particles.
The higher the value, the longer the trajectory will be.

• Keep in mind that the Starting Timestep value you selected from the Time toolbar should be at
least the Number of Timesteps before the end of the simulation.

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Particle Stride: Defines how the particles will be sampled. One out of n particles will be tracked,
where n is the size of the sample. The higher the value, the lower will be the number of trajectories.
If 1 is set, all the particles will be tracked.

Now to visualize the trajectories, we'll show them in a 3D View:

1. From the Data panel under User Processes, right-click Particles Trajectory <01>, point to Show
in new, and then click 3D View.

The default view that appears is not ideal for viewing trajectories for the following reasons:

• It shows Particles, which get in the way of seeing the trajectory vectors.

• It shows the trajectories in black on a black background.

Fix these issues with the view by doing the following:

1. To hide the Particles, from the Data panel, click the eye icon next to Particles.

Note that even if you hid Particles on your first 3D View, you will have to repeat this process for
each new 3D View.

2. To color the trajectories by particle velocity, from the Data Editors panel, select the Coloring tab,
and then under Edges, select the Property type of Absolute Translational Velocity (as shown).

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3. To change the background color, right-click on the 3D View, point to Background color, and
then click White.

4. To change the font color, right-click on the 3D View, point to Font color, and then click Black.

4.2.8. EULERIAN STATISTICS

By using the Eulerian Statistics User Process, discrete Properties can be converted into continuous
values by averaging the values over discretized regions.

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Eulerian Statistics can only be created for a Cube or a Cylinder User Process.

4.2.9. USER PROCESS – CYLINDER

For this tutorial, a Cylinder will be created for this analysis.

1. From the Data panel, right-click Particles, point to Processes, and then select Cylinder.

The Cylinder (and Cube) User Processes can be manually changed using the 3D view, or adjusted
using their parameters. For this case, we'll enter exact values.

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2. From the Data Editors panel, select the Cylinder tab and then enter the Size, Center, Orientation
| Method, Local Angles, and Rotation values (as shown).

4.2.10. EULERIAN STATISTICS

1. From the Data panel under User Processes, right-click the new Cylinder <01> entry, point to
Processes, and then select Eulerian Statistics.

2. From the Data Editors panel, on the Eulerian Statistics tab, enter the Radial, Tangential and
Axial Divisions.

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This will discretize the Cylinder into 36 circular sectors, each one divided in 20 bins in the radial dir-
ection. A single bin is defined in the axial direction, as shown on the following slide.

Note:

You may have to use the Data panel eye icons to hide other data (such as Particles or
Particles Trajectories) that you no longer wish to see.

Once the Eulerian Statistics is created, you can modify which Properties are shown through the
Colorings tab.

1. For example, under Faces select the Property called Volume Fraction.

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 Part B: Post-Processing (Wear and Contacts Analyses)

Note:

The values you end up with are time dependent, and the ones you get in your project
may vary slightly from the ones shown in this Tutorial.

4.2.11. VISUALIZE EULERIAN STATISTICS

To better visualize the data, you can adjust the limits of the color scale.

1. From the 3D View window, right-click the color scale, point to Limits options, and then select
User Defined.

2. From the Coloring tab on the Data Editors panel, set the Limits values.

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To see a continuous display of the plotted Properties, you can also enable Shown on Node? option.

1. From the Data panel, under User Processes, select Eulerian Statistics <01> and then from the
Data Editors panel, select the Coloring tab.

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2. Under Faces, enable the Show on Node? checkbox (as shown).

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4.2.12. PLOT EULERIAN STATISTICS

On the Properties tab for Eulerian Statistics, several new properties are available to plot on the
Eulerian bins, including:

• Static properties

• Transformed Velocity properties

• Transient properties

• Stress Component properties

Important:

Important: To be able to analyze Stress Components, you must have enabled the
Collect Contacts Data checkbox from Contacts entity on Data panel prior to processing
your simulation.

– As a reminder, we took this step in Part A, so this data should be now available to analyze.

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4.2.13. HELP – USER MANUAL

This completes Part B of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

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To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

4.2.14. CONCLUSION
Rocky was used to post-process a simulation of a rotating SAG Mill slice.

During this tutorial, it was possible to:

• Visualize surface Wear modifications, and compare them to the original wall geometry.

• Export the worn geometries to an .stl file for further analysis outside of Rocky.

• View the Trajectory of the particles within the mill.

• Define a Cylinder User Process.

• Evaluate the particle volume fraction in various regions of the mill slice by using Eulerian Statistics.

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

4.3. Part C: Post-Processing (Energy Analyses)

4.3.1. OBJECTIVES
The purpose of this tutorial is to evaluate the energy balance of the rotating SAG Mill slice simulation
we performed earlier in Part A.

You will learn how to analyze the following Curves:

• Energy Spectra

• Boundary Collision Statistics Power

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 Part C: Post-Processing (Energy Analyses)

• Inter-group Collision Statistics Power

• Particle Instantaneous Energies Energy

And you will use these features:

• Cross Plots

• Custom Curves

• Output Variables

4.3.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

• If this is not the case, please refer to Tutorial 01 Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

• If you are not sure which Rocky license you have, contact your IT Administrator or Rocky Support
for assistance.

4.3.3. OPEN PROJECT

1. If you completed Part A (or Part B) of this tutorial, ensure that Rocky project is open. (Part C will
continue from where either Part A or B left off.)

2. If you did not complete Part A (nor Part B), do all of the following:

a. Download the dem_tut04_files.zip file .

b. Unzip dem_tut04_files.zip to your working directory.

c. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut.)

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut04_files folder,
then from the tutorial_04_A_pre-processing folder, open the tutorial_04_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Simulation toolbar, click the Start button.)

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4.3.4. ENERGY SPECTRA ANALYSES

Size reduction is a very energy-intensive process, representing a major percentage of mineral benefi-
ciation costs.

Although mills have great energy consumption, only a small part of this energy is converted into ac-
tual particle fragmentation.

Because of this, it is crucial to understand how power is consumed during comminution processes
in order to improve grinding efficiency and reduce costs.

One way this can be accomplished in Rocky is by using a tool called Energy Spectra.

Unlike breakage simulations, which require additional computational costs to calculate and visualize
each individual broken fragment, Energy Spectra uses energy statistics of particle collisions to predict
breakage and attrition rates in a graphical format.

This provides answers to breakage questions faster by avoiding the computationally intensive visual-
ization step of the particles actually breaking.

In Energy Spectra plots, the collision data collected during a simulation is classified based on the
energy levels of the individual collisions and then displayed accordingly.

Three types of collision energy can be evaluated using Energy Spectra plots:

• Dissipated energy: The fraction of the mechanical energy of the particle transformed irreversibly
into other forms of energy during a collision.

• Impact energy: The maximum collision energy transferred during the normal loading phase. This
kind of energy is considered in the instantaneous breakage models to evaluate breakage.

• Shear energy: The work done by the tangential contact forces during a collision. This kind of energy
is used in the abrasive wear models.

Depending upon the source of the energy values considered, two types of Energy Spectra plots are
available in Rocky:

• Contacts energy spectra: Energy values are collected collision-wise and are classified by contact
pair (particle and/or geometry).

• Particles energy spectra: Specific energy values are collected particle-wise, and are classified by
size and particle group.

To demonstrate how to evaluate breakage rate using an Energy Spectra curve, consider Cumulative
Specific Power : Impact as it relates to the energy used in the instantaneous breakage models:

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 Part C: Post-Processing (Energy Analyses)

The blue dashed line defines the minimum specific energy for a certain particle to break.

All collisions with specific impact energy higher than this value may lead to breakage. The remaining
collisions do not lead to breakage.

The power consumed that actually promotes particle fragmentation is given by the corresponding
Y-value.

After the simulation is complete, information about Energy Spectra will be available on the Curves
tab for the Particles entity.

1. From the Data panel, select Particles and then from the Data Editors panel, click the Curves
tab.

The new Energy Spectra Curves will be displayed under two separate groups:

• Energy, which shows the Contacts energy spectra energy curves.

• Specific Energy, which shows the Particle energy spectra curves.

Both Energy and Specific Energy are separated into Impact, Shear, and Dissipation energies.

4.3.5. CONTACTS ENERGY SPECTRA

For Energy (Contacts energy spectra), each pair composed of either Particles & Particles or Particles
& Geometries will present a separate Energy Spectra.

Energy Curves are displayed in three ways:

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• Cumulative Power: Displays the sum of all power coming from a collision with energy greater
than a specified energy.

• Power: Displays the time average of energy resulting from all collisions of that type and pair.

• Rate: Displays the mean frequency of collision for that type and pair.

Cumulative sums and averages making use of Cumulative Power, Power, and Rate are computed
from the Energy Spectra Start time (which is defined on the Solver | Energy Spectra tab) to the
current timestep.

4.3.6. PARTICLES ENERGY SPECTRA

For Specific Energy (Particle energy spectra), each Particle set and Particle Size group will present
a separate Energy Spectra.

Specific Energy curves are displayed only as Cumulative Specific Power, which displays the sum
of all specific power coming from a collision with energy greater than a specified energy level.

Cumulative Power is computed from the Energy Spectra Start time (which is defined on the Solver
| Energy Spectra tab) to the current timestep.

To plot the curves, follow these steps:

1. Under Specific Energy : Impact right-click the first Cumulative Specific Power : Impact entry
and then click Show curve in new Plot. (Or click Show curve in selected Plot if a plot is already
created.)

2. A new Cross Plot window appears with the data.

3. Plot the next two Cumulative Specific Power: Impact entries on the same plot so that it contains
all 3 Rock Particles size ranges.

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4. Change the axis display option by right-clicking the grid and then under Axes Layout, choosing
By Quantity.

To edit the scale, do the following:

1. Right-click in the plot area and then select Settings.

2. From the Window Editors panel, select the Axes tab and then from the Axis box, select Specific
Energy : Impact (J/kg).

3. Under Values, ensure Limits are set to Automatic.

4. Under Scale Options, enable the Logarithmic Scale checkbox.

5. Select the last output from the Time Toolbar.

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The resulting plot is shown on the next slide.

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4.3.7. CONTACTS ENERGY SPECTRA

Repeat this same procedure to show Energy : Impact values:

1. In the Data Editors, on the Curves tab under Energy : Impact, you can repeat the same procedures
to create a new Cross Plot showing both the Power: Impact and Cumulative Power : Impact
of the collisions between Rock Particles and Mill (only). (Resulting plot shown.)

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Note:

The Logarithmic Scale is enabled only for the horizontal axis in the plots shown in
these analyses.

Tip:

Add lines to your points by right-clicking a point on the plot and then choosing the
Edit option. From the Edit Curves dialog that appears, choose the line options you
want under Pen Style. Here, Solid Line is selected for both Curves.

2. Also under Energy : Impact, create a new Cross Plot of the Rate : Impact between Rock Particles
and Mill (only). (Resulting plot shown.)

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4.3.8. ENERGY BALANCE ANALYSES

In Rocky, it is possible to analyze how the energy is distributed in the system.

In this tutorial, the energy supplied by the mill is transferred to the particles. Part of this energy is
dissipated and another part is transformed into mechanical energy. The equation below shows the
Energy Balance of this system:
(4.1)

In terms of Power:
(4.2)

Where:

• is the energy supplied by the mill.

• is the dissipated energy.

• is the variation in mechanical energy of the particles.

• is the dissipated power.

• is the power supplied by the mill.

• is the time interval in which the power was applied.

In Rocky, the power supplied by the mill and the mechanical energy variation of the particles are
directly obtained.

The dissipated energy can be obtained directly or by using power curves depending upon how we
want to analyze it.

In this way, we have two equations that can be used to calculate the Energy Balance:
(4.3)

(4.4)

For this tutorial, we will use Output Variables to compute the terms of these equations.

1. From the Tools menu, ensure that Expressions/Variables is enabled.

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2. From the Expressions/Variables panel, select the Output tab (as shown).

4.3.9. ENERGY BALANCE – SUPPLIED POWER

The value can be obtained from the Mill geometry by using the Power Curve.

Note:

This Curve is available only if the Intensities checkbox is enabled on the Boundary Collision
Statistics module prior to processing, which we did in Part A.

1. From the Data panel, select Mill and, from the Data Editors panel, select the Curves tab.

2. Drag-and-drop the Power Curve onto the Output tab of the Expressions/Variables panel.

3. From the Output tab, select the newly added Power entry, and then click the Edit button
(as shown).

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4. From the Edit Properties dialog, enter the Name and Domain Range (as shown), and then click
OK.

The power supplied by the mill during the last timestep is shown in the Output tab.

4.3.10. ENERGY BALANCE – MECHANICAL ENERGY

The value can be obtained from any of the following Particles data:

• Energy Delta Curve

• Energy : Kinetic : Rotational Property

• Energy : Kinetic : Translational Property

• Energy : Potential Property

Note:

These Curves and Properties are available only if the Particles Instantaneous Energies
module is enabled prior to processing, a step which we took in Part A of this tutorial.

For this tutorial, we will use the Energy Delta to compute the Mechanical Energy variation contri-
bution to the energy balance.

The Energy Delta is the variation of the Mechanical Energy in a given timestep.

Since the term that involves the variation of Mechanical Energy is divided by , we can create a
Custom Curve of Energy Delta divided by the Output Frequency (which is ).

To calculate the mechanical energy balance, follow these steps:

1. From the Data panel, select Particles, and then from the Data Editors panel, select the Curves
tab.

2. Under Time, select the Energy Delta Curve, and then click the Add new custom curve button
(as shown).

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3. From the Add new dialog, define the Name and Output Unit, and then click OK (as shown).

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4. From the Custom Curves dialog, enter the Expression, and then click OK (as shown).

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5. From the Data Editors panel, under custom, drag-and-drop the newly created Power (Mechan-
ical Energy) (Custom) Curve onto the Output tab of the Expressions/Variables panel.

6. From the Output tab, select the newly added Power_Mechanical_Energy_Custom_ entry, and

then click the Edit button.

7. From the Edit Properties dialog, enter the Name and Domain Range (as shown), and then click
OK.

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The power transferred to Mechanical Energy during the last output is shown in the Output tab.

Alternate Method:

• You can also calculate the Mechanical Energy by summing up the Energy : Kinetic : Rotational
and Energy : Kinetic : Translational and Energy : Potential properties from Particles in a Custom
Property.

• With the Mechanical Energy calculated, compute its variation from 24.9s to 25.0s and then divide
it by the time variation.

• This should result the same value we've obtained in the previous step.

4.3.11. ENERGY BALANCE – DISSIPATED POWER

can be obtained from the following Particles Properties or Curves:

• Power : Dissipation

Note:

This Property is available only if the Power checkbox is enabled on the Inter-particle
Collision Statistics module prior to processing, a step which we took in Part A of this
tutorial.

• Energy : Dissipation (between pairs of groups)

Note:

This Curve is available only if the Energy Dissipation checkbox is enabled on the Inter-
group Collision Statistics module prior to processing, a step which we took in Part A
of this tutorial.

• Cumulative Power : Dissipation

Cumulative Specific Power : Dissipation

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Power : Dissipation (listed under Energy : Dissipation)

Note:

These Curves are available only if Energy Spectra is enabled prior to processing, a step
which we took in Part A of this tutorial.

For this tutorial, we will estimate in two different ways:

• By Energy : Dissipation (between pairs of groups)

• By Cumulative Power : Dissipation from energy spectra

First, to calculate using Energy : Dissipation (between pairs of groups), do the following:

1. From the Data panel, select Particles, and from the Data Editors panel, select the Curves tab
and click the Add new custom curve button.

2. From the Add new dialog, define the Name and the Output Unit, and then under Inputs, enable
all the Energy : Dissipation Curves between pairs (as shown), and then click OK.

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Tip:

This should involve 5 separate pairs.

3. From the Custom Curves dialog, set the Expression, and then click OK (as shown).

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4. From the Data Editors panel, under custom, drag-and-drop the newly created Dissipated Power
(pairs of groups) (Custom) onto the Output tab of the Expressions/Variables panel.

5. From the Output tab, select the newly added Dissipated_Power_pairs_of_groups_Custom entry,

and then click the Edit button.

6. From the Edit Properties dialog, enter the Name and Domain Range (as shown), and then click
OK.

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The Dissipated Power during the last timestep is shown on the Output tab.

Now, we recall the Energy Balance equation we stated before:

(4.5)

If we compare the values in a spreadsheet, we see that the Energy Balance is satisfied with a difference
of ≈ 0.5%.

Tip:

To analyze the data outside of Rocky, you can copy the values directly out of the Value
column and paste them into a spreadsheet program.

Next we will calculate using the Cumulative Power : Dissipation from Energy Spectra.

As implied earlier, the Energy Spectra curves are temporal averages.

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To compare the dissipated power of the two different methods, instead of using Specific Time as
the Operation on Curve in the Dissipated Power (pairs of groups) Output variable, we will be using
Average from 7 s (Energy Spectra Start) to 25 s (Simulation Duration).

Since the Cumulative Power : Dissipation are cumulative curves, we just have to sum the maximum
value of each pair of groups to obtain the Dissipated Power.

Follow the steps below to compare the dissipated power obtained by the Energy Spectra and the
Inter-group Collision Statistics calculation methods.

1. From the Expressions/Variables panel, in the Output tab, double-click Dissipated Power (pairs
of groups).

2. From the Edit Properties dialog box, set Operation on Curve and Domain Range (as shown).

3. For the Particles entity, from the Data Editors panel, select the Curves tab.

4. Under Energy : Dissipation, multi-select all the Cumulative Power : Dissipation Curves.

5. Drag and drop all five Curves onto the Output tab of the Expressions/Variables panel (resulting
panel shown).

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 Part C: Post-Processing (Energy Analyses)

Note:

It is not necessary to alter these output variables properties, since the default values already
select the maximum value of each curve in the last output.

4.3.12. ENERGY BALANCE ANALYSES

If we compare the values in a spreadsheet, we see that the difference between the two Dissipated
Power calculations is ≈ 1%.

Tips for further exploration:

• To compute the Dissipated Power using the Power : Dissipation property from Particles, sum
the power dissipated for each particle for each timestep and then average the values from 7s until
the end of the simulation.

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• To compute the Dissipated Power using the Cumulative Specific Power : Dissipation Curves,
use the method we used earlier for Cumulative Power : Dissipation but instead, multiply each
Curve by the total particle mass for that size range.

• To compute the Power : Dissipation Curves, use the method we used earlier for Cumulative
Power : Dissipation but instead, sum all the points of the Curve instead of picking only the first
point.

4.3.13. HELP – USER MANUAL

This completes Part C of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

4.3.14. CONCLUSION
Rocky was used to evaluate the energy balance of a rotating SAG Mill slice simulation.

During this tutorial, it was possible to:

• Use a Cross Plot to evaluate Energy Spectra for particles and contacts.

• Use the Output Variables to estimate average values of Power and Energy from the following
sources:

– Boundary Collision Statistics Power Curves

– Inter-group Collision Statistics Power Curves

– Particle Instantaneous Energies Energy Curves

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– Contacts Energy Spectra Curves

– Particles Energy Spectra Curves

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 5: Tutorial - Drop Weight Test
(Part A) Set up and process a Drop Weight Test (DWT) using free body translations and the Ab-T10
breakage model.

(Part B) Learn how to evaluate the PSD and total amount of broken fragments.

5.1. Part A: Project Setup and Processing

5.1.1. OBJECTIVE
The purpose of this tutorial is to set up and process a Drop Weight Test (DWT) and learn how to
change Ab-T10 breakage parameters in order to adjust the particle breakage properties for future
Rocky simulations.

Important:

Even though this tutorial involves running only one drop-weight test, the random nature
of the expected results dictates that the average of many multiple tests should be used
as the basis for any real-life calibrations.

Note:

We will post-process this simulation in Part B.

You will learn how to:

• Create a circular surface

• Define a free body translation motion

• Enable the Ab-T10 breakage model

And you will use these features:

• Motion Frames

• Particle Breakage

5.1.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

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Tutorial - Drop Weight Test

If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

Tip:

If you are unsure which version of Rocky you have, ask your IT department, or contact
Rocky Support for assistance.

5.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Drop Weight

• (2) Anvil

• (3) Walls

In the tutorial directory, the .stl files can be found.

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 Part A: Project Setup and Processing

5.1.4. INTRODUCTION
To help you determine the breakage parameters to use for your simulated material, there are experi-
mental tests that can be done, such as the JK Drop Weight Test (DWT).

The DWT involves releasing a drop weight over a rock sample from a specific height and then observing
the resulting behavior.

By using this method on your real-world material, you can:

• Calculate the mass of fragments that have sizes less than 1/10th of the original size.

• Calculate the impact specific energy.

The results can then be used to calibrate particle parameters in Rocky to achieve similar breakage
results in your simulations.

Important:

Unlike the single run demonstrated in this Tutorial, an average of many multiple
Rocky tests should be used as the basis for any real-life breakage calibrations.

5.1.5. PROJECT CREATION

To start the tutorial, let's create a new project:

1. Download the dem_tut05_files.zip file .

2. Unzip dem_tut05_files.zip to your working directory.

3. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop shortcut.)

4. From the Rocky program, click the New Project button, or from the File menu, click New Project
(Ctrl+N).

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5.1.6. PROJECT DETAILS

The Study entity covers the first step of the simulation setup. The purpose is to define any useful
information for the project.

1. From the Data panel, click Study.

2. From the Data Editors panel, enter the Study Name and other project details (as shown).

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5.1.7. PHYSICS DEFINITION

For the Physics step, from the Gravity tab, you are able to define the gravity components and the
time during which gravity is applied during the simulation.

For this tutorial, we will use the default values (no changes).

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5.1.8. GEOMETRY IMPORT

For the Geometries step, we will import wall geometry files in .stl format.

1. From the Data panel, right-click Geometries and then select Import Wall.

2. From the Select file to import dialog, navigate to the dem_tut05_files folder that you previously
downloaded, find the geometry folder, and then while pressing either the Ctrl or Shift key, multi-
select all of the following files, and then click Open:

• anvil.stl

• dropweight.stl

• wall.stl

3. Save your project now if you have not already done so.

4. From the Import File Info dialog, select "mm" as Import Unit, ensure that the option Convert Y
and Z axes is cleared (unchecked), and then click OK.

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5.1.9. INLET SURFACE DEFINITION

The next step is to define a geometry Surface from which to release particles into the domain.

1. From the Data panel, right-click Geometries and then click Create Circular Surface.

2. Under Geometries, select the newly created Circular Surface <01>.

3. From the Data Editors panel, on the Circular Surface sub-tab, define the Center Coordinates
and Max Radius.

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5.1.10. BOUNDARY MOVEMENT

For this test, the drop weight is raised to a prescribed height and then dropped.

The mass will have a free vertical body motion, since the only force will be the weight force (due to
gravity).

5.1.11. MOTION FRAME

When the motion Type of Free Body Translation or Free Body Rotation is selected, the following
options are available:

• Free Motion Direction: Specifies in which directions the geometry can move due to particle forces,
which is given in the local coordinates of the frame related to the initial frame orientation.

• Free Body Linear Limits and Free Body Angular Limits: Specifies how much the geometry can
move in each direction.

Each Motion Frame has its own orientation reference (coordinate system) upon which its movements
are based.

The current (i.e., instantaneous) orientation is represented in the Motion Preview window by the axes
for the Frame (as shown).

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 Part A: Project Setup and Processing

In this version of Rocky, all Frames use only an implicit local reference, which uses the current orient-
ation of the selected Frame to define the next movement.

In this way, the reference is always moving along with the Frame.

Let's look at an example.

5.1.12. MOTION FRAME – EXAMPLE 1

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In this example, the rail (yellow dotted line) rotates as the Body A rotates (left image).

The frame's orientation rotates together with Body A.

The gravity is set to the +y direction and a force F is applied on the top of Body A.

As the Free Body Rotation is set to the z direction for Body A, it will be allowed to rotate around its
center on the xy plane.

As the Free Body Motion for Body B is set to the y direction, it will be allowed to move along the rail
direction (center image).

The maximum free body limit restricts the displacement of the Body B in the local y direction, keeping
it inside the rail (right image).

5.1.13. MOTION FRAME – EXAMPLE 2

Besides the Frame reference, the orientation of the Frame helps define how the body will behave
when it is in motion.

In this next example, the Motion Frame is oriented so that the y axis points upwards.

With the Free Body Motion set to the y direction and the minimum limit in the y set to -0.3 m, the
geometry will be able to move freely as much as 0.3 m downwards, stopping when it reaches the
bottom.

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5.1.14. MOTION FRAME – EXAMPLE 3

In this next example, the Motion Frame is oriented in the opposite way (the y axis now points
downwards).

If the minimum y limit is still set to -0.3 m and the maximum y limit is set to 0 m, the geometry will
not move, as it can only move 0 m in the positive y direction.

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5.1.15. MOTION FRAME

To define a Motion Frame, do the following:

1. From the Data panel, right-click Motion Frames and then select Create Motion Frame.

2. From the Data panel, select the newly added Frame <01> entry.

Now we'll define the motion for this frame:

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 Part A: Project Setup and Processing

1. From the Data Editors panel, define the Name: Drop Weight Motion.

2. Click the green plus button (Add Motion) to create a motion using this frame.

3. Define Start Time, Type and Motion Direction.

4. Enable the Free Body Linear Limits checkbox.

5. Set the Minimum Y limit to ensure that the dropweight stops at the anvil.

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Once the Motion Frame has been created, it must be assigned to the geometry.

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 Part A: Project Setup and Processing

1. From the Data panel under Geometries, select dropweight.

2. From the Data Editors panel, on the Wall tab, and then select Drop Weight Motion from the
Motion Frame drop-down list.

Note:

Only effects from gravity forces and not effects from particles, which have yet to be
calculated will be displayed for the Free Body Motion in the Motion Preview window.

5.1.16. BOUNDARY SETUP

Once the Free Body Motion is enabled, the mass properties of the moving boundary should be defined.

1. From the Wall tab, select the Mass sub-tab, and then define the Boundary Mass.

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Tip:

If Free Body Rotation was used, it would be needed to specify the moment of inertia to
correctly account for the angular acceleration and velocity.

The drop weight will be raised to a prescribed height, according to the experiment to be reproduced.

1. From the Wall tab, select the Transform sub-tab, and then define Translation.

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5.1.17. MOTION PREVIEW

To visualize the newly created Frame, from the Data panel click Motion Frames and then on the
Data Editors click Preview. A new window will appear showing the geometry and the created Frame.

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Tip:

• To better see all the geometries, enable their Transparency settings from the Geometries
Coloring tab.

• To better see the Frame's axes, increase the Default axes size parameter from the Motion
Frames Data entity.

5.1.18. MATERIAL DEFINITION

For the Materials step, only two materials will be used: one for all geometry parts (Default Boundary)
and another for the particles (Default Particle).

1. For Default Boundary, keep all the values as default.

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2. For Default Particles, change only the Young's Modulus.

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5.1.19. INTERACTION BETWEEN MATERIALS

Now let's check the interaction properties for the materials:

1. From the Data panel, select Materials. From the Data Editors panel, select Materials Interactions
main tab.

2. From the left drop-down list, select Default Particles, and from the right drop-down list, select
one of its pairs: Default Particles or Default Boundary.

3. Check the values. We will use the default ones for this tutorial.

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5.1.20. PARTICLE GROUP DEFINITION

For the Particles step, we will create a new (rock-like) polyhedron-shaped particle group and will
define the Ab-T10 breakage parameters for it.

1. From the Data panel, right-click Particles and then click Create Particle.

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 Part A: Project Setup and Processing

A new particle group is created under Particles.

2. Select the newly created Particle <01> entry.

3. From the Data Editors panel, on the main Particle tab, define the Shape parameter.

4. From the Size sub-tab, define Size.

5. From the Shape sub-tab, define the Superquadric Degree.

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6. To visualize the newly created particle, click View, next to the particle name.

5.1.21. BREAKAGE MODEL

In this simulation, the Ab-T10 Breakage model (Instant Fragmentation) will be enabled.

This model works with any shaped (non-spherical) Solid particle shape that comes with Rocky (Poly-
hedron, Briquette, and Faceted Cylinder).

When this model is enabled, the following settings are available on the Breakage | Criteria sub-tab:

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 Part A: Project Setup and Processing

• Reference Size: The reference size used for measuring the other breakage parameters (experimentally
derived).

• Reference Minimum Specific Energy: The minimum energy that can lead to the breakage of a
reference-sized particle.

• Selection Function Coefficient: A measure of the material hardness (known as S in the breakage
expression discussed below).

• Maximum t10 Value: The maximum mass percentage of particles that can be broken into fragments
below 1/10th of the original particle size (known as M in breakage expression discussed below).

In the mining industry, the two values Maximum t10 Value (M) and Selection Function Coefficient
(S) are normally not used.

Rather, their product M·S (or more commonly seen as A·b) is used. This is because having a separate
breakage probability and product fineness are not as important for understanding the breakage
process in most cases only the combined value.

To calculate A·b [ton/kWh], use the following units and expression:

(5.1)

Where

• [S] = kg/J

• [M] = %

• This relation will be valid for Reference Size equal to 1

Shi, F. N.; Kojovic, T. "Validation of a model for impact breakage incorporating particle size effect",
International Journal of Mineral Processing, 82-3, p. 156-163. 2007.

In addition, the following settings are available on the Breakage | Fragments sub-tab:

• Limits:

– Minimum Absolute Size: Smallest size the particle fragments can be at each breakage incident.

– Minimum Size Ratio: Smallest size the particle fragments can be at each breakage incident, rel-
ative to the parent particle (either a whole particle or a fragment).

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– Minimum Volume Fraction for Fragment Disabling: Defines the minimum volume fraction
that a broken particle (fragment) can have before being considered too small to be included in
calculations. Note: In these cases, the too-small fragments will be removed from the system.

• Distribution model: The type of fragment size distribution used in the model.

5.1.22. PARTICLE GROUP DEFINITION

To define the breakage model for the Particle <01> group, do the following:

1. From the Particle tab, on the Breakage sub-tab, check the Enable Breakage checkbox.

2. From the Criteria sub-sub-tab, define Reference Minimum Specific Energy and Selection
Function Coefficient.

3. From the Fragments sub-sub-tab, define the Minimum Absolute Size.

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5.1.23. MASS FLOW DEFINITION

For the Inlets and Outlets step, we will create a Particle Inlet and then set our inlet as the location
from which we want particles to enter the simulation.

1. From the Data panel, right-click Inlets and Outlets and then select Create Particle Inlet.

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A new entry is created under Inlets and Outlets.

2. Select the newly created Particle Inlet <01> entry and then from the Data Editors panel, modify
the parameters as specified below.

3. From the Entry Point drop-down list, select Circular Surface <01>.

4. From the Particles sub-tab, click the Add (green plus) button to add a new mass flow rate row.

5. From the Particle column, select Particle <01> from the drop-down list and then define the Mass
Flow Rate in t/h.

Note:

For this simulation, the small Mass Flow Rate combined with the small injection time
limits the inlet to a single particle only, which is the minimum amount that Rocky can
release.

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 Part A: Project Setup and Processing

6. From the Time sub-tab, enter the Stop time.

5.1.24. SOLVER DEFINITION

Now let's set up the solver:

1. From the Data panel, click Solver and then from the Data Editors panel, select the Solver tab.

2. From the Time sub-tab, define the: Simulation Duration, and Output Frequencies: Simulation.

Note:

The smaller Output Frequency will help us to better visualize the particle breaking.

3. Under Breakage, define also the Start and Delay after Release values (as shown).

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4. From the General sub-tab, under Execution, select CPU (or GPU/Multi GPU) as Simulation Target,
and then set the Number of Processors (or Target GPU(s)).

5. Click Start.

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5.1.25. SOLVER DEFINITION

Once you click Start, the Simulation Summary window will be displayed.

Once initialization is complete, this screen will close automatically and Rocky will process your simu-
lation.

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Tip:

You can also review this information from the Solver | Summary tab.

5.1.26. SIMULATION
To visualize the simulation as it's processing:

1. From the Window menu, click New 3D View.

Tip:

Hide or make Transparent the wall geometry to better visualize the particle.

2. Click the Refresh button (or use the Auto Refresh checkbox) to see the results during processing.

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The speed of the simulation depends on various factors such as:

• Number of mesh elements used to define the geometry

• Number of contacts in the simulation domain at any time

• Smallest particle size and material stiffness

• The particle shape and the number of vertices used to define the shape

• Frequency of file output

5.1.27. HELP – USER MANUAL

This completes Part A of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

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Tutorial - Drop Weight Test

5.1.28. CONCLUSION
Rocky was used to simulate a single-particle Drop Weight Test (DWT) breakage experiment.

Note:

The average of many multiple tests should be used as the basis for any real-life calibra-
tions.

During this tutorial, it was possible to:

• Create a circular Inlet.

• Use Motion Frames to set up a freely translating motion.

• Define basic Ab-T10 Breakage Model parameters for a Polyhedron-shaped particle.

What's Next?

• Now that you have set up and processed this simulation, you are ready to move on to Part B and
post-process this project.

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 Part B: Post-Processing

5.2. Part B: Post-Processing

5.2.1. OBJECTIVE
The purpose of this tutorial is to learn how to post-process the Drop Weight Test (DWT) Ab-T10
breakage simulation we set up and ran in Part A.

Note:

Even though Part A of this tutorial involved running only one drop-weight test, the random
nature of the results expected dictates that the average of many multiple tests should
be used as the basis for any real-life calibrations.

You will learn how to:

• Evaluate the Particle Size Distribution (PSD) and total amount of the broken fragments

• Evaluate the free body motion and displacement of the drop weight

And you will use these features:

• Histograms

• Time Plots

• Multi Time Plots

5.2.2. PREREQUISITES
This tutorial assumes that you are already familiar with the Rocky user interface (UI) and with the
project workflow.

If this is not the case, please refer to Tutorial 01 – Transfer Chute for a basic introduction about
Rocky usage before beginning this tutorial.

Tip:

If you are unsure which version of Rocky you have, ask your IT department, or contact
Rocky Support for assistance.

5.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut05_files.zip file .

b. Unzip dem_tut05_files.zip to your working directory.

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Tutorial - Drop Weight Test

c. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut.)

d. From the Rocky program, click the Open Project button, find the dem_tut05_files folder,
then from the tutorial_05_A_pre-processing folder, open the tutorial_05_A_pre-pro-
cessing.rocky file.

3. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

5.2.4. HISTOGRAM
To evaluate the fragments' Particle Size Distribution (PSD), a Histogram will be used.

1. From the Window menu, click New Histogram, or use the shortcut Ctrl+H.

2. From the Data panel, select Particles and then from the Data Editors panel, from the Properties
tab drag and drop Particle Size within the Histogram window.

3. To improve the resulting plot, from the top left of the Histogram window, click the Configure
histogram icon.

4. From the Configure Histogram dialog, change the parameters and then click OK.

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 Part B: Post-Processing

The resulting histogram is displayed below.

Note:

These values correspond to the last output time (1 s).

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Tutorial - Drop Weight Test

5.2.5. BROKEN PARTICLES

The number of resulting fragments can be evaluated using a Time Plot and creating a curve of the
Fragments Count.

1. From the Window menu, click New Time Plot (Ctrl+T).

2. From the Data panel, select Particles and then from the Data Editors panel, from the Curves
tab drag and drop Fragments Count within the plot. Results are shown.

5.2.6. FREE BODY MOTION ANALYSIS

Lastly, we will use a Multi Time Plot to evaluate both the velocity and the displacement of the drop
weight.

1. From the Window menu, select New Multi Time Plot, or use the shortcut Ctrl+M.

2. From the Data panel, under Motion Frames, select Drop Weight Motion.

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 Part B: Post-Processing

3. From the Data Editors panel, select the Curves tab and then drag and drop Velocity Y within
the Multi Time Plot window.

4. Select Position Y, drag it to the plot area, press and hold the Ctrl key, and then drop it within
the same Multi Time Plot window.

The resulting plots are shown below.

You can open a 3D View to better understand the resulting Multi Time Plot.

Note how the distance L corresponds to the difference between the Free Body Motion Limits and
the final dropweight position.

Also note that it happens because the dropweight stands on a fragment of the particle in the final
output times. Otherwise, the dropweight would fall for 0.3 m (corresponding to the Frame Limits).

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Tutorial - Drop Weight Test

5.2.7. HELP – USER MANUAL

This completes Part B of this tutorial.

For further information on any topic presented, we suggest searching the User Manual, which provides
in-depth descriptions of the tools and parameters.

To access this manual, from the main Toolbar click Help, point to Manuals, and then click User
Manual.

5.2.8. CONCLUSION
Rocky was used to post-process the single-particle Drop Weight Test (DWT) breakage experiment we
ran in Part A.

Note:

The average of many multiple tests should be used as the basis for any real-life calibra-
tions.

During this tutorial, it was possible to:

• Use Time Plots and Histograms to evaluate the resulting Particle Size Distribution (PSD) and
fragment amount generated after breakage.

• Set up a Multi Time Plot to evaluate the free body motion of the drop weight.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to next tutorial.

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Chapter 6: Tutorial - High Pressure Grinding Roll
(HPGR)
(Part A) Set up and process a HPGR simulation using the Boundary Collision Statistics Module, the Ab-
T10 breakage model, and the surface wear modification model. Also define a Motion Frame with a free
body rotation and spring-dashpot moment.

(Part B) Learn how to collect and analyze particle fragments, create a color map for the shear wear, and
calculate and compare the power draw in the rollers.

6.1. Part A: Project Setup and Processing

6.1.1. OBJECTIVE
The main purpose of this tutorial is to set up and process a High Pressure Grinding Roll (HPGR) simu-
lation, with the goal of later (in Part B) analyzing both power and wear data on the boundaries.

• In the mining industry, HPGRs are commonly used to reduce the size of hard materials, such as
rock and ore, for further processing.

You will learn how to:

• Turn on the collection of data related to boundary collisions

• Add a default Feed Conveyor

• Create a Motion Frame with a Free Body Rotation and Spring-Dashpot Moment

• Enable the surface wear modification model

• Set up and define a particle group for breakage modeling

And you will use these features:

• Boundary Collision Statistics Module

• Motion Frames

• Surface Wear Modification Model

• Ab-T10 Breakage Model

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Tutorial - High Pressure Grinding Roll (HPGR)

6.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

6.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Feed Conveyor

• (2) Hopper

• (3) Deflector

• (4) Roll 1

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 Part A: Project Setup and Processing

• (5) Roll 2

For all but the first item, which will come from a conveyor template within Rocky, the .stl files can be
found in the tutorial directory.

6.1.4. PROJECT CREATION

To begin the steps for this tutorial, do the following:

1. Download the dem_tut06_files.zip file .

2. Unzip dem_tut06_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the table that follows to start setting up your Rocky project.

Step Data Entity Editors Location Parameter or Action Settings

A Study 01 Study Study Name HPGR
B Physics Momentum Numerical Softening 0.1 [-]
Factor

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

6.1.5. MODULES DEFINITION

For the Modules step, we will be turning on the collection of some Boundary Collision Statistics
so that we may later analyze Intensities information, such as power and shear.

Tip:

Refer to Tutorial 04 – SAG Mill | Part A: Project Setup and Processing for further details
on Modules.

1. Use the information in the table that follows to define your Modules.

Step Data Entity Editors Location Parameter or Settings

Action
A Modules Modules Boundary Collision (Enabled)
Statistics

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Tutorial - High Pressure Grinding Roll (HPGR)

Step Data Entity Editors Location Parameter or Settings

Action
B Modules Boundary Collision Intensities (Enabled)
Statistics
Boundary
Collision
Statistics

6.1.6. GEOMETRIES

Besides importing the HPGR components, a Feed Conveyor will be added to this tutorial, which will
come from a Conveyor Template included by default within Rocky.

Rocky not only allows Custom geometry import but also provides some default geometries that you
can add to your projects and then customize.

The Feed Conveyor can input the particles if you associate an inlet to it, so you don't need a separate
surface.

1. From the Data panel, right-click Geometries, point to Conveyor Templates, and then click Create
Feed Conveyor.

2. From the Data Editors panel, define the parameters for the resulting Feed Conveyor <01> item
and import the necessary HPGR components by using the information in the table below.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Geometry Belt Width 1.5 [m]
Orientation Belt Incline Angle 10 [dega]
Feed
Conveyor Vertical Offset 3 [m]
<01> Horizontal Offset -1 [m]
Out-of-Plane Offset 1 [m]
Feeder Box Front Plane Offset 1 [m]
B Geometries Import Wall Deflector.stl,
Hopper.stl, Roll

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Settings

Action
1.stl with "mm" for
Import Unit

6.1.7. VISUALIZE GEOMETRIES

1. To visualize the geometries, click and drag Geometries from the Data panel, releasing it over the
Workspace. The workspace should look similar to the image below.

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Tutorial - High Pressure Grinding Roll (HPGR)

6.1.8. BOUNDARY MOVEMENT

For the Motion Frames step, we will create three separate Motion Frames: one each for the HPGR
rolls, and one for the deflector plate.

• Both Rolls have rotational movements in opposite directions.

– The left roll rotates in a clockwise direction.

– The right roll rotates in counter-clockwise direction.

• The Deflector has a Free Body Rotation motion around its axis with a Spring-Dashpot Moment
resisting the torsional motion.

6.1.9. MOTION FRAME – SPRING-DASHPOT FORCE/MOMENT

When the motion Type of Spring-Dashpot Moment (or Spring-Dashpot Force) is selected, you
must then prescribe the direction and the coefficients of the Spring/Dashpot.

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 Part A: Project Setup and Processing

The moment (M) and force (F) components at the selected direction for this motion will be propor-
tional to the displacement (Spring) and velocity (Dashpot) of the geometry, compared to the original
position.
(6.1)
(6.2)

Where:

• and are the Spring Coefficients

• and are the Dashpot Coefficients

• is the Linear Displacement

• is the Linear Velocity

• is the Angular Displacement

• is the Angular Velocity

6.1.10. MOTION FRAMES

1. Use the information in the following table to set up the Roll 1 and 2 Motion Frames for this tutorial:

Step Data Entity Editors Location Parameter or Settings

Action
A Motion Frames Create Motion Frame
B Motion Frames Frame Name Roll 1 Motion
Add Motion
Frame <01>
Type Rotation
Initial Angular 0, 0, -50 [rad/s]
Velocity
C Motion Frames Create Motion Frame
D Motion Frames Frame Name Roll 2 Motion
Relative Position 1.2, 0, 0 [m]
Frame <01>
Add motion
Type Rotation
Initial Angular 0, 0, 50 [rad/s]
Velocity

2. Similarly, set up the Deflector Motion Frame.

Step Data Entity Editors Location Parameter or Settings

Action
E Motion Frames Create Motion Frame

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Tutorial - High Pressure Grinding Roll (HPGR)

Step Data Entity Editors Location Parameter or Settings

Action
F Motion Frames Frame Name Deflection Motion
Relative Position 1.105, 2.75, 0 [m]
Frame <01>
Add motion
Type Free Body Rotation
Motion Direction Z direction
Add motion
Type Spring-Dashpot
Moment
Direction Z direction
Spring Coefficient 1000 [Nm/dega]
Dashpot Coefficient 100 [Nms/dega]

3. Once the Motion Frames are created, they can be assigned to their respective geometries.

Step Data Entity Editors Location Parameter or Settings

Action
G Geometries Wall Motion Frame Deflection Motion

Deflector
H Geometries Wall Motion Frame Roll 1 Motion

Roll 1
I Geometries Wall Motion Frame Roll 2 Motion

Roll 2

4. To visualize the newly created Frames, click Motion Frames and then click Preview.

Note:

• The Feed Conveyor does not need a Motion Frame since its movement is already
predefined in the default geometry settings.

• Since the Feed Conveyor has motion without displacement and the Free Body Motions
can only predict the effects of gravity prior to particle interactions being calculated, you
will see only minor movements in the Deflector and more obvious movements on only
the two Roll motions.

6.1.11. BOUNDARY DEFINITION

Since the Deflector has a free body motion, it is important to correctly define the Boundary Mass,
Gravity Center and Moment of Inertia properties.

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 Part A: Project Setup and Processing

• Doing so enables Rocky to properly calculate the resulting accelerations.

In addition, the Surface Wear Modification model will be enabled for the Deflector.

1. Use the information in the table below to set up the boundary parameters.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Wall | Transform Triangle Size 0.1 [m]
… | Mass Boundary Mass 2810 [kg]
Deflector
Gravity Center 1.125, 2.144, 1 [m]
Principal Moment of 1546.4, 8489.87,
Inercia 705.72 [kg.m2]
… | Wear War Model Shear Work
Proportionality
(Archard's Law)
Volume/Shear Work 5e-07 [m3/J]
Ration

6.1.12. INTERACTION BETWEEN MATERIALS

Next, we will define the interactions between materials.

1. To set the interaction properties, use the information in the table below.

Step Data Entity Editors Location Parameter or Settings

Action
A Materials Materials Static Friction 0.5 [-]
Interactions Dynamic Friction 0.5 [-]
Default
Particles

Default
Boundary
Materials Dynamic Friction 0.5 [-]
Interactions

Default
Particles

Default
Particles

For the Particles step, we will create a new (rock-like) polyhedron-shaped particle group in a range
of sizes, and will define for it Ab-T10 breakage parameters.

1. Use the information in the table that follows to define these settings.

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Tutorial - High Pressure Grinding Roll (HPGR)

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create Particle
B Particles Particle Shape Polyhedron
Particle | Size Add row (x2)
Particle <01>
(1) Size | Cumulative 0.3 [m] @ 100 [%]
%
(2) Size | Cumulative 0.2 [m] @ 30 [%]
%
(3) Size | Cumulative 0.15 [m] @ 10 [%]
%
… | Shape Horizontal Aspect 1 [-]
Ration
Number of Corners 15 [-]
… | Breakage Enable Breakage (Enabled)
Model Ab-T10
Reference Minimum 1 [J/kg]
Specific Energy
Selection Function 0.001 [kg/J
Coefficient
… | Breakage | Minimum Absolute 0.05 [m]
Fragments Size

6.1.13. SOLVER DEFINITION

Lastly, we will define an inlet and solver information for this project.

1. Use the information in the table below to continue setting up your project.

Step Data Entity Editors Location Parameter or Settings

Action
A Inlets and Outlets Create Particle Inlet
B Inlets and Outlets Particle Inlet Entry Point Feed Conveyor
<01>
Particle Inlet
Particle Inlet | Add row (x1)
<01>
Particles (1) Particle | Mass Particle <01> @
Flow Rate 1500 [t/h]
C Solver Solver | Time Breakage | Start 3 [s]
Breakage | Delay 3 [s]
after Release
Wear | Start 3 [s]
… | General Simulation Target CPU

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 Part A: Project Setup and Processing

6.1.14. SETUP CONFIRMATION

With a 3D View opened, your Data and Workspace should look similar to the image below.

6.1.15. SOLVER DEFINITION

1. From the Solver entity, click Start.

The Simulation Summary window will be displayed, and then processing begins.

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Tutorial - High Pressure Grinding Roll (HPGR)

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 Part A: Project Setup and Processing

Tip:

You can use the Auto Refresh checkbox to view the results during processing.

6.1.16. CONCLUSION
This completes Part A of this tutorial.

Rocky was used to set up and process an HPGR simulation with the goal of later analyzing both power
and wear data on the boundaries.

During this tutorial, it was possible to:

• Use Modules to enable the collection of boundary collisions data.

• Set up a Motion Frame using a free body rotation and a spring-dashpot moment.

• Enable the Surface Wear Modification model.

• Enable the Ab-T10 Breakage model.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to Part B and post-process
this project.

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Tutorial - High Pressure Grinding Roll (HPGR)

6.2. Part B: Post-Processing

6.2.1. OBJECTIVE
The main purposes of this tutorial are to analyze the particle fragments, view the surface wear
modifications, and compare the power data that we collected in the High Pressure Grinding Roll
(HPGR) simulation we processed in Part A.

You will learn how to:

• Collect and analyze Particle fragments

• Measure and visualize surface displacement

• Measure and visualize wear volume loss

• Create a color map of Intensity : Shear

• Calculate and compare power draw

And you will use these features:

• 3D View window

• User Processes (Cube, Particles Time Selection, Filter)

• Histogram

• Time Plot

6.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

6.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

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 Part B: Post-Processing

a. Download the dem_tut06_files.zip file .

b. Unzip dem_tut06_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade to the latest version,
or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut06_files folder, and
then from the tutorial_06_A_pre-processing folder, open the tutorial_06_A_pre-pro-
cessing.rocky file.

e. Process the simulation.

6.2.4. ANALYZE BREAKAGE

Because in Part A, we enabled the Ab-T10 Breakage Model on our particles, we are now able to
analyze those breakage results.

As particles pass through the rolls of the HPGR, they break into fragments.

By creating a Cube User Process under the rolls, we can collect these fragments and then analyze
them by size.

1. To start this first analysis, use the information in the table that follows.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Cube User Process

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Tutorial - High Pressure Grinding Roll (HPGR)

Step Data Entity Editors Location Parameter or Settings

Action
B User Processes Cube Center 0.59, -0.32, 1 [m]
Magnitude 0.57, 0.46, 2 [m]
Cube <01>
C User Processes Create a Particle Time Selection User
Process
Cube <01>
D User Processes Time Selection Domain Range All

Particles Time
Selection <01>

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

2. From the Data panel, under User Processes, right-click Particles Time Selection <01>, point to
Show in new | Histogram, and then click Particle Size.

A Histogram window will be created showing the count of particles (and fragments) for each size
range that made it into the Cube over the full course of the simulation.

3. From the upper left corner of the Histogram window, click the Configure histogram icon, and
then use the information in the table below to define the settings.

Step Location Parameter or Action Settings

A Histogram <01> | Configure Weight Particle Mass
Histogram Cumulative Bins (Enabled)
Percent Values (Enabled)
Properties Particle Size
Limits User Defined
Min 0.05 [m]
Max 0.25 [m]

4. Click OK.

The final Histogram shows the cumulative particle (and fragment) size after the original particles go
through the rolls.

Note that more than 50% of the particle mass accounted for within the Cube is of a smaller particle
size ([0.13, 0.15] (m)) than the smallest particle originally injected (0.15 m).

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 Part B: Post-Processing

6.2.5. DISPLACEMENT
Because in Part A we enabled the Surface Wear Modification model for the Deflector wall, we are
now able to evaluate the results.

Modifications to the geometry can be viewed using the Filter User Process, and then defining Dis-
placement as the Property to analyze. This will show the distance each node was moved.

1. Use the information in the table below to begin this analysis.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Add a Filter User Process

Deflector
B User Processes Property Property Displacement : X
Mode Cut
Filter <01>
Type Range
Minimum Value 0.0001 [m]
Maximum Value 1 [m]

2. Create or select a 3D View window.

3. Then, use the information in the table below to change the coloring.

Step Data Entity Editors Location Parameter or Settings

Action
A User Processes Coloring Transparency (Enabled)
Face (Enabled)
Filter <01>
Face | Property <Solid color>
Face color Dark red
Edges (Enabled)

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Tutorial - High Pressure Grinding Roll (HPGR)

Step Data Entity Editors Location Parameter or Settings

Action
Edges | Property <Solid color>
Edge color Red

The results should show only the triangles of the deflector surface that had displacements within the
selected displacement range (as shown).

Tip:

• Use the Data panel eye icons to hide all but the Deflector Geometry and the Property
<01> User Process.

• Use the options on the Time toolbar to view how wear changes over time.

6.2.6. DISPLACEMENT AREA

The worn area on the surface of the Deflector geometry can be evaluated using a Time Plot of the
Property <01> User Process you just created.

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 Part B: Post-Processing

1. Use the information in the table below to continue this analysis.

Step Item Editors Location Parameter or Settings

Action
A Window (menu) Create a New Time Plot
B User Processes Properties Drag and drop Area : Cell onte the new
Time Plot window.
Filter <01>
C Select the Statistics to Plot (dialog box) Sum (Enabled)

The resulting plot should look similar to the one below.

6.2.7. WEAR VOLUME LOSS

After analyzing the Displacement and Displacement Area, you were able to visualize the affected
area on the Geometry Surface and plot this.

Another possible analysis is to verify the Wear Volume Loss that the Geometry suffered. Follow the
steps below to visualize the Deflector Geometry's volume loss due to wear and create a Time Plot of
the Wear Volume Loss property.

1. Use the table below to create a color map of the wear volume loss data.

Step Item Editors Location Parameter or Settings

Action
A Window (menu) Create a New 3D View
B Geometries Properties Drag and drop Wear Volume Loss onto
the 3D View Window
Deflector
C Color Scales Coloring Limits Options User Defined

Wear
Volume Loss

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Tutorial - High Pressure Grinding Roll (HPGR)

Step Item Editors Location Parameter or Settings

Action
Limits 0, 0.0001 [m3]

Note:

Hide every geometry component but the Deflector Geometry.

2. Under Color Scales select Wear Volume Loss. In the Coloring Tab, click the three dots option
to the right of "Color-scale".

3. You should have the following Color Scale Window open:

4. Right-click the blue Mark on the left side of the scale and select grey for the Geometry.

5. Double-click the scale near the Mark you have just altered to create a new Mark. Drag it to
1% (0.01) and set its color to blue.

This process allows you to only color the regions that were actually hit by particles, according
to its degree of volume loss.

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 Part B: Post-Processing

The Image below represents the Deflector Geometry colored by its degree of wear volume
loss due to the interaction with particles.

Tip:

• You can alter the Color Scale Limits and the colors used in the process to
perform an analysis to your own liking.

• Use the options on the Time toolbar to view how wear changes over time.

6. Use the information in the table below to plot the property over time.

Step Item Editors Location Parameter or Settings

Action
A Window (menu) Create a New Time Plot
B Geometries Properties Drag and drop Wear Volume Loss onto
the New Time Plot
Deflector
C Select the Statistics to Plot (dialog box) Sum (Enabled)

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Tutorial - High Pressure Grinding Roll (HPGR)

The resulting Plot should look similar to the one below:

6.2.8. COLOR MAP OF SHEAR WEAR

You can also analyze wear on the geometries without modifying the surface.

You might recall that in Part A we enabled the Module for Boundary Collision Statistics, and chose
to collect Intensities.

Now that we have that data, we can use it to create a color map of the intensities data, such as shear.

1. Use the table below to create a color map of the Intensity : Shear.

Step Item Editors Location Parameter or Settings

Action
A Window (menu) Create a New 3D View
B Geometries Properties Drag and drop Intensity : Shear onto the
3D View Window
Deflector
C Color Scales Coloring Limits options User Defined
Limits 0, 15000 [W/m2]
Intensity :
Shear

2. Under Geometries, use the eye icons to hide all but the Deflector component.

The color map should look similar to the image below.

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 Part B: Post-Processing

Tip:

You can use the Time slider to see how shear intensity changes over time.

6.2.9. POWER MEASURE

It takes a certain amount of power for the two Roll geometries to successfully comminute the mater-
ial.

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Tutorial - High Pressure Grinding Roll (HPGR)

We can use the same Intensities data we chose to collect in Part A to measure the power draw directly
from the geometries.

1. Use the information on the table below to create a Time Plot of the power used for the rolls.

Step Item Editors Location Parameter or Settings

Action
A Window (menu) Create a New Time Plot
B Geometries Curves Drag and drop onto the Time Plot

Roll 1
C Geometries Curves Drap and drop Power onto the Time Plot

Roll 2

The results should look similar to the plot below.

This is a useful way to compare the results with real data and to calibrate the material properties
correctly.

6.2.10. CONCLUSION
This completes Part B of this tutorial.

Rocky was used to study breakage, surface wear, and power draw in an HPGR.

During this tutorial, it was possible to:

• Use a Cube and a Particles Time Selection User Process to collect and analyze particles and
fragments.

• Use a Filter User Process to visualize the surface area displacement.

• Use the collected intensities data to view a color map of wear.

• Use the Wear Volume Loss property to view a color map of wear.

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 Part B: Post-Processing

• Use Time Plots and Curves to compare power draw.

What's Next?

• If you have completed this tutorial successfully, then you are ready to move on to next tutorial.

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Chapter 7: Tutorial - Conical Dryer
(Part A) Model conductive heat transfer by enabling the thermal model and use the motion features
included by default in Rocky to define complex, combined motions.

(Part B) Analyze conductive heat transfer by using Camera Presets, plotting particle temperature, and
tracking individual particles using the Cell Inspector.

7.1. Part A: Project Setup and Processing

7.1.1. OBJECTIVE
The two main purposes of this tutorial are to learn how to:

1) Model conductive heat transfer by enabling the thermal model.

2) Use the motion features included by default in Rocky to define complex, combined motions in the
simulation of a Conical Double Screw Vacuum Dryer.

• This equipment is commonly used in the chemical and pharma industries to gently dry sensitive
products using low amounts of heat.

You will learn how to:

• Set up complex, combined motions

• Enable thermal modeling

• Define thermal properties for Materials and Geometries

And you will use these features:

• Thermal Model

• Motion Frames

7.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

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Tutorial - Conical Dryer

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

7.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Lid

• (2) Tank

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 Part A: Project Setup and Processing

• (3) Valve

• (4) Central Shaft

• (5) Longer Screw

• (6) Short Screw

• (7) Ball

The .stl files can be found in the tutorial directory.

7.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut07_files.zip file .

2. Unzip dem_tut07_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the table that follows to start setting up your Rocky project.

Step Entity Editors Location Parameter or Settings

Action
A Study 01 Study Study Name Conical Dryer
B Physics Physics | Numerical Softening 0.1 [-]
Momentum Factor

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials.

7.1.5. PHYSICS DEFINITION

Also for the Physics step, we will be enabling both the Thermal Model and a Conduction Correction
Model.

• In the previous step, we chose a numerical softening factor lower than 1, which can cause errors
within the heat transfer calculations due to the material being modeled softer than it is in reality.

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Tutorial - Conical Dryer

• Adding a conduction correction model helps to avoid over-predictions on the contact area in these
cases.

Tip:

For more information about these models and when to apply them, refer to the Thermal
conduction correction models chapter in the DEM Technical Manual.

1. From the Thermal sub-tab, mark the Enable Thermal checkbox, and then define the Conduction
Correction Model (as shown).

7.1.6. PROJECT SETUP

For the Geometries step, we will import the following 7 files in .stl format.

1. From the Data panel, right-click Geometries and then click Import Wall.

2. From the Select file to import dialog, navigate to the dem_tut07_files folder that you previously
downloaded, find the geometry folder, multi-select all of the 7 files shown above, and then click
Open.

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 Part A: Project Setup and Processing

3. From the Import File Info dialog, select "mm" as Import Unit, ensure that the option Convert Y
and Z axes is cleared (unchecked), and then click OK.

7.1.7. BOUNDARY MOVEMENT

For the Motion Frames step, we will use nested frames to create a planetary motion, where each
screw will rotate around its own axis and the central shaft will rotate the screws around the cone.

• In order to create complex motions, Rocky allows new Motion Frames (children) to be linked to
previously created Motion Frames (parents).

• The children Motion Frames will move together with the parent Motion Frame and will also
have their own unique motions.

Note:

To enable even more complex nested motions, a child Motion Frame is allowed to have
a Local Keep in Place axis while its parent frame is set to Global Keep in Place. However,
since we want to have motions with displacement in this simulation (Keep in Place is
Disabled). See Tutorial 21 for an exemple of application of this functionality.

For this case, three separate Rotations will be created:

• (1) Central Shaft Motion: This will rotate the whole system (Central Shaft, Longer Screw, and Short
Screw) around the dryer's vertical axis.

• (2) Longer Screw Motion: This will rotate the longer screw around its own axis.

• (3) Short Screw Motion: This will rotate the short screw around its own axis.

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7.1.8. MOTION FRAME

1. Use the information in the table that follows to create the first of these three Motion Frames.

Step Data Entity Editors Location Parameter or Settings

Action
A Motion Frames Create Motion Frame
B Motion Frames Frame Name Central Shaft
Motion
Frame <01>
Add Motion
Start Time 1 [s]
Type Rotation
Initial Angular 0, -4, 0 [rev/min]
Velocity

This will be the parent frame upon which the next two frames will depend.

2. To create a child frame that is dependent upon the parent frame you just created, from the Data
panel, right-click Central Shaft Motion, and then select Create Motion Frame.

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 Part A: Project Setup and Processing

A new (child) frame called Central Shaft Motion <01> appears nested under the first (parent)
frame. Besides the names, the connection between the two frames is also indicated by the name
of the parent appearing in bold when the child is selected.

3. Use the table that follows to define the parameters for this first child Motion Frame.

Step Data Entity Editors Location Parameter or Settings

Action
A Motion Frames Frame Name Longer Screw
Motion
Central Shaft
Relative Position -0.521, 0, 0 [m]
Motion <01>
Relative Orientation -161.045 [dega]
| Angle
Relative Orientation 0, 0, 1 [-]
| Vector
Add motion
Star Time 0.5 [s]
Type Rotation
Initial Angular 0, 57, 0 [rev/min]
Velocity

4. To create the second dependent (child) frame, use the information in the table that follows.

Step Data Entity Editors Location Parameter or Settings

Action
A Motion Frames Create Motion Frame

Central Shaft Motion

B Motion Frames Frame Name Short Screw
Motion
Central Shaft
Relative Position 0.463, 0, 0 [m]
Motion <01>
Relative Orientation 161.045 [dega]
| Angle
Relative Orientation 0, 0, 1 [-]
| Vector
Add Motion
Start Time 0.5 [s]
Type Rotation

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Tutorial - Conical Dryer

Step Data Entity Editors Location Parameter or Settings

Action
Initial Angular 0, 57, 0 [rev/min]
Velocity

Once the Motion Frames have been created, each frame must be assigned to a geometry.

1. Use the information in the table below to complete these assignations.

Step Data Entity Editors Location Parameters or Settings

Action
A Geometries Wall Motion Frame Central Shaft Motion

Central Shaft
B Geometries Wall Motion Frame Longer Screw
Motion
Longer Screw
C Geometries Wall Motion Frame Short Screw Motion

Short Screw

2. From the Data panel, select Motion Frames.

3. From the Data Editors panel, click the Preview button.

A new Motion Preview window appears.

7.1.9. MOTION PREVIEW

For this tutorial, since the geometries have motions with displacement assigned (Keep in Place is
Disabled), the movement can be previewed using the Motion Preview window.

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 Part A: Project Setup and Processing

Tip:

Use the eye icons on the Data panel to hide the Tank and Lid geometries.

The Time toolbar can be used to "play" the preview. The yellow color of the slider indicates that the
simulation has not yet been processed.

Note:

For this tutorial, no movement will be seen until after 0.5 s.

7.1.10. BOUNDARY DEFINITION – THERMAL BOUNDARY

In order to evaluate the heating of the Particles that come into contact with the Tank, Thermal
Boundary conditions should be defined for this geometry.

1. From the Data panel, under Geometries, select Tank.

2. From the Data Editors panel, select the Wall tab, and then from the Thermal sub-tab, define
Thermal Boundary Type and Temperature (and unit).

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Tutorial - Conical Dryer

7.1.11. MATERIAL DEFINITION

For the Materials step, two materials will be used: one for all the geometry parts (Default Boundary)
and another for the particles (Default Particles).

1. Use the table below to define the material values for this tutorial.

Step Data Entity Editors Location Parameter or Settings

Action
A Materials Material Density 7900 [kg/m3]
Young's Modulus 2e+11 [N/m2]
Default
Boundary Thermal 400 [W/m.K]
Conductivity
Specific Heat 385 [J/kg.K]
Poisson's Ratio 0.27 [-]
B Materials Material Bulk Density 492 [kg/m3]
Young's Modulus 2e+08 [N/m2]
Default
Particles Thermal 311 [W/m.K]
Conductivity

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Settings

Action
Specific Heat 17.56 [J/kg.K]

Note:

For this tutorial, the Materials Interactions values will be left as default.

7.1.12. COMPLETE PROJECT SETUP

For the Particles step, we will create a new spherical particle group.

For the Inlets and Outlets step, we will create a volumetric inlet with thermal properties, which will
inject all the particles at once before the simulation starts.

1. Use the information in the table below to finish setting up your project.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create Particle
B Particles Particle | Size (1) Size | Cumulative 0.08 [m] @ 100 [%]
%
Particle <01>
C Inlets and Outlets Create Volumetric Inlet
D Inlets and Outlets Volumetric Inlet | Add row (x1)
Volumetric Inlet Particles (1) Particle | Mass | Particle <01> | 180
<01> Temperature kg | 25 [degC]
Volumetric Inlet | Seed Coordinates 0, -0.9, 0 [m]
Region Geometries All Enabled ("Check
All")
Use Geometries to (Enabled)
Compute
E Solver Solver | Time Simulation Duration 25 [s]
Solver | General Simulation Target CPU

7.1.13. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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7.1.14. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

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Tutorial - Conical Dryer

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

7.1.15. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a thermal sim-
ulation of a Conical Double Screw Vacuum Dryer.

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 Part B: Post-Processing

During this tutorial, it was possible to:

• Use Motion Frames to set up and preview complex, nested motions

• Define basic Thermal Modeling parameters for materials and geometries

What's Next?

• If you completed this tutorial successfully, you are ready to move on to Part B and post-process
this project.

7.2. Part B: Post-Processing

7.2.1. OBJECTIVE
The main purpose of this tutorial is to learn how to analyze conductive heat transfer within the
Conical Double Screw Vacuum Dryer simulation we created in Part A.

You will learn how to:

• Use Camera Presets to save and apply exact views

• Export project post-processing settings

• View and plot particle temperature

• Track an individual particle

And you will use these features:

• Custom Presets toolbar

• 3D View windows

• Export Project Context

• Properties

• Color Scale

• Cell Inspection User Process

7.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

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Tutorial - Conical Dryer

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

7.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut07_files.zip file .

b. Unzip dem_tut07_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut07_files folder,
then from the tutorial_07_A_pre-processing folder, open the tutorial_07_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

7.2.4. SET AND REUSE EXACT VIEWS

For this tutorial, we will define three specific 3D View Presets of the Dryer geometry: Full View,
Shaft View, and Valve View.

• A preset enables you to save the exact rotation (tilt), magnification (zoom), and location (pan) settings
you have defined in a 3D View.

• In this way, you can reuse those exact views for other analyses in the same project.

You can define 3D Views using the keyboard, mouse or the Camera Visualization toolbar (shown
in blue).

For this tutorial, we will use the Fit menu (shown in yellow) and mouse to change our 3D View, and
will then use the Custom Preset toolbar (shown in red) to save our views for reuse later.

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 Part B: Post-Processing

Let's start by making the Full View preset.

1. From the Window menu, click New 3D View.

2. By default, the view is centered and oriented to the +Z axis. Let's change it as follows:

a. With the new window selected, ensure the Change projection button is set to Orthogonal
(as shown).

b. Find the Fit menu, and then select Camera Preset: -Z.

c. Use your mouse to make the window approximately square.

d. Select the Fit button (or click R) to reorient the geometry in the center of the window.

e. Use your mouse's center wheel to zoom (increase magnification) into the view as much as you
can while keeping all the parts in view.

f. Use your mouse's right button to drag the geometry towards the right side of the window,
leaving a empty area on the left.

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The results are shown below.

3. With your new view changed (as shown), from the Custom Presets toolbar, click the Add preset
button (green plus) (as shown).

4. From the Create new preset dialog, enter the name (as shown) and click OK.

The new Full View preset is listed in the toolbar.

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 Part B: Post-Processing

Now, let's create the Shaft View preset:

1. With the same 3D View window selected, from the Fit menu, select Camera Preset: +Y 30.

2. Use your mouse's center wheel to zoom (increase magnification) into the view as much as you
can while keeping all the parts still within view.

3. Use your mouse's right button to drag the geometry towards the right side of the window, leaving
an empty area on the left (results shown).

4. From the Custom Presets toolbar, click the Add preset button (green plus).

5. From the Create new preset dialog, enter the name (as shown) and click OK.

Finally, let's create the Valve view preset:

1. Within the same 3D View window, use your left mouse button to rotate the view straight up until
the Y (green) and Z (blue) axes are both pointing towards you.

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2. Click the Fit button.

3. Use your mouse's center wheel to zoom into the view until the tank touches both sides of the
window.

4. Use your mouse's right button to drag the geometry up until the valve is fully in view and only
the bottom third of the tank is visible. (Results shown.)

5. From the Custom Presets toolbar, click the Add preset button (green plus).

6. From the Create new preset dialog, enter the name (as shown) and click OK.

Next, create two more 3D View windows (Ctrl+D) and apply the other two presets to those.

You should now have three separate windows, each with a different preset view (as shown).

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 Part B: Post-Processing

Now that these views and windows are set up exactly the way we want, let's export that setup criteria
so that we can re-use it in a similar project later.

7.2.5. EXPORT PROJECT CONTEXT

When you choose to Export project context, Rocky saves in a rocky_template file (or to the clipboard)
setup information about all the following items you have defined in your project:

• 3D View windows

• most User Processes

• Workspace tabs

Limitations: This method does not currently export setup information for the following:

• Windows: Plot, Histogram, Motion Preview, nor Particles Details

• User Processes: Cell Inspector, Particle to Contact, nor Contact to Particle

Before we start, let's organize the windows on our Workspace.

1. From the View menu, ensure Windows is enabled.

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2. From the Windows panel, use the checkboxes to disable all but the 3D View windows (as shown).

3. From the Window menu, select Tile 2 Columns (as shown).

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 Part B: Post-Processing

Your Workspace should now contain only neatly organized 3D View windows.

1. From the File menu, point to Export project context, and then click To file.

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Tutorial - Conical Dryer

2. From the Save project context dialog, choose a location and enter a File name for the
.rocky_template file, and then click Save.

The Finished exporting context window appears, confirming the items exported (as shown).

When you are ready to re-use this setup information, open a similar project, and then from the File
menu, point to Import project context, click From file, navigate to and select the .rocky_template
file you want, and then click Open.

The setup items you exported will appear in your project.

7.2.6. SET AND REUSE EXACT VIEWS

For the next analysis, let's use the Full View preset with transparent geometries.

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 Part B: Post-Processing

1. Select the 3D View window that is showing the Full View preset. (Or, from any other 3D View
window, switch to that view by selecting Full View from the Custom Presets toolbar.)

2. From the Data panel, under Geometries multi-select the Lid and Tank geometry components.

3. From the Data Editors panel, select the Colorings tab, and then enable the Transparency
checkbox (as shown).

7.2.7. EVALUATING PARTICLE TEMPERATURE

We can analyze properties data like temperature by coloring simulation components by property in
the 3D View window.

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Tutorial - Conical Dryer

1. From the Data panel, select Particles and then from the Data Editors panel, select the Properties
tab.

2. Drag and drop the Temperature property (available only when the Thermal Model is enabled)
to the 3D View window.

3. Rocky will create a Color Scale using the default color scheme and limits based upon the minimum
and maximum values of the selected Property at the given time.

4. To change the display options, right-click the Color Scale and then select Edit. This shows options
from the Coloring tab on the Data Editors panel.

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 Part B: Post-Processing

7.2.8. COLOR SCALE

1. From the Coloring tab, edit the color scheme by clicking on the ... button next to the Color-scale
bar.

2. In the Color-scale dialog that appears, a predefined Color-scale can be selected or a custom one
created by moving and/or changing the color of the dots. For this tutorial, click the ... button and
select the blue-to-red color scale (as shown), and then click OK.

3. Back on the Coloring tab, the Limits options can be set manually by selecting User Defined from
the drop down list. For this tutorial, define the Limits values and the Color-scale unit (as shown).

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7.2.9. EVALUATING PARTICLE TEMPERATURE

Use the Time toolbar to display the Temperature at different Output times.

7.2.10. TIME PLOT

The Temperature property can also be used in plot to analyze the uniformity of the Particles being
heated.

1. From the Window menu, click New Time Plot (or press Ctrl+T).

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 Part B: Post-Processing

2. Use the information in the table below to define the Time Plot.

Step Item Location Parameter or Settings

Action
A Particles Properties | Drag and drop onto the Time Plot window
Temperature
B Select The Statistics to Plot (dialog box) Min (Enabled)
Max (Enabled)
Average (Enabled)

3. Right-click the Plot grid, point to Axes Layout, and then select By Quantity.

Tip:

From the Select The Statistics to Plot dialog box, clear any other checkbox that is possible
enabled.

The results are shown below.

7.2.11. CELL INSPECTOR

It may be useful to correlate simulation results with instrumentation data, such as a probe on the
geometry or a particle tracer.

The Cell Inspector User Process allows you to evaluate results on a single selected Triangle (Geomet-
ries), Particle, or Eulerian Bin.

For this tutorial, two Particles will be located when motion starts and then their Temperatures
tracked over time: One at the top-center of the Cone and the other at the bottom. (Note that the
actual ID of your particles might differ slightly.)

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Tutorial - Conical Dryer

To find the two particles you will use:

1. Find (or create from new) the 3D View window you created earlier that uses the Shaft view
Preset, and the other that uses the Valve view Preset.

2. For both windows, turn the Particles color to gray, and then make the Lid and Tank Geometries
transparent.

3. From the Time toolbar, set the output time to 0 s.

4. With the Shaft view window selected, from the Data panel right-click Particles, point to Processes,
and then click Cell Inspector.

5. From the Data Editors panel, on the Coloring tab (for the Inspector <01> entity), change the
Node color to red.

6. From the Inspector tab, change the Name (as shown) and then use the arrows (or type numbers)
on the Particle ID list box to show on the 3D View the location of individual particles until you
find one at the top of the Cone (in this tutorial, ID 802).

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 Part B: Post-Processing

7. With the Valve view window selected, repeat this process to create another Cell Inspector User
Process identifying a particle at the bottom of the Cone (in this tutorial, ID 334). Change the Name
of this process to Bottom of Cone.

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8. From the Properties sub-tab, clear the Hide unchecked items checkbox (as shown).

9. From the Properties sub-tab, right-click Temperature, point to Time Plot, and then click Show
in New.

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 Part B: Post-Processing

10. From the Data panel, under User Processes, select the Top-center of Cone inspector.

11. From the Properties sub-tab, ensure the Hide unchecked items checkbox is still cleared.

12. From the Properties sub-tab, right-click Temperature, point to Time Plot, and then click Show
in Current.

7.2.12. TIME PLOT

The exact behavior of your two particles will likely be different than the ones shown here. But for
example, here's what we can observe from this particular plot:

• Up until 4 seconds, the particle at the bottom of the cone experienced heating due to wall contact.
After this, it experiences some heat loss due to conduction with cooler neighboring particles, until
it starts to heat up again around 7 seconds.

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Tutorial - Conical Dryer

• The particle at the top-center of the cone remained more in the middle of the equipment and in-
creased its temperature more steadily.

• By the end of the simulation, both particles have the temperature increased.

7.2.13. CONCLUSION
This completes Part B of this tutorial, in which Rocky was used to post-process a thermal simulation
of a Conical Double Screw Vacuum Dryer.

During this tutorial, it was possible to:

• Use Camera Presets to save and apply exact views

• Save those views for use in similar projects by Exporting project context

• Use Properties to evaluate particle temperature and uniformity parameters

• Create tracers using the Cell Inspector User Processes to evaluate individual particle behavior

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to next tutorial.

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Chapter 8: Tutorial - Cone Crusher
(Part A) Define the mantle and shaft movements required for a Cone Crusher, set up Tavares breakage
parameters, and collect Boundary Collision Statistics for later post-processing.

(Part B) Track the position of tagged particles, compute the resulting PSD of resulting fragments, isolate
broken fragments from whole particles, and calculate the average power draw.

8.1. Part A: Project Setup and Processing

8.1.1. OBJECTIVES
The two main purposes of this tutorial are to learn how to define the mantle and shaft movements
required for a Cone Crusher simulation, and how to set up Tavares breakage model parameters.

You will learn how to:

• Turn on the collection of intensities data for later post-processing of power draw

• Define mantle and shaft movements for a cone crusher simulation

• Turn on random particle orientation

• Set up Tavares breakage model parameters

And you will use these features:

• Boundary Collision Statistics Module

• Cone Crusher Motion Frame

• Particle Orientation

• Tavares Particle Breakage

8.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

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Tutorial - Cone Crusher

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

8.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Feed Hopper (Choke Feed)

• (2) Housing

• (3) Transmission Axis

• (4) Mantle Cone

• (5) Mantle Shaft

• (6) Concave

The .stl files can be found in the tutorial directory.

8.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

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 Part A: Project Setup and Processing

1. Download the dem_tut08_files.zip file .

2. Unzip dem_tut08_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

8.1.5. PROJECT SETUP

For this tutorial, information about Power on the boundary will be used.

Therefore, we must enable the collection of Boundary Collision Statistics during the Modules step.

1. Use the information in the table that follows to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Entity Editors Location Parameter or Settings

Action
A Study 01 Study Study Name Cone Crusher
B Modules Modules Boundary Collision (Enabled)
Statistics
C Modules Boundary Collision Intensities (Enabled)
Statistics
Boundary
Collision
Statistics

Note:

With Intensities enabled, Rocky will collect the average dissipation and impact power
values measured by each individual geometry triangle.

8.1.6. GEOMETRY IMPORT

For the Geometries step, we will import the following six separate geometry files in .stl format, disable
the Feed Hopper geometry during initial particle release, and then add a surface (to associate with
an inlet) to release particles into the domain.

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1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Import Wall All six .stl geometry
files with "mm" for
Import Unit
B Geometries Wall Enable Time 3 [s]

Feed Hopper
C Geometries Create a Circular Surface
D Geometries Circular Surface Center Coordinate 0, 1.65, 0 [m]
Max Radius 0.46 [m]
Circular
Surface <01>

8.1.7. MOTION FRAME CONE CRUSHER

In this tutorial, we will be creating cone crusher movements, which are defined by the following
motions:

• The Mantle rotates eccentrically around the vertical axis, pressing the particles on the Concave
and promoting breakage. At the same time, it is free to rotate around the Shaft.

• The intersection between the Mantle Axis and the Rotation Axis characterizes the Pivot Point.

• It is important to have your mantle geometry rotated by the desired Mantle Angle and to know
in which direction this is done to properly set up the Cone Crusher movement.

These motions can be created in Rocky with a special Cone Crusher Frame that is added during the
Motion Frames step.

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 Part A: Project Setup and Processing

When the new Cone Crusher Frame is added to your project, the following options are available in
the Data Editors panel:

• Pivot Point: Coordinate of the point around which the Mantle and Shaft will pivot.

• Rotation Axis: The axis around which the Mantle and Shaft are rotated.

• Rotational Velocity: The angular velocity along the Rotation Axis.

• Initial Orientation: The vector about which the Mantle and Shaft begin their rotation.

• Start/Stop Time: Time in which the motion starts and stops.

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In addition, the Cone Crusher Frame will automatically create two separate motions that are designed
to be applied to the appropriate geometries.

Important:

These motions appear only in the Motion Frame list for the imported Geometry and are
not listed under Motion Frames in the Data panel.

These two motions include the following:

• Cone Crusher <01> (Mantle) for the Mantle Cone geometry.

• Cone Crusher <01> (Shaft) for the Mantle Shaft geometry.

How to calculate Initial Orientation:

• Mantle Angle:

(8.1)

• Initial Orientation:

(8.2)

For the Motion Frames step, we will add a type of motion frame that is specific to the cone crusher:

1. From the Data panel, right-click Motion Frames, and then select Create Cone Crusher Frame.

2. Use the information in the table below to define the new frame.

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Settings

Action
A Motion Frames Cone Crusher Frame Pivot Point 0, 0.687, 0 [m]
Rotational Velocity 15.708 [rad/s]
Cone Crusher
<01> Initial Orientation 0.03943, 0.9992, 0
[m]
Start Time 2.5 [s]

The frame's two components can now be assigned to their respective geometries.

1. Use the information in the table that follows to assign the new motions.

Step Data Entity Editors Location Parameter Settings

Location
A Geometries Wall Motion Frame Cone Crusher <01>
(Mantle)
Mantle Cone
B Geometries Wall Motion Frame Cone Crusher <01>
(Shaft)
Mantle Shaft

At this point, the movement can be previewed.

1. From the Data panel, click Motion Frames and then click Preview.

A new Motion Preview window will appear. To better see the results:

2. Use the Data panel eye icons to hide all the geometries except Mantle Cone and Mantle Shaft.

3. Also, to better see the two separate frame axes, enable the Transparency checkbox for both the
Mantle Cone and Mantle Shaft geometries.

Note:

When you play the preview, no motions will be seen before 2.5 s.

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8.1.8. MATERIAL DEFINITION

For the Materials step, two materials will be used:

• One for all wall parts (Default Boundary), which we will use as defined by default.

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 Part A: Project Setup and Processing

• Another for the particles (Default Particles), which we will modify.

1. Use the information in the table below to define these materials and their interactions.

Step Data Entity Editors Location Parameter or Settings

Action
A Materials Material Use Bulk Density (Cleared)
Density 2500 [kg/m3]
Default
Particles Young's Modulus 1e+07 [N/m2]
B Materials Materials Static Friction 0.7 [s]
Interactions | Dynamic Friction 0.7 [s]
Default
Particles

Default
Boundary

Important:

The Young's Modulus value was lowered to speed up tutorial processing. For breakage
simulations, it is recommended to set these values between 5e+08 and 1e+09 Pa.

8.1.9. PARTICLE GROUP DEFINITION

For the Particles step, we will create a new (rock-like) polyhedron-shaped particle group, in a range
of sizes, with random orientation, and with the Tavares breakage model enabled.

1. Use the information in the table below to start defining your particles.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create Particle
B Particles Particle Shape Polyhedron
Particle | Size Add size row (x3)
Particle <01>
(1) Size | Cumulative 0.2 [m] @ 100 [%}
%
(2) ... 0.15 [m] @ 70 [%]
(3) ... 0.1 [m] @ 30 [%]
(4) ... 0.08 [m] @ 10 [%]

8.1.10. RANDOM PARTICLE ORIENTATION

For this tutorial, we will change the orientation of the particles as they are injected into the inlet.

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Tutorial - Cone Crusher

• By default, particles are injected into the domain perpendicular to the inlet (top image).

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 Part A: Project Setup and Processing

• You can change the orientation to have all particles come in at a defined angle (middle image),
come in at random angles (bottom image), and many options in between.

• For this tutorial, we will set a random orientation, as specified below.

8.1.11. PARTICLE GROUP DEFINITION

To set the orientation of the particle:

1. From the Orientation sub-tab, enable the Random Angle checkbox, and then define the Half
Range (x,y,z) values (as shown).

Tip:

• For default particle shapes, or other symmetrical custom shapes, setting your values to
90, 90, 90 ensures a completely random orientation in all directions.

• For non-symmetrical custom particle shapes (such as a bottle), you will need to set your
values to 180, 180, 180 to ensure a completely random orientation.

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8.1.12. TAVARES BREAKAGE MODEL

For this tutorial, we will enable the Tavares breakage model.

Like Ab-T10, the Tavares model is based upon the Voronoi fracture particle subdivision algorithm.

However, the breakage energy probability and resulting fragment size distribution are based upon
the Tavares et al. (UFRJ) approach, which:

• Models fractures by low-energy stressing, which is most relevant when particles are subject to a
complex series of loading events, as within crushers.

• Has been able to describe the progressive growth of crack-like damage that ultimately leads to the
fracture of a particle under stresses significantly lower than those required for breakage in a first
event.

Tip:

Refer to the Tavares Breakage Model Description and Calibration Guidelines white paper
for more information.

8.1.13. PARTICLE GROUP DEFINITION

To set the Breakage Model:

1. From the Breakage sub-tab, select the Enable Breakage checkbox.

2. From the Breakage | Criteria tab, define the Model and leave all the model's parameters as default.

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 Part A: Project Setup and Processing

3. From the Breakage| Fragments sub-tab, define Minimum Absolute Size and Distribution
model.

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Tutorial - Cone Crusher

Important:

The Minimum Absolute Size value used in this tutorial was increased to speed up pro-
cessing time. Refer to the Fragment size distribution models section of the DEM Tech-
nical Manual for details on how best to set this value.

8.1.14. MASS FLOW DEFINITION

For the Inlets and Outlets step, we will create a Particle Inlet and then set our Circular Surface as
the location from which we want particles to enter the simulation.

For the Solver step, we will also define our breakage start and delay times.

1. Use the information in the table below to finish setting up your project.

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Settings

Action
A Inlets and Outlets Create Particle Inlet
B Inputs Particle Inlet Entry Point Circular Surface
<01>
Particle Inlet
Particle Inlet | Add row (x1)
<01>
(1) Particle | Mass Particle <01> @ 350
Particles
Flow Rate [t/h]
… | Time Stop 3 [s]
C Solver Solver | Time Simulation Duration 12 [s]
Breakage | Start 2.5 [s]
… | Delay After 1 [s]
Release
Solver | General Simulation Target CPU

8.1.15. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the image
below.

8.1.16. SIMULATE PROJECT

1. From the Solver entity, click Start.

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Tutorial - Cone Crusher

The Simulation Summary screen appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

8.1.17. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a cone crusher
simulation.

During this tutorial, it was possible to:

• Collect Boundary Collision Statistics data for later post-processing of power draw.

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Tutorial - Cone Crusher

• Use the specialized Cone Crusher Frame to easily set up and apply specific mantle and shaft mo-
tions.

• Set particles to be released in a random orientation.

• Enable the simulation of Breakage phenomena using the Tavares model.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to Part B and post-process
this project.

8.2. Part B: Post-Processing

8.2.1. OBJECTIVES
The main purpose of this tutorial is to learn how to analyze the results from the Cone Crusher simu-
lation that we set up and processed in Part A.

You will learn how to:

• Track the position of tagged particles

• Compute the PSD of the resulting fragments

• Isolate the broken fragments from the whole particles

• Calculate the Average Power Draw

And you will use these features:

• Histograms

• Time Plots

• User Processes, including:

– Cylinder

– Cube

– Particles Time Selection

– Property

• Particle Calculations, including:

– Divisions Tagging

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 Part B: Post-Processing

8.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

8.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut08_files.zip file .

b. Unzip dem_tut08_files.zip to your working directory.

c. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut.)

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the tutorial_08_A_pre-processing
folder, and then open the tutorial_08_A_pre-processing.rocky file.

e. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

8.2.4. POST PROCESS PSD HISTOGRAM

Once processing is complete, you can analyze the resulting Particle Size Distribution (PSD) of the
fragments.

We will do this by:

• Using a Cube User Process to define the area beneath the cone.

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Tutorial - Cone Crusher

• Applying a Particles Time Selection User Process to the Cube in order to capture data for the
whole simulation length.

• Plotting the resulting Particle Size data in a Histogram.

1. Use the information in the table below to set up the Cube and Particles Time Selection User
Processes.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Cube User Process
B User Process Cube Center 0, 0.08, 0 [m]
Magnitude 1.4, 1.1, 1.4 [m]
Cube <01>
C User Processes Create a Particles Time Selection User
Process
Cube <01>

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 Part B: Post-Processing

Step Data Entity Editors Location Parameter or Settings

Action
D User Processes Time Selection Domain Range All

Particles Time
Selection <01>

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials to find the detailed in-
structions you need.

2. Use the information in the table below to create and configure the Histogram.

Step Item Parameter or Action Settings

A User Processes Show in new Histogram by Particle Size

Particles Time
Selection <01>
B Histogram (window) Configure histogram (button)
C Configure Histogram Weight Particle Mass
(dialog box) Number of Bins 20
Cumulative Bins (Enabled)
Percent Values (Enabled)

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8.2.5. POST PROCESS - DIVISIONS TAGGING

In the last Timestep of the simulation, you can observe that some Particles are accumulating in an
open space of the transmission housing (in the Blue cube) (as shown).

Using the Divisions Tagging Calculation of the Particles in the hopper, we can identify from what
section of the hopper these particles are coming from, which is helpful information for improving
the equipment design.

For this case, we will create a Cylinder User Process at an Output Time far enough into the simulation
that the Hopper is full of particles.

1. From the Time toolbar, select the [60] 3 s output time.

2. Use the information in the table below to create and configure the Cylinder.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Cylinder User Process
B User Processes Cylinder Size 1.01, 1.01, 1.01 [m]
Center 0, 1.2, 0 [m]
Cylinder <01>

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 Part B: Post-Processing

3. With the Cylinder set up, right-click Particles, point to Particles Calculations, point to Divisions
Tagging, and then click Cylinder <01>.

This will generate divisions within the cylinder that was selected, the result of which can be seen
in a 3D View window.

4. From the Data panel, under Calculations, select the new Divisions Tagging (Cylinder <01>)
entry.

5. Use the information in the table to define the Tagging values.

Step Data Entity Editors Location Parameter or Settings

Action
A Calculations Tagging Time Ranger Filter | After Time
Domain Range
Divisions
Time Range Filter | 3 [s]
Tagging
Initial
(Cylinder
<01>)... Tangential Divisions 12 [s]

Tip:

With a 3D View window open and selected, you can visualize the tagged particles by en-
abling the Transparency checkbox from the Coloring tab.

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Color Particles using the newly added Property:

1. From the Data panel, select Particles.

2. From the Data Editors panel, select the Coloring tab.

3. Under Nodes, change the Property to Divisions Tagging (Cylinder <01>)

Tip:

Use the eye icons next to Cylinder and Cube (under User Processes in the Data
panel) to hide the Cylinder and Cube coloring and show only the Particles coloring.

4. Display the final Output Time.

You should now see all of the following:

• Hopper divided in 12 circular sectors.

• Particles and Fragments colored by the division they started in.

• The accumulated Fragments colored by their original position in the hopper.

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 Part B: Post-Processing

Lastly for this analysis, a Cube will be added to separate the accumulated Fragments from the rest
of the Particles.

1. Use the information in the table to define this new Cube.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Cube User Process
B User Processes Cube Center 0.77, -0.017, 0 [m]
Magnitude 0.24, 0.24, 0.54 [m]
Cube <02>

Then, another Histogram will be created to show the hopper region from which the accumulated
Fragments are originating.

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Tutorial - Cone Crusher

1. Use the information in the table to define the Histogram.

Step Item Location Parameter or Settings

Action
A User Processes Properties | Show in new Histogram

Cube <02> Divisions

Tagging
(Cylinder
<01>)...
B Histogram (window) Configure histogram (button)
C Configure Histogram (dialog box) Number of Bins 12
Properties Divisions Tagging
(Cylinder <01>)...
Limits User Defined
Min 0.5 [-]
Max 12.5 [-]

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 Part B: Post-Processing

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From the Histogram, it can be seen that most of the accumulated Fragments are coming from bins
1 and 12 of the hopper.

This information may not have been obvious before the Divisions Tagging analysis. Now, an appro-
priate solution can be devised if this particular result is undesirable.

8.2.6. POST PROCESS - ISOLATE FRAGMENTS

It might also be useful to filter out the particles that actually broke; in Rocky, these broken particles
are called fragments.

One way to isolate these fragments is by using the Laguerre-Vonoroi Size property, which has the
following characteristics:

• It is measured only for breakage fragments.

• It is equal to the diameter of a sphere used to generate the fragments using the Laguerre-Voronoi
tessellation.

• This diameter, , can be defined as twice the minimum distance between a particle's center of
gravity, , and the particle's sides, , as shown in the following equation:
(8.3)

Using this property, the particles that did not break will have values equal to zero.

Therefore, to filter out only the fragments, we will select only the particles that have a Laguerre-
Vonoroi Size value greater than zero.

8.2.7. POST PROCESS - ISOLATE FRAGMENTS

Let's start by creating the Filter User Process.

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 Part B: Post-Processing

1. Use the information in the table below.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Filter User Process
B User Processes Property Property Laguerre-Voronoi
Size
Filter <01>
Type Range
Minimum Value 1e-10 [m]
Maximum Value 0.2 [m]

Then, to visualize in a 3D View window only the filtered fragments:

1. Select a 3D View window (or create a new one by pressing Ctrl + D).

2. Ensure the geometries are transparent (or hidden).

3. From the Data panel, hide Particles and all other Particles Calculations and User Processes
(besides Filter <01>) using the eye icons.

4. From the Data Editors panel, on the Filter <01> entity, select the Properties tab, and then drag
and drop Laguerre-Vonoroi Size onto the 3D View window. (Results shown below.)

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Tutorial - Cone Crusher

8.2.8. POST PROCESS - ISOLATE FRAGMENTS

The view now shows only the particles that have broken (fragments).

8.2.9. POST PROCESS - POWER DRAW

Earlier in Part A, we turned on the collection of some Boundary Collision Statistics; specifically,
those regarding Intensities.

We can now use the resulting data to estimate how much power is required by the equipment, which
is commonly known as Power Draw.

The Average Power Draw of the geometries can be estimated by the following expression:

(8.4)

where:

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 Part B: Post-Processing

• is the output time.

• is the Average Power Draw at the current output time.

• is the output time in which the operating conditions begin.

• is the output time in which the analysis ends.

• is the Output Frequency.

First, let's define .

1. Use the information in the table below to plot the power curves for the cone and shaft geometries.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Curves | Power Show Curve in New Plot

Mantle Cone
B Geometries Drag and Drop onto Time Plot <01>
window
Mantle Shaft

The plot shows the operation conditions start after 2.5 seconds (in which the breakage starts), so
= 2.5s.

Now, let's apply the Average Power Draw formula to the Power curve.

1. Use the information in the table below to continue with the analysis.

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Tutorial - Cone Crusher

Step Item Location Parameter Settings

or
Action
A Geometries Curves Add new custom curve (button)

Mantle
Shaft
B Add new Name Average Power
Output W
(dialog box)
unit
Inputs | (Enabled)
Power
C Custom Curves Expression cumsum(A)*OUTPUT_FREQUENCY/(TIME_ELAPSED-2.5)
(dialog box)

The new Average Power (Custom) curve appears on the Curves tab for the selected geometry, but
is also made available for all other geometries automatically.

Now, let's sum the Average Power of the Mantle Cone and the Mantle Shaft geometries to estimate
the Average Power Draw of the equipment:

1. Use the information in the table below to continue with the analysis.

Step Item Location Parameter or Settings

Action
A Geometries Curves | Average Show curve in new plot
Power (Custom)
Mantle Cone
B Geometries Drag and drop onto open Time Plot <02>
window
Mantle Shaft
C Time Plot <02> Table (tab) Add Formula
(window)
D Add Expression (dialog box) Curve Caption Average Power
Draw
Curve Expression B+C

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 Part B: Post-Processing

Each row of this table shows the average power measured from 2.5s to the time shown in Column
A.

Thus, the Average Power Draw of the simulation is in the last row of this table and it is 4840.28 W
(as shown).

Note:

The values you end up with in your project may vary slightly from the ones shown in this
Tutorial.

8.2.10. CONCLUSION
This completes Part B of this tutorial, in which Rocky was used to analyze the results from a cone
crusher simulation.

During this tutorial, it was possible to:

• Use Cube and Particles Time Selection User Processes to plot the PSD of fragments in a Histo-
gram.

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• Use a Cylinder User Process and Divisions Tagging Particle Calculations to track specific particles
and fragments through the equipment.

• Use the Property User Process and the Laguerre-Voronoi Size Property to isolate the particle
fragments from the whole particles.

• Use the Intensities Boundary Collision Statistics data we collected to calculate the power draw.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to next tutorial.

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Chapter 9: Tutorial - Tablet Coater
(Part A) Set up and process a simulation that can make use of the intra- and inter-particle collision
statistics modules that are included by default in Rocky, and import a custom convex particle shape.

(Part B): Use custom Polyhedron (Envelope) User Process shape to define the spray zone, and then make
use of the Residence Time information from that area to calculate the Coefficient of Variability (CoV).
Analyze the collision statistics and contacts data that was collected.

9.1. Part A: Project Setup and Processing

9.1.1. OBJECTIVE
The main purpose of this tutorial is to learn how to set up and process a simulation that can make
use of the intra and inter-particle collision statistics modules that are included in Rocky.

• We will be analyzing the simulation results and data collected in Part B and C.

The scenario considered is that of analyzing the performance of a tablet coating operation, which is
often used in the pharmaceutical and food processing industries.

You will learn how to:

• Import a custom particle shape

• Use Original Size Scale to define particle size

• Turn on the collection of various particle and contacts data

And you will use these features:

• Modules, including:

– Inter-particle Collision Statistics

– Intra-particle Collision Statistics

• Custom Polyhedron Import

9.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

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• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

9.1.3. GEOMETRY

The primary geometry used in this tutorial is the Drum, shown above.

Also, two additional geometries will be used, including:

• Spray_cone (used to create the polyhedron envelope)

• Tablet (used to create the custom particle shape)

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 Part A: Project Setup and Processing

9.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut09_files.zip file .

2. Unzip dem_tut09_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the table below to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar
with, please refer to the Rocky User Manual and/or other Tutorials (via the Intro-
ductory Tutorials and Advanced Tutorials) to find the detailed instructions you
need.

Step Data Entity Editors Location Parameter or Settings

Action
A Study Study Study Name Coater
B Physics Physics | Numerical Softening 0.01 [ - ]
Factor
Momentum

9.1.5. PROJECT SETUP

For the Modules step, we will be turning on the collection of some additional data for particles, in-
cluding:

• Inter-particle Collision Statistics | Normal Impact Velocity:

Collects the mean, standard deviation, skewness, and kurtosis values of the impact relative ve-
locity in the normal directions, resulting from the collisions recorded for each particle, during an
output timestep.

• Intra-particle Collision Statistics | Frequency:

Collects the collision frequency values measured by different regions of the representative particle
of the selected particle set. This can be useful for analyzing collision incidence on the particle surface.

1. Use the information in the table that follows to define your modules and other project settings.

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Tutorial - Tablet Coater

Step Data Entity Editors Location Parameter or Action Settings

A Modules Modules Inter-Particle (Enabled)
Collision Statistics
Intra-Particle (Enabled)
Collision Statistics
B Modules Inter-Particle Normal Impact (Enabled)
Collision Statistics Velocity
Inter-Particle
Collision
Statistics
C Modules Intra-Particle Frequency (Enabled)
Collision Statistics
Intra-Particle
Collision
Statistics
D Geometries Import Wall Drum.stl with "m"
for Import Unit
E Motion Frames Create Motion Frame
F Motion Frames Frame Name Rotation Motion
Add Motion
Frame <01>
Start Time 1 [s]
Type Rotation
Initial Angular 0, 0, 12 [rev/min]
Velocity
G Geometries Wall Motion Frame Rotation Motion

Drum
H Materials Material Use Bulk Density (Cleared)
Density 1150 [kg/m3]
Default
Particles
I Materials Materials Interactions Static Friction 0.39 [ - ]
| Dynamic Friction 0.39 [ - ]
Default Restitution 0.78 [ - ]
Particles Coefficient

Default
Boundary
Materials Interactions Static Friction 0.45 [ - ]
| Dynamic Friction 0.45 [ - ]
Default Particles Restitution 0.78 [ - ]
Coefficient
Default
Particles
J Particles Create Particle

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 Part A: Project Setup and Processing

For the Particles step, we will create a custom polyhedron particle set by importing an .stl file of a
tablet shape, as explained on the next section.

9.1.6. PARTICLE GROUP DEFINITION

1. Select the new <Particle <01> entry, and then from the main Particle tab, define the Shape as
Custom Polyhedron.

2. From the Select file to import dialog, navigate to the dem_tut09_files folder that you previously
downloaded, find the geometry folder, select the Tablet.stl file, and then click Open.

3. From the Import File Info dialog, ensure Import Unit is defined as m, and then click OK.

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Tutorial - Tablet Coater

Note:

The tablet shape we just imported is a perfect convex. To learn how Rocky handles im-
porting convex shapes that are not perfect, refer to the Appendix section at the end of
this tutorial.

9.1.7. ORIGINAL SIZE SCALE

For this tutorial, because we are importing our own custom shape, we will be using Original Size
Scale for the Size Type.

The Original Size Scale method allows you to use the size of the imported particle geometry as the
base from which you can scale your final particle size.

For example:

• A Scale Factor of 1 is equal to the original imported size (100%).

• A Scale Factor or 0.5 is equal to half the original size (50%).

• A Scale Factor of 2 is equal to double the original size (200%).

9.1.8. PARTICLE GROUP DEFINITION

To set the particle size, do the following:

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 Part A: Project Setup and Processing

1. From the Size sub-tab, select Original Size Scale from the Size Type list.

2. To visualize the newly created particle, click the View button. A new Particles Details window
will appear showing the (transparent) particle geometry, its geometric center (yellow dot), and its
center of mass (blue dot).

3. From the Coloring tab, enable the Edges checkbox to see the meshing in the Particle Details
view.

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Tutorial - Tablet Coater

Tip:

To ensure a good analysis of properties distribution on the particle surface, ensure that
you use a particle with a high resolution of triangles next to the edges.

9.1.9. INLET SETUP

1. Use the information in the table that follows to continue setting up your project.

Step Data Entity Editors Location Parameter or Settings

Action
A Inlets and Outlets Create Volumetric Inlet
B Inputs Volumetric Inlet | Add row (x1)
Particles (1) Particle | Particle <01> @ 2.7
Volumetric
[kg]
Inlet <01> Mass
Volumetric Region | Seed Coordinates 0, -0.1, 0 [m]
Region Geometries | Drum (Enabled)
Use Geometries to (Enabled)
Compute

9.1.10. CONTACTS COLLECTION

A Contact in Rocky refers to a specific location on a geometry or particle that has experienced a
collision with another particle during the simulation.

Always during processing, Rocky calculates and makes use of Contacts data. But to save file space,
you can choose whether or not to keep it.

For this tutorial, we will enable the collection of the Contacts data so that we can analyze the Stress
Components of the particles later in post-processing.

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 Part A: Project Setup and Processing

1. From the Data panel, select Contacts and then from the Data Editors panel, ensure the Contacts
tab is selected.

2. Enable the Collect Contacts Data checkbox.

9.1.11. SOLVER DEFINITION

1. Now, use the information in the table that follows to define your Solver parameters.

Step Data Entity Editors Location Parameter or Settings

Action
A Solver Solver | Time Simulation Duration 60 [s]
Solver | General Simulation Target GPU

Note:

Because this tutorial has convex particles, processing with GPU will be faster if you have
that option.

9.1.12. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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9.1.13. SIMULATION SUMMARY

1. From the Solver entity, click Start.

The Simulation Summary screen appears, then processing begins.

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 Part A: Project Setup and Processing

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

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9.1.14. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a tablet coating
simulation.

During this tutorial, it was possible to:

• Turn on the collection of particle collision statistics and contacts data for later analysis.

• Import a custom particle shape.

• Use Original Size Scale to define particle size.

What's Next?

• If you have completed this tutorial successfully, then you are ready to move on to Part B and post-
process this project.

9.1.15. APPENDIX: CONVEX AND CONCAVE DETECTION

The tablet shape we imported in this tutorial is a perfect convex, meaning it contains no faces that
form dents or hollows.

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 Part B: Post-Processing

Rocky categorizes even mostly convex shapes as concave if there is even the smallest dent or hollow
detected.

• In a convex shape, any straight line that connects any two faces will always be contained inside
the shape (a).

• In a concave shape, a similar line connecting two faces may have portions that fall outside the
shape (b).

Because Rocky uses different calculations for shapes it categorizes as concave, it is very important
that you make sure Rocky categorizes your shape the way you want.

If you ever want to import a particle shape that is not a perfect convex (but you still want Rocky to
treat it as such), you can take one of the following steps:

1. Improve your convex .stl design and then re-import it into Rocky.

-OR-

2. Allow Rocky to redraw the shape to ensure it is categorized as convex.

If Rocky detects that your convex shape is imperfect, it will ask you to choose one of the following
options (as shown):

1. Keep the shape as is: The particle will be treated as concave, and will use concave-based calcu-
lations.

2. Convert the shape to convex: Rocky will redraw the imperfect shape to ensure it is categorized
as convex, and will use convex-based calculations.

9.2. Part B: Post-Processing

9.2.1. OBJECTIVE
The main purpose of this tutorial is to analyze the results and data that was collected from the tablet
coating simulation we set up and processed in Part A.

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You will learn how to:

• Import a custom Polyhedron User Process shape

• Use the Residence Time information to calculate the Coefficient of Variability (CoV)

• Analyze the collision statistics and contacts data that was collected

And you will use these features:

• Polyhedron (envelope) User Process

• Particles Calculations (Residence Time)

• Eulerian Statistics

• Time Statistics properties

9.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

9.2.3. OPEN PROJECT

If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue from
where Part A left off.)

If you did not complete Part A, do all of the following:

1. Download the dem_tut09_files.zip file .

2. Unzip dem_tut09_files.zip to your working directory.

3. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop shortcut.)

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or later.
If you have an earlier version of Rocky, please upgrade Rocky to the latest version, or
complete Part A from scratch.

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 Part B: Post-Processing

4. From the Rocky program, click the Open Project button, find the dem_tut09_files folder, then
from the tutorial_09_A_pre-processing folder, open the tutorial_09_A_pre-processing.rocky
file.

5. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

With the processing complete, we can now begin analyzing the simulation results.

9.2.4. PARTICLE RESIDENCE TIME

With coating processes like the one shown, it is really important to guarantee that each Particle
spends enough time in the coating region (spray zone).

Rocky allows the creation of a new Property variable, Residence Time, which computes the time
each particle spent inside a predefined User Process region (Cube, Cylinder, or Polyhedron).

For this tutorial, two Polyhedron User Processes, representing two elliptic spray cones, will be im-
ported using an .stl geometry.

Representation of the Tablet Coating Process with Nozzles and Spray Cone:

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Drum Showing Newly Imported Polyhedron User Process Shape:

9.2.5. USER PROCESS – POLYHEDRON 1

To import the first Polyhedron:

1. From the Data panel, right-click Particles, point to Processes, and then select Polyhedron (En-
velope).

2. From the Select the STL file for the polyhedron dialog, navigate to the dem_tut09_files folder
that you previously downloaded, find the geometry folder and then select the Spray_Cone.stl
file, and then click Open.

3. From the Import File Info dialog, set the Import Unit to mm, and then click OK.

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 Part B: Post-Processing

4. From the Data panel, under User Processes, select the newly created Polyhedron <01> entry.

5. From the Data Editors panel, on the Polyhedron tab, set the Center and the Scale.

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9.2.6. USER PROCESS – POLYHEDRON 2

To import the second Polyhedron:

1. Repeat the process on the previous section to create another Polyhedron (Envelope) User Process,
select the same Spray_Cone.stl geometry, and import it in mm.

2. From the Data panel, under User Processes, select this new Polyhedron <02> entry and then
from the Data Editors panel, set the Center and the Scale.

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 Part B: Post-Processing

After this second import you should have two Polyhedrons representing the spray nozzles.

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9.2.7. POST PROCESSING – PARTICLE RESIDENCE TIME

Now that we have imported the two cones, we can apply the Residence Time Particle Calculation
over them to analyze how much time each Particle spends inside each of the cone regions.

1. From the Data panel, right-click Particles, point to Particles Calculations, point to Residence
Time, and then select Polyhedron <01> (as shown). A new Calculations entity named Residence
Time (Polyhedron <01>) will be created.

2. Repeat this step for the Polyhedron <02> User Process.

By combining the Residence Time results from each cone, we will be able to see how well the full
spray zone is coating the particles over time.

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 Part B: Post-Processing

We will do this combination by creating a Custom Property for Particles.

1. Use the information in the table that follows to continue setting up your project.

Step Item Location Parameter or Action Settings

A Particles Properties Add new custom property (button)
B Add new (dialog box) Name Total Residence
Time
Output unit s
Inputs | Residence Time (Enabled)
(Polyhedron <01>)
Inputs | Residence Time (Enabled)
(Polyhedron <02>)
C Custom Property (dialog Expression A+B
box)

A new property called Total Residence Time (Custom) will appear among the Particles Properties.

This can be used like any other Property to color the Particles and/or create new plots.

1. From the Data Editors panel for the main Particles entity, select the Coloring tab and then under
Nodes, select Total Residence Time (Custom) for Property.

2. Use the Time slider to view the changes at different output times.

Note:

You may have to hide the Polyhedrons user processes using the eye icons on the Data
panel.

As shown in the screenshots below, some particles spend more time in the spray zone than others.
At 60 s, the coating is still rather uneven as seen by the presence of many different colored particles.

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9.2.8. POST PROCESSING – INTER TABLET VARIABILITY (COV)

The Inter-tablet Coefficient of Variability (CoV) can be defined as the ratio between the Standard
Deviation of coating mass over the Average of coating mass.

The coating mass depends primarily on the Residence Time inside the spray zone, so we can define
the CoV as:

(9.1)

To create the CoV analysis, we need to start with a Time Plot. Follow the instructions on the next
few slides.

1. Create a new Time Plot. (From the Window menu, click New Time Plot (Ctrl+T).)

2. Use the information in the table that follows to define the Time Plot.

9.2.9. TIME PLOT

Step Item Location Parameter or Action Settings
A Particles Properties | Total Drag and drop onto the Time Plot window
Residence Time
(Custom)
B Select the Statistics to Plot (dialog box) Average (Enabled)
Std. Deviation (Enabled)

1. Right-click whithin the plot grid, point to Axes Layout, and then click By Quantity.

Now, let's calculate the Coefficient of Variability (CoV) by creating a new Formula in the Time Plot.

1. Use the information in the table that follows to define the formula.

Step Item Location Parameter or Settings

Action
A Time Plot Table (tab) Add Formula

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 Part B: Post-Processing

Step Item Location Parameter or Settings

Action
B Add Expression (dialog box) Curve Caption CoV
Curve Expression B/C

Note:

For the formula to work, the expression must represent the Std. Deviation divided by
the Average of the Total Residence Time (Custom) property. If your columns appear
in a different order, adjust the formula accordingly.

2. Scroll down to the end of the table and note that the CoV at 60 s reaches only 20%.

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3. Switch back to the Plot tab.

4. At the top of the tab, click the curve names for Std. Deviation and then Average to hide them
from the plot (as shown). The CoV curve will be the only one visible.

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 Part B: Post-Processing

5. From the Plot tab, right-click the Time axis, and then click Customize Axis.

6. Use the information in the table below to define the Axis Configuration values.

Step Item Location Parameter or Action Settings

A Axis Axis | Time Values | Limits User
Configuration (s) Defined
(dialog box) Values | Min 0.05 [s]
Values | Max 100 [s]
Values | Step 1 [s]
Scale Options | Logarithmic (Enabled)
Scale
Axis | Values | Limits User
Defined
CoV(
Values | Min 0.1 [s]
B/C ) ( -
) Values | Max 10 [s]
Values | Step 1 [s]
Scale Options | Logarithmic (Enabled)
Scale

7. Click OK.

9.2.10. POST PROCESSING – COV

When you configure the graph with the CoV results in a log-log plot (right and bottom axes only),
you obtain the graph shown.

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A common analysis is to extrapolate the CoV results to estimate the time needed for a specific value
of CoV.

With the extrapolation, you do not need to run the full, extended simulation (which can take many,
many hours to process).

The linear region at the end of the log-log plot (steady state) is seen after 10 s of simulation time,
and will be used as the basis for the extrapolation.

It is possible to extrapolate the CoV results by using a separate spreadsheet program.

We will accomplish this by exporting the data out of the plot into a .csv file, opening that file in a
separate spreadsheet program, and then using that program to manipulate the data as needed.

Let's start by exporting the Curve data:

1. Right-click an empty space within the plot, point to Export, and then click Curves.

2. From the Export Configuration dialog, clear the Average and Std. Deviation checkboxes (as
shown), and then click OK.

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3. From the Export Curve(s) dialog, enter a File Name for the resulting .csv file, choose a folder
location, and then click Save.

4. Open the resulting .csv file in a spreadsheet program.

5. Using the spreadsheet program, fit a curve to the CoV results by using the following equation:

(9.2)

where:

• is the CoV

• and are fitting constants

• is the time

6. For the extrapolation, use the steady state time range between 10 - 60 s. (Results shown as orange
dotted line.)

7. Using a desired regularization limit of 6.25% CoV (shown as green dotted line), locate the time it
meets the fitted CoV (shown as red dot).

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According to the literature (Boehling et al., 2016 [1] (p. 543)), the value of the exponential constant
should be close to -0.5.

Based on the graph on the previous slide, the following conclusions can be made:

• The adjusted value obtained by the Rocky CoV results achieved a value of -0.524, which is close to
the desired value.

• To reach the desired 6.25% CoV regulation limit, you need approximately 0.149 hours (or 536.4
seconds) of simulation time.

9.2.11. EULERIAN STATISTICS

The discrete Properties can be converted into continuous values, by averaging the values over dis-
cretized regions, using the Eulerian Statistics User Process.

The Eulerian Statistics should be created on a Cube or Cylinder User Process.

For this case, a Cylinder will be created.

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9.2.12. USER PROCESS – CYLINDER

1. Use the table below to define these processes.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Cylinder User Process
B User Processes Cylinder Size 0.365, 0.2, 0.365
[m]
Cylinder <01>
Center 0, 0, 0 [m]
… | Orientation Method Angles
Rotation 90, 0, 0 [dega]
C User Processes Create a Eulerian Statistics User Process

Cylinder <01>
D User Processes Eulerian Statistics Radial Divisions 20 [ - ]
Tangential Divisions 72 [ - ]
Eulerian
Statistics <01> Axial Divisions 1[-]

This will discretize the Cylinder into 72 circular sectors, each one having 20 divisions in the radial
direction. A single bin is defined in the axial direction.

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9.2.13. EULERIAN STATISTICS

New Properties specifically for Eulerian Statistics will be available to plot on the Eulerian's bins, in-
cluding Stress Components, Transformed Velocity, and so on.

Once the Eulerian Statistics is created, the Transparency, Edges, and Color can be modified on the
Coloring tab:

1. With a 3D View opened, use the information in the table that follows to define these values.

Step Data Entity Editors Location Parameter or Settings

Action
A User Processes Coloring Faces | Property Local T-Velocity
Faces | Show on (Enabled)
Eulerian
Node?
Statistics <01>
Edges (Cleared)

Tip:

When you enable a Property for Faces, the option Show on Node? allows for the
continuous display of the plotted Property.

Tip:

Ensure the Visible checkbox is enabled.

2. From the Data panel, click the Particles eye icon to hide the previous particle calculation.

Updated results shown.

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9.2.14. TIME STATISTICS PROPERTIES

Rocky can also create Time Statistics of those Properties, providing Average, Maximum, Minimum,
and Sum values.

To evaluate the maximum shear stress during the bed cycles, do the following:

1. From the Data Editors panel, select the Properties tab for the Eulerian Statistics.

2. From the top right of the selected tab, click the icon for Add and edit time statistics properties
(as shown).

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3. From the Edit time statistics properties dialog, click the Add button (green plus).

4. From the Add time statistics properties window, specify the Start and Stop time of the analysis,
the Operations and the Properties to evaluate (as shown), and then click OK.

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 Part B: Post-Processing

5. Click OK again on the Edit time statistics properties window.

6. From the Properties tab, under Time Analysis, select the newly created Average of Stress
Component [40 s, 60 s] property, and then drag and drop it onto the 3D View for Eulerian
Statistics. (Results shown below.)

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This average analysis helps identify the location in the coater where particles experience a higher
value of Stress.

Important:

To be able to analyze Stress Components, you must have enabled the Collect Contacts
Data checkbox from Contacts entity on the Data panel prior to processing your simula-
tion.

As a reminder, we took this step in Part A, so this data should now be available to analyze.

9.2.15. INTRA-PARTICLE COLLISION STATISTICS

Earlier in the setup portion of this tutorial (Part A), you turned on the collection of Intra-particle
Collision Statistics.

The intra-particle collision statistics represent the full transient analysis of all particles in the domain
shown on a single representative particle.

During the simulation, relevant collision data is stored between two consecutive output time levels.

It is important to note that each result represents the time average between the current output and
the previous.

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 Part B: Post-Processing

So, if you want to do an analysis spanning the full simulation time, you need to include a new ex-
pression to account for all of the outputs.

Another important point is the geometry resolution of the particle. To achieve a good analysis, ensure
that you use a particle with a high resolution of triangles next to the edges.

1. Use the information in the table below to create this new particle time statistics property.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Properties Add and edit time statistics properties
(button)
Particles <01>
B Edit time statistics properties (dialog box) Add property (button)
C Add time statistics properties (dialog box) Start time 40 [s]
Stop time 60 [s]
Operations | (Enabled)
Average
Properties | (Enabled)
Frequency

2. From the Data panel, under Particles, select Particle <01>.

3. From the Data Editors panel, on the Particle tab, click View.

A new Particles Details window opens.

4. From the Properties tab, under Time Analysis, select the newly created Average of Frequency
[40s, 60s] property, and then drag and drop it onto the Particles Details window. (Results shown
below.)

5. From the Particle <01> entity, on the Coloring tab, clear the Transparency checkbox.

This shows the average collision frequency per particle recorded in different regions (triangles) of the
particle shape.

• We can see that the number of collisions is highest at the corners and edges and lowest on the
flat surfaces of the particle.

• We can therefore conclude that when particles of this shape collide with other particles and with
the drum walls, they do so most often on their corners and edges.

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9.2.16. INTER-PARTICLE COLLISION STATISTICS

Earlier in the setup portion of the tutorial (Part A), we turned on the collection of Inter-particle
Collision Statistics.

These can be useful when you need to extract data considering all collisions that happened to a
certain particle during an interval between two consecutive output times.

For example, with impact velocity, you could relate that data to the chances of the particle breaking
or causing it to de-agglomerate. With duration, you could relate that data to a certain mass or heat
transfer process, or to a certain chemical reaction.

It is important to note that each result represents the time average of data collected during an interval
between two consecutive output times.

On the next slides, the Impact Velocity will be analyzed to show potential moments of high energies
(and possible breaking).

1. From the Data panel, select Particles.

2. From the Data Editors panel, select the Properties tab.

3. Under Translational Velocity, right-click Velocity : Impact : Normal : Mean, point to 3D View,
and then click Show in new 3D View. (Results shown.)

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Tip:

To see the particles, you may need to make the Drum geometry transparent.

9.2.17. CONCLUSION
This completes Part B of this tutorial, in which Rocky was used to post-process a Tablet Coating
simulation.

During this tutorial, it was possible to:

• Import two custom polyhedron user process shapes to analyze residence time.

• Calculate, plot, and then extrapolate the Coefficient of Variability (CoV).

• Analyze the Intra- and Inter-particle collision statistics data that was collected.

• Use Eulerian Statistics and Time Statistics to evaluate Stress Components.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to Part C and further
analyze the spray zone.

9.3. Part C: Spray Zone Evaluation

9.3.1. OBJECTIVE
The purpose of this tutorial is to use the Coating Visibility Wizard on the tablet coating simulation
we set up and processed in Part A to further investigate the coating variability on the particles.

This method uses the camera position of a 3D View window to define the spray area. The wizard then
computes the amount of exposure on each particle (or particle region), which is a more accurate
method than the procedure we used in Part B.

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You will learn how to:

• Import and run saved PrePost scripts in the PrePost Scripts panel

• Use the wizard results to analyze the Coefficient of Variability (CoV)

• Use the wizard results to analyze the visibility on the particle shape itself

And you will use these features:

• PrePost Scripts panel

9.3.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

9.3.3. OPEN PROJECT

If you completed Part A (and/or Part B) of this tutorial, ensure that Rocky project is open. (Part C will
continue from where Part A and/or Part B left off.)

If you did not complete Part A (nor Part B), then do all of the following:

1. Download the dem_tut09_files.zip file .

2. Unzip dem_tut09_files.zip to your working directory.

3. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or later.
If you have an earlier version of Rocky, please upgrade Rocky to the latest version, or
complete Part A from scratch.

4. From the Rocky program, click the Open Project button, find the dem_tut09_files folder, then
from the tutorial_09_A_pre-processing folder, open the tutorial_09_A_pre-processing.rocky
file.

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 Part C: Spray Zone Evaluation

5. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

With the processing complete, we can now begin analyzing the simulation results.

9.3.4. PARTICLE VISIBILITY

The spray area of the coating operation will be determined by the camera location, orientation, and
level of zoom of a 3D View window.

The window's focus will act like a nozzle and the visible particles will be exposed to the coating.

Representation of the tablet coating process with nozzles and spray region:

Region of interest (in yellow) where the 3D View window should be focused:

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The Visibility is the Percentage that a particle (or particle region) occupies within the camera view
in a given time and is accounted by a pixel by pixel verification.

Particles Visibility (camera view)

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 Part C: Spray Zone Evaluation

Particles Visibility (another angle)

The visibility computation is available only through the Coating Visibility Wizard.

9.3.5. COATING VISIBILITY WIZARD

The Coating Visibility Wizard is a complete application that runs inside Rocky and enables you to
quickly and easily define the nozzle parameters for your coating applications.

• Preview capabilities are available inside the wizard, which enables to visualize the Spray Mask and
Nozzle parameters before running the wizard.

• The wizard includes embedded post-processing capabilities, which enables you to analyze the
coating Visibility results.

This wizard calculates the coating Visibility for each output time and then automatically creates new
properties based on those calculations.

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1. To start, show the PrePost Scripts panel by selecting it from the Tools menu.

2. Click here to download the Coating Visibility Wizard, and then extract the coating_visibility_wiz-
ard folder from the zip folder to your computer.

3. From the coating_visibility_wizard folder, copy both the script_coating_visibility_wizard.py

script and the script_coating_visibility_wizard.py.files folder to your clipboard.

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4. From the Rocky PrePost Scripts panel, with the first Scripts shared across projects tab selected,
click the Open Scripts Directory button.

5. Within the %HOMEPATH%\Documents\Rocky\Scripts folder that opens, paste the script and
folder you copied.

6. The new script will appear in the PrePost Scripts panel on the Scripts shared across projects
tab.

To run the Coating Visibility Wizard, do the following:

1. Click the Playback Script button.

Note:

The wizard calculates the visibility at each separate output. Because of that, it might take
some time to complete the calculations.

Because the Coating Visibility Wizard is a complete application that runs inside Rocky,
you can not interact with Rocky while the wizard is running.

The Coating Visibility Wizard will appear as a new window showing the Setup tab.

This wizard enables you to easily define the nozzles parameters. You can add as many nozzles as you
need and then configure them.

Note:

When more than one nozzle is used, the wizard will change the camera position at each
output time in order to analyze the region of each nozzle.

Follow the procedures below to define your setup (as shown).

1. On the Nozzle Injection sub-tab, from the Axis Direction field, define the Drum rotation direction
as +Z.

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2. From the Nozzles field, click the Add button (green plus) to create an nozzle entry.

3. For both 1 and 2 nozzles, define the Y coordinate, Z coordinate and Orientation angle.

Note:

The options for the Axis Direction will be used to position the nozzles. Ensure you define
it correctly and check it on the Nozzles Preview field.

This wizard supports masks for the visibility calculation in case you want to calculate the visibility in
rectangular, elliptical and custom areas.

• The mask emulates the spray shape of the nozzle.

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1. Select the Spray Mask sub-tab, and then define all of the following (as shown):

• Spray mask type

• White core horizontal length

• White core vertical length

Note:

The Mask Preview will help you to correctly define the mask (as shown).

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The darker the pixel, the higher the opacity. Thus, the black borders of the image will be ignored by
the camera. The images below illustrate how the visibility is computed combining the camera view
and the mask:

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On the General sub-tab, you can define options for the Spray Time and Post Processing.

Follow the procedures below to continue defining your wizard setup.

1. Select the General sub-tab, define the Spray start time as 3.0 (as shown) and check the other
options to match the screenshot.

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For more information about this wizard and its parameters, access the Scripts Manual from the Help
menu tab (as shown).

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1. Now your Coating Visibility Wizard is set up. From the Setup tab, click the Calculate button:

Note:

The wizard calculates the visibility at each separate output. Because of that, it might take
some time to complete the calculations.

After the wizard finishes its calculations, a confirmation message will appear (as shown).

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Note:

You can remain inside the wizard to do some types of visibility post-processing (as shown
on the next sections). Outside of the wizard, you also have new properties for the Particles
entity in Rocky and new files located in the project's simulation folder.

9.3.6. COATING VISIBILITY WIZARD – INTER-TABLET VARIABILITY (CoV)

After the wizard finishes its calculations, the wizard will point to a new Results tab.

This wizard automatically generates an analysis of Inter-tablet coating variability (CoV). It also generates
an extrapolation for the available data.

You can easily find the amount of time related to a specific CoV value.

In addition, the wizard also gives you the option to change the extrapolation parameters. From the
Results tab, in the Power Law Extrapolation section, you have the following options (as shown):

• Initial time (used to define the beginning of the interpolation range)

• CoV limit

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To generate the CoV plot of the previous side, firstly the wizard need to estimate the coating mass
one particle receives in a given output interval:
(9.3)

where:

• is the coating mass of the -th particle, when time is equal to .

• is the spray mass flow rate.

• is the particles visibility of the -th particle, when time is equal to .

• is the output interval.

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To estimate the total coating mass:

(9.4)

where:

• is the cumulative visibility of the -th particle, when time is equal to .

The Inter-tablet coating variability ( ) can be defined as the ratio between the Standard Deviation
of coating mass over the Average of coating mass in a given time.

(9.5)

It can be rewritten as:

(9.6)

The product is constant, so:

(9.7)

Therefore, it is possible to calculate the through the ratio between the Standard Deviation of
Total Cumulative Visibility over the Average of Total Cumulative Visibility.

(9.8)

The Coating Visibility Wizard shows the CoV results in a log-log plot (vertical and horizontal scales
shown).

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A common analysis is to extrapolate the CoV results to be able to estimate the time needed for a
specific value of CoV.

With the extrapolation, you do not need to run the full, extended simulation (which can take many,
many hours to process).

The wizard itself defines the linear region, which is at the end of the log-log plot (steady state) after
30 s of simulation time, and was used as the basis for the extrapolation.

The linear region can be fitted by a power law equation:

(9.9)

where:

• is the CoV.

• and are fitting constants.

• is the time.

According to the literature (Boehling et al., 2016 [1] (p. 543)), the value of the exponential constant
should be close to -0.5.

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Based on the graph on the previous slide, the following conclusions can be made:

• The adjusted value obtained by the Coating Visibility Wizard's CoV results achieved a value of -
0.486, which is close to the desired value.

• To reach the desired 6.25% CoV regulation limit, you need approximately 0.7 hours (or 2520 seconds)
of simulation time, which is much longer than the simulation time estimated earlier in Part B of
this tutorial.

9.3.7. POST PROCESSING – VISIBILITY

After finishing the analyses inside the Coating Visibility Wizard, you can close the wizard and go
back to the Rocky UI.

The wizard has created two new particles properties for each nozzle:

Note:

You will also have these properties for each particle group in case you have a shaped
particle. In this case, these properties are related to each triangle of the particle surface.

• Instantaneous Visibility: Returns the fraction of the 3D View area exposed per particle at the
currently selected output time. If a faceted particle is used, this returns the average triangle visibility
at the current output for all the particles in each Particle Group.

• Cumulative Visibility: Returns the cumulative visibility from the initial output time up to the cur-
rently selected one. If a faceted particle is used, this returns the cumulative triangle visibility from
the initial output time up to the currently selected output time for all the particles in each Particle
Group.

Also, for each of the previously properties, the wizard has created a new property to evaluate the
contribution of each nozzle. The following equation was applied for each property:

(9.10)

where:

• is the total visibility property for the coater.

• is the visibility property of each nozzle.

The wizard has created two new particles properties for the total visibility:

Note:

You will also have these properties for each particle group in case you have a shaped
particle. In this case, these properties are related to each triangle of the particle surface.

• Instantaneous Visibility Coater

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 Part C: Spray Zone Evaluation

• Cumulative Visibility Coater

9.3.8. POST PROCESSING – PARTICLES VISIBILITY

To access the Particles Visibility property:

1. From the Data panel, select Particles.

2. From the Data Editors panel, select the Properties tab.

3. To visualize the Particles Visibility, drag and drop Instantaneous Visibility Coater onto a 3D
View window (results shown).

To visualize the Cumulative Visibility:

1. From the Data panel, select Particles.

2. From the Data Editors panel, select the Properties tab, and then drag and drop Cumulative
Visibility Coater onto a 3D View window. (Results shown.)

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For this tutorial, we are mainly interested in the Cumulative Visibility, which is directly proportional
to the injected mass.

Note:

Use the Time slider to see how the property changes over time.

As shown in the screenshots below, some particles spend more time in the spray zone than others.
At 60 s, the coating is still rather uneven as seen by the presence of different colored particles.

9.3.9. POST PROCESSING – TRIANGLE VISIBILITY

To visualize the Cumulative Visibility on the Particle Group:

1. From the Data panel under Particles, select Particle <01>.

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 Part C: Spray Zone Evaluation

2. From the Data Editors panel, on the main Particle tab, click the View button. A new Particles
Details window appears.

3. From the Data Editors panel, select the Properties tab, and then drag and drop Cumulative
Visibility Coater onto the Particles Details window.

4. From the Time toolbar, select the last output time.

5. From the Coloring tab, clear the Transparency checkbox (results shown).

6. From the Data Editors panel, on the Coloring tab, under Faces, enable the Show on Node?
checkbox (as shown).

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The results show that at 60 seconds into the simulation, most parts of the particle achieved some
amount of coating coverage, with the highest values concentrated on the corners as well as the the
upper and lower flat regions of the particle.

9.3.10. CONCLUSION
This completes Part C of this tutorial, in which Rocky was used to analyze the spray zone and particle
coating results from the Tablet Coating simulation we set up and processed in Part A.

During this tutorial, it was possible to:

• Import and run the Coating Visibility Wizard.

• Analyze the CoV results generated by Coating Visibility Wizard, and the particle visibility itself.

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What's Next?

• If you completed this tutorial successfully, then you are ready to move on to next tutorial.

9.3.11. BIBLIOGRAPHY

Bibliography
[1] Boehling et al.. Analysis of large-scale tablet coating: Modeling, simulation and experiments. European
Journal of Pharmaceutical Sciences. 90. 14–24. 2016.

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Chapter 10: Tutorial - Bucket Conveyor
(Part A) Learn how to set up and process a simulation using periodic motions, replicated geometries
and periodic injection of material.

(Part B) Learn how to analyze the trajectories of the particles from the periodic injection, as well as the
mass flow during surge periods and the mass load in each bucket.

10.1. Part A: Project Setup and Processing

10.1.1. OBJECTIVE
The purpose of this tutorial is to learn how to use periodic motions with replicated geometries.

The scenario considered is a bucket conveyor experiencing surges of material from inconsistent
loading.

• We will post-process the results of this simulation in Part B.

You will learn how to:

• Define a motion that can be repeated on a periodic basis

• Replicate a geometry component multiple times along a defined path

• Simulate a surge loading scenario by using periodic injection

And you will use these features:

• Inlets

• Periodic Motion

• Geometry Replication

• Periodic Injection

10.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

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• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

10.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Feed Conveyor

• (2) Belt

• (3) Box

• (4) Bucket

• (5) Hopper

• (6) Rolls

• (7) Structure

The first item will be created from a Rocky conveyor template.

The remaining components will be imported as .stl files, all of which can be found in the tutorial
directory.

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 Part A: Project Setup and Processing

10.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut10_files.zip file .

2. Unzip dem_tut10_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the table below to start setting up your Rocky project.

Step Data Editors Location Parameter or Action Settings

Entity
A Study Study Study Name Bucket Conveyor
B Physics Physics | Momentum Rolling Resistance Model Type C: Linear Spring
Rolling Limit
Numerical Softening 0.1 [ - ]
Factor

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

10.1.5. GEOMETRY SETUP

For the Geometries step, we will import the following 6 geometry files in .stl format:

We will also add a default Feed Conveyor, and then create two separate Inlets (from two different
Surfaces) from which to release the regular and surge material, respectively.

1. Use the information in the table that follows to import and create these components.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Import Wall All 6 .stl files with "mm"
for Import Unit
B Geometries Create Feed Conveyor

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Tutorial - Bucket Conveyor

Step Data Entity Editors Location Parameter or Settings

Action
C Geometries Feed Conveyor | Transition Length 1 [m]
Loading Length 2 [m]
Feed Geometry
Conveyor Belt Width 0.5 [m]
<01> Belt Thickness 0.0125 [m]
D Geometries Feed Conveyor | Alignment Angle 90 [dega]
Vertical Offset 0.6 [m]
Feed Orientation
Conveyor Horizontal Offset -0.07 [m]
<01> Out-of-plane Offset 0.95 [m]
E Feed Conveyor | Width 0.45 [m]
Length 1.5 [m]
Skirtboard
Skirtboard Length 0.2 [m]
Length Offset 0.5 [m]
F Feed Conveyor | Drop Box Length 1 [m]
Drop Box Width 0.75 [m]
Feeder Box
Drop Box Heigth 0.25 [m]
Wall Thickness 0.00625 [m]
G Feed Conveyor | Face Width 0.5 [m]
Diameter 0.1 [m]
Head Pulley
H Geometries Feed Conveyor | Belt Speed 0.75 [m/s]

Feed Belt Motion

Conveyor
<01>
I Geometries Create Rectangular Surface
J Geometries Rectangular Name Regular Feed
Surface Center Coordinates -0.05, 1.6, 3.2 [m]
Rectangular Length 0.7 [m]
Surface Width 0.55 [m]
<01>
Orientation Angles
Rotation 310, 0, 0 [dega]

Tip:

For more information about setting up Feed Conveyors, refer to Tutorial 06 – High
Pressure Grinding Roll (HPGR).

2. From the Data panel, under Geometries, right-click Regular Feed and then click Duplicate.

3. Use the information in the table that follows to define the new Regular Feed <01> component.

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Settings

Action
K Geometries Rectangular Surface Name Surge Feed
Center Coordinates -0.05, 1.6, 3.75 [m]
Regular Feed
<01> Rotation 50, 0, 0 [dega]

Now that all of the geometries are included in your project, you can visualize them in a 3D View
window.

10.1.6. BOUNDARY MOVEMENT

Turning the geometry for a single bucket into a full, 20-bucket conveyor involves the following steps:

• (1) The complex motion of the single bucket moving up and around the conveyor is defined using
a single motion frame.

• (2) Periodic motions are turned on for this frame, which enables the entire motion set to be re-
peated at a prescribed interval.

• (3) The motion frame is assigned to the bucket geometry.

• (4) Rocky is then instructed to repeat the geometry (including its assigned motions) 20 times at
regular intervals along the motion path.

For the Motion Frames step, we will accomplish the first two steps above by creating a single frame
with four separate motions, as explained below.

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Tutorial - Bucket Conveyor

The complex bucket motion can be defined on a single frame using four separate motions:

• The translation motion of the right-side-up bucket moving up the front side of the conveyor.

• The rotation motion of the bucket arching over the top of the conveyor to turn upside down.

• The translation motion of the upside-down bucket moving down the back side of the conveyor.

• The rotation motion of the upside-down bucket arching over the bottom of the conveyor to turn
right-side up again.

The fourth motion brings the bucket back to the starting point, so to keep the bucket moving, the
entire, four-part motion set must be repeated.

In Rocky, this motion repetition is done via Periodic Motions.

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 Part A: Project Setup and Processing

The four separate motions within the frame will be defined using the bucket velocity and belt length.

Important:

Note that the full bucket motion includes two straight paths and two curved paths.

• The bucket velocity: 1.15 m/s

• The length of the straight path (w): 4.66174 m

• The radius of the curved path (r): 0.15999 m

• The bucket takes 4.05368 s to complete the straight path and 0.43706 s to complete the curved
path

Using this information, we can then determine that one full revolution takes 8.98148 s.

Note:

This value will be important both when setting up Periodic Motions and Geometry
Replications later.

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Tutorial - Bucket Conveyor

10.1.7. PERIODIC MOTION

When Enable Periodic Motion is turned on for a frame, the full list of motions contained within that
frame will be repeated as soon as the Periodic Motion Period completes.

The total time between the earliest motion's Start Time (in our case, 0 s) and the latest motion's
Stop Time (in our case, 8.98148 s) is saved within Rocky as the periodic motion period.

As we want the motion to repeat as soon as the last motion finishes, we will set the Periodic Motion
Period as equal to the motion total time.

The full list of motions contained within the frame will be repeated until it reaches the Periodic Stop
Time.

10.1.8. MOTION FRAME

Now that you understand more about periodic motions, you can create the single motion frame that
will contain the four separate bucket motions.

1. Use the information in the table that follows to define this Motion Frame, and assign it to the
bucket geometry.

Step Data Entity Editors Location Parameter or Action Settings

A Motion Frames Create Motion Frame
B Motion Frames Frame Name Bucket Motion
Relative Orientation | -30 [dega]
Frame <01>
Angle
Enable Periodic Motion (Enabled)
Period 8.98148 [s]

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Action Settings

Add Motion
Stop Time 4.05368 [s]
Velocity 0, 1.15, 0 [m/s]
C Motion Frames Frame Add motion (2 of 4)
Start Time 4.05368 [s]
Bucket
Motion Stop Time 4.49074 [s]
Type Rotation
Initial Angular Velocity -7.18794, 0, 0
[rad/s]
Add motion (3 of 4)
Start Time 4.49074 [s]
Stop Time 8.54442 [s]
Velocity 0, 1.15, 0 [m/s]
Add motion (4 of 4)
Start Time 8.54442 [s]
Stop Time 8.98148 [s]
Type Rotation
Initial Angular Velocity -7.18794, 0, 0
[rad/s]
D Geometries Wall Motion Frame Bucket Motion

Bucket

The completed Motion Frame setup should now look similar to the image below.

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For this tutorial, since the geometry has a motion with displacement assigned, the movement can
be previewed using the Motion Preview window.

Tip:

Use the eye icons on the Data panel to hide all but the Bucket and Belt components from
the view.

Later in Part B of this tutorial we will analyze two buckets separately using moving cubes.

Note:

A moving cube is a definition for a Cube User Process with a Motion Frame assigned to
it.

Motions must be created before processing any simulation.

Follow the steps in the table below to create the second Motion Frame.

Step Data Entity Editors Location Parameter or Action Settings

A Motion Frames Duplicate Motion Frame

Bucket Motion

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Action Settings

B Motion Frames Frame Relative Position 0, 4.04, -2.33 [m]
Relative Orientation | -210 [dega]
Bucket
Angle
Motion <01>

10.1.9. BOUNDARY DEFINITION – REPLICATION

For this tutorial, the Replicate Geometry option will be activated for the Bucket geometry, which
will create copies of the geometry (and its assigned motions) at specified intervals along the motion's
path.

1. From the Data panel, under Geometries, select Bucket.

2. From the Data Editors panel, select the Wall | Replication tab, and then enable the Replicate
Geometry checkbox.

1. Define the Number of Replications value.

2. Enable the Periodic Replication checkbox.

3. To have the buckets appear in the correct location, enter the full periodic motion period (8.98148
s) for the Replication Period.

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Tutorial - Bucket Conveyor

The results are shown below.

As seen in the Motion Preview (and/or 3D View) window, the single bucket has now been replicated
into 20 buckets evenly spaced along the path of the bucket motion.

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 Part A: Project Setup and Processing

10.1.10. CONTINUE PROJECT SETUP

For the Materials step, default values will be used for all three default materials.

We will slightly modify the friction values for the Materials Interactions step.

And for the Particles step, we will create a new sphere-shaped particle group in a range of sizes with
some added rolling resistance.

1. Use the information in the table below to continue setting up your project.

Step Data Entity Editors Location Parameter or Action Settings

A Materials …| Static Friction 0.5 [ - ]
Interactions Dynamic Friction 0.5 [ - ]
Default
Particles

Default
Boundary
B Particles Create Particle

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Tutorial - Bucket Conveyor

Step Data Entity Editors Location Parameter or Action Settings

C Particles Particle | Size Add size row (x1)
(1) Size | Cumulative 0.15 [m] @ 100 [%]
Particle
%
<01>
(2) ... 0.05 [m] @ 10 [%]
Particle | Movement Rolling Resistance 0.4 [ - ]

10.1.11. MASS FLOW DEFINITION – CONSTANT FEED

For the Inlets and Outlets step, we will create two particle inlets: one to provide a consistent feed
for the conveyor and another to provide additional surges of material through the inlet.

1. Use the information in the table below to create the first inlet representing the regular feed.

Step Data Entity Editors Location Parameter or Action Settings

A Inlets and Outlets Create Particle Inlet
B Inlets and Particle Inlet Name Regular Injection
Outlets Entry Point Regular Feed
Particle Particle Inlet | Add row (x1)
Inlet Particles (1) Particle | Mass Flow Particle <01> @ 70
<01> Rate [t/h]

10.1.12. PERIODIC INJECTION

For the second inlet, we want the material surge to be represented by 5-second bursts of material
that appear every 5 seconds, starting 5 seconds into the simulation (as shown).

To replicate the material surge, we will set this second Particle Inlet to have a Periodic injection,
which will enable particles to be released from the Entry Point in bursts.

These bursts are defined via the following parameters:

• Period: Defines the length of time for each injection cycle.

• Injection Duration: Defines the amount of time during each Period when particles will be actively
released.

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 Part A: Project Setup and Processing

Rocky calculates the particle mass released in each periodic burst by equally dividing the total particle
mass by the total number of bursts during the simulation.

10.1.13. MASS FLOW DEFINITION – SURGE FEED

1. Use the information in the table below to create a second Particle Inlet for the material surge,
and to complete your simulation setup.

Step Data Editors Location Parameter or Action Settings

Entity
A Inlets and Outlets Create Particle Inlet
B Inputs Particle Inlet Name Surge Injection
Entry Point Surge Feed
Particle Particle Inlet | Add row (x1)
Inlet Particles (1) Particle | Mass Flow Particle <01> @ 40
<01> Rate [t/h]
… | Time Start 5 [s]
… | Entry Periodic (Enabled)
Periodic | Period 10 [s]
Periodic | Injection 5 [s]
Duration

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Tutorial - Bucket Conveyor

Step Data Editors Location Parameter or Action Settings

Entity
C Solver Solver | Time Simulation Duration 30 [s]
Solver | General Simulation Target CPU

10.1.14. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

10.1.15. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears, then processing begins.

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 Part A: Project Setup and Processing

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Tutorial - Bucket Conveyor

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

10.1.16. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a simulation
of a Bucket Conveyor.

During this tutorial, it was possible to:

• Define a motion that repeats periodically

• Replicate a single geometry into multiple copies with identical motion paths

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 Part B: Post-Processing

• Set up a material surge scenario using a periodic injection inlet

What's Next?

• Now that you have set up and processed this simulation, you are ready to move on to Part B and
post-process this project.

10.2. Part B: Post-Processing

10.2.1. OBJECTIVE
The purpose of this tutorial is to analyze the results from the Bucket Conveyor simulation we processed
in Part A.

You will learn how to:

• Visualize the two separate injections

• Evaluate the mass flow during the surge periods

• Evaluate the mass load for each bucket that has reached a steady state

• Analyze the trajectory of the particles being dumped into the bin

And you will use these features:

• 3D View

• User Processes (Cube, Particle Trajectory)

• Time Plot and Custom Formulas

10.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

10.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

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Tutorial - Bucket Conveyor

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut10_files.zip file .

b. Unzip dem_tut10_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut10_files folder,
then from the tutorial_10_A_pre-processing folder, open the tutorial_10_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

10.2.4. VISUALIZE SEPARATE FEEDS

Now that our project has finished processing, we can begin analyzing the results.

Let's start by viewing the contributions from each separate inlet.

1. From the Data panel, select Particles.

2. From the Data Editors panel, on the Properties tab, right-click Particle Boundary, point to 3D
View, and then click Show in new 3D View.

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 Part B: Post-Processing

Each inlet's contribution is represented by a separate color.

Note:

Particle boundaries are numbered from zero in the order in which they were added to the
Geometries entity.

Tip:

Use the slider on the Time toolbar to investigate the surges at different times.

10.2.5. PLOT PARTICLE COUNT

Another way to evaluate the effect of the surges is to plot the particles count.

1. From the Data panel, select Particles again.

2. From the Data Editors panel, on the Curves tab, drag and drop Particles Count onto the
Workspace.

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Tutorial - Bucket Conveyor

The resulting plot shows a steeper curve whenever the mass flow is increased from a surge.

We can also filter the particles by the Particle Boundary property and plot the Particles Count for
each Inlet separately.

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 Part B: Post-Processing

First we will isolate the particles that result from the Regular Feed.

1. Use the information in the table below to begin this analysis.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Filter User Process
B User Processes Property Name Regular Feed
Particles
Filter <01>
Property Particle Boundary
Type Value
Cut value 7 [<ind>]

Next, we will isolate the particles that result from the Surge Feed.

2. From the Data panel, under User Processes, right-click Regular Feed Particles, and then click
Duplicate.

3. Use the information in the table below to define the newly created Regular Feed Particles <01>
item.

Step Data Entity Editors Location Parameter or Settings

Action
A User Processes Property Name Surge Feed
Particles
Regular Feed
Cut value 8 [<ind>]
Particles <01>

4. Now, from the Data panel, under User Processes, multi-select both Regular Feed Particles and
Surge Feed Particles.

5. Drag-and-drop both processes onto the previous plot.

The resulting plot shows two more curves:

• The Surge Feed is represented by a "stairstep" curve that shows the different periods of injection
over time.

• The Regular Feed is represented by a curve that grows at constant rate.

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Tutorial - Bucket Conveyor

10.2.6. EVALUATING BUCKET MASS

Next, let's evaluate the draw efficiency.

This can be done by using two moving cubes (each one for a bucket) and a Time Plot to analyze
the carried Particle Mass for each bucket.

We will use the motion frames we created in Part A to describe the cubes motion.

1. Use the information in the table below to create the moving cubes.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create a Cube User Process
B User Processes Cube Motion Frame Bucket Motion
Center -0.06, 0.27, 0.2 [m]
Cube <01>
Magnitude 0.5, 0.5, 0.3 [m]
Orientation | Angles
Method
Orientation | -30, 0, 0 [m]
Rotation
C User Processes Duplicate Cube User Process

Cube <01>
D User Processes Cube Motion Frame Bucket Motion
<01>
Cube <02>

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 Part B: Post-Processing

Step Data Entity Editors Location Parameter or Settings

Action
Center -0.06, 3.8, -2.55 [m]

This results in two cubes encompassing two buckets (as shown).

Due to the assigned motion frames, the cubes will accompany the buckets for the whole simulation
(check this on Motion Preview and by multi-selecting both cubes with the Bucket wall visible).

10.2.7. TIME PLOT

Now that we have the Cube selections, we can use it to create a Time Plot showing the Sum of Particle
Mass for the two buckets.

1. Use the information in the table below to create the Time Plot.

Step Item Location Parameter or Settings

Action
A Window (menu) Create a New Time Plot
B Cube <01> Properties | Particle Drag and drop onto the Time Plot
Mass window
C Select the Statistics to Plot (dialog box) Sum (Enabled)
(All others) (Cleared)
D Cube <02> Properties | Particle Drag and drop onto the Time Plot
Mass window
E Select the Statistic to Plot (dialog box) Sum (Enabled)
(All others) (Cleared)

The resulting plot represents the Particle Mass in each Cube region.

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Tutorial - Bucket Conveyor

Note:

Each bucket we are analyzing pass through the Hopper 3 times.

Note that when crossing the Hopper (at 13.3 s for example), the cubes encompass particles that are
not necessarily being carried by the buckets, and it causes peaks on the plot.

The relevant values are the ones that keep constant for more than a second in the plot, when all the
particles inside the cube are being carried by the bucket (15 s). (Compare the images shown.)

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 Part B: Post-Processing

The particle mass carried by the buckets varies between 2.6 kg (at the beginning, with few particles
on the Hopper) and 16 kg.

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Note:

Your values may differ slightly from the ones presented in this tutorial.

10.2.8. PARTICLE TRAJECTORY

Another analysis we can do with this project involves using the Particles Trajectory User Process,
which displays the path particles take by translating their movements into 3D curves.

Tip:

To learn more about Particle Trajectories, refer to Tutorial 04 – SAG Mill Tutorial - SAG
Mill (p. 247).

To visualize the trajectory of the particles, do the following:

1. From the Time toolbar, ensure that you have selected the [120] 6 s timestep. This will be your
Starting Timestep.

2. Use the information in the table below to create the Particles Trajectory.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Particles Trajectory User Process
B User Processes Particle Number of Intervals 300 [ - ]
Trajectory Particle Stride 1[-]
Particles Trajectory
<01> Update Particles Selection

Your Starting Timestep value should be updated accordingly.

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 Part B: Post-Processing

10.2.9. POST PROCESSING – PARTICLE TRAJECTORY

1. To view the trajectories, use the information in the table below.

Step Item Location Parameter or Settings

Action
A Window (menu) Create a New 3D View
B User Processes | Coloring Visible (Enabled)
Edges (Enabled)
Particles Trajectory
<01> Edges | Property Particle
Mass

Tip:

Hide Particles from the view by using its Data panel eye icon.

10.2.10. CONCLUSION
This completes Part B of this tutorial, in which Rocky was used to analyze the results from a Bucket
Conveyor simulation.

During this tutorial, it was possible to:

• Visualize and plot the effects of the two separate injections

• Evaluate the mass load for a single bucket using Cubes and Time Plots

• Visualize the trajectory of the particles

What's Next?

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Tutorial - Bucket Conveyor

• If you completed this tutorial successfully, then you are ready to move on to the next tutorial.

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Chapter 11: Tutorial - Discharge Air Flow
(Part A) Set up and process a simulation using 1-Way coupling between Rocky (DEM) and LBM.

(Part B) Learn how to visualize air flow using vectors and velocity contours, and isolate high-velocity
air flow cells using User Processes.

11.1. Part A: Project Setup and Processing

11.1.1. OBJECTIVE
The purpose of this tutorial is to set up and process a simulation using the 1-Way coupling abilities
within Rocky, between DEM and the Lattice-Boltzmann Method (LBM).

• This method is a useful tool for comparing how equipment design affects the flow of dust and air
due to particle interactions.

11.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

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11.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Feed Conveyor

• (2) Surface

The first item will come from a conveyor template within Rocky. The second item's .stl file can be
found in the tutorial directory.

11.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut11_files.zip file .

2. Unzip dem_tut11_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the tables that follow to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

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 Part A: Project Setup and Processing

11.1.5. PROJECT SETUP

Step Data Entity Editors Location Parameter or Action Settings
A Study Study Study Name LBM
B Physics Physics | Rolling Resistance Model Type C: Linear Spring
Momentum Rolling Limit
Numerical Softening 0.1 [ - ]
Factor
C Geometries Import Wall surface.stl with "mm"
for Import Unit
D Geometries Create Feed Conveyor
E Geometries Feed Conveyor | Belt Incline Angle 20 [dega]
Orientation Vertical Offset 0.2 [m]
Feed
Conveyor Feed Conveyor | Drop Box Length 1.8 [m]
<01> Feeder Box Drop Box Width 1.8 [m]
F Materials Material Density 1400 [kg/m3]

Default
Boundary
G Materials Materials Use Bulk Density (Cleared)
Density 2800 [kg/m3]
Default
Particles
H Materials …| Static Friction 0.4 [ - ]
Interactions Dynamic Friction 0.35 [ - ]
Default
Particles

Default
Particles
I Particles Create Particle
J Particles Particle | Rolling Resistance 0.2 [ - ]
Movement
Particle
<01>
K Inlets and Outlets Create Particle Inlet
L Inlets and Particle Inlet Entry Point Feed Conveyor <01>
Outlets … | Particles Add row (x1)
Particle (1) Particle | Mass Flow Particle <01> @ 2000
Inlet<01> Rate [t/h]

Tip:

For more information about setting up a Feed Conveyor, refer to Tutorial 06 – High
Pressure Grinding Roll (HPGR).

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Tutorial - Discharge Air Flow

11.1.6. AIR FLOW DEFINITION

For the CFD Coupling step, we will turn on and then set up the 1-Way LBM air flow model.

• This model is useful for simulating how air and dust flow are affected by the flow of particles in
the simulation.

Tip:

For more information on how Rocky calculates boundary conditions, see the paper by
Verberg and Ladd. [1] (p. 590)

The properties that are able to be adjusted when this model is enabled are described below.

• Operation Properties

– Use Air Flow: Enables/Disables Lattice-Boltzmann Air Flow calculations.

– Start When Particles Enter: Enables air flow calculations to start as soon as particles appear in
the air flow limit box.

• Air Properties

– Air Density: The density of the air.

– Air Kinematic Viscosity: The kinematic viscosity of the air.

• Lattice-Boltzmann Details

– Cell Size: The size of the Air Flow cell.

– Interaction Scale: Determines the interaction between the Particle and the air.

– Start Time: Disabling the Start When Particles Enter option makes the Start Time parameter
available. This is the time that Air Flow calculations begin during the simulation.

– Speed of Sound: The speed of sound, which is used to calculate Air Flow.

– Boundary Conditions: Method applied for the calculations, affecting accuracy and stability.

– Coordinate Limits: The domain limits of the Air flow box.

To set up the CFD Coupling, do the following:

1. From the Data panel, click CFD Coupling.

2. From the Data Editors panel, from the Coupling Mode list, select the LBM (Particle → Fluid)
option under 1-Way.

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 Part A: Project Setup and Processing

A new entry is created under CFD Coupling.

3. From the Data panel, select this new 1-Way LBM entry, and then from the Data Editors panel,
modify the parameters as described on the next slide.

4. From the main 1-Way LBM tab, define the Cell Size, Interaction Scale, and Coordinate Limits
(as shown).

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Tutorial - Discharge Air Flow

Note:

The Coordinate Limits can be different than the DEM domain limits.

The Interaction Scale was increased from the original default value (0.25) to reduce the
simulation time for the purposes of the tutorial.

Tip:

In most cases, it is recommended that you use the default Interaction Scale number.

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 Part A: Project Setup and Processing

11.1.7. CONTINUE PROJECT SETUP

For the Domain Settings step, we will define a custom boundary box that exceeds the limits of our
geometries.

Tip:

To learn more about setting boundary limits for your domain, refer to Tutorial 03 – Vibrating
Screen.

1. Use the information in the table that follows to finish setting up your project.

Step Data Entity Editors Parameter or Settings

Location Action
A Domain Domain Use Boundary (Cleared)
Settings Settings Limits
Max Values 20, 10, 10
[m]
B Solver Solver | Simulation Target CPU
General

11.1.8. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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Tutorial - Discharge Air Flow

11.1.9. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part B: Post-Processing

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

11.1.10. CONCLUSION
This completes Part A of this tutorial, during which Rocky was used to set up and process a simulation
using the Lattice-Boltzmann Method (LBM) Air Flow model.

What's Next?

• Now that you have set up and processed this simulation, you are ready to move on to Part B and
post-process this project.

11.2. Part B: Post-Processing

11.2.1. OBJECTIVE
The purpose of this tutorial is to use the results from the 1-Way LBM (Lattice-Boltzmann Method)
simulation we set up and processed in Part A to analyze how particle flow influences air flow in and
around the equipment.

• Reminder: The LBM method is a useful tool for comparing how equipment design affects the flow
of dust and air due to particle interactions.

You will learn how to:

• Visualize air flow using vectors

• Analyze velocity contours

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Tutorial - Discharge Air Flow

• Isolate high-velocity air flow cells

And you will use these features:

• Air flow vector visualization

• Plane User Process

• Property User Process

11.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

11.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut11_files.zip file .

b. Unzip dem_tut11_files.zip to your working directory.

c. Open Rocky 2025 R1. (Look for Rocky 2025 R1 in the Program Menu or use the desktop
shortcut.)

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut11_files folder,
then from the tutorial_11_A_pre-processing folder, open the tutorial_11_A_pre-pro-
cessing.rocky file.

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 Part B: Post-Processing

e. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

11.2.4. POST PROCESS – AIR FLOW

One way to visualize the effects of particles upon the air flow is to use vectors.

1. From the Data panel, under CFD Coupling, select the 1-Way LBM entity.

2. From the Data Editors panel, select the Coloring tab and then ensure both the Visible and
Vectors checkboxes are enabled.

3. Under Vectors, select Velocity from the Property list, and ensure the Vectors scale is 0.25 (as
shown).

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Tutorial - Discharge Air Flow

11.2.5. USER PROCESS – PLANE

You can also analyze the velocity contours of a cross section of the air flow by creating a cut plane.

1. From the Data panel, right-click 1-Way LBM, point to Processes, and then click Plane.

2. From the Data Editors panel, on the Plane tab, define Orientation (Angle and Vector, as shown).

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 Part B: Post-Processing

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Tutorial - Discharge Air Flow

3. After the cut plane is defined, switch to the Properties tab and then drag and drop Velocity:
Absolute onto the 3D View window.

Tip:

To see only the velocity contour, use the Data panel eye icons hide Particles and the
1-Way LBM vectors from the view.

11.2.6. USER PROCESS – PROPERTY

To identify which regions around the equipment are affected most by air flow, you can use a Filter
User Process to isolate air flow cells containing velocity values above a certain threshold.

1. Set up this analysis by using the information in the table below.

Step Data Entity Editors Parameter or Settings

Location Action
A CFD Coupling Create a Filter User Process

1-Way LBM
B User Processes Property Property Velocity:
| Absolute
Type Range
Filter
<01> Minimum Value 0.5 [m/s]
Maximum Value 10 [m/s]

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 Part B: Post-Processing

2. After the cells have been isolated, from the Properties tab, drag and drop Velocity: Absolute
onto the 3D View.

Tip:

To see only the selected cells and Particles, you may need to use the eye icons on the
Data panel to hide the Plane <01> User Process and show the Particles entity.

11.2.7. CONCLUSION
This completes Part B of this tutorial, in which Rocky was used to post-process a 1-Way LBM (Lattice-
Boltzmann Method) simulation by analyzing how particle flow influences air flow in and around
equipment.

During this tutorial, it was possible to:

• Visualize air flow using vectors

• Analyze velocity contours using a cut Plane User Process

• Isolate high-velocity air flow cells using a Filter User Process

What's Next?

• If you have completed this tutorial successfully, then you are ready to move on to next tutorial.

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11.2.8. BIBLIOGRAPHY

Bibliography
[1] R. Verberg and A. J. C. Ladd. Lattice-Boltzmann Model with Sub-Grid-Scale Boundary Conditions.
Physical Review Letters. 84. 5164–5176. 2000.

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Chapter 12: Tutorial - Static Structural
In (Part A), you will create a Workbench project, and will set up and run a Rocky DEM simulation through
Workbench.

In (Part B), you will couple the completed DEM simulation with Static Structural - Mechanical to calculate
the FEA portion of the project. You will also use Workbench's Design Exploration feature to run addi-
tional simulations that optimize key project parameters.

12.1. Part A: Project Setup and Processing

12.1.1. OBJECTIVE
The main purpose of this tutorial is to use Ansys Workbench to set up and run a DEM case in Rocky
that will later be 1-way coupled with Ansys Static Structural - Mechanical.

• Part B will cover 1-way coupling the DEM results with Static Structural - Mechanical to obtain the
FEA results.

The scenario considered in this tutorial is that of a bin whose inadequate structure requires design
modifications to better support its intended load.

You will learn how to:

• Create a Workbench project and import a geometry

• Connect the Workbench project to both Rocky and Ansys Static Structural - Mechanical

• Open Rocky through Workbench

• Ensure that Rocky is set up for FEA analysis

• Refine the geometry mesh for optimal analysis

• Define which load data to share with Mechanical

And you will use these features:

• Ansys Workbench

• (Rocky) Boundary Collision Statistics Module

• (Rocky) External Coupling entity

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Tutorial - Static Structural

12.1.2. PREREQUISITES
To complete this tutorial, you are required to have a Windows machine, both of the following:

• (1) A valid license for Ansys Mechanical 2025 R1, compatible with Transient Structural.

• (2) A license of Rocky 2025 R1 or later.

Important:

This ADVANCED tutorial assumes that you are already familiar the the following programs
and resources:

• The Rocky 2025 R1 program.

– If this is not the case, it is recommended that you complete at least Tutorials 01- 05
before beginning this tutorial.

• The Ansys Workbench platform.

– If that is not the case, please refer to the Ansys Workbench user documentation for
basic introduction about Workbench usage before beginning this tutorial.

12.1.3. GEOMETRY

The geometry in this tutorial is composed of:

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 Part A: Project Setup and Processing

• (1) Bin with supports

In the tutorial directory, the .scdoc file for this geometry can be found.

Note:

This geometry has been saved with the support components hidden as Rocky requires
only the bin to interact with the particles.

12.1.4. GEOMETRY PREPARATION

To begin setting up the project, do the following:

1. Download the dem_tut12_files.zip file .

2. Unzip dem_tut12_files.zip to your working directory.

3. Open Ansys Workbench 2025 R1.

4. Save the empty Workbench Project from the File, Save As... menu item.

5. From the Toolbox panel, under the Component Systems item, drag and drop Geometry to the
Project Schematic.

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6. Right-click Geometry, point to Import Geometry, and then click Browse....

7. From the dialog that appears, locate the geometry folder inside dem_tut12_files you downloaded,
select the input file Geometry.dsco, and then click Open.

Tip:

The Geometry will show a green checkmark if the .scdoc file is correctly imported.

12.1.5. WORKBENCH SETUP

1. From the Toolbox panel, under the Analysis Systems item, drag and drop Rocky onto the Geo-
metry component of the Geometry block.

Note:

Dropping the Rocky block onto the Geometry component will automatically generate
a connection between the Geometry and Rocky.

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 Part A: Project Setup and Processing

2. From the Toolbox, under Analysis Systems, drag and drop the Static Structural component
onto the Results component of the Rocky block.

• This creates an extra connection between the Results component on the Rocky block and the
Model component on the Static Structural block that is not needed for this tutorial.

• We must remove this extra connection otherwise Workbench will prevent us from opening
Mechanical later (because it will be looking for Model information that does not exist).

3. Right-click the purple line connecting Results and Model, and then click Delete.

4. Save the Workbench project.

Tip:

If you have only a single-instance Rocky license (typical for most users), ensure that the
Rocky program is closed at this point.

In this next step, Workbench will open Rocky for you, and you will get errors if Rocky is already open.

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Tutorial - Static Structural

1. From the Rocky block, right-click Setup, and then click Edit.

Note:

While Rocky is processing, do not modify/save/close the connected Workbench session.

The Rocky interface opens automatically with the linked geometries already set up.

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 Part A: Project Setup and Processing

12.1.6. PROJECT SETUP

To start setting up your Rocky project, do the following:

1. From the Physics entity, on the Momentum tab, enable the Rolling Resistance Model of Type
C: Linear Spring Rolling Limit.

For this tutorial, information about particle forces on the geometry will be used.

Enabling the collection of this data is accomplished through the Boundary Collision Statistics
Module, by enabling the Forces for FEM Analysis checkbox.

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Tutorial - Static Structural

Because the Rocky project is connected to Ansys Mechanical through Workbench, this collection is
automatically enabled. However, to verify, do the following:

1. From the Data panel, under Modules, select Boundary Collision Statistics.

2. From the Data Editors panel, verify that the Forces for FEM Analysis checkbox is enabled.

12.1.7. GEOMETRY MESH

For the Geometries step, you will notice that the geometries are automatically imported from the
Geometry box in Workbench.

1. From the Data panel, under Geometries, select this already-imported surface item.

2. With a 3D View window open, visualize the meshing. (From the Data Editors panel, select the
Coloring tab, and then enable the Edges checkbox.)

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 Part A: Project Setup and Processing

Since a coupled simulation with Ansys Mechanical will be carried out for this geometry part, it is im-
portant to refine the mesh so that the pressure field transferred to Mechanical has an adequate res-
olution for the desired structural analysis.

Every triangle node will provide a pressure vector, which will then be applied as a load inside Mech-
anical.

12.1.8. VISUALIZING THE GEOMETRY

Refine the mesh as follows, then continue setting up your Rocky project:

1. From the Wall tab, on the Transform sub-tab, change the Triangle Size to 0.1 [m] (results shown).

2. Use the information in the table that follows to continue setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

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Tutorial - Static Structural

Step Data Entity Editors Location Parameter or Action Settings

A Geometries Create Rectangular Surface
B Geometries Rectangular Surface Center Coordinates 3.25, 3, 0 [m]
Length 2.5 [m]
Rectangular Width 1.5 [m]
Surface
<01>
C Particles Create Particle
D Particles Particle | Size (1) Size | Cumulative (%) 0.2 [m] @ 100%
Particle | Movement Rolling Resistance 0.3 [ - ]
Particle
<01>
E Inlets and Outlets Create Particle Inlet
F Inputs Particle Inlet Entry Point Rectangular
Surface <01>
Particle
Particle Inlet | Add row (x1)
Inlet <01>
Particles (1) Particle | Mass Flow Particle <01> @
Rate 10000 [t/h]
… | Time Stop 3 [s]

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 Part A: Project Setup and Processing

12.1.9. EXTERNAL COUPLING

For this Tutorial, static loads on the bin geometry will be exported to Ansys Static Structural - Mech-
anical.

Because the loads are static, we need only to export the last output.

1. From the Data Panel, under External Coupling, select Wall Loads.

2. From the Data Editors panel, under Select Walls, select the surface checkbox, and then ensure
the remaining options match the image below.

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12.1.10. FINISH PROJECT SETUP

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Editors Parameter or Settings

Entity Location Action
A Solver Solver | Time Simulation Duration 5 [s]
Solver | Simulation Target CPU
General

With a 3D View window opened, your Data panel and Workspace should look similar to the image
shown.

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 Part A: Project Setup and Processing

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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Tutorial - Static Structural

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

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 Part A: Project Setup and Processing

12.1.11. POST PROCESS – OUTPUT

Later in Part B of this tutorial, we will use the Force in the Y direction of the bin geometry to help
determine whether modifications made during parameterization are improving the design.

We will expose this parameter to Workbench by making it available on the Output tab of the Expres-
sions/Variables panel.

1. From the Data panel, under Geometries, select the surface geometry, and then from the Data
Editors panel, select the Curves tab.

2. From the Tools menu, open the Expressions/Variables panel, and then select the Output tab.

3. From the Data Editors panel, select the Force : Y curve, and then drag and drop it onto the
Output tab.

4. Select the newly added output, and then click the edit button.

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5. From the Edit Properties dialog, define the values for Domain Range, and then click OK.

Your output should now be configured and ready to use (as shown).

Note:

Your results might differ slightly from those shown in this tutorial.

12.1.12. COMPLETE PROJECT

To complete this part of the tutorial, do the following:

1. Save your Rocky project.

2. Close Rocky.

3. Switch back to your Workbench project.

Note:

Due to its connection with Workbench, nothing further is required in Rocky after processing
is complete. There is no need to export any files. All necessary data transfers will happen
in Workbench.

12.1.13. CONCLUSION
This completes Part A of this tutorial.

Through Ansys Workbench, we imported a bin geometry, set up the connection between Rocky and
Ansys Static Structural - Mechanical, and set up and processed a simulation in Rocky that will later
be 1-way coupled with Ansys Static Structural - Mechanical.

During this tutorial, it was possible to:

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 Part B: Mechanical Coupling (Workbench)

• Verify that Rocky is ready for coupling with Ansys.

• Create a new Ansys Workbench project, and import a geometry into Workbench.

• Set up and run the Rocky portion of the simulation through Workbench.

• Ensure the collection of forces data for later FEM analysis.

• Expose several DEM parameters to Workbench for later analysis.

• Define what geometry load data to later share with Mechanical.

What's Next? If you completed this part successfully, then you are ready to move on to Part B and
set up and run the FEA simulation based upon these DEM results.

12.2. Part B: Mechanical Coupling (Workbench)

12.2.1. OBJECTIVE
The main purposes of this tutorial are to use Ansys Workbench to run a 1-Way coupled DEM-FEA
simulation using Rocky and Ansys Static Structural - Mechanical, and then optimize those results using
Design Exploration.

• We will make use of the Rocky DEM results we created in Part A.

• As a reminder, the scenario considered in this tutorial is that of a bin whose inadequate structure
requires design modifications to better support its intended load.

You will learn how to:

• Use Workbench to transfer DEM results from Rocky to Static Structural - Mechanical

• Set up and process the FEA simulation in Static Structural - Mechanical

• Optimize key project parameters using Design Exploration

And you will use these programs:

• Ansys Workbench, including Design Exploration

• Ansys Static Structural - Mechanical

12.2.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine, both of the following:

• (1) A valid license for Ansys Mechanical 2025 R1, compatible with Transient Structural.

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Tutorial - Static Structural

• (2) A license of Rocky 2025 R1 or later.

Important:

This ADVANCED tutorial assumes that you are already familiar the the following programs
and resources:

• The Ansys Workbench platform, including the Design Exploration functionality.

– If that is not the case, please refer to the Ansys Workbench user documentation for
basic introduction about Workbench and Design Exploration usage before beginning
this tutorial.

• The Ansys Static Structural - Mechanical program.

– If this is not the case, please refer to the Ansys Mechanical user documentation for
a basic introduction about Mechanical usage before beginning this tutorial.

12.2.3. WORKBENCH SETUP

1. If you completed Part A of this tutorial, ensure that the Ansys Workbench project you created is
open. (Part B will continue from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut12_files.zip file .

b. Unzip dem_tut12_files.zip to your working directory.

c. Open Ansys Workbench.

Important:

To make use of the Workbench project file provided, you must have Ansys 2025
R1 or later and Rocky 2025 R1 or later. If you have an earlier version of either of
these programs, please upgrade to the latest version of Rocky and the latest version
of Ansys that is supported by Rocky, or complete Part A from scratch.

d. From the Workbench program, click the Open Project button, find the dem_tut12_files folder,
and then from the tutorial_12_A_processing-rocky folder, open the tutorial_12_A_pro-
cessing-rocky.wbpj file.

With the project open in Workbench, you are now ready to begin Part B.

12.2.4. WORKBENCH – STATIC STRUCTURAL ANALYSIS

Before we set up the Mechanical project, we need to update the results:

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 Part B: Mechanical Coupling (Workbench)

1. From your Workbench project, on the Rocky block, right-click Results, and then click Update
(as shown). Repeat this and click Refresh also.

This transfers the DEM results into Workbench, thereby making the data available to Mechanical.

Then, to initialize a static structural analysis using the DEM results:

2. From the Static Structural block, right-click Model, and then click Edit (as shown).

Ansys Mechanical opens with the linked geometry already included (shown on next screen).

12.2.5. MECHANICAL – DEFINING THE STRUCTURAL ANALYSIS

Now, let's set up the Mechanical project.

1. From the Outline panel, under Model, select Geometry.

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2. In the Details of "Geometry" panel, under Update Options, define the Assign Default Material
option.

3. From the Outline panel, under Model | Geometry, select surface\surface.

4. In the Details of "surface\surface" panel, under Definition, define the Thickness as 0.01 m and
then click the box next to the Thickness label to create a parameter.

5. Under Properties, click the box next to the Mass label to create another parameter .

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Note:

The parameters we create here will later become outputs that we can use for design
optimization in Workbench.

Create the first of two Named Selections by doing the following:

1. In the view, with the Face selection, multi-select the three lower faces of the support (as shown
in red).

2. Right-click in the view, and then select Create Named Selection.

3. Define the Selection Name as "support".

Create the second of two Named Selections by doing the following:

1. In the view, with the Body selection, select the three support bodies (as shown in red).

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2. Right-click in the view, and then select Create Named Selection.

3. Define the Selection Name as "body-support".

Now, let's generate the mesh.

1. From the Outline panel, under Model, right-click Mesh, point to Insert, and then select Sizing.

2. Select the new Sizing entry, and then define the Scoping Method, Named Selection, and Element
Size.

3. From the Outline panel, right-click Mesh, and then click Generate Mesh.

You can view the generated mesh by selecting Mesh from the Outline panel.

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Define the imported pressure:

1. From the Outline panel, under Model | Static Structural, right-click Imported Load (B4), point
to Insert, and then click Pressure.

2. Select the newly added Imported Pressure entry.

3. From the Details of "Imported Pressure" section, under Scope, define the Scoping Method,
and then using the Face selection, select all 7 faces of the bin.

4. From the Details of "Imported Pressure", select the Geometry field, and click Apply.

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5. In the Definition section, define Apply To and Define By.

6. From the Data View window, define: X Component (Pa), Y Component (Pa), and Z Component
(Pa) from the drop down lists (as shown).

7. From the Outline panel, right-click Imported Pressure, and then select Import Load.

8. From the Outline panel, select Imported Pressure to show the vector plot of the imported load.

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Next, define the fixed supports:

1. From the Outline panel, right-click Static Structural, point to Insert, and then click Fixed Support.

2. Select the new entry for Fixed Support.

3. From the Details of "Fixed Support" section, define the Scoping Method and Named Selection.

Now, let's define which solutions we want to analyze:

1. From the Outline panel, under Model | Static Structural, right-click Solution, point to Insert,
point to Deformation, and then click Total (as shown).

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2. Right-click Solution again, point to Insert, point to Stress, and then click Equivalent (von-Mises).

3. Select the newly added Total Deformation entry.

4. From the Details of "Total Deformation" panel, under Results, click the box next to the Maximum
label to create a parameter.

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 Part B: Mechanical Coupling (Workbench)

5. Repeat the sequence for Equivalent Stress.

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12.2.6. MECHANICAL – POST-PROCESSING

We also want to add a forces resultant in order to validate the coupling between Rocky and Mechan-
ical.

1. From the Outline panel, right-click Solution, point to Insert, point to Probe, and then click Force
Reaction.

2. From the Details of "Force Reaction" panel, define both Location Method and Boundary Con-
dition.

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Now we can solve the FEA portion of the coupled project.

1. From the Outline panel, right-click Solution, and then click Solve.

The FEA simulation starts processing.

When the simulation concludes, the effects caused by the particles on the surfaces can be easily seen:

1. Under Solution, select Total Deformation and then view the results (as shown).

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2. Repeat for Equivalent Stress (as shown).

The static structural analysis provides the stress and deformation responses given the particle load
for the assessment of the structural integrity of the bin.

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 Part B: Mechanical Coupling (Workbench)

The Equivalent (von-Mises) Stress analysis provides information on where the structure can fail due
to high stress levels on the surface.

The Total Deformation analysis helps to identify the regions with higher displacements and possible
issues with contacting geometries.

We can also evaluate the forces.

1. Under Solution, select Force Reaction and then view the results for Y Axis.

Reminder: Your results might differ slightly from those shown in this tutorial.

When compared to the Force_Y values we collected in Rocky in Part A (shown above), we can observe
a good agreement between the values, which indicates that the loads were correctly interpolated.

Note:

Some differences might be observed due to the interpolation methods used.

1. Close the Static Structural analysis and go back to Workbench.

12.2.7. WORKBENCH – RUNNING MULTIPLE SIMULATIONS

Now that our initial simulations are complete, let's view what parameters we can vary for our next
iterations.

1. In Ansys Workbench, double-click the Parameter Set block.

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2. From the Parameter Set tab, select the Outline of All Parameters window.

Here, all the parameters created during the analysis are listed, no matter in which application they
were created or if they are input or output parameters.

Such input and output parameters can be directly changed to create different scenarios in Workbench.

This provides you valuable information on how to improve your design.

For example, it is possible to parametrize and investige the influence of:

• Bin design quantities in Discovery, such as the overall shape of the bin, the number and position
of bin supports, and so on.

• Particle-related quantities in Rocky, such as material density, tonnage, the particle geometry, the
particle size distribution, and so on.

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 Part B: Mechanical Coupling (Workbench)

• Bin structural quantities in Mechanical, such as the material properties of the bin, the resulting
stress and strain, and so on.

Parameter variations can be made in Workbench manually using Design Points (see Tutorial 15 for
a walkthrough example of this method) or automatically using Design Exploration.

For this tutorial, we will use the latter method to optimize our bin design.

12.2.8. WORKBENCH – DESIGN EXPLORATION

Our optimization goal is to reduce the mass of the bin as much as safely possible without compromising
the structure.

We will accomplish this by setting an objective and then defining constraints on the input and output
parameters we exposed in Mechanical.

The optimization problem for this case can be defined as follows:

• Single-objective function: Minimize the surface Mass of the bin

• Constraint: Equivalent Stress Maximum of the bin should be less than 1e+08 Pa

• Free parameter: Bin surface Thickness can range between 0.001 - 0.020 m

Workbench will then use Design Exploration to search for feasible solutions to the problem as
defined.

Let's start by defining a new Direct Optimization study.

1. Switch back to the Project tab.

2. From the Toolbox panel, under Design Exploration, drag Direct Optimization onto the Project
Schematic, and drop it under the Parameter Set block.

3. From the new Direct Optimization block, right-click the Optimization component, and then click
Edit.

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4. From the Outline of Schematic D2: Optimization window, select the first Optimization item.

5. From the Properties of Outline A2: Optimization window, review the settings but keep all
parameters set as default (as shown).

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 Part B: Mechanical Coupling (Workbench)

6. From the Outline of Schematic D2: Optimization window, select the Objectives and Constraints
item (as shown).

7. From the Table of Schematic D2: Optimization window, from the 3rd row, define the Parameter
and Objective Type (as shown).

8. From the 4th row, define the Parameter, Constraint Type, and Constraint Upper Bound (as
shown).

9. From the Outline of Schematic D2: Optimization window, under Domain | Static Structural
(C1), select the P2 - surface\surface Thickness item.

10. From the Table of Schematic D2: Optimization window, from the 3rd row, define the Lower
Bound and Upper Bound values (as shown).

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11. Click the Update button to run the optimization cases.

Note:

Because many new coupled cases are being calculated, this optimization step can take
some time to complete.

Many coupled DEM-FEA cases are run using different parameters that are varied within the constraints
set (around 20 scenarios).

As the various cases complete, you can see the parameter values that were used and what results
were achieved using those values.

1. From the Outline of Schematic D2: Optimization window, select Raw Optimization Data (as
shown).

2. From the Table of Schematic D2: Optimization window, notice that each case that completes
and its parameter values are listed in a separate row.

When all the cases are complete, we can view the final results.

3. From the Outline of Schematic D2: Optimization window, under Results, select Samples (as
shown).

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 Part B: Mechanical Coupling (Workbench)

4. View information on the Table of Schematic D2: Optimization window (as shown).

Based upon these results, we can make the following conclusions:

• The three cases with values most closely aligning with the objective and constraints are considered
Candidates.

• Candidate Point 1 (dark blue plot line) shows that by reducing the surface Thickness to 0.0086
m, the surface Mass can be reduced to 980.48 kg while still keeping within the Equivalent Stress
Maximum threshold we defined.

• As Candidate Point 1 represents the highest stress value allowed for this design optimization,
another Candidate that allows for slightly more mass but results in lower stress values might be
chosen instead.

12.2.9. CONCLUSION
This completes Part B of this tutorial.

Through Ansys Workbench, Ansys Static Structural - Mechanical was used to set up and run a FEA
simulation using the particle forces calculated previously by Rocky.

During this tutorial, it was possible to:

• Make the Rocky DEM results available to Mechanical

• Set up and process the FEA simulation in Mechanical

• Use key input and output parameters in Workbench to set up and run new optimization cases in
Design Exploration

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What's Next? If you completed this part successfully, then you are ready to move on to the next tu-
torial.

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Chapter 13: Tutorial - Windshifter
In (Part A), you will create the initial Workbench project, and will set up and run the CFD case using
Ansys Fluent.

In (Part B), you will set up and run (without coupling) the DEM portion of the simulation in Rocky.

In (Part C), you will re-run the Rocky case one-way coupled with the results from Ansys Fluent, and will
then analyze the coupled simulation results in Rocky.

13.1. Part A: Fluent Case Setup (Workbench)

13.1.1. OBJECTIVE
The main purpose of this tutorial is to use Ansys Workbench to set up and run a CFD case using Ansys
Fluent that will be later used in a one-way coupling simulation with Rocky DEM.

Important:

Even if you are already familiar with CFD, please follow Part A in order to understand the
main limitations and needs for coupling with Rocky.

• Part B will cover setting up the Rocky project and running the initial DEM simulation; Part C will
cover one-way coupling the DEM project with the CFD results.

The windshifter scenario considered in this tutorial evaluates how air flowing upwards through a pipe
affects the different materials that discharge into it.

In this tutorial, you will learn how to:

• Verify and install Ansys coupling components within Rocky

• Create a project in Ansys Workbench

• Import a geometry into Ansys Discovery

• Set up a CFD case in Ansys Fluent

13.1.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine the following:

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• (1) A valid license for the following Ansys products: Discovery, Rocky and Workbench 2025 R1.

Important:

This ADVANCED tutorial assumes that you are already familiar the the following programs
and resources:

• The Ansys Workbench platform

Note:

Rocky and Ansys Workbench integration is currently supported only on

Windows.

• The Ansys Discovery program

• The Ansys Fluent program and project workflow

If you are not familiar with these programs, please refer to the Ansys user documentation
for introduction and usage instructions before beginning this tutorial.

13.1.3. ANSYS COMPONENT INSTALLATION IN ROCKY

For Windows machines, during Rocky installation, ensure that the following default options remain
selected:

• Ansys Fluent Coupling Support

• Ansys Workbench Addin

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 Part A: Fluent Case Setup (Workbench)

Important:

If by chance you install Rocky without these components, you must reinstall the Rocky
program with these checkboxes selected.

In addition, under Ansys Workbench Addin Integration, ensure that you have selected Ansys 2025
R1.

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13.1.4. GEOMETRY

The geometry for Part A of this tutorial includes the following component:

• (1) pipe, which itself has the following regions:

– (a) inlet (fluid flow)

– (b) outlet (fluid flow)

– (c) opening (material flow)

In the tutorial directory the .scdoc file for the pipe geometry can be found.

13.1.5. GEOMETRY PREPARATION

To begin setting up the tutorial:

1. Download the dem_tut13_files.zip file .

2. Unzip dem_tut13_files.zip to your working directory.

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3. Open Ansys Workbench 2025 R1 (or other supported version).

4. Save the empty Workbench Project from the File, Save As... menu item.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Next, we'll add the Geometry component to the project.

1. From the Toolbox panel, under the Component Systems item, drag and drop Geometry onto
the Project Schematic.

2. On the Geometry block, right-click Geometry, point to Import Geometry, and then click Browse....

3. From the dialog that appears, locate the geometry folder inside the dem_tut13_files folder you
downloaded, select the input file tutorial_13_geometry.dsco, and then click Open.

Tip:

The Geometry will show a green checkmark if the .dsco file is correctly imported.

To prepare the Geometry for later coupling with Rocky and Fluent, do the following:

1. On the Geometry block, right-click Geometry and select Edit Geometry in Discovery....

Ansys Discovery opens with the linked geometry already imported (as shown).

The geometry will be composed of a solid (fluid volume for CFD) and a surface (walls for DEM).

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 Part A: Fluent Case Setup (Workbench)

For this tutorial, we want Rocky to import only the Surface of the geometry, as this is the only part
that will be interacting with the particles.

Important:

Rocky imports only the non-hidden components.

1. From the Structure tree, check if the Solid component is hiden (as shown).

2. Close Discovery and return to Workbench.

3. Save the Workbench Project.

13.1.6. WORKBENCH SETUP

Next, add the Fluent component to the Workbench project:

1. From the Toolbox panel, under Analysis Systems, drag and drop Fluid Flow (Fluent) onto the
Geometry component of the Geometry block.

Note:

This creates an automatic connection between the Discovery geometry and the geometry
to be used by Fluent.

Then set the parameters for the Fluent Mesh:

1. From the Fluid Flow (Fluent) block, double-click the Mesh component. Meshing software auto-
matically opens with the linked geometry already imported.

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13.1.7. MESH
1. From the Outline panel, under Model | Geometry, right-click Geom\Surface, and then click
Surppress Body.

Define the inlet and outlet boundary conditions by creating two Named Selections as follows:

1. In the main view, using the face selection tool, select the lower face of the pipe, and then do the
following:

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 Part A: Fluent Case Setup (Workbench)

a. Right-click this selection and then click Create Named Selection....

b. Define the Name as "inlet", and then click OK.

2. Select the upper face of the pipe, and then do the following:

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a. Right-click this selection and then click Create Named Selection....

b. Define the Name as "outlet", and then click OK.

You should now have two entries under Named Selections (as shown).

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 Part A: Fluent Case Setup (Workbench)

3. Under Model, click Mesh.

4. From the Details of "Mesh" panel, define (as shown):

a. Under Defaults, the Element Size.

b. Under Sizing, the Max Size.

c. Under Inflation, the Use Automatic Inflation parameter.

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5. From the Outline panel, right-click Mesh and then click Generate Mesh.

6. Right-click Mesh again, and then select Update (this will export the mesh to Fluent).

The mesh for the CFD analysis is now ready.

1. Close the Meshing program and return to Workbench.

2. Save your Workbench project.

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13.1.8. FLUENT SETUP

Let's set up the Fluent portion of our project:

1. From the Fluid Flow (Fluent) block, double-click the Setup component.

2. From the Fluent Launcher dialog that appears, select Double Precision (as shown), ensure 3D
is selected for Dimension, and then click Start.

Important:

Double Precision and 3D are required for coupling with Rocky.

Note:

Fluent allows parallel processing, which means that separate solver resources can be used
for Fluent. If you want to enable this feature, under Parallel (Local Machine), define the
Solver Processes or Solver GPUs you want Fluent to make use of.

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Ansys Fluent will open with a new project and the meshed geometry already imported.

13.1.9. MODELS
Then, define the Model settings:

1. From the Outline View tree panel, under Setup | Models, double-click Viscous.

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 Part A: Fluent Case Setup (Workbench)

2. On the Viscous Model dialog, under Model, select k-epsilon (2 eqn).

3. Under Near-Wall Treatment, select Scalable Wall Functions.

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4. Click OK.

Later in this tutorial, we will run the one-way coupled case with the Thermal Model enabled in Rocky.

To enable thermal properties for the fluids, do the following:

1. From the Outline View tree panel, under Setup | Models, double-click Energy.

2. From the Energy dialog, enable the Energy Equation checkbox (as shown).

3. Click OK.

13.1.10. MATERIALS
Next, we need to define both the Specific Heat and Thermal Conductivity for the fluid.

Note:

In this version of Rocky, both constant and polynomial thermal properties for fluid mater-
ials are supported.

In this tutorial, we want constant values set for the fluid thermal properties. Let's verify:

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 Part A: Fluent Case Setup (Workbench)

1. From the Outline View tree panel, under Setup | Materials | Fluid, double-click air.

2. From the Create/Edit Materials dialog, verify that both Cp (Specific Heat) and Thermal Conduct-
ivity are defined as constant.

3. Click Close (no changes).

13.1.11. BOUNDARY CONDITIONS

Next, let's define the boundary conditions:

1. From the Outline View tree panel, under Setup | Boundary Conditions |Inlet, double-click inlet
(velocity-inlet, id=6).

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2. From the Velocity Inlet dialog, on the Momentum tab, define the Velocity Magnitude (as shown).

3. On the Thermal tab, define the Temperature (as shown).

4. Click Apply and then click Close.

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13.1.12. INITIALIZATION
To initialize the Fluent case, do the following:

1. From the Outline View tree panel, under Solution, double-click Initialization.

2. From the Task Page, click Initialize (as shown).

13.1.13. SOLUTION
Finally, solve the Fluid case by doing the following:

1. From the Outline View tree panel, under Solution, double-click Run Calculation.

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2. From the Run Calculation Task Page, define the Number of Iterations (as shown), and then
click Calculate.

The Scaled Residuals window appears (as shown).

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 Part A: Fluent Case Setup (Workbench)

13.1.14. RESULTS
Once the calculation is finished and the fluid results are available, it is possible to analyze the fluid
flow.

1. From the Outline View tree panel, under Results | Graphics, right-click Contours, and then click
New.

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2. From the Contours dialog, define Contours of (as shown).

3. From the New Surface list, click Plane....

4. On the Plane Surface dialog, do all of the following:

a. Define the New Surface Name (as shown).

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 Part A: Fluent Case Setup (Workbench)

b. Under Method, select Point and Normal (as shown).

c. Under both Point and Normal, define the x, y, and z values (as shown), and then click Create.

d. Click Close.

5. From the Contours dialog, select only the new plane-middle surface, and then click Save/Display.

The results are shown on below.

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6. Close the Contours dialog.

7. Close Fluent and return to Workbench.

Tip:

If you get a Settings have changed! message at this point, you can select either of
the first two options (as shown), and then click OK.

8. Save the Workbench project.

13.1.15. HELP
This completes Part A of this tutorial.

• For more information about setting up a Fluent case for one-way coupling with Rocky, we suggest
referencing the Rocky CFD Coupling Technical Manual.

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 Part B: Rocky Project Setup (Workbench)

• To access it, from the main Rocky Toolbar click Help, point to Manuals, and then click CFD
Coupling Technical Manual.

• For further information about any of the Ansys products used in this tutorial, please refer to your
Ansys user documentation.

13.1.16. CONCLUSION
Through Ansys Workbench, Ansys Fluent was used to set up and run a CFD simulation that will later
be one-way coupled with Rocky.

During this tutorial, it was possible to:

• Verify that Rocky is ready for coupling with Ansys.

• Create a new Ansys Workbench project.

• Import a geometry into Workbench using Ansys Discovery.

• Use Ansys Meshing to generate the geometry's mesh.

• Use Ansys Fluent to set up a CFD case.

What's Next? If you completed this part successfully, then you are ready to move on to Part B and
create the Rocky project that will later be one-way coupled with this CFD case.

13.2. Part B: Rocky Project Setup (Workbench)

13.2.1. OBJECTIVE
The main purpose of this tutorial is to use Ansys Workbench to set up and run a DEM case using
Rocky that will later be one-way coupled with the Fluent case we created in Part A.

• Part C will cover one-way coupling the DEM project with the CFD results.

• As a reminder, the windshifter scenario considered in this tutorial evaluates how air flowing upwards
through a pipe affects the different materials that discharge into it.

You will learn how to:

• Open Rocky through Workbench

• Enable a thermal model

• Collect particle-fluid statistics

• Use Equivalent Sphere Diameter to specify particle size

• Set up and run a DEM case (without coupling)

• Delete results within a Rocky project

And you will use these features:

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• Thermal Modeling

• CFD Coupling Particle Statistics

• Particle Size Type

• Continuous Injection Input

• Coloring by Property

13.2.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine the following:

• (1) A valid license for the following Ansys products: Discovery, Rocky and Workbench 2025 R1.

Important:

This ADVANCED tutorial assumes that you are already familiar the the following programs
and resources:

• The Ansys Workbench platform.

– If that is not the case, please refer to the Ansys Workbench user documentation for
basic introduction about Workbench usage before beginning this tutorial.

Note:

Rocky and Ansys Workbench integration is currently supported only on Win-

dows.

• The Rocky user interface (UI) and the Rocky project workflow.

– If this is not the case, it is recommended that you complete at least Tutorials 01- 05
before beginning this tutorial.

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13.2.3. GEOMETRY

The geometries for Part B of this tutorial includes:

• (1) pipe, which itself includes the following regions:

– (a) inlet (fluid flow)

– (b) outlet (fluid flow)

– (c) opening (material flow)

• (2) Receiving Conveyor

The pipe will be imported from the Workbench project.

The Receiving Conveyor will be created in Rocky.

13.2.4. WORKBENCH SETUP

1. If you completed Part A of this tutorial, ensure that the Ansys Workbench project you created is
open. (Part B will continue from where Part A left off.)

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2. If you did not complete Part A, do all of the following:

a. Download the dem_tut13_files.zip file .

b. Unzip dem_tut13_files.zip to your working directory.

c. Open Ansys Workbench.

Important:

To make use of the Workbench project file provided, you must have Ansys Work-
bench 2025 R1. If you have an earlier software version, please upgrade it or com-
plete Part A from scratch.

d. From the Workbench program, click the Open Project button, find the dem_tut13_files folder,
and then from the tutorial_13_A_processing-fluent folder, open the tutorial_13_A_pro-
cessing-fluent.wbpj file.

With the project open in Workbench, you are now ready to begin Part B.

In Workbench, add the Rocky component as follows:

1. From the Toolbox panel, under the Analysis Systems item, drag and drop Rocky onto the Geo-
metry component of the Fluid Flow (Fluent) block.

• If Rocky is not available in Workbench, it is necessary to reinstall Rocky and be sure to follow
Part A for instructions on what to select during installation.

• Because the Fluent Geometry block was already connected to the Discovery Geometry block,
dropping the Rocky block onto the Fluent Geometry block will automatically generate a con-
nection between the pipe geometry and the Rocky program.

2. From the Workbench File menu, click Save As.

3. From the dialog that appears, select a file location, define the File Name for the Workbench
project as tutorial_13_B-processing-rocky.wbpj, and then click Save.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory Tutorials
and Advanced Tutorials) to find the detailed instructions you need.

Next, let's define the Rocky project through Workbench.

Important:

Ensure Rocky is closed before you begin.

1. From the Workbench project's Rocky block, double-click the Setup component.

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 Part B: Rocky Project Setup (Workbench)

• The Rocky program opens automatically with a connected project that has the pipe geometry
(Design1) already included. 0

2. From the Rocky Menu, go to Options | Ansys and select Install Fluent/Rocky export.

Important:

This step is necessary for Rocky to obtain Fluent information when running the
coupled simulation later.

Now that Rocky is open, we can begin setting up our DEM project.

13.2.5. PROJECT SETUP

For the Physics step, we will enable thermal.

For the Modules step, we will be turning on the collection of CFD Coupling Particle Statistics.

• This module collects particle-fluid interactions for later post-processing.

• For this tutorial, we are primarily interested in collecting the drag-related data.

1. Use the information in the table below to begin setting up your Rocky project.

Step Data Entity Editors Location Parameter or Action Settings

A Physics Thermal Enable Thermal (Enabled)
B Modules Modules CFD Coupling Particle (Enabled)
Statistics
C Modules CFD Coupling Particle Drag Force (Enabled)
Statistics
CFD Coupling
Particle
Statistics

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

13.2.6. RECEIVING CONVEYOR DEFINITION

For this tutorial, a Receiving Conveyor will be created to transport the material to the pipe.

1. From the Data panel, right-click Geometries, point to Conveyor Templates and then select
Create Receiving Conveyor.

A new geometry component will appear.

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2. Select the newly added Receiving Conveyor <01> component.

Step Data Entity Editors Location Parameter or Settings

Action
3. A Geometries Receiving Conveyor | Geometry Length 1.5 [m]
Belt Width 0.25 [m]
Receiving
Conveyor Triangle Size 0.01 [m]
<01> Belt Thickness 0.01 [m]
… | Orientation Vertical Offset 1.5 [m]
Horizontal Offset -1.7125
[m]
… | Belt Profile Lower Corner Radius 0.1 [m]
… | Belt Motion Belt Speed 1 [m/s]

Step Data Entity Editors Location Parameter or Settings

Action
4. A Geometries Create Rectangular Surface
B Geometries Rectangular Center Coordinates -1.55, 1.7, 0
Surface [m]
Rectangular Surface
Length 0.3 [m]
<01>
Width 0.15 [m]
Orientation | Angle 30 [dega]
Orientation | Angle 0, 0, 1 [ - ]

13.2.7. MATERIAL AND SHAPE DEFINITIONS

For this tutorial, we want four particle groups, each with different material characteristics, but with
the same particle size distribution (PSD) and the same volume flow rates in each group.

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 Part B: Rocky Project Setup (Workbench)

In this way, we can later verify how the drag force computed using a drag law that takes into account
shape and orientation will act on these particles depending on the particle density and volume.

13.2.8. MATERIAL DEFINITION

For the Materials step, we will use Default Particles to define four new materials.

1. From the Data panel, under Materials, right-click Default Particles, and then click Duplicate.

2. Repeat this process until you have 3 new entries for Materials.

3. Use the information in the tables that follow to define each of these four materials.

Step Data Entity Editors Parameter or Settings

Location Action
A Materials Material Name Metal
Use Bulk Density (Cleared)
Default Particles
Density 8000
[kg/m3]
Thermal 80 [W/m.K]
Conductivity
Specific Heat 400
[J/kg.K]
B Materials Material Name Paper
Use Bulk Density (Cleared)
Default Particles <01>
Density 800
[kg/m3]
Thermal 0.05
Conductivity [W/m.K]

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Step Data Entity Editors Parameter or Settings

Location Action
Specific Heat 2000
[J/kg.K]
C Materials Material Name Stone
Use Bulk Density (Cleared)
Default Particles <02>
Density 3000
[kg/m3]
Thermal 3 [W/m.K]
Conductivity
Specific Heat 840
[J/kg.K]
D Materials Material Name Wood
Use Bulk Density (Cleared)
Default Particles <03>
Density 900
[kg/m3]
Specific Heat 2000
[J/kg.K]

13.2.9. PARTICLE GROUP DEFINITION

For the Particles step, we will be creating four separate particle groups corresponding to the four
different materials we have defined.

In this tutorial, we want all these groups to have the same PSD.

To accomplish this, we'll be using the Equivalent Sphere Diameter Size Type.

This option is especially useful for irregular objects, as it allows the particle size to be based upon
the diameter of a sphere with equivalent volume.

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 Part B: Rocky Project Setup (Workbench)

1. Use the information in the tables that follow to define each of these four particle shapes.

Step Data Entity Editors Parameter or Action Settings

Location
A Particles Create Particle
B Particles Particle Name Metal
Shape Sphero-Cylinder
Particle Material Metal
<01>
C Particles Particle | Size Size Type Equivalent Sphere
Diameter
Metal
Add row (x2)
(1) Diameter | Cumulative 0.08 [m] @ 100 [%]
%
(2) Diameter | Cumulative 0.05 [m] @ 40 [%]
%
(3) Diameter | Cumulative 0.02 [m] @ 10 [%]
%
… | Shape Vertical Aspect Ratio 3.00 [ - ]
D Particles Duplicate

Metal

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Step Data Entity Editors Parameter or Action Settings

Location
E Particles Particle Name Paper
Shape Sphero-Polygon
Metal
<01> Material Paper
… | Shape Vertical Aspect Ratio 1.00 [ - ]
Horizontal Aspect Ratio 0.10 [ - ]
Number of Corners 4[-]
F Particles Duplicate

Paper
G Particles Particle Name Stone
Shape Sphere
Paper
<01> Material Stone
H Particles Duplicate

Stone
I Particles Particle Name Wood
Shape Briquette
Stone
<01> Material Wood
… | Shape Vertical Aspect Ratio 0.30 [ - ]
Side Angle 30.00 [ - ]
Number of Corners 16 [ - ]

13.2.10. MASS FLOW DEFINITION

For the Inlets and Outlets step, we will create one Particle Inlet to release from Rectangular Surface
<01> all four of the particle groups we just defined.

Specifically:

• Each particle group will be given a mass flow rate that, along with the material density, will help
us reach our goal of achieving the same volume flow rate per group.

• We will also be prescribing these particle groups with the same initial temperature.

1. Use the information in the table that follows to define your Inputs.

Step Data Editors Parameter or Action Settings

Entity Location
A Inlets and Outlets Create Particle Inlet

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 Part B: Rocky Project Setup (Workbench)

Step Data Editors Parameter or Action Settings

Entity Location
B Inputs Particle Inlet Entry Point Rectangular Surface <01>
Particle Inlet | Add row (x4)
Particles (1) Particle | Mass Flow Metal @ 240 [t/d] 25
Particle
Inlet Rate | Temperature [degC]
<01> (2) ... Paper @ 24 [t/d] 25 [degC]
(3) ... Stone @ 90 [t/d] 25 [degC]
(4) ... Wood @ 27 [t/d] 25
[degC]

13.2.11. FINISH PROJECT SETUP

For illustration purposes, we will first run the case without fluid flow.

1. Use the information in the table that follows to finish setting up your Rocky project.

Step Data Editors Parameter or Settings

Entity Location Action
A Solver Solver | Time Simulation Duration 5 [s]
Solver | Simulation Target CPU
General

With a 3D View window opened, your Data panel and Workspace should look similar to the image
shown below.

13.2.12. PROCESS SIMULATION

1. From the Solver entity, click Start.

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The Simulation Summary screen appears (as shown), then processing begins.

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 Part B: Rocky Project Setup (Workbench)

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

Note:

When the simulation processing is done inside Workbench—as is done in this Tutorial—all
files are saved in the Workbench file directory, including the ones needed for Rocky.

13.2.13. POST PROCESSING

• After Rocky is finished processing, you may post-process the (pre-fluid) particle-only results.

• Because as of yet, there is still no fluid coupling, we are able to analyze only the particle behavior
at this point.

• Doing so now can later help us see the changes in behavior once fluid effects are applied (in Part
C).

Let's start by looking at particle trajectory through the pipe.

1. Select or create a 3D View window.

2. Use the information in the table below to define what is shown in this window.

Step Data Editors Parameter or Settings

Entity Location Action
A Particles Coloring Nodes (Enabled)

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Step Data Editors Parameter or Settings

Entity Location Action
Nodes | Property Particle
Group
B Geometries Coloring Transparency (Enabled)

Design1

3. Use the options on the Time toolbar to see the particles' trajectory through the pipe.

Notice that without fluid effects, all particle groups fall downwards through the pipe.

4. At the final timestep (5 s), save a copy of this image by right-clicking within the 3D View window,
and then clicking Save Image.

Now, let's look at temperature.

1. Use the information in the table below to re-define what is shown in the 3D View window.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Coloring Nodes | Property Temperature
B Color Scales Coloring Limit options Automatic PER View

Temperature

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 Part B: Rocky Project Setup (Workbench)

Notice that even over time, without fluid effects, all particles maintain their same initial temperature.

2. At the final timestep (5 s), save a copy of this image by right-clicking within the 3D View window,
and then clicking Save Image.

Now that we have analyzed the particle flow without the effects of fluids, let's have Rocky delete the
simulation results so that we can re-run them (through Workbench) with the fluid results included.

An easy way to delete the results in Rocky is to use the Clear Results button.

1. From the Simulation toolbar, select the Clear Results button.

2. A Dialog will appear asking whether you want to delete the results. Click Yes to delete the results.

3. Save and Close Rocky and return to Workbench.

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4. Save the Workbench project.

13.2.14. CONCLUSIONS
This completes Part B of this tutorial, in which Ansys Workbench was used to set up and run an initial
Rocky simulation that will later be one-way coupled with the CFD results we created in Part A.

During this tutorial, it was possible to:

• Set up and run the initial Rocky simulation through Workbench.

• Analyze the (pre-fluid) behavior of the particle flow through the pipe.

• Delete the DEM results to reset the Rocky project back to just the setup portion.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part C
and use Workbench to one-way couple the CFD results with this Rocky project.

13.3. Part C: One-Way Coupling (Workbench)

13.3.1. OBJECTIVE
The main purposes of this tutorial are to use Ansys Workbench to run a one-way coupled DEM-CFD
simulation using Rocky and Ansys Fluent, and then analyze those results.

• We will make use of the CFD results we obtained in Part A and the Rocky project setup we created
in Part B.

• As a reminder, the windshifter scenario considered in this tutorial evaluates how air flowing upwards
through a pipe affects the different materials that discharge into it.

You will learn how to:

• Create the link between Rocky and Fluent in Workbench

• Set up the fluid forces models in Rocky

• View a slice of the fluid vectors

• Process a one-way coupled simulation

• Analyze particle flow, drag, and temperature

And you will use these features:

• 1-Way Fluent CFD Coupling

• Cube User Process

• Coloring Vectors by Property

• Coloring Nodes by Property

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 Part C: One-Way Coupling (Workbench)

13.3.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine the following:

• (1) A valid license for the following Ansys products: Discovery, Rocky and Workbench 2025 R1.

Important:

This ADVANCED tutorial assumes that you are already familiar the following programs
and resources:

• The Ansys Workbench platform.

– If that is not the case, please refer to the Ansys Workbench user documentation for
basic introduction about Workbench usage before beginning this tutorial.

Note:

Rocky and Ansys Workbench integration is currently supported only on Win-

dows.

• The Rocky user interface (UI) and the Rocky project workflow.

– If this is not the case, it is recommended that you complete at least Tutorials 01- 05
before beginning this tutorial.

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13.3.3. GEOMETRY

As a reminder, the geometry for Part C of this tutorial is composed of:

• (1) pipe, which itself has the following regions:

– (a) inlet (fluid flow)

– (b) outlet (fluid flow)

– (c) opening (material flow)

• (2) Receiving Conveyor

Note:

These components were added in Part A and Part B of this tutorial.

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 Part C: One-Way Coupling (Workbench)

13.3.4. WORKBENCH SETUP

1. If you completed Part B of this tutorial, ensure that the Ansys Workbench project you last saved
is open. (Part C will continue from where Part B left off.)

2. If you did not complete Part B, do all of the following:

a. Download the dem_tut13_files.zip file .

b. Unzip dem_tut13_files.zip to your working directory.

c. Open Ansys Workbench.

Important:

To make use of the Workbench project file provided, you must have Ansys 2025
R1 or later and Rocky 2025 R1 or later. If you have an earlier version of either of
these programs, please upgrade to the latest version of Rocky and the latest version
of Ansys that is supported by Rocky, or complete Parts A and B from scratch.

d. From the Workbench program, click the Open Project button, find the dem_tut13_files folder,
and then from the tutorial_13_B_processing-rocky folder, open the tutorial_13_B_pro-
cessing-rocky.wbpj file.

With the project open in Workbench, you are now ready to begin Part C.

Let's start by connecting the Fluent results with Rocky in Workbench.

1. From the Fluid Flow (Fluent) component, right-click Solution and select Refresh.

2. From the Fluid Flow (Fluent) component, right-click Solution and select Update.

3. From the Fluid Flow (Fluent) component, right-click Results and select Refresh.

4. From the Project Schematic, drag and drop the Solution component from the Fluid Flow (Fluent)
block onto the Setup component of the Rocky block (as shown).

Note:

This action will automatically generate a link between the CFD results and the Rocky
project.

5. From the Rocky block, double-click the Setup component.

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• Due to the link created in Workbench, the Rocky project opens with CFD results automatically
included.

13.3.5. CFD COUPLING

Define the CFD Coupling options in Rocky:

1. From the Data panel, under CFD Coupling, select 1-Way Fluent.

2. From the Data Editors panel, select the 1-Way Fluent | Interactions tab, and then from the
Particle list, multi-select all four of the particle groups listed (as shown).

3. Define the Drag Law.

Note:

This drag law was selected because it is suitable for both spherical and non-spherical
particles.

4. Also define the Convective Heat Transfer Law (as shown).

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 Part C: One-Way Coupling (Workbench)

13.3.6. CFD VISUALIZATION

Now that the CFD results are within Rocky, you can visualize the nodes of the cell centroids making
up the Fluent mesh.

Important:

Given the amount of elements, showing all vectors for your CFD meshes is not considered
good practice as it can freeze the Rocky interface.

A better practice is to create a thin slice of your mesh and show only the vectors within that slice.
We will start by creating a Cube.

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1. Use the information in the below table to begin creating this view.

Step Data Entity Editors Parameter or Settings

Location Action
A CFD Coupling Create a Cube User Process

1-Way Fluent
B User Cube Center 0.4, 1.5, 0
Processes [m]
Magnitude 1.4, 3, 0.02
Cube
[m]
<01>

2. From the Data panel, under User Processes, right click the Cube <01> entry, point to Show in
new, and then click 3D View.

3. With the new 3D View window selected, hide all the geometry components and Particles by
clicking the eye icon to the right of the entries on the Data panel so that the icon appears closed.

4. Use the information in the table below to finish setting up the view.

Step Data Entity Editors Parameter or Action Settings

Location
A User Processes Coloring Vectors (Enabled)
Vectors | Property Velocity
Cube <01>

Vectors | Vector scale 0.2 [ -

]
Vectors | Normalized (Enabled)
Vectors

The colored vectors within the slice of pipe indicate that the fluid moves up and around the bend of
the pipe.

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 Part C: One-Way Coupling (Workbench)

13.3.7. SOLVER DEFINITION

As the previous iteration did not include CFD results, it is necessary to run the simulation again to
calculate how the fluid flow affects the particles.

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1. Use the information in the table below to ensure your solver parameters are correct.

Note:

The parameters are the same ones we defined earlier in Part B to simulate only particles,
so you shouldn't have to make any changes for this step.

Step Data Editors Parameter or Settings

Entity Location Action
A Solver Solver | Time Simulation Duration 5 [s]
Solver | Simulation Target CPU
General

2. Click Start.

13.3.8. PROCESS SIMULATION

The Simulation Summary screen appears (as shown), then processing begins.

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 Part C: One-Way Coupling (Workbench)

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during

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processing.

Reminder: When the simulation processing is done inside Workbench as is done in this Tutorial all
files are saved in the Workbench file directory, including the ones needed for Rocky.

13.3.9. CFD COUPLING POST PROCESSING

After the simulation is done processing, you can analyze the coupled particle-fluid flow that was
simulated, and compare it to the particle-only flow we analyzed in Part B.

1. With a 3D View window selected, use the information in the table below to define what is shown
in the window.

Tip:

Both particles and geometries will be analyzed in this comparison. Use the eye icons
on the Data panel to show the related entities if they are hidden.

Step Data Editors Parameter or Settings

Entity Location Action
A Particles Coloring Nodes (Enabled)
Nodes | Property Particle
Group
B Geometries Coloring Transparency (Enabled)

Design1

2. Use the options on the Time toolbar to view the particles' trajectory over time.

3. At the final timestep (5 s), compare these particle-fluid results (on the right) with the image you
took of the particle-only flow in Part B (on the left).

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 Part C: One-Way Coupling (Workbench)

In the particle-fluid simulation (on the right), the lighter Wood and Paper particles are carried up
the pipe due to the fluid flow.

4. Take note of the Particle Group number shown on the color scale. We will need the values for
Metal (shown here as 0) and Stone (shown here as 2) later in this tutorial.

A similar comparison can be made with Temperature.

1. Use the information in the table below to re-define what is shown in the 3D View window.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Coloring Nodes | Property Temperature
B Color Scales Coloring Limit Options Automatic PER View

Temperature

2. Use the options on the Time toolbar to view how the particles' temperature changes over time.

3. At the final timestep (5 s), compare these particle-fluid results (right) with the image you took of
the particle-only flow in Part B (left).

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In the particle-fluid simulation (right), heat is transferred from the fluid to the particles.

Note:

Particles reach different temperatures due to the different combinations of heat capacity,
conductivity and surface area.

13.3.10. EVALUATE DRAG FORCE

Earlier in Part B of this tutorial, we turned on the CFD Coupling Particle Statistics module, and
chose to collect data on Drag Force.

We can now evaluate how the drag force affects the particles.

1. With a 3D View window selected, use the information in the table below to define what is shown.

Step Data Editors Parameter or Settings

Entity Location Action
A Particles Coloring Nodes (Enabled)
Nodes | Property Force:
Drag

2. Use the Time toolbar to see how drag affects the particles over time.

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 Part C: One-Way Coupling (Workbench)

We can further evaluate the drag force by comparing its effects on different groups of particles.

1. Enable the Expressions/Variables panel (from Menu | Tools).

2. Follow the steps in the table below to filter the Metal particle group into a specific size range.

Step Data Entity Editors Location Parameter or Action Settings

A Particles Create a Cube User Process
B User Processes Cube Center 0, 1.4, 0 [m]
Magnitude 0.5, 0.5, 0.5 [m]
Cube <02>
C User Processes Create a Particles Time Selection User Process

Cube <02>
D User Processes Time Selection | Domain Range All
Time Range Filter
Particles
Time
Selection
<01>
E User Processes Create a Property User Process

Particles Time Selection <01>

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Step Data Entity Editors Location Parameter or Action Settings

F User Processes Property Name All Smalls
Property Particle Equivalent
Property
Diameter
<01>
Type Range
Minimum Value 0.02 [m]
Maximum Value 0.03 [m]

3. Follow the steps in the table below to filter the Stone particle group into a specific size range
and then compare the resulting drag forces

Step Data Entity Editors Location Parameter or Action Settings

G User Processes Create a Property User Process

All Smalls
H User Property Name Metal Smalls
Processes Property Particle Group
Type Value
Property Cut value 0
<01>
Properties | Force: Drag and drop to Expressions/Variables |
Drag Output
I User Processes Create a Property User Process

All Smalls
J User Property Name Stone Smalls
Processes Property Particle Group
Type Value
Property Cut Value 2
<01>
Properties | Force : Drag and drop to Expressions/Variables |
Drag Output

Note:

For steps H and J, ensure that what you enter for Cut value corresponds to the correct
Particle Group number displayed on the color scale within your own project (see
3 (p. 679)).

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 Part C: One-Way Coupling (Workbench)

At this point, we have successfully filtered the particles that we want to evaluate drag forces by both
size (only the smallest) and group (only Metal and Stone).

Tip:

• To better visualize the particles we are analyzing, use the eye icons on the Data panel
to hide Particles and every entity under User Processes except the Metal Smalls and
Stone Smalls entities.

• Refer to Tutorial 03 - Vibrating Screen for an introduction about Particles Time Selec-
tion if you are not familiar with it.

• You can also color each property by Particle Group to better differentiate between the
metal and stone.

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Tutorial - Windshifter

1. Use the table below to configure the output variables you just created.

Step Item Parameter or Settings

Action
A Expressions/Variables | Output Edit (button)

Drag_Force
B Edit Properties (dialog box) Name Drag_Force_Metal
Property to Curve average

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 Part C: One-Way Coupling (Workbench)

Step Item Parameter or Settings

Action
C Expressions/Variables | Output Edit (button)

Drag_Force_0
D Edit Properties (dialog box) Name Drag_Force_Stone
Property to Curve average

Now you have the average values of the drag forces that acted on the Metal and Stone particles (as
shown).

Tip:

Your values may differ from the ones presented in this tutorial.

You can also color your Metal Smalls and Stone Smalls by Drag Force (as shown).

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Tutorial - Windshifter

1. Use the information in the table below to check your results.

Step Data Entity Editors Parameter or Settings

Location Action
A User Coloring Nodes (Enabled)
Processes Nodes | Property Drag
Force
Metal
Smalls
B ... Nodes (Enabled)
Nodes | Property Drag
Stone
Force
Smalls

Note that the drag forces calculation depends on the particle shape, orientation, size, velocity and
other properties.

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 Part C: One-Way Coupling (Workbench)

Also note that we are visualizing a Particles Time Selection, which shows the particles we've chosen
to filter at the position they were just before they left the region specified, for all times in the simu-
lation. The visualization does not change with time because the selection itself includes multiple
times.

13.3.11. CFD COUPLING POST PROCESSING

Another way to evaluate these results is to take a closer look at the two outlets to analyze what kind
of particles are passing through each end of the pipe.

We will do this by creating two Cube User Processes:

• One for the outlet (at the top)

• Another for the inlet (at the bottom)

We will then use again Particle Time Selection to evaluate which Particle Groups go through each
Cube.

1. Use the information in the table that follows to create these User Processes.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Cube User Process
B User Cube Name Outlet
Processes Center 0.7, 2.7, 0
[m]
Cube
<03> Magnitude 1, 0.6, 0.6
[m]
Cube | Method Angles
Orientation Rotation 0, 0, 45
[dega]
C Particles Create a Cube User Process
D User Cube Name Inlet
Processes Center 0, 0.4, 0 [m]
Cube Magnitude 0.6, 1, 0.6
<03> [m]

The placements of the two Cubes are shown below.

Using these two Cubes, we can now create a Particle Time Selection to evaluate which particles are
passing through each outlet.

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Tutorial - Windshifter

1. Use the table below to create the Particles Time Selection User Processes.

Step Data Entity Editors Parameter or Action Settings

Location
A User Processes Create a Particles Time Selection User
Process
Outlet
B User Processes Time Selection Name Outlet All Time
Domain Range All
Particles Time
Selection <02>
C User Processes Create a Particles Time Selection User
Process
Inlet

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 Part C: One-Way Coupling (Workbench)

Step Data Entity Editors Parameter or Action Settings

Location
D User Processes Time Selection Name Inlet All Time
Domain Range All
Particles Time
Selection

Now that we have our user processes, let's plot them.

2. Use the information in the table that follows to define a histogram.

Step Item Parameter or Action Settings

A User Processes Show in new Histogram by Particle Group

Outlet All Time

B Histogram (window) Configure Histogram (button)
C Configure Histogram (dialog Weigth Particle Mass
box) Number of Bins 4[-]
Percent Values (Enabled)
Properties Particle Group
Limits User Defined
Min 0 [<ind>]
Max 4 [<ind>]
D User Processes Show in current Histogram by Particle
Group
Inlet All Time

Results of the Histogram are shown. Take note the following:

• The 1st and 3rd bins are Metal and Stone particles, respectively. Only the (lower) Inlet (in orange)
had these groups.

• The 2nd and 4th bins are Paper and Wood particles, respectively. Only the (upper) Outlet (in black)
had these groups.

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Tutorial - Windshifter

Using these results, we can conclude that:

• The lighter and flatter Paper and Wood particles were more affected by the drag force than by the
gravity force, and were therefore carried up the pipe.

• The heavier and thicker Metal and Stone particles were more affected by the gravity force than by
the drag force, and therefore fell down the pipe.

13.3.12. CONCLUSIONS
This completes Part C of this tutorial, in which Ansys Workbench was used to set up, run, and post-
process a one-way coupled simulation between Rocky and Ansys Fluent.

During this tutorial, it was possible to:

• Apply Fluent CFD results to the Rocky project through Workbench.

• Set up the fluid forces models in Rocky.

• View a slice of the fluid vectors in Rocky.

• Process the one-way coupled simulation in Rocky.

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 Part C: One-Way Coupling (Workbench)

• Analyze particle flow, temperature, and drag effects.

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 14: Tutorial - Fluidized Bed
(Part A) Set up a CFD case with heat transfer in Ansys Fluent to be later used in a two-way coupling
simulation with Rocky DEM.

(Part B) Use the CAS file you created in Part A to set up the Rocky portion of the two-way simulation,
and then run it coupled with Ansys Fluent.

(Part C) Post-process in Rocky the 2-Way Fluent coupling simulation you completed in Part B.

14.1. Part A: Fluent Case Setup

14.1.1. OBJECTIVES
The main purpose of this Tutorial is to set up a CFD case with heat transfer in Ansys Fluent to be
later used in a two-way coupling simulation with Rocky DEM.

Important:

Even if you are already familiar with CFD, please follow Part A in order to understand the
main limitations and needs for single-phase coupling with Rocky.

• Part B and Part C of this tutorial will cover setting up the Rocky project and running the two-way
coupled simulation, respectively.

The scenario being used in this tutorial includes a bed of initially hot particles being fluidized in a
colder air current.

• Fluidized beds are widely adopted in the chemical industry due to the enhanced mixing and im-
proved heat and mass transfer between the particles and fluid.

You will learn how to: Set up and save a single-phase heat transfer case in Ansys Fluent that can
later be used for two-way coupling with Rocky DEM.

14.1.2. PREREQUISITES
To complete this tutorial, you are required to have a valid license for Ansys Fluent and Rocky 2025
R1.

Important:

This ADVANCED tutorial assumes that you are already familiar with the Ansys Fluent UI
and project workflow.

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Tutorial - Fluidized Bed

• If that is not the case, please refer to the Ansys Fluent user documentation for basic
introduction about Fluent usage before beginning this tutorial.

14.1.3. GEOMETRY INTRODUCTION

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 Part A: Fluent Case Setup

The walled rectangular container used in this tutorial is composed of the following geometries:

• (1) walls, which itself contains two additional components:

– (a) inlet

– (b) outlet

Note:

These three geometries will come from the Fluent .cas file that you will set up as part of
this tutorial.

14.1.4. OPEN ANSYS FLUENT

To set up the Fluent Case, do the following:

1. Open Ansys Fluent.

2. From the Fluent Launcher, under Dimension, ensure that 3D is selected; also, under Options,
ensure that Double Precision is selected (as shown).

Important:

Double Precision and 3D are required for coupling with Rocky.

3. Click Start.

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Tutorial - Fluidized Bed

14.1.5. IMPORT MESH

For this tutorial, we will start by importing a mesh file.

1. Download the dem_tut14_files.zip file .

2. Unzip dem_tut14_files.zip to your working directory.

3. From the File menu, point to Read, and then click Mesh.

4. From the Select File dialog, do the following:

a. From the Files of type list, select All Mesh Files (*.msh* *.MSH*).

b. From the dem_tut14_files/mesh folder, select the tutorial_14_mesh.msh file, and then click
OK.

14.1.6. FLUID MESH SETUP

Now that the Fluent .msh file is imported, we can start setting up the Fluent case.

1. Use the information in the table that follows to visualize and set up the mesh.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to your Ansys Documentation to find detailed instructions.

Step Item Location Parameter or Action Settings

A Setup Task Page Display Mesh (inlet, outlet, walls | Display)
Check Mesh
General
Time Transient
Gravity (Enabled)
Gravitational -9.81 [m/s2] in the Z
Acceleration direction

Important:

Transient must be selected in order to run a two-way coupled simulation.

14.1.7. SINGLE PHASE SETUP

In this tutorial, we will be setting up the Fluent case with only one fluid phase (air).

This single phase approach is:

• Faster than the equivalent simulation using multiple phases.

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 Part A: Fluent Case Setup

• Easier to set up and allows for a broader range of models.

Tip:

Since this tutorial refers only to the single phase approach, refer to the Rocky CFD
Coupling Technical Manual for information about using the multiphase approach.

(From the Rocky Help menu, point to Manuals, and then click CFD Coupling Technical
Manual.)

1. From the Outline View, under Models, leave the Multiphase model Off (no changes).

14.1.8. ENABLE ENERGY AND TURBULENCE

For this tutorial, we want to enable both heat transfer and turbulence.

1. Use the information in the table that follows to continue setting up your case.

Step Item Location Parameter or Settings

Action
A Setup Energy (dialog box) Energy Equation (Enabled)

Models

Energy
B Setup Viscous Model Model k-epsilon (2-eqn)
(dialog box) Near-Wall Scalable Wall Functions
Models
Treatment
Viscous

Note:

The choice of turbulence model depends upon the application.

14.1.9. MATERIALS AND BOUNDARY CONDITIONS

For the Materials properties, we will be using the default Fluid properties for air.

For the Boundary Conditions properties, we will use the default (adiabatic) properties for Wall, but
we will define new conditions for the Inlet and Outlet.

1. Use the information in the table below to continue setting up your case.

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Tutorial - Fluidized Bed

Step Item Location Parameter or Action Settings

A Setup Velocity Inlet Velocity Magnitude 2 [m/s]
(dialog box) | Turbulence | Specification Intensity and
Momentum Method Hydraulic Diameter
Boundary
Conditions Turbulence | Hydraulic 0.1 [m]
Diameter
Inlet Temperature 293.15 [K]
B Setup Pressure Outlet Backflow Total Temperature 293.15 [K]
(dialog box) |
Thermal
Boundary
Conditions

Inlet

14.1.10. METHODS
1. Use the information in the table that follows to define the solution methods.

Step Item Location Parameter or Action Settings

A Solution Task Page Pressure-Velocity Coupling | SIMPLE
Scheme
Transient Formulation First Order
Methods
Implicit

Note:

With the single phase approach, there is no limitation on which pressure-velocity

coupling scheme you can use.

In addition, for all two-way coupling simulations, First Order Implicit must be set for
Transient Formulation.

14.1.11. INITIALIZE AND CALCULATE

1. Use the information in the table that follows to initialize and set the calculation parameters.

Step Item Location Parameter or Action Settings

A Solution Task Initialization Methods Standard
Page Initialization
Compute from all-zones
Initialization
Initialize

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 Part A: Fluent Case Setup

Step Item Location Parameter or Action Settings

B Solution Task Time Advancement | Fixed
Page Type
Run
Time Step Size 0.001 [s]
Calculation

Important:

To run a coupled simulation, the Time Advancement | Type must remain Fixed.

14.1.12. SAVE CASE

Because this is a two-way coupled simulation, we will not be solving the CFD case at this point but
will be saving this setup to a .cas file that will be connected with Rocky later.

Save the case by doing the following:

1. From the File menu, point to Write and then click Case.

2. From the Select File dialog, do all of the following:

a. Choose a folder location.

b. Enter the Case File name as fluidized_bed.cas.h5.

c. Click OK.

14.1.13. HELP
This concludes Part A of this tutorial.

For further information on the topic presented, we suggest searching the CFD Coupling Technical
Manual, which provides descriptions of the DEM-CFD coupling methods.

To access it, from the Rocky Help menu, point to Manuals, and then click CFD Coupling Technical
Manual.

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Tutorial - Fluidized Bed

For further information about Ansys Fluent, please refer to the Ansys Fluent user documentation.

14.1.14. CONCLUSION
Ansys Fluent was used to set up a single-phase CFD simulation with heat transfer that will later be
used for two-way coupling with Rocky.

During this tutorial, it was possible to:

• Use Ansys Fluent to set up a single-phase CFD case

• Save the case file for later two-way coupling with Rocky

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to Part B and create the
Rocky project that will later be coupled with this CFD case.

14.2. Part B: Setup and Processing in Rocky

14.2.1. OBJECTIVES
The main purpose of this Tutorial is to use the .cas file we created in Part A to set up the Rocky
portion of the two-way simulation, and then run it coupled with Ansys Fluent.

As a reminder, the scenario covered includes a bed of initially hot particles that are fluidized in a
colder air flow.

You will learn how to:

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 Part B: Setup and Processing in Rocky

• Import geometry components from a Fluent .cas file

• Set up and save a fluidized bed simulation with Rocky

• Save a Rocky project for restart

• Set up and run a 2-Way Fluent coupled simulation in Rocky

And you will use these features:

• Thermal Model

• Custom Geometry Import

• 2-Way Fluent CFD Coupling

14.2.2. PREREQUISITES
To complete this tutorial, you are required to have a valid license for Ansys Fluent and Rocky 2025
R1.

Important:

This ADVANCED tutorial assumes that you are already familiar with the following programs
and resources:

• The Rocky program.

– If this is not the case, it is recommended that you complete at least Tutorials 01- 05
before beginning this tutorial.

• The Ansys Fluent program.

– If this is not the case, please refer to the Ansys Fluent user documentation for a basic
introduction about Fluent usage before beginning this tutorial.

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14.2.3. GEOMETRY INTRODUCTION

As a reminder, the walled rectangular container used in this tutorial is composed of the following
geometries:

• (1) walls, which itself contains two additional components:

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 Part B: Setup and Processing in Rocky

– (a) inlet

– (b) outlet

Note:

These three geometries will come from the Fluent .cas file that you will import into Rocky.

14.2.4. PROJECT CREATION

1. Do one of the following:

• If you completed Part A of this tutorial, ensure you have available the fluidized_bed.cas.h5
file you created in Fluent. (Part B will make use of that file.)

• If you did not complete the project from Part A, ensure you have downloaded and extracted
the dem_tut14_files.zip file .

2. Open Rocky 2025 R1.

3. Create a new project.

4. Save the empty project to a location of your choosing.

14.2.5. PROJECT SETUP

1. Use the information in the tables that follow to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Data Entity Editors Parameter or Action Settings

Location
A Study Study Study Name Fluidized Bed
B Physics Gravity Y-direction 0 [m/s2]
Z-direction -9.81 [m/s2]
Momentum Numerical Softening Factor 0.1 [ - ]
Thermal Enable Thermal (Enabled)
Conduction Correction Morris et al. Area+Time
Model
C Geometries Import Wall fluidized_bed.cas.h5 with
"m" for Import Unit

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Tutorial - Fluidized Bed

Step Data Entity Editors Parameter or Action Settings

Location
D Geometries Wall | Thermal Boundary Type Adiabatic
Thermal
walls
E Materials Material Use Bulk Density (Cleared)
Density 1500 [kg/m3]
Default Young's Modulus 1e+07 [N/m2]
Particles
Thermal Conductivity 1.4 [W/m.K]
Specific Heat 800 [J/kg.K]
F Particles Create Particle
G Particles Particles Name smaller
Particles | Size 0.003 [m] @ 100%
Size
Particle
<01>
H Particles Create Particle
I Particles Particles Name bigger
Particles | Size 0.005 [m] @ 100%
Size
Particle
<01>

Note:

The walls may be already set as Adiabatic for Step D.

14.2.6. VOLUMETRIC INLET

Next, we will create a Volumetric Inlet and will constrain it to achieve a flat pile.

Where you place your Seed Coordinate and how you constrain your fill affects the behavior of
particles after release. For example, when constraining by Geometries:

• (1) A Seed Coordinate placed too high above the geometry base might cause particles to fall.

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 Part B: Setup and Processing in Rocky

• (2) To achieve a more settled pile, locate your Seed Coordinate closer to the base of the geometry
(but avoid the very bottom).

• (3) Choosing to Use Geometries to Compute the Box bounds could result in a rounded pile.

• (4) To achieve a flat pile, define your own Box bounds.

14.2.7. CONTINUE PROJECT SETUP

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Parameter or Action Settings

Location
A Inlets and Outlets Create Volumetric Inlet
B Inputs Volumetric Add 2 entry rows
Inlet | (1) Particle | Mass | smaller @ 0.06 [kg] &
Volumetric Particles Temperature 363 [K]
Inlet <01>
(2) Particle | Mass | bigger @ 0.06 [kg] &
Temperature 363 [K]
Volumetric Seed Coordinates 0, 0, 0.01 [m]
Inlet | Geometries (All Enabled ("Check
Region All"))
Box bounds | Center 0, 0, 0.025 [m]
Coordinates
Box bounds | Dimensions 0.1, 0.1, 0.1 [m]

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Tutorial - Fluidized Bed

14.2.8. VISUALIZE VOLUMETRIC INLET BOUNDS

Tip:

From a 3D View window, you can visualize the Seed Coordinate (blue dot) and the Box
bounds (blue cube) that will constrain your Volumetric Inlet.

Important:

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 Part B: Setup and Processing in Rocky

The Seed Coordinate must be located within your Box Bounds.

• You can change the location and dimensions of the bounding box from within the 3D
View window by clicking and dragging the handles (colored dots) representing the
center, and the local X, Y, and Z locations respectively.

• You must still move the Seed location by using only the Seed Coordinates values.

1. For this tutorial, keep the both the Box bounds and Seed Coordinates as defined previously.

14.2.9. FINISH PROJECT SETUP

1. Use the information in the table that follows to finish setting up your Rocky project.

Step Data Entity Editors Location Parameter or Action Settings

A Solver Solver | Time Simulation Duration 0.1 [s]
Output Settings | Time 0.02 [s]
Interval
Solver | General Simulation Target CPU

14.2.10. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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14.2.11. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part B: Setup and Processing in Rocky

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Tutorial - Fluidized Bed

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

14.2.12. SIMULATION
Once the simulation is done processing, do the following:

1. From the Coloring service toolbar, color the Particles by Velocity : Translational : Absolute (as
shown).

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 Part B: Setup and Processing in Rocky

2. From the Time toolbar, do all of the following:

a. Click the Play simulation button or use the Next timestep button to move through the sim-
ulation output times. You will see the particle pile settle (slightly) due to gravity.

b. Click the Pause simulation button, and then click the Last timestep button to go to the end
of the simulation.

This will be the initial state of the particles when coupling with Fluent.

14.2.13. SAVE FOR RESTART

Now that the bed of particles is defined, save this simulation for Restart.

1. From the File menu, click Save project as...

2. From the Save As dialog, select the last option, Save as a New Project for Restart, and then
click OK.

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Tutorial - Fluidized Bed

This will save the project (setup and current particle location information) at the timestep you
have selected, which for this example, should be the last time step.

3. From the Save File dialog, select a location and File name for the new project, and then click
Save.

The newly saved project should now have the same bed of particles with the timestep reset to zero.

This is the Rocky project with which we will now two-way couple with Fluent.

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 Part B: Setup and Processing in Rocky

14.2.14. IMPORTING CFD SOLUTION

For the CFD Coupling step, we will select the 2-Way Fluent option.

This option in Rocky takes into account fluid forces acting on particles and transfers particle information
back to Fluent.

1. From the Data panel, click CFD Coupling and then from the Data Editors panel, select Fluent
under 2-Way from the Coupling Mode list.

2. From the Select Fluent CAS file dialog, navigate to and select the same Fluent .cas file you used
earlier to import geometries*, and then click Open.

* As a reminder, do one of the following:

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• If you completed Part A of this tutorial, navigate to and select the .cas file that you created in Part
A (fluidized_bed.cas.h5).

• If you did not complete Part A, navigate to the dem_tut14_files folder that you previously
downloaded, find the Fluent folder, and then select the fluidized_bed.cas.h5 file.

Important:

A mesh validation step will occur immediately after the .cas file import. This requires a
valid Fluent license on the same machine upon which you are running the Rocky simulation.

1. From the Data panel under CFD Coupling, select the new 2-Way Fluent option.

From the Data Editors panel, on the main 2-Way Fluent tab, there are five sub-tabs:

• Interactions: This is where the particle-fluid correlations are defined, and where you will set the
turbulent dispersion force (if applied).

• Coupling: This is where you set the Fluent calculation mapping method and sub-stepping options.

• Zones and Interfaces: This is where you can define how fluid cell zones and interfaces are treated
in the coupled calculations.

• Fluent: This is where you set solver options for the Fluent portion of the coupled simulation.

• Variables: This is where additional variables or data that Fluent will receive from Rocky are listed
(if defined).

For this tutorial, we will define only the Interactions and Fluent tab options.

1. From the Data Editors panel, select Interactions sub-tab.

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 Part B: Setup and Processing in Rocky

2. Under Particle, multi-select both Particle groups, and then define the Convective Heat Transfer
Law.

3. From the Data Editors panel, select the Fluent sub-tab, and then do all of the following:

a. From the Version list, select the Fluent version you want to use.

b. Clear the Keep all files checkbox (as shown). This allows you to save on disk space by choosing
how many Fluent .dat files you want to keep.

c. Set the Files to keep option set to 2. This saves only the last two Fluent .dat files.

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Tutorial - Fluidized Bed

Tip:

If you want to be able to post-process the CFD files in Fluent after processing, ensure
that the Keep all files checkbox is enabled. (For this tutorial, however, keep the
checkbox cleared.)

14.2.15. REDEFINE SOLVER

1. Use the information in the table that follows to set the Solver parameters for the coupled simulation.

Step Data Entity Editors Parameter or Settings

Location Action
A Solver Solver | Time Simulation Duration 3 [s]
Solver | Simulation Target CPU
General

Tip:

If you have a GPU, you can use it for Rocky while Fluent uses the CPU processors.

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 Part B: Setup and Processing in Rocky

2. From the Solver entity, click Start.

The Simulation Summary screen appears again.

In addition, Ansys Fluent will open automatically, and both Rocky and Fluent will begin processing
your coupled simulation.

Tip:

In Fluent, there is no need to refresh to see the results.

In Rocky, use the Refresh button or Auto Refresh checkbox to see the updated results in
your 3D View window.

14.2.16. HELP
This concludes Part B of this tutorial.

For further information about setting up a Rocky project for coupling with Fluent, we suggest
searching the Rocky User Manual.

For further information about setting up a Fluent case for coupling with Rocky, we suggest the fol-
lowing resources:

• The webinar DEM and CFD Coupling

• The Rocky CFD Coupling Technical Manual

14.2.17. CONCLUSIONS
The Fluent .cas file we created in Part A was used to set up the Rocky portion of the coupled simula-
tion, and then we ran that Rocky simulation two-way coupled with the Ansys Fluent simulation.

During this tutorial, it was possible to:

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Tutorial - Fluidized Bed

• Verify that Rocky has the components necessary to couple with Ansys

• Import geometries from a Fluent .cas file into Rocky

• Set up and Save for Restart a fluidized bed simulation in Rocky

• Use Rocky to set up and run a two-way coupled simulation with Fluent

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part C
and post-process this project.

14.3. Part C: Post-Processing in Rocky

14.3.1. OBJECTIVES
The main purpose of this Tutorial is to post-process in Rocky the two-way coupling simulation we
completed in Part B.

As a reminder, the scenario covered includes a bed of initially hot particles that are fluidized in a
colder air current.

You will learn how to:

• Evaluate particle segregation

• Analyze the mixing efficiency

• Evaluate average particle temperature

• Visualize fluid temperature

• Analyze the pressure drop

And you will use these features:

• User Processes, including:

– Cube

– Property

• Divisions Tagging Particle Calculations

• Graphs and Plots, including:

– Histograms

– Time Plots

– Table Time Plots

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 Part C: Post-Processing in Rocky

14.3.2. PREREQUISITES
To complete this tutorial, you are required to have a valid license for Ansys Fluent and Rocky 2025
R1.

Important:

This ADVANCED tutorial assumes that you are already familiar with the Rocky program.

• If this is not the case, it is recommended that you complete at least Tutorials 01- 05
before beginning this tutorial.

14.3.3. OPEN PROJECT

1. If you completed Part B of this tutorial, ensure that Rocky project is open and has completed
processing. (Part C will continue from where Part B left off.)

2. If you did not complete Part B, do all of the following:

a. Ensure you have a valid Fluent license on the same machine upon which you are running
Rocky. (This is required in order to validate the mesh within the linked .cas file.)

b. Download the dem_tut14_files.zip file .

c. Unzip dem_tut14_files.zip to your working directory.

d. Open Rocky 2025 R1.

e. From the Rocky program, click the Open Project button, find the dem_tut14_files folder, and
then from the tutorial_14_B_pre-processing-rocky folder, open the tutorial_14_B_pre-
processing-rocky-restart.rocky file.

f. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

Note:

Ansys Fluent will open automatically, and both Rocky and Fluent will begin pro-
cessing your coupled simulation.

14.3.4. ROCKY – POST-PROCESSING

Now that the project has completed processing, we can begin to analyze it.

Lets start by looking at particle segregation.

1. Use the information in the table below to begin this analysis.

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Step Item Location Parameter or Settings

Action
A Window (menu) Create a New 3D View
B Particles Coloring Nodes | Property Particle
Group

Using the buttons on the Time toolbar, you can view how particles in the bed segregate as they are
moved by the air injected from below.

Segregation: The bigger particles settle to the bottom while the smaller particles rise to the top of
the bed.

14.3.5. ROCKY – POST-PROCESSING – DIVISIONS TAGGING

We can also visualize how well particles in different regions of the container mix as the simulation
progresses.

For this kind of analysis, we can use a Cube User Process along with Divisions Tagging to color the
particles by the regional layers in which they were originally located.

To start this analysis, do all of the following:

1. From the Time toolbar, select the very first output time (0.00 s).

2. Use the information in the following table to create the Cube and Divisions Tagging processes.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Cube User Process

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 Part C: Post-Processing in Rocky

Step Data Entity Editors Parameter or Settings

Location Action
B User Processes Cube Center 0, 0, 0.04 [m]
Magnitude 0.1, 0.02, 0.08 [m]
Cube <01>
C Calculations | Particles Calculations Create a Division Tagging on <Cube 01>
D Calculations Tagging Heigth Divisions 1
Depth Divisions 5
Divisions
Tagging (Cube Coloring Faces | Property Divisions Tagging
<01>)... (Cube <01>)...

Particles inside the Cube have now been subdivided into 5 different axial divisions based on their
position at t=0s.

3. Use the Data panel eye icons to hide Divisions Tagging(Cube <01>), hide Cube <01>, and show
Particles.

4. From the Data panel, select Particles.

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Tutorial - Fluidized Bed

5. From the Data Editors panel, select the Coloring tab, and then under Nodes, select Divisions
Tagging (Cube <01>) as the Property to be colored.

6. Notice how particles are distributed at the beginning of the simulation and advance in time to
observe mixing.

Observe mixing: Based upon the particles' initial position (t=0), you can watch how they move around
the bed as time advances.

14.3.6. ROCKY – POST-PROCESSING – CREATING A NEW CUBE

Rather than looking at the entire bed as a whole, you can also focus your analysis on a single segment.

For this analysis, we will create another Cube in the middle of the bed and visualize how particles
that originated from other segments are moved into that particular segment over time.

To start this new analysis, do all of the following:

1. From the Time toolbar, select the very first output time (0.00 s).

2. Use the information in the following table to create the Cube.

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 Part C: Post-Processing in Rocky

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Cube User Process
B User Cube Center 0, 0, 0.056 [m]
Processes Magnitude 0.1, 0.02, 0.0155
[m]
Cube
<02>

This new Cube should encompass the 4th axial division and should therefore contain only particles
with Division Tagging equal to 4 at the beginning of the simulation.

14.3.7. ROCKY – POST-PROCESSING – CREATING A HISTOGRAM

Let's verify:

1. Use the information in the table that follows to create a histogram.

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Step Item Parameter or Action Settings

A User Processes Show in new Histogram by Divisions Tagging (Cube <01>)...

Cube <02>
B Histogram (window) Configure histogram (button)
C Configure Number of Bins 5
Histogram (dialog Percent Values (Enabled)
box)
Properties | Divisions Tagging (Selected)
(Cube <01>)...
Limits User Defined
Min 1[-]
Max 5[-]

The results (shown below) verify that at initial time (t=0), the 4th bin contains 100% of the particles.

2. Use the Time toolbar to advance the time and verify that particles coming from different initial
positions move into this second cube, reducing the percentage of particles with tagging = 4.

3. Then, observe how particles are distributed at the final output time.

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 Part C: Post-Processing in Rocky

The results are shown below.

At the final output time (3 s), particles that originated from other divisions are more evenly distributed
into the 4th axial segment of the bed.

Note:

Your results may differ slightly from the ones presented in this tutorial.

14.3.8. ROCKY – POST-PROCESSING – CREATING A PROPERTY

You can also use a Property User Process to further visualize and calculate the number of particles
that enter and exit the segment of the bed we defined earlier (Cube <02>).

For this analysis, do all of the following:

1. From the Time toolbar, select the very first output time (0.00 s).

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2. Use the table below to create the Property process and plot the results by particles mass.

Step Data Entity Editors Location Parameter or Settings

Action
A User Processes Create a Property User Process

Cube <02>
B User Processes Property Property Divisions Tagging (Cube
<01>)
Property
Cut Value 4[-]
<01>
C User Processes Show in New Time Plot by Particle Mass

Cube <02>
D User Processes Show in Current Time Plot by Particle Mass

Property <01>

14.3.9. ROCKY – POST-PROCESSING – CREATING A TIME PLOT

The resulting plot shows the total mass of particles that have the divisions tagging equal to 4 inside
the cube at each output time (blue), along with the total mass of particles inside the cube (orange).

At the start of fluidization, particles in section 4 were pushed out of their initial region, but moved
back as time progressed and mixing continued.

1. Use the information in the table below to continue with this analysis.

Step Item Location Parameter or Settings

Action
A Time Plot <01> Table (tab) Add Formula
(window)
B Add Expression (dialog box) Curve Caption Tagging 4 mass
fraction

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 Part C: Post-Processing in Rocky

Step Item Location Parameter or Settings

Action
Curve Expression C/B

This expression represents the ratio between the mass of particles that were initially in the 4th
axial bin (Tagging = 4) and the current mass of particles inside that same bin area.

2. From the upper left corner of the Time Plot window, select the Plot tab.

The new curve (green) enables you to observe how the mass fraction of particles with Tagging 4 inside
the Cube <02> has changed with time.

14.3.10. ROCKY – POST-PROCESSING – PARTICLE TEMPERATURE

We can also analyze the Particles cooling down due to interactions with the fluid and container by
plotting the Temperature property.

1. Use the information in the table to create the new plot.

Step Item Location Parameter or Settings

Action
A Window (menu) Create a New Time Plot
B Particles Properties | Drag and drop onto the Time Plot
Temperature window
C Select The Statistics To Plot (dialog box) Min (Enabled)
Max (Enabled)
Average (Enabled)

2. Right-click the grid, point to Axes Layout, and then select By Quantity.

In this plot, we can see how the average temperature of the particles decreases with time.

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Tutorial - Fluidized Bed

We can also visualize both the particle and fluid temperature in a 3D View window.

1. Use the table below to create this new view.

Step Item Location Parameter or Settings

Action
A Window (menu) Create a New 3D View
B Fit (menu) Select Camera Preset: -Y
C Geometries Coloring Transparency (Enabled)

walls
D Particles Coloring Nodes (Enabled)
Nodes | Property Temperature

The temperature of the particles is shown.

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 Part C: Post-Processing in Rocky

Let's adjust the temperature scale to match the tutorial minimum and maximum limits, which are
equal to the initial temperatures of the inlet (in Fluent) and particles (in Rocky), respectively.

1. Use the information in the table below to adjust the color scale.

Step Data Entity Editors Parameter or Settings

Locations Action
A Color Scales Coloring Limit options User Defined

Limits 293.15, 363

Temperature
[K]
Color-scale unit degC

2. Continue defining the view by adding in the fluid temperature display.

Step Data Entity Editors Parameter or Settings

Locations Action
A CFD Coloring Nodes (Enabled)
Coupling Nodes | Property Fluid
Temperature
2-Way
Fluent Nodes | Point size 6

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Tutorial - Fluidized Bed

3. Follow the instructions for Step A to adjust the color-scale for Fluid Temperature so it matches
the scale for particle Temperature.

The temperature of the fluid is shown along with the particles.

Tip:

To better analyze the results, consider setting up both Color Scales with the same Limits
and colors.

14.3.11. ROCKY – POST-PROCESSING – PRESSURE DROP

We can also calculate the pressure drop by using the fluid properties that come by default with 2-
Way Fluent coupling.

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 Part C: Post-Processing in Rocky

To do this, we will create two Cubes one at the bottom of the container and another at the top and
will calculate the difference in fluid pressure between the two locations.

1. Use the information in the table to create these two Cubes.

Step Data Entity Editors Parameter or Settings

Location Action
A CFD Coupling Create a Cube User Process

2-Way Fluent
B User Process Cube Name bottom
Center 0, 0, 0.008 [m]
Cube
<03> Magnitude 0.1, 0.02, 0.0155
[m]
C User Processes Create a Duplicate

bottom
D User Cube Name top
Processes Center 0, 0, 0.492 [m]

bottom
<01>

You should now have two Cubes at each end of the container (as shown).

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Now, lets plot the fluid pressure in both Cubes.

1. Use the information in the following table to create this plot.

Step Item Location Parameter or Settings

Action
A User Processes Properties | Static Presure Show in New Time Plot by Average

top

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 Part C: Post-Processing in Rocky

Step Item Location Parameter or Settings

Action
B User Processes Properties | Static Pressure Show in Selected Time Plot by Average

bottom
C Time Plot Table (tab) Add Formula
<03>
(window)
D Add Expression (dialog box) Curve Caption Pressure Drop
Curve Expression C-B

2. Select the Plot tab.

3. In the plot, right-click the grid area, point to Axes Layout, and then select By Quantity.

4. At the top of the plot, click both Average data lines to turn off their displays (as shown).

The results show that after ~1 s, the system reaches a stabilized state. This period of time can be
used to estimate an average pressure drop.

14.3.12. ROCKY – POST-PROCESSING – SOLID VOLUME FRACTION

We can also post-process fluid information with Eulerian Statistics.

It is possible to calculate instantaneous or time-averaged fluid statistics based on the CFD cells
located inside of each block from the eulerian division.

A property that can be analyzed within the divisions is the Solid Volume Fraction, that is the ratio
between the summation of the particle volumes within a CFD cell and the volume of the cell.

1. Open a 3D View and use the information in the following table to analyze the instantaneous
Solid Volume Fraction.

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Tutorial - Fluidized Bed

Step Item Location Parameter or Settings

Action
A CFD Coupling Create a Cube User Process

2-Way Fluent
B User Processes Create a Eulerian Statistics User Process

Cube <03>
C User Processes Eulerian Heigth Divisions 3
Statistics Depth Divisions 20
Eulerian Statistics
<01> Coloring | Property Solid Volume
Faces Fraction
Show on Node? (Enabled)

2. Hide the Particles entity and all the Geometries to visualize the Eulerian Statistics.

3. Click Shift+Y to see the instantaneous Solid Volume Fraction in the flow direction (as shown).

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 Part C: Post-Processing in Rocky

• Take a moment and use the slider of the Time Toolbar to visualize the Solid Volume Fraction
for different output times.

14.3.13. ROCKY – POST-PROCESSING – FLUID VELOCITY

It is also interesting to visualize the fluid instantaneous velocity.

1. From the Coloring tab of the Eulerian Statistics <01> entity, define Property as Local Z-Velocity.

2. Use the slider bar from the Time Toolbar to see how the fluid velocity changes with the time.

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Tutorial - Fluidized Bed

This way you can get a continuous contour plot of the fluid velocity.

You can make Particles visible to see their influence on fluid behavior.

Note that the flow velocity is usually higher where particles are present due to the flow section area
reduction.

Also note that the fluid gets decelerated by the particles due to energy dissipation.

Often we need to extract time averaged statistics instead of instantaneous information to compare
against experimental data. This can be easily accomplished by using the Eulerian Statistics tool.

1. Use the table below to set up the time averaged fluid velocity.

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 Part C: Post-Processing in Rocky

Step Item Location Parameter or Action Settings

A User Processes Properties Add and edit time statistics properties (button)

Eulerian
Statistics
<01>
B Edit time statistics properties (dialog Add (button)
box)
C Add time statistics properties (dialog Start time 1 [s]
box) Stop time 3 [s]
Operations | Average (Enabled)
Properties | Local (Enabled)
Z-Velocity
D User Processes Coloring | Faces Property Average of Local
Z-Velocity [1s, 3s]
Eulerian
Statistics
<01>

Note:

We choose a time interval that represents a steady state for the system to calculate the
property average.

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Note that, on average, the flow velocity is higher when passing through the particles area.

Also note that after passing through the particles, the average fluid velocity is almost the same for
the rest of the bed.

14.3.14. HELP – USER MANUAL

This concludes Part C of this tutorial.

For more information about the tagging and divisions tagging tools, we recommend:

• Reviewing the available post about Tagging and Divisions Tagging.

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 Part C: Post-Processing in Rocky

• Searching the Rocky User Manual.

For more information about two-way coupling between Rocky and Ansys Fluent, refer to the CFD
Coupling Technical Manual.

14.3.15. CONCLUSIONS
Rocky was used to post-process the Fluent Two-Way simulation that we ran in Part B.

During this tutorial, it was possible to:

• Use the Particle Group property to analyze segregation.

• Use User Processes and Divisions Tagging to analyze the mixing efficiency over time in discrete
areas of the particle bed.

• Plot the average Particle temperature as a function of Time.

• Visualize both the particle and fluid temperature in a 3D View window.

• Calculate the pressure drop using Cube User Processes and 2-Way Fluent Fluid Properties.

• Visualize the fluid velocity profile in the air flow direction with Eulerian Statistics.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to the next tutorial.

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Chapter 15: Tutorial - Transient Structural
15.1. Part A: Rocky Setup and Processing (Workbench)

15.1.1. OBJECTIVES
The main purpose of this tutorial is to use Workbench to set up a 1-Way coupled DEM-FEA simulation
between Rocky and Ansys Transient Structural - Mechanical.

• This Part A will cover Workbench project creation, Rocky project setup, and running the DEM
simulation in Rocky.

• Part B will cover 1-Way coupling with Transient Structural - Mechanical to calculate the FEA portion
of the project.

The scenario considered in this tutorial is evaluating the structural integrity of a transfer chute given
varying feeder belt speeds.

You will learn how to:

• Create a Workbench project

• Connect the Workbench project to both Rocky and Ansys Transient Structural - Mechanical

• Set up the DEM portion of the project in Rocky to share data for later FEM analysis

• Process and post-process the DEM results

And you will use these programs:

• Ansys Workbench

• Rocky

15.1.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine, both of the following:

• (1) A valid license for Ansys Mechanical 2025 R1, compatible with Transient Structural.

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Tutorial - Transient Structural

• (2) Rocky 2025 R1 or later.

Important:

This ADVANCED tutorial assumes that you are already familiar with the following programs
and resources:

• The Ansys Workbench platform.

– If that is not the case, please refer to the Ansys Workbench user documentation for
basic introduction about Workbench usage before beginning this tutorial.

Note:

Rocky and Ansys Workbench integration is currently supported only on Win-

dows.

• The Rocky 2025 R1 program.

– If this is not the case, it is recommended that you complete at least Tutorials 01 - 05
before beginning this tutorial.

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 Part A: Rocky Setup and Processing (Workbench)

15.1.3. GEOMETRY

The geometries in this tutorial include the following components:

• (1) Feed Conveyor

• (2) Chute

• (3) Receiving Conveyor

Note:

The chute geometry will be imported into Workbench as a Discovery file. The conveyors
will be added within the Rocky program.

15.1.4. GEOMETRY PREPARATION

To begin setting up the project, do the following:

1. Download the dem_tut15_files.zip file .

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Tutorial - Transient Structural

2. Unzip dem_tut15_files.zip to your working directory.

3. Open Ansys Workbench 2025 R1 (or later version).

4. Save the empty Workbench Project from the File, Save As... menu item.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

5. Use the information in the table below to start setting up your Workbench project:

Step Toolbox Project Schematic Action

Entity Item
A Component Systems Drag and drop onto Project Schematic

Geometry
B Geometry Import Chute.dsco from
workshop_15_input_files
Geometry
C Analysis Systems Drag and drop onto Geometry | Geometry

Particle Dynamics (Rocky)

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 Part A: Rocky Setup and Processing (Workbench)

Step Toolbox Project Schematic Action

Entity Item
D Analysis Systems Drag and drop onto Rocky | Results

Transient Structural
E Rocky Delete the link to Transient Structural | Model

Results
F Save the Workbench Project
G Rocky Edit...

Setup

15.1.5. WORKBENCH SETUP

While performing the steps in the table above, note the following:

• Dropping the Rocky block onto the Geometry component will automatically generate a connection
between the Geometry and Rocky.

• While Rocky is processing, you should not modify/save/close the connected Workbench session.

• When Rocky interface opens (Step G), the linked geometry component is automatically imported
from Ansys Discovery. In addition, the Boundary Collision Statistics module is automatically enabled
with Forces for FEM Analysis option pre-selected.

Note:

It also happens for the SPH Boundary Interaction Statistics and the Nodal Forces
option. For this setup, it will not be used.

Now that the Workbench project is set up, let's define the Rocky project settings.

15.1.6. VISUALIZING THE GEOMETRY

Since a coupled simulation with Ansys Mechanical will be carried out for this geometry part, it is im-
portant to refine the mesh so that the pressure field transferred to Mechanical has an adequate res-
olution for the desired structural analysis.

Every triangle node will provide x, y, z pressure components, which will then be applied as a load
inside Mechanical.

To visualize and refine the mesh, do the following:

1. Drag and drop Geometries to the Workspace.

2. Use the information in the tables that follow to modify the Chute meshing and set up the Feed
Conveyor.

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Step Data Editors Parameter or Settings

Entity Location Action
A Geometries Coloring Edges (Enabled)
Wall | Triangle Size 0.1 [m]
Transform
Chute

Step Data Entity Editors Location Parameter or Action Settings

B Geometries Create Feed Conveyor template
C Geometries Feed Conveyor | Transition Length 1 [m]
Geometry Loading Length 2.5 [m]
Feed Conveyor
Belt Width 0.6 [m]
… | Orientation Alignment Angle -90 [m]
Belt Incline Angle 10 [m]
… | Skirtboard Width 0.5 [m]
Length 1 [m]
Skirtboard Height 0.3 [m]
… | Feeder Box Drop Box Width 0.5 [m]
… | Head Pulley Face Width 0.8 [m]
Diameter 0.2 [m]
Offset to Idlers -0.1 [m]

15.1.7. FEED CONVEYOR DEFINITION

1. On the Belt Motion sub-tab, define the Belt Speed.

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 Part A: Rocky Setup and Processing (Workbench)

This will automatically create a new variable for this parameter, as indicated by the Variable
Creation dialog.

2. For the Initial value, input 3 m/s (as shown), and then click Create variable.

Creating this input variable will expose it as a parameter in Workbench, which we will make use of
in Part B.

15.1.8. FEED CONVEYOR – EXPRESSION/VARIABLES

Verify the new input variable as follows:

1. From the Tools menu, ensure that the Expressions/Variables panel is enabled.

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Tutorial - Transient Structural

2. On the Expressions/Variables panel, the new BeltSpeed variable and value you defined is shown.

You may change the Value to see how this influences the Feed Conveyor geometry. However, for
the purposes of this tutorial, please keep the value as 3.0 m/s.

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 Part A: Rocky Setup and Processing (Workbench)

15.1.9. RECEIVING CONVEYOR DEFINITION

Now that our feed conveyor is set up, we can create the receiving conveyor.

1. Use the table below to continue setting up your project.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Create Receiving Conveyor template
B Geometries Receiving Conveyor | Length 5 [m]
Geometry
Receiving
… | Orientation Belt Incline Angle 10 [deg]
Conveyor
<01> Vertical Offset -5 [m]
Horizontal Offset -0.6 [m]
Out-of-Plane Offset 0.2 [m]

For this tutorial, the default Materials and Materials Interactions settings will be used without
changes.

15.1.10. PARTICLE AND MASS FLOW DEFINITION

Next we will add a rock-shaped polyhedron particle set in multiple sizes that will be injected through
a Particle Inlet.

1. Use the information in the table below to continue setting up your project.

Step Data Entity Editors Parameter or Action Settings

Location
A Particles Create Particle
B Particles Particle Shape Polyhedron
… | Shape Horizontal Aspect Ratio 1
Particle
<01> Number of Corners 15
… | Size Add size row (x1)
(1) Size | Cumulative % 0.15 [m] @ 100 [%]
(2) ... 0.1 [m] @ 30 [%]
C Inlets and Outlets Create Particle Inlet
D Inputs Particle Inlet Entry Point Feed Conveyor <01>
… | Particles Add row (x1)
Particle
Inlet (1) Particle | Mass Flow Particle <01> @ 300
<01> Rate [t/h]

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Tutorial - Transient Structural

15.1.11. EXTERNAL COUPLING AND SOLVER

For this Tutorial, transient loads on only the chute geometry will be exported to Ansys Transient
Structural - Mechanical.

1. Follow the steps in the table below to set Wall Loads and Solver parameters.

Step Data Entity Editors Parameter or Action Settings

Location
A External Wall Loads Select Walls | Chute (Enabled)
Coupling Time Range Filter | Domain All
Range
Wall
Loads
B Solver Solver | time Simulation Duration 10 [s]
Output Settings | Time Interval 0.1 [s]
… | General Execution | Simulation Target CPU

15.1.12. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

15.1.13. SIMULATE PROJECT

1. From the Solver entity, click Start.

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 Part A: Rocky Setup and Processing (Workbench)

The Simulation Summary screen appears (as shown), then processing begins.

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Tutorial - Transient Structural

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

Note:

When the simulation processing is done inside Workbench as is done in this Tutoria all
files are saved in the Workbench file directory, including the ones needed for Rocky.

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 Part A: Rocky Setup and Processing (Workbench)

15.1.14. POST PROCESS – TIME PLOT

One analysis you can do after the simulation is done processing is to quantify the force of the particles
as they collide with the Transfer Chute. By plotting the Force : Z, we can visualize this quantity over
time.

1. From the Data panel, under Geometries, select Chute.

2. From the Data Editors panel, select the Curves sub-tab, right-click Force : Z and then click Show
curve in new Plot.

• The result will be a new time plot showing the summed nodal forces observed by the Chute
wall over the duration of the simulation.

15.1.15. POST PROCESS – OUTPUT

Later in Part B of this tutorial, we will use the Force : Z of the chute geometry to help determine
whether modifications made during parameterization are improving the design.

We will expose this parameter to Workbench by making it available on the Output tab of the Expres-
sions/Variables panel.

1. Follow the steps in the table below to expose the Force : Z parameter for later analysis.

Step Item Location Parameter or Action Settings

A Geometries Curves | Force: Drag and drop to Expression/Variables |
Z Output
Chute
B Expressions/Variables Output Force_Z Edit (button)
C Edit Properties (dialog box) Operation on Curve average
Domain Range Time Range
Initial 3.5 [s]
Final 10 [s]

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Tutorial - Transient Structural

Note that we have set the time range for the force output to start a few seconds into the simulation.
This is to account for the time it takes for the particle flow to reach the chute.

Once processing is complete, do the following:

1. Save your Project.

2. Close Rocky.

3. Switch back to your Workbench project.

Note:

Due to its connection with Workbench, nothing further is required in Rocky after processing
is complete. There is no need to export any files. All necessary data transfers will happen
in Workbench.

15.1.16. CONCLUSION
This completes Part A of this tutorial, in which through Ansys Workbench Rocky was used to set up
and process a Transfer Chute simulation that will later be 1-Way coupled with Ansys Transient Struc-
tural - Mechanical.

During this tutorial, it was possible to:

• Verify that Rocky is ready for coupling with Ansys.

• Create a new Ansys Workbench project that connects an imported geometry to both Rocky and
Ansys Transient Structural - Mechanical.

• Set up and run the Rocky portion of the simulation through Workbench.

• Ensure the collection of forces data for later FEM analysis.

• Enable a DEM setup field to be later parameterized in Workbench.

• Expose a DEM parameter to Workbench for later analysis.

• Define what geometry load data to later share with Mechanical.

What's Next? If you completed this part successfully, then you are ready to move on to Part B and
set up and run the FEA simulation based upon these DEM results.

15.2. Part B: Mechanical Coupling (Workbench)

15.2.1. OBJECTIVE
The main purposes of this tutorial are to use Ansys Workbench to run a 1-Way coupled DEM-FEA
simulation using Rocky and Ansys Transient Structural - Mechanical, and then analyze those results.

• We will make use of the Rocky DEM results we created in Part A.

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 Part B: Mechanical Coupling (Workbench)

• As a reminder, the scenario considered in this tutorial is evaluating the structural integrity of a
transfer chute given varying feeder belt speeds.

You will learn how to:

• Use Workbench to transfer DEM results from Rocky to Transient Structural - Mechanical

• Set up and process the FEA simulation in Transient Structural - Mechanical

• Analyze key input and output project parameters in Workbench

And you will use these programs:

• Ansys Workbench, including the Parameter Set (Table of Design Points)

• Ansys Transient Structural - Mechanical

15.2.2. PREREQUISITES
To complete this tutorial, you are required to have in a Windows machine, both of the following:

• (1) A valid license for Ansys Mechanical 2025 R1, compatible with Transient Structural.

• (2) Rocky 2025 R1 or later.

Important:

This ADVANCED tutorial also assumes that you are familiar with all of the following pro-
grams and resources:

• The Ansys Workbench platform.

– If that is not the case, please refer to the Ansys Workbench user documentation for
basic introduction about Workbench usage before beginning this tutorial.

Note:

Rocky and Ansys Workbench integration is currently supported only on Win-

dows.

• The Ansys Transient Structural - Mechanical program.

– If this is not the case, please refer to the Ansys Mechanical user documentation for
a basic introduction about Mechanical usage before beginning this tutorial.

15.2.3. WORKBENCH SETUP

1. If you completed Part A of this tutorial, ensure that the Ansys Workbench project you created is
open. (Part B will continue from where Part A left off.)

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Tutorial - Transient Structural

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut15_files.zip file .

b. Unzip dem_tut15_files.zip to your working directory.

c. Open Ansys Workbench.

Important:

To make use of the Workbench project file provided, you must have Ansys 2025
R1 or any Rocky-supported version and Rocky 2025 R1 or later. If you have an
earlier version of either of these programs, please upgrade to the latest version of
Rocky and the latest version of Ansys that is supported by Rocky, or complete Parts
A from scratch.

d. From the Workbench program, click the Open Project button, navigate to the tutori-
al_15_A_processing-rocky folder and open the tutorial_15_A_processing-rocky.wbpj file.

With the project open in Workbench, you are now ready to begin Part B.

Before we set up the Mechanical project, we need to update the results.

1. Follow the steps in the table below to transfer the DEM results into Workbench and open Mech-
anical with this data available.

Step Project Schematic Item Action

A Rocky | Setup Refresh
B Rocky | Results Update
C Transient Structural | Edit...
Model

Note:

Step A is only necessary if you are using the already set-up tutorial_15_A_processing-
rocky.wbpj project file that you downloaded together with the tutorial files.

15.2.4. DEFINING THE STRUCTURAL ANALYSIS

1. Use the information in the table below to set up your Mechanical project.

Step Outline Entity Details Parameter or Settings

Location Action
A Model Definition Thickness 0.01 [m]

Geometry

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 Part B: Mechanical Coupling (Workbench)

Step Outline Entity Details Parameter or Settings

Location Action

Chute/Surface1
B Model Generate Mesh

Mesh
C Model Insert Fixed Support

Transient
D Model Scope Geometry With the Face tool,
multi-select the 12 faces (as
Transient shown on next slide) and
then Apply
Fixed
Support
E Model Step Controls Step and End Time 10 [s]
Auto Time Stepping Off
Transient
Time Step 0.1 [s]
Analysis
Settings
F Model Insert Pressure
G ... Scope Geometry With the Mode of Box
Select, select the whole
Imported chute (as shown) (35 faces)
Load and then Apply

Imported Definition Define By Components

Pressure

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Tutorial - Transient Structural

2. From the Data View panel, fill in the Imported Pressure table by defining the following compon-
ents for each output recorded (X Component (Pa), Y Component (Pa), and Z Component (Pa))
as described below.

3. In the directory to which you have saved your Workbench files, navigate to the ../dp0/Rock-
yEx/Rocky folder.

4. From within this folder, find the loadref.csv file and open it with a text editor (for example,
Notepad).

5. Select all of the content, and then copy it.

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 Part B: Mechanical Coupling (Workbench)

6. Return to Ansys Mechanical, and then on the first column and line of the Imported Pressure
table, paste all of the information you copied. (Results shown below.)

Using this method enables you to skip defining the components for each exported file manually.

Note:

For this method to work, your operational system language should be defined as English
or another that consider "." as the separator for decimals. Otherwise, the Analysis Time
column will automatically make a conversion and assume wrong values (for example,
0.1 will be assumed as 1).

7. Use the information in the table below to define which solutions to include in the calculations.

Step Outline Details Parameter or Settings

Entity Location Action
A Model Insert | Deformation | Total
Insert | Stress | Equivalent (von-Mises)
Transient

Solution
B Model Solve

Transient

Solution

15.2.5. POST-PROCESSING
The FEA simulation starts processing.

When the simulation concludes, the effects caused by the particles colliding with the chute surfaces
can be easily seen:

1. Under Solution, select Total Deformation and then view the results (as shown).

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Tutorial - Transient Structural

2. Repeat for Equivalent Stress (as shown).

Tip:

Use the Graph and the Tabular Data panel to see how the results vary through the
simulation time.

It is possible to analyze variables in relation to others if we parameterize them.

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 Part B: Mechanical Coupling (Workbench)

1. Follow the steps in the table that follows to define the solutions we want to analyze as parameters.

Step Outline Entity Details Parameter or Settings

Location Action
A Model Results Maximum Define as a parameter (P)
by clicking the box
Transient

Solution

Total
Deformation
B ...

Solution

Equivalent
Stress

Save the project, close Mechanical, and return to Workbench.

15.2.6. WORKBENCH – RUNNING MULTIPLE SIMULATIONS

The last part of this tutorial is to make use of Workbench's Design Points feature.

1. In Ansys Workbench, double-click the Parameter Set block.

2. From the Parameter Set tab, select the Outline Of All Parameters window.

• Here, all the parameters created during the analysis are listed, no matter in which application
they were created or if they are input or output parameters.

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Tutorial - Transient Structural

In the Outline of All Parameters window, both the input and output parameters we defined earlier
in this tutorial are listed. Specifically:

• Under Input Parameters, you can adjust the BeltSpeed of the Feed Conveyor we set up in Part
A in Rocky (shown in green).

• And see how it affects the results under Output Parameters (shown in yellow), including:

– The resulting Force_Z output from Rocky due to the particles on the chute liner.

– The Total Deformation Maximum and Equivalent Stress Maximum outputs we parameterized
earlier in Mechanical.

These parameters can be directly changed to compare different scenarios, in order to provide you
information on how to improve the chute design for the bulk material flow.

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 Part B: Mechanical Coupling (Workbench)

For example, you can also change and compare:

• Particle-related quantities such as material density, tonnage, the particle geometry, the particle size
distribution, and so on.

• Chute structural quantities such as the number of supports, the material properties, supports, the
overall design of the chute, and so on.

Now that we have analyzed the structural load on the original chute design, let's see how the results
change when we change the input values.

Let's analyze what happens to the chute when we change the Feed Conveyor's BeltSpeed.

We will do this in the Table of Design Points by adding two new Design Points (DPs) and changing
the input parameters.

1. Right-click DP 0 (the current Design Point) and then click Duplicate Design Point.

2. Repeat a second time to create another duplicate.

3. From the new DP 1 and DP 2 lines, define the P1 - BeltSpeed (as shown).

4. Run the new analyses by clicking the Update All Design Points button.

The new DPs will be run in both Rocky and Mechanical, and the resulting output parameters will be
shown in this table for analysis.

Each DP is run sequentially as the previous is finished.

For each DP, Workbench will save the files (setup and results) if the Retain checkbox is enabled. If
not, it will delete the results as soon as the simulation is done and the output parameters were ob-
tained.

This is useful when you run several cases and are in danger of running out of space. You can then
re-run only the best scenario cases (or the worst in case you want to identify failure scenarios).

Tip:

For a more automated method of varying parameters to achieve defined design goals, you
can also use Design Exploration. (Refer to Tutorial 12 for a step-by-step example.)

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Tutorial - Transient Structural

After the new DPs have been updated, we can look at the resulting output parameters and can see
that the results match what we might have expected:

• Reducing the feed conveyor belt speed (DP 1, in yellow) resulted in lower overall forces and stresses
on the chute.

• Increasing the feed conveyor belt speed (DP 2, in green) resulted in higher overall forces and
stresses on the chute.

Tip:

To open the applications for the new design points, you have to enable the Retain
checkmark on the Table of Design Points.

15.2.7. CONCLUSION
This completes Part B of this tutorial, in which through Ansys Workbench / Ansys Transient Structural
- Mechanical was used to set up and run a FEA simulation using the particle forces calculated previously
by Rocky.

During this tutorial, it was possible to:

• Make the Rocky DEM results available to Mechanical

• Set up and process the FEA simulation in Mechanical

• Analyze key input and output project parameters and set up new cases in Workbench

What's Next? If you completed this part successfully, then you are ready to move on to the next tu-
torial.

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Chapter 16: Tutorial - Mixing Tank
(Part A) Set up, process, and save an initial fluid field of a Multiphase case in Ansys Fluent that can later
be used for 2-Way Fluent coupling with Rocky DEM.

(Part B) Use the .cas and .dat files you created in Part A to set up the Rocky portion of the 2-Way Mul-
tiphase simulation, and then run it coupled with Ansys Fluent.

16.1. Part A: Fluent Case Setup

16.1.1. OBJECTIVES
The main purpose of this Tutorial is to set up and process a Multiphase CFD case with Ansys Fluent
to be later used in a 2-Way coupling simulation with Rocky.

Important:

Even if you are already familiar with CFD, please follow Part A in order to understand the
main limitations and needs for coupling a Multiphase case with Rocky.

• Part B of this tutorial will cover setting up the Rocky project.

The scenario considered is that of a Mixing Tank into which solid material (particles) fall through air
into water that is being mixed by a rotating impeller.

You will learn how to: Set up, process, and save an initial fluid field of a Multiphase case in Ansys
Fluent that can later be used for 2-Way Fluent coupling with Rocky.

16.1.2. PREREQUISITES
To complete this tutorial, you are required to have a valid license for Ansys Fluent 2025 R1.

Important:

This ADVANCED tutorial assumes that you are already familiar with the Ansys Fluent UI
and project workflow.

• If that is not the case, please refer to the Ansys Fluent user documentation for basic
introduction about Fluent usage before beginning this tutorial.

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Tutorial - Mixing Tank

16.1.3. GEOMETRY INTRODUCTION

The geometry in this tutorial is composed of:

• (1) Tank walls

• (2) Mixing shaft

• (3) Mixing impeller

Note:

These geometries will come from the Fluent .cas file that you will import as part of this
tutorial.

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 Part A: Fluent Case Setup

16.1.4. OPEN ANSYS FLUENT

To set up the Fluent Case, do the following:

1. Open Ansys Fluent.

2. From the Fluent Launcher, under Dimension, ensure that 3D is selected; also, under Options,
ensure that Double Precision is selected (as shown).

Important:

Double Precision and 3D are required for coupling with Rocky.

3. Click Start.

16.1.5. IMPORT CASE

For this tutorial, the tank and the impeller were meshed separately.

This is so the Body of Influence (BOI) region where the air and water meet can have a higher resolution.

Both regions will be solved together by a sliding interface approach in Fluent.

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Tutorial - Mixing Tank

For this tutorial, the mesh interface is already created in the provided Fluent file. Follow the steps
below to open it.

1. Download the dem_tut16_files.zip file .

2. Unzip dem_tut16_files.zip to your working directory.

3. From the File menu, point to Read, and then click Case

4. From the Select File dialog, select Mixing_Tank.cas.h5 from the dem_tut16_files/mesh folder,
and then click OK.

16.1.6. FLUID MESH SETUP

Now that the Fluent .cas file is imported, we can start setting up the Fluent case.

1. Use the information in the table that follows to visualize and set up the mesh.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to your Ansys Documentation to find detailed instructions.

Step Location Parameter or Action Settings

A Setup | General Display Mesh (impeller, opening, shaft, walls | Display)
Check Mesh
Time Transient
Gravity (Enabled)
Gravitational Acceleration -9.81 [m/s2] in the Y
direction

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 Part A: Fluent Case Setup

16.1.7. FLUID PHASES SETUP

For this tutorial, we want two fluid phases representing water and air, respectively, so we will use
the Multiphase approach.

Important:

Even though we will be simulating only two fluid phases in this tutorial, the number of
Eulerian phases will be set to three (number of phases + 1) to account for a required
particle phase.

1. Use the information in the tables that follow to set up the fluid materials.

Note:

We will leave the air fluid as it is set by default.

Step Location Parameter or Settings

Action
A Step | Materials | Create New Fluid
Fluid Name particles
Chemical Formula particles

Note:

This new particles fluid material will be used as the required dispersed phase.

For this material, the properties set in Fluent will be later overridden by Rocky.

To create each new fluid material, from the Create/Edit Materials dialog, click
Change/Create and select No if asked to overwrite other material.

Step Location Parameter or Settings

Action
B Step | Materials | Create New Fluid
Fluid Name water-liquid
Chemical Formula h20<l>
Constant Density 998.2 [kg/m3]
Constant Viscosity 0.001003 [kg/(m
s)]

2. Next, use the information in the tables that follow to set up the Eulerian Muliphase model, define
the three phase materials, and set the interactions between the phases.

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Tutorial - Mixing Tank

Step Location Parameter or Action Settings

A Step | Materials | Models | Inhomogeneous Eulerian
Multiphase Models
… | Number of Eulerian Phases 3
… | Eulerian Parameters (All Cleared)
… | Formulation Implicit

Important:

These first four settings are required for any Rocky coupled Multiphase case.

Step Location Parameter or Settings

Action
B … | Phases | phase-1 - Primary Phase Name water
Phase Material water-liquid

C … | Phases | phase-2 - Secondary Name air

Phase Phase Material air
Constant Diameter 0.005 [m]
D … | Phases | phase-3 - Secondary Name particles
Phase Phase Material particles

3. Click Apply to update phase names for the next step.

Step Location Parameter or Action Settings

E … | Phase Interaction | Surface Tension Force Modeling (Enabled)
Forces | water : air Surface Tension Coefficient constant 0.072
[N/m]
F … | Phase Interaction | Interfacial Area [m-1] (all the ia-symmetric
Interfacial Area three)

Note:

Fluid-particle interphase transfers are calculated on the Rocky side and not in Fluent,
so we do not need to worry about setting values for this third phase (particles).

Fluid-particle momentum exchange terms are calculated on the Rocky side and not in
Fluent, so we need only to define the interactions between the fluid phases.

The only interaction you must define between fluids is Drag. For this tutorial, the Drag
Coefficient was left as default (Schiller-Naumann) and the Interfacial Area parameters
were defined in Step F.

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 Part A: Fluent Case Setup

Since this tutorial includes a free surface problem, we have also chosen to consider
surface tension.

16.1.8. TURBULENCE DEFINITION

1. Use the information in the table that follows to set up the turbulence model.

Step Location Parameter or Action Settings

A Setup | Models | Model k-epsilon (2-eqn)
Viscous Near-Wall Treatment Scalable Wall
Functions
Options | Production Limiter (Enabled)
Turbulence Multiphase Per Phase
Model

Note:

The choice of turbulence model depends upon the application.

Since for this problem fluid phases are completely segregated, the Turbulent Mul-
tiphase Model should be set to Per Phase.

16.1.9. CELL ZONE CONDITIONS

To account for the impeller rotation, we need to define a mesh motion.

1. Use the information in the table that follows to set up the cell zone conditions.

Step Location Parameter or Action Settings

A Setup | Cell Zone Conditions | Fluid | movingregion Mesh Motion (Enabled)
Speed 12
[rad/s]
Rotation-Axis 0, -1, 0 [
Direction -]

Note:

If moving meshes are prescribed for any Zone in Fluent, the Zone Name defined here
(movingregion) will become a new Motion Frame in Rocky once the Fluent .cas file
is imported. (We will cover this later in Part B of this tutorial.)

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16.1.10. BOUNDARY CONDITIONS

1. Use the information in the table that follows to set up the boundary conditions on the shaft
component.

Step Location Parameter or Action Settings

A Setup | Boundary Conditions Wall Motion Moving Wall
| shaft Motion Rotational
Speed 12 [rad/s]
Rotation-Axis Direction 0, -1, 0 [ - ]

Note:

This should match the rotation we defined for the movingregion zone earlier.

Now, a pressure outlet condition must be set to the top opening.

1. With Boundary Conditions selected, from the Task Page, double-click the opening component
and do the following:

a. Keep the default settings for water and particles Phases. (No backflow volume fraction).

b. For air Phase, on the Multiphase tab, change the Backflow Volume Fraction to 1.

Note:

Every remaining surface is modeled as a non-slipping boundary.

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 Part A: Fluent Case Setup

16.1.11. METHODS
1. Use the information in the table that follows to define the solution methods.

Step Location Parameter or Action Settings

A Solution | Methods Pressure-Velocity Coupling Phase Coupled SIMPLE
Scheme
Transient Formulation First Order Implicit
High Order Term Relaxation (Enabled)
View Relaxation Options

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Step Location Parameter or Action Settings

B Relaxation Options Relaxation Factor 0.6 [ - ]
(dialog box)

Note:

For all Multiphase coupling simulations, the Pressure-Velocity Coupling Scheme must
be set to Phase Coupled SIMPLE.

In addition, for all 2-Way coupling simulations, First Order Implicit must be set for
Transient Formulation.

Relaxation is used only to help make this example simulation run easier for tutorial
purposes.

16.1.12. CONTROLS
For the purposes of this tutorial only, we'll modify the controls to increase stability.

1. Use the information in the table that follows to define the Under-Relaxation Factors.

Step Location Parameter or Action Settings

A Solution | Pressure 0.2 [ -
Controls ]
Momentum 0.5 [ -
]
Volume Fraction 0.7 [ -
]
Turbulent Kinetic Energy 0.7 [ -
]
Turbulent Dissipation 0.7 [ -
Rate ]
Turbulent Viscosity 0.7 [ -
]

16.1.13. INITIALIZATION
It is important to provide Rocky with the correct initial volume fraction fields.

For this tutorial:

• air phase is initialized with a volume fraction of 1.0 in the entire domain and then it is patched to
a volume fraction of zero in the water region.

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 Part A: Fluent Case Setup

• Also, air turbulence quantities are patched to zero inside water region and vice-versa. This is done
by two cell register regions.

Important:

For particles phase, volume fraction MUST be initialized as zero everywhere.

16.1.14. CELL REGISTERS

1. Before initializing, use the information in the table that follows to define the two new cell registers.

Step Location Parameter or Action Settings

A Solution | Cell Registers Create New Region
B Region Register (dialog Name air
box) Input Coordinates | -1, 0.1, -1
Min [m]
Input Coordinates | 1, 1, 1 [m]
Max
C Solution | Cell Registers Create New Region
D Region Register (dialog Name water
box) Input Coordinates | -1, -1, -1
Min [m]
Input Coordinates | 1, 0.1, 1
Max [m]

16.1.15. INITIALIZE AND PATCH

1. Then, use the information in the table that follows to initialize, and then patch the phases.

Step Location Parameter or Settings

Action
A Solution | Reference Frame Absolute
Initialization air Volume Fraction 1[-]
Initialize
Patch
B Patch (dialog box) Phase air
Variable Volume Fraction
Value 0[-]
Registers to Patch water
Patch
C Patch (dialog box) Phase air
Variable Turbulent Kinetic
Energy

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Step Location Parameter or Settings

Action
Value 0 [m2/s2]
Registers to Patch water
Patch
D Patch (dialog box) Phase water
Variable Turbulent Kinetic
Energy
Value 0 [m2s2]
Registers to Patch air (only)
Patch

16.1.16. CALCULATION SETUP

1. Finally, use the information in the table that follows to set up the calculation.

Step Location Parameter or Action Settings

A Run Time Advancement Fixed
Calculation Type
Number of Time Steps 50 [ - ]
Time Step Size 0.005
[s]
Max Iterations/Time 50 [ - ]
Step

Important:

Fixed should always be selected for the Time Stepping Method.

Ensure the Time Step Size value you set matches the minimum initial Output Frequency
value you want for your Rocky and Fluent files.

Tip:

You can change the outputs to be less frequent than this minimum in your Rocky setup
later.

16.1.17. SETUP CONFIRMATION

At this point in your Fluent setup, your program screen should look similar to the image shown.

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 Part A: Fluent Case Setup

16.1.18. CALCULATE PROJECT

1. From the Run Calculation Task Page, click Calculate.

2. Let the simulation run for a few time steps until you can confirm that it is converging (as shown).

3. Stop processing the case.

It is important to have stabilized CFD results to use as initial conditions in Rocky.

These CFD results will be imported as an Initialization file when we define the CFD Coupling in
Rocky in Part B.

1. Write the Case & Data to a file named Mixing_Tank_B.cas.h5

2. Close Fluent.

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16.1.19. CONCLUSION
This concludes Part A of this tutorial, in which Ansys Fluent was used to set up a Multiphase CFD
simulation that will later be used for 2-Way coupling with Rocky.

During this tutorial, it was possible to:

• Use Ansys Fluent to set up and process an initial fluid field of a CFD case involving two fluids
(water and air) and a particulate phase (particles).

• Understand what Fluent settings are required when coupling Multiphase cases with Rocky.

What's Next?

• You are ready to move on to Part B and create the Rocky project and 2-way couple it with this
CFD case.

16.2. Part B: Rocky Coupling Setup

16.2.1. OBJECTIVES
The main purpose of this Tutorial is to use the .cas and .dat files we created in Part A to set up the
Rocky portion of the 2-Way Multiphase simulation, and then run it coupled with Ansys Fluent.

As a reminder, the scenario considered is that of a Mixing Tank into which solid material (particles)
fall through air into water that is being mixed by a rotating impeller.

You will learn how to:

• Import geometry components from a Fluent .cas file

• Import geometry motions from a Fluent .cas file

• Enable the collection of CFD Coupling Particle Statistics data

• Set up and run a Multiphase 2-Way Fluent coupled simulation in Rocky

And you will use these features:

• CFD Coupling Particle Statistics Module

• Custom Geometry Import

• Motion Frames

• 2-Way Fluent CFD Coupling

16.2.2. PREREQUISITES
To complete this tutorial, you are required to have both of the following on the same machine upon
which you will be running the coupled simulation:

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 Part B: Rocky Coupling Setup

• (1) A valid license for Ansys Fluent 2025 R1.

• (2) A license of Rocky 2025 R1.

Important:

This ADVANCED tutorial assumes that you are already familiar the the following programs
and resources:

• The Rocky 2025 R1 program.

– If this is not the case, it is recommended that you complete at least Tutorials 01- 05
before beginning this tutorial.

• The Ansys Fluent program.

– If this is not the case, please refer to the Ansys Fluent user documentation for a basic
introduction about Fluent usage before beginning this tutorial.

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16.2.3. GEOMETRY INTRODUCTION

The geometry in this tutorial is composed of:

• (1) Tank walls

• (2) Mixing shaft

• (3) Mixing impeller

Note:

These geometries will come from the Fluent .cas file that you exported out of Fluent in
Part A.

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 Part B: Rocky Coupling Setup

16.2.4. PROJECT CREATION

1. Do one of the following:

• If you completed Part A of this tutorial, ensure you have available the Mixing_Tank_B.cas.h5
and Mixing_Tank_B.dat.h5 files you exported. (Part B will make use of those files.)

• If you did not complete the project from Part A, ensure you have downloaded and extracted
the dem_tut16_files zip folder that was provided along with this PDF.

2. Open Rocky 2025 R1.

3. Create a new project.

4. Save the empty project to a location of your choosing.

16.2.5. PROJECT SETUP

For this tutorial, we want to do all of the following:

• Enable Coarse Grain Modeling (CGM) to help with simulating micron-sized particles.

Tip:

For a walk-through example using CGM, refer to Tutorial 17 - Mixing Tee.

• Use the CFD Coupling Particle Statistics module to collect particle-fluid interaction statistics for
later post-processing.

Tip:

For a walk-through example using this module, refer to Tutorial 13 - Windshifter.

• Import the same geometries motion definitions that we used in the Multiphase Fluent case.

1. Use the information in the table that follows to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Tutorial Index)
to find the detailed instructions you need.

Step Data Entity Editors Location Parameter or Action Settings

A Study Study Study Name Mixing Tank
B Physics Physics | Enable Coarse-Graining (Enabled)
Coarse-Graining

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Step Data Entity Editors Location Parameter or Action Settings

C Modules Modules CFD Coupling Particle (Enabled)
Statistics
D Modules CFD Coupling Drag Force (Enabled)
Particle Statistics Pressure Gradient Force (Enabled)
CFD
Coupling
Particle
Statistics
E Geometries Import Wall Mixing_Tank_B.cas.h5
with "m" for Import
Unit

After importing the .cas file, there are three geometry components we do not need for the Rocky
simulation that we can remove.

We will also create an Inlet from which to inject particles.

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Parameter or Settings

Location Action
A Geometries Remove Geometry

interface_mr
B Geometries Remove Geometry

interface_tank
C Geometries Remove Geometry

opening
D Geometries Create Circular Surface
E Geometries Circular Surface Center Coordinates 0, 0.0125, 0
[m]
Circular
Max Radius 0.07 [m]
Surface <01>
Min Radius 0.008 [m]

16.2.6. GEOMETRY MOTION SYNC

In order for our coupled simulation to work properly, the impeller and shaft geometries in the DEM
portion need to rotate with the same velocity and position as in the CFD solver.

To ensure that the motions are identical and remain in sync, Rocky will automatically create a new
Motion Frame based on the motion information Fluent saved in the .cas file.

This Motion Frame will appear once we set up the CFD Coupling portion of the project, which isn't
until later in this tutorial.

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 Part B: Rocky Coupling Setup

For now, we will skip the Motion Frames step and will come back to it later.

16.2.7. PROJECT SETUP

For this tutorial, we will have two Particle groups and we want each group to have different Materials.

Therefore, we will modify the Default Particles Material, and then create a duplicate of it for the
second Particle group.

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Parameter or Settings

Location Action
A Materials Material Use Bulk Density (Cleared)
Density 1100
Default
[kg/m3]
Particles
Young's Modulus 1e+06
[N/m2]
Duplicate
B Materials Material Density 1300
[kg/m3]
Default
Particles <01>

Note:

We will leave all the Material Interactions as they are set by default.

Next, let's create the two Spherical-shaped particle groups making use of the same CGM Scale Factor,
but with different Materials.

We can also define the Input from which to release these two Particle groups, and reduce the injection
time to only the very beginning of the simulation.

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Location Parameter or Action Settings

A Particles Create Particle
B Particles Particle | Size CGM Scale Factor 3[-]
Size 0.0005 [m] @ 100 %
Particle
<01>
C Particles Create Particle

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Step Data Entity Editors Location Parameter or Action Settings

D Particles Particle Material Default Particles <01>
Particle | Size CGM Scale Factor 3[-]
Particle Size 0.0005 [m] @ 100%
<02>
E Inlets and Outlets Create Particle Inlet
F Inputs Particle Inlet Entry Point Circular Surface <01>
Particle Inlet | Add row (x2)
Particles (1) Particle | Mass Flow Particle <01> @ 0.15
Particle
Inlet Rate [t/h]
<01> (2) Particle | Mass Flow Particle <02> @ 0.15
Rate [t/h]
… | Time Stop 1 [s]

16.2.8. IMPORTING CFD SOLUTION

For the CFD Coupling step, we will select the Fluent option under 2-Way.

• This option in Rocky takes into account fluid forces acting on particles and transfers particle inform-
ation back to Fluent.

• Choosing this option will enable us to select the same .cas file that we created in Part A of this
tutorial.

Important:

A validation step immediately following this selection requires that a valid and active
version Ansys Fluent be available on the same machine that we are doing the Rocky
setup.

For this tutorial, we want Rocky to consider drag and turbulent dispersion interactions.

We will also make use of the .dat file we exported in Part A to start the simulation with an initial
fluid field.

1. Use the information in the table that follows to set your 2-Way Fluent coupling options.

Step Data Editors Location Parameter or Settings

Entity Action
A CFD Coupling Coupling Mode 2-Way | Fluent
Slect Fluent CAS file Mixing_Tank_B.cas.h5

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 Part B: Rocky Coupling Setup

Step Data Editors Location Parameter or Settings

Entity Action
B CFD 2-Way Fluent | Interactions Turbulent (Enabled)
Coupling Dispersion
2-Way Fluent | Fluent Rocky Phase particles
2-Way Use Data (Enabled)
Fluent Initialization
Import File (button)
Load File Mixing_Tank_B.dat.h5
Execution mode Local Parallel
Solver Processes 6[-]
Keep all files (Cleared)
Files to keep 2[-]
Additional Args -g

Note:

For Solver Processes, enter a value based upon how many processors you have avail-
able.

The Additional Argument is optional but enables the Fluent portion of the coupled
simulation to run in batch mode (i.e., without the GUI), which can result in faster pro-
cessing.

2. Click Open.

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16.2.9. IMPORTED MOTION FRAME

Now that the .cas file is imported, we can see a new entry in the Data panel under Motion Frames
called "movingregion" Motion Frame.

This item is automatically named for the Zone Name we set for the mesh motion in Fluent (Part A).

When this item is viewed in the Data Editors panel, a Rotation motion is already defined (as shown).

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 Part B: Rocky Coupling Setup

Note that the options are all disabled. This is to ensure that the motion in Rocky matches exactly the
motion in Fluent.

16.2.10. ASSIGN IMPORTED MOTION FRAME

Even though the Motion Frame is automatically created, we must still manually assign it to the geo-
metries we want to move.

For this tutorial, we want only the impeller and shaft to rotate, so we will assign the new motion
only to these two components.

1. Use the information in the table that follows to assign your geometry motions.

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Tutorial - Mixing Tank

Step Data Editors Parameter or Settings

Entity Location Action
A Geometries Wall Motion Frame "movingregion" Motion Frame

impeller
B Geometries Wall Motion Frame "movingregion" Motion Frame

shaft

Tip:

Once assigned, you can preview these motions in a Motion Preview window.

16.2.11. FINISH PROJECT SETUP

Lastly, we need to define the Solver setup.

For this tutorial, it is important to note the Fluent Outputs Multiplier, which enables you to change
the frequency of outputs.

Tip:

A higher multiplier will result in fewer Rocky and Fluent files.

1. Use the information in the table that follows to finish your Rocky setup.

Step Data Editors Location Parameter or Action Settings

Entity
A Solver Solver | Time Simulation Duration 3 [s]
Output Settings | Fluent Outputs 2 [s]
Multiplier
Solver | General Simulatio Target CPU

Tip:

When you are making CPU selections, remember that some CPUs have been allocated
to the CFD solver. Select only the ones you want Rocky to use here.

16.2.12. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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 Part B: Rocky Coupling Setup

16.2.13. SIMULATE PROJECT

1. Close Fluent if it is opened, and from the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

A new dialog also appears due to the 2-Way Fluent coupling calculations (as shown).

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Tutorial - Mixing Tank

16.2.14. SETUP CONFIRMATION

Tip:

After getting all information from Fluent, the black dialog closes. In Rocky you can use
the Auto Refresh checkbox to view the results in a 3D View window during processing.

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 Part B: Rocky Coupling Setup

16.2.15. POST-PROCESSING OPTIONS

Once your simulation has finished processing, you can choose to post-process the results in several
ways, as explained below.

• In Rocky, you can post-process the CFD and DEM results of the simulation by following the same
steps as listed in the following Tutorials:

– Tutorial 13 - Windshifter | Part C: One-Way Coupling (Workbench)

– Tutorial 14 - Fluidized Bed | Part C: Post-Processing Rocky

• In Fluent, you can post-process the CFD results of the simulation using the tools included in that
program, or you can use other programs such as Ansys CFD-Post or Ansys EnSight.

Tip:

Refer to your Ansys Documentation to learn more about how to use these tools.

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16.2.16. CONCLUSIONS
This concludes Part B of this tutorial.

The .cas and .dat files we created in Part A were used to set up the Rocky portion of the 2-Way
Multiphase simulation, and then run it coupled with Ansys Fluent.

During this tutorial, it was possible to:

• Import geometry components from a Fluent .cas file into Rocky

• Import Mesh Motions from a CFD .cas file into Rocky and assign them to geometries

• Use Rocky to set up and run a 2-Way coupled Multiphase simulation with Fluent

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 17: Tutorial - Mixing Tee
(Part A) Learn how to set up and process a simulation using Coarse Grain Modeling (CGM) and import
an *.f2r file into Rocky for 1-Way Fluent coupling.

(Part B) Learn how to identify when particle flow reaches a steady state, compare the mass flow between
outputs, and build Custom Properties to estimate the work of shear forces.

17.1. Part A: Project Setup and Processing

17.1.1. OBJECTIVES
The main purpose of this tutorial is to learn how to use Coarse-Graining to increase the particle size
while maintaining the system behavior, but using a reduced number of (larger) particles.

We will also learn how to export Ansys Fluent results as an .f2r file (optional) and further couple this
already-processed CFD simulation with our DEM simulation setup in Rocky.

• The scenario considered is a pneumatic transport of micrometer-sized particles within a mixing

tee.

You will learn how to:

• (Optional) Export Fluent CFD results as an .f2r file

• Import an .f2r file into Rocky

• Use Coarse-Graining to scale-up the particle size (and reduce the processing time)

• Collect Intensities data via Boundary Collisions Statistics

And you will use these programs and features:

• (Optional) Ansys Fluent:

– Export Solution to Rocky

• Rocky:

– Coarse-Graining

– Fluent 1-Way Steady State coupling

– Boundary Collision Statistics

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17.1.2. PREREQUISITES
This ADVANCED tutorial assumes that you are already with the Rocky user interface (UI) and Rocky
project workflow.

• If this is not the case, it is recommended that you complete at least Tutorials 01- 05 before begin-
ning this tutorial.

Important:

Even though this tutorial makes use of CFD results from Ansys Fluent, you are not required
to have a Fluent license. Specifically:

• If you do not have Ansys Fluent, you can skip the CFD setup steps and just use the
provided results when you are ready to import them into Rocky.

• (Optional) If you do have Ansys Fluent and want to process the CFD results yourself,
ensure that you have a valid license for Ansys 2025 R1.

17.1.3. GEOMETRY

The geometry in this tutorial is composed of:

• (1) Mixing Tee

In the tutorial directory, a .cas file containing this geometry can be found.

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17.1.4. (OPTIONAL) FLUENT CASE SETUP

Note:

If you are completing this tutorial without Ansys Fluent, please skip ahead to the Rocky
setup steps, which begin on ROCKY PROJECT SETUP (p. 797).

To set up the Fluent Case, do the following:

1. Download the dem_tut17_files.zip file .

2. Unzip dem_tut17_files.zip to your working directory.

3. Open Ansys Fluent.

4. From the Fluent Launcher, under Dimension, ensure that 3D is selected; also, under Solver
Options, ensure that Double Precision is selected.

Important:

Double Precision and 3D are required for coupling with Rocky.

5. From the Solution workspace, below Capability Level, select Case from the dropdown list.

6. From the Browsing Case File dialog, navigate to the geometry folder that you previously
downloaded, select the mixing_tee_fluent.cas file, and then click Open.

7. Under Parallel, set the number of Solver Processes.

8. Click Start.

17.1.5. (OPTIONAL) VERIFY EXPORT COMPONENT

In this tutorial, we will export an .f2r (Fluent to Rocky) file, which requires prior installation of a special
Fluent/Rocky export component.

Ensure that you have this component by doing the following:

1. At the top of the Fluent program window, see if you have listed the Rocky Export menu (as
shown).

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2. If you do not see this menu in Fluent, then do the following: From the Rocky program's Options
menu, point to Ansys and then click Install Fluent/Rocky export (as shown).

Tip:

It is also possible to couple Fluent and Rocky through the Ansys Workbench program.
(See also Tutorial - Windshifter (p. 629)).

17.1.6. (OPTIONAL) FLUENT CASE PROCESSING

1. From the Fluent Outline View tree panel, under Solution, double-click Run Calculation.

2. From the Run Calculation Task Page, click Calculate. If you are asked to initialize the case, click
Yes.

3. After the calculation completes, from the Rocky Export menu, point to Export one-way data,
and then click Export current data to Rocky (as shown).

The .f2r file will be automatically saved in the same location as the .cas file.

4. Close Fluent. (It is not necessary to save the case for this tutorial.)

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17.1.7. ROCKY PROJECT CREATION

Note:

If you are completing this tutorial without Ansys Fluent, you can begin the tutorial from
this step.

1. Download the dem_tut17_files.zip file .

2. Unzip dem_tut17_files.zip to your working directory.

3. Open Rocky 2025 R1

4. Create a new project.

5. Save the empty project to a location of your choosing.

17.1.8. ROCKY PROJECT SETUP

For this tutorial, we want to do all of the following:

• Enable Coarse-Graining to help with simulating micron-sized particles.

• Use the Boundary Collision Statistics module to collect Intensities. This data can be useful for
analyzing impact wear and power draw.

• Import geometries via the same Fluent .cas file we used earlier (in the optional steps).

Let's start by learning about Coarse-Graining.

17.1.9. PHYSICS DEFINITION - COARSE-GRAINING

Coarse-Graining enables you to increase the original particle size to study the system behavior using
a feasible number of (larger) particles.

This physics accomplishes this by doing the following:

• Scales-up the particle size, which reduces the number of particles that need to be processed,
thereby lowering the computational load.

• Adjusts the particle interactions of the newly scaled-up particles so that the larger particles behave
more like the smaller particles they represent.

Rather than creating an impractical case involving, perhaps, hundreds of millions of tiny particles,
Coarse-Graining makes it possible to analyze an approximated case with a more manageable particle
count all without sacrificing accuracy.

Note:

The Coarse-Graining model used in Rocky is based on the work of Bierwisch et al. (2009).
Refer to the Rocky DEM Technical Manual for further details.

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17.1.10. PHYSICS DEFINITION - COARSE-GRAINING

To apply Coarse-Graining in Rocky, you specify a unique CGM Scale Factor for each Particle set.

This factor is multiplied by the original particle size to obtain an easier-to-process scaled-up particle,
called a parcel.

The job of a single, scaled-up parcel is to represent many original-sized particles while retaining
the same interaction behaviors as the smaller particles it represents.

To achieve this latter goal, the CGM Scale Factor is also used to adjust the contact, adhesion, thermal,
drag, and other interaction properties of the scaled-up parcel so that it behaves more like the original-
sized particles.

17.1.11. ROCKY PROJECT SETUP

1. Use the information in the table below to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Data Entity Editors Location Parameter or Action Settings

A Study Study Study Name CGM Study
B Physics Physics | Gravity Y-direction 0 [m/s2]
Z-direction -9.81 [m/s2]
Physics | Numerical Softening 0.1 [ - ]
Momentum Factor

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Action Settings

Physics | Enable Coarse-Graining (Enabled)
Coarse-Graining
C Modules Modules Boundary Collision (Enabled)
Statistics
D Modules Boundary Collision Intensities (Enabled)
Statistics
Boundary
Collision
Statistics
E Geometries Import Wall mixing_tee_fluent.cas
with "m" for Import
Unit

Note:

"CGM" refers to Coarse Grain Modeling.

17.1.12. REMOVE GEOMETRIES

Five separate geometry components are imported.

For this tutorial, we need only the wall geometry.

1. From the Data panel, multi-select the two inlet and two outlet geometry components.

2. Right-click the selection of four items, and then click Remove Geometries.

Important:

Only the wall geometry component should remain at this point.

17.1.13. ROCKY PROJECT SETUP

Next, we will define a surface that will be used as an inlet to release the particles into the domain.

We will also be creating a spherical-shaped particle group with a range of three different sizes.

Note that we will be using default values for both the Materials and Materials Interactions settings.

1. Use the information in the table below to continue setting up your Rocky project.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Create Circular Surface

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Tutorial - Mixing Tee

Step Data Entity Editors Location Parameter or Settings

Action
B Geometries Circular Surface Center Coordinates 0, 0, 0.36 [m]
Max Radius 0.048 [m]
Circular Surface <01>
Angle 90 [dega]
C Particles Create Particle

17.1.14. PARTICLE GROUP DEFINITION

1. From the Data Editors panel, on the main Particle tab, select the Size sub-tab, and then check
the CGM Scale Factor:

• For now, we will leave the CGM Scale Factor as 1 (particles equal to the original size).

• Later in this tutorial, we will compare the particles count for CGM Scale Factors of 1 and 30.

2. Click the Add button (green plus) twice to add two more particle size rows.

3. For each row, define the Size (and Units) and Cumulative % values (as shown). Click View.

• Reminder: The Particles Details window always reflects the size of the largest particle in the
set. (In this case 7.5e-05 m.)

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 Part A: Project Setup and Processing

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17.1.15. ROCKY PROJECT SETUP

For the Inlets and Outlets step, we will create a Particle Inlet.

1. Use the information in the table below to continue setting up your Rocky project.

Step Data Entity Editors Location Parameter or Action Settings

A Inlets and Outlets Create Particle Inlet
B Inputs Particle Inlet Entry Point Circular Surface <01>
Particle Inlet | Add row (x1)
Particles (1) Particle | Mass Flow Particle <01> @ 0.1
Particle
Inlet Rate [t/h]
<01> … | Time Stop 1 [s]
… | Entry Target Normal Velocity (Enabled)
4 [m/s]

17.1.16. COARSE-GRAINING COMPARISON

Now, let's see how many particles are estimated if we simulate at this (original) particle size.

1. From the Data panel, click Inlets and Outlets.

2. From the Data Editors panel, on the Info tab, view the estimated number of particles.

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 Part A: Project Setup and Processing

Note:

This estimate is made using the Inlet parameters (e.g. Start and Stop Times, Target Velocity
and Surface Dimensions) and the Particles parameters (e.g. Size and Material).

For this tutorial, we will assume that we do not have the computational resources to process
the hundreds of millions of estimated particles.

To make this simulation more reasonable to process, we will now set a higher CGM Scale Factor to
reduce the particle count.

1. From the Data panel, under Particles, click Particle <01>.

2. From the Data Editors panel, on the Size sub-tab, increase the CGM Scale Factor.

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Tutorial - Mixing Tee

By viewing again the particle estimates in Inlets and Outlets, a significant reduction of particles can
be seen.

1. From the Data panel, click Inlets and Outlets.

2. From the Data Editors panel, on the Info tab, view the updated particle estimate.

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 Part A: Project Setup and Processing

Now ranging in only the tens of thousands of particles, this case should be much easier to process.
In addition, the corrections made by the Coarse-Graining will ensure that the interactions closely
approximate those of the original case.

Important:

As a reminder, the CGM factor f is multiplied by the particle diameter, which means that
the parcel's volume and mass are f3 times bigger when compared with those from the
original particle. The outcome is a reduction in the particle count by f3 times.

For this tutorial, an exaggerated CGM factor of 30 is used to speed up simulation time.
However, note that an over-scaled CGM factor may cause unrealistic physical results and
numerical instability (e.g. 2-Way Coupling cases).

17.1.17. CFD COUPLING DEFINITION

For the CFD Coupling step, we will be importing some steady-state CFD results that were already
processed in Fluent.

1. From the Data panel, select CFD Coupling.

2. From the Data Editors panel, from the Coupling Mode list, select (under 1-Way) the Fluent
(Fluid > Particle) option.

3. From the Select Fluent 2 Rocky export file dialog, do one of the following:

• If you completed the earlier steps in Ansys Fluent, navigate to the geometry folder, find the
fluent_to_rocky.f2r file (which was generated by Ansys Fluent when you exported the results),
and then click Open.

• If you did not complete the earlier steps in Ansys Fluent, navigate to the geometry/cfd-one-
way folder, select the mixing_tee_cfd.f2r file, and then click Open.

4. From the Data Editors panel, on the 1-Way Fluent | Interactions tab, enable the Turbulent
Dispersion checkbox.

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Tutorial - Mixing Tee

17.1.18. CFD VISUALIZATION

Now that the CFD results are within Rocky, you can visualize the nodes of the cell centroids making
up the Fluent mesh.

Important:

Given the amount of elements, showing all vectors for your CFD meshes is not considered
good practice as it can freeze the Rocky interface.

A better practice is to create a thin slice of your mesh and show only the vectors within that slice.

1. Use the information in the table that follows to set up and visualize this slice.

Step Data Entity Editors Parameter or Action Settings

Location
A CFD Coupling Create a Cube User Process

1-Way Fluent
B User Cube Name Flow Vectors
Processes Center 0.45, 0, 0 [m]
Cube Magnitude 1.7, 0.02, 0.9
<01> [m]
C User Processes Show in new 3D View

Flow Vectors
D User Coloring Vectors (Enabled)
Processes Vectors | Property Velocity
Flow Vectors | Vector scale 0.025 [ - ]
Vectors Vectors | Normalized (Enabled)
vectors

The colored vectors show that the fluid enters the domain through two inlets, (left portion of the
figure) and flow through two outlets (right portion of the figure).

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 Part A: Project Setup and Processing

Tip:

To see the vectors, you might need to make the wall geometry transparent or hidden.

17.1.19. FINISH PROJECT SETUP

Lastly, we need to define the Solver setup.

1. Use the information in the table that follows to finish your Rocky setup.

Step Data Entity Editors Location Parameter or Action Settings

A Solver Solver | Time Simulation Duration 1 [s]
Output Settings | Time 0.01 [s]
Interval
Solver | General Simulation Target CPU

17.1.20. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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Tutorial - Mixing Tee

17.1.21. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears, then processing begins.

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 Part A: Project Setup and Processing

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

17.1.22. CONCLUSION
This completes Part A of this tutorial.

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Tutorial - Mixing Tee

Rocky was used to set up and process a Mixing Tee simulation.

During this tutorial, it was possible to:

• (Optional) Export CFD results out of Ansys Fluent as an .f2r file.

• In Rocky, set Boundary Collision Statistics in order to collect Intensities data.

• Use Coarse-Graining to scale-up micro-sized particles for easier processing.

• Import CFD results into Rocky by enabling 1-Way Fluent CFD Coupling.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

17.2. Part B: Post-Processing

17.2.1. OBJECTIVES
The purpose of this tutorial is to use the results from the Mixing Tee simulation we set up and pro-
cessed in Part A to analyze which wall regions are most susceptible to wear and discover how the
particles are distributed between the outlets.

You will learn how to:

• Identify when particle flow reaches a steady state

• Compare the mass flow between the geometry outlets

• Build Custom Properties to estimate the work of shear forces

And you will use these features:

• Time Plots

• Histograms

• User Processes, including:

– Cubes

– Particles Time Selections

– Property

– Particles Trajectory

• Custom Properties

17.2.2. PREREQUISITES
This ADVANCED tutorial assumes that you are already with the Rocky user interface (UI) and Rocky
project workflow.

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 Part B: Post-Processing

• If this is not the case, it is recommended that you complete at least Tutorials 01- 05 before begin-
ning this tutorial.

Important:

Even though this tutorial makes use of CFD results from Ansys Fluent, you are not required
to own a Fluent license in order to complete this tutorial.

17.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut17_files.zip file .

b. Unzip dem_tut17_files.zip to your working directory.

c. Open Rocky 2025 R1

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the tutorial_17_A_pre-processing
folder, open the tutorial_17_A_pre-processing.rocky file.

e. Process the simulation. (From the Data panel, select Solver and then from the Data Editors
panel, click the Start button.)

With the processing complete, we can now analyze the results.

17.2.4. STEADY STATE

In order to perform statistical analysis, it is necessary to select a period of time in which the amount
of particles inside the mixing tee remains stable.

We will do this by measuring the Particles Count curve over time.

1. Use the information in the table below to create this plot.

Step Item Location Parameter or Action Settings

A Window (menu) Create a New Time Plot
B Particles Curves | Particles Drag and drop onto open Time Plot <01> window
Count

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Tutorial - Mixing Tee

The resulting time plot shows that after approximately 0.5 seconds, the amount of particles inside
the domain remains stable.

The range between 0.5 s and 1.0 s is a period of continuous operation of the equipment, and could
be used for a statistical analysis.

17.2.5. MASS FLOW CALCULATION

We next want to compare the mass flow between the two outlets and understand how the particles
separation occurs.

We will therefore define three Cube User Processes; one for the inlet and another two for the outlets.

1. Use the information in the tables that follow to define these Cubes.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Cube User Process
B User Processes Cube Name Inlet Cube
Center 0, 0, 0.305 [m]
Cube <01>
Magnitude 0.121, 0.157, 0.234 [m]
C Particles Create a Cube User Process
D User Processes Cube Name Outlet Cube
(Downwards)
Cube <01>
Center 0.9, 0, -0.334 [m]
Magnitude 0.128, 0.157, 0.153 [m]
E Particles Create a Cube User Process
F User Processes Cube Name Outlet Cube (Main)
Center 1.174, 0, -0.005 [m]
Cube <01>
Magnitude 0.188, 0.157, 0.19 [m]

It is now possible to visualize the cubes in a 3D View.

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 Part B: Post-Processing

17.2.6. MASS FLOW CALCULATION

In order to measure the total mass that passed through each cube once a steady state is reached
(from 0.5 s on), we will create a Particles Time Selection process for each Cube.

1. Use the information in the tables that follow to define these processes.

Step Data Entity Editors Parameter or Action Settings

Location
A User Processes Create a Particles Time Selection User Process

Inlet Cube
B User Processes Time Selection Name Inlet Measurement
Domain Range After Time
Particles
Time Initial 0.5 [s]
Selection
<01>
C User Processes Create a Particles Time Selection User Process

Outlet Cube (Downwards)

D User Processes Time Selection Name Outlet Measurements
(Downwards)
Particles
Domain Range After Time
Time
Selection Initial 0.5 [s]
<01>
E User Processes Create a Particles Time Selection User Process
F User Processes Time Selection Name Outlet Measurement
(Main)
Particles
Domain Range After Time
Time
Initial 0.5 [s]

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Tutorial - Mixing Tee

Step Data Entity Editors Parameter or Action Settings

Location
Selection
<01>

Next, we will build a Histogram comparing the total mass and particle sizes between each Cube.

1. Use the information in the table below to create this plot.

Step Item Location Parameter or Action Settings

A Window (menu) Create a New Histogram
B User Processes Properties | Drag and drop onto open Histogram
Particle Size <01> window
Inlet Measurement
C User Processes

Outlet Measurement
(Downward)
D User Processes

Outlet Measurement
(Main)
E Histogram (window) Configure histogram (button)
F Configure Histogram (dialog box) Weight Particle Mass
Number of Bins 3
Percent Values (Enabled)

The Histogram shows the mass fraction of three ranges of particle sizes.

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 Part B: Post-Processing

Note:

Your histogram's bin colors might differ from the ones shown.

The dark red bins show that approximately 66% of the Inlet mass fraction is of small particles. The
middle-sized and big particles have almost 17% of mass fraction each.

For the Main Outlet (orange bins), we have almost 80% of small particles mass fraction.

The blue bins (Downwards Outlet) show that the bigger the particle, the higher the mass fraction.
In other words, bigger particles tend to flow downwards.

These results make sense as bigger particles (with greater mass) would require more energy to accel-
erate and escape the downwards outlet as the gravity force acts.

Note:

Because we are using CGM, the particle sizes listed on the horizontal axis are 30 times
bigger than the sizes we set in the Particles step.

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Tutorial - Mixing Tee

17.2.7. INTENSITY AND WEAR

In Rocky, you are able to visualize the effects of wear using the surface wear modification feature.

The wear law used in that feature takes into account the shear work on the geometry surface to
predict how it will wear down over time.

Tip:

For hands-on experience with surface wear modification, refer to Tutorial - SAG Mill (p. 247)
and Tutorial - High Pressure Grinding Roll (HPGR) (p. 391).

However, for the case we are studying in this tutorial, the surface modification of the geometry would
not be noticeable due to the short simulation time.

Instead, we can compute the total work done by the shear forces on each triangle surface and then
verify which regions of the geometry have the highest shear work.

You might recall that in Part A, we enabled the collection of Intensities data for Boundary Collision
Statistics. We can use that data to perform the shear work analysis.

A good approximation of it would be:

(17.1)

Where:

• is a given time step.

• is the given boundary triangle.

• [J] is the Cumulative Shear Work from 0s to on the triangle.

• [W/m2] is the instantaneous Intensity : Shear on the triangle.

• [m2] is the Area : Cell, which is the area of the triangle.

• is the time [s].

• [s] is the time between 2 outputs, which is dictated by the Output Frequency.

Let's now create a new custom Property that defines this.

17.2.8. SHEAR WORK CALCULATION

First, we are going to calculate the Cumulative Intensity : Shear, which is the factor of
the equation.

1. Use the information in the table below to create this custom property.

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 Part B: Post-Processing

Step Item Location Parameter or Action Settings

A Geometries Properties Add new custom property (button)

wall
B Add new (dialog box) Name Cumulative Intensity:
Shear
Output unit W/m2
Inputs | Intensity: (Enabled)
Shear
C Custom Property (dialog box) Expression sum(A[:t+1]

The new Cumulative Intensity : Shear (Custom) property will appear on Properties tab under
Transient.

Now, we are going to calculate the actual Cumulative Shear Work.

1. Use the information in the table below to create a second custom property.

Step Item Location Parameter or Action Settings

A Geometries Properties Add new custom property (button)

wall
B Add new (dialog box) Name Cumulative Shear Work
Output unit J
Inputs | Area: Cell (Enabled)
Inputs | Cumulative Intensity: (Enabled)
Shear (Custom)
C Custom Property (dialog Expression A*B*OUTPUT_FREQUENCY
box)

The new Cumulative Shear Work (Custom) property will appear on the Properties tab under
Transient.

1. To visualize this new Cumulative Shear Work (Custom) property, drag-and-drop it onto a 3D
View window.

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Tutorial - Mixing Tee

To highlight the surface triangles that are most affected by wear, we will create a Property process
to filter them out.

1. Use the information in the table below to create a this Property process.

Step Data Editors Parameter or Action Settings

Entity Location
A Geometries Create a Property User
Process
wall
B User Property Property Cumulative Shear Work
Processes (Custom)
Mode Cut
Property Type Range
<01> Minimum value 5e-06 [N.m]
Maximum value 0.001 [N.m]
Coloring Faces (Enabled)
Faces | Property Cumulative Shear Work
(Custom)
Faces | Show on Node? (Enabled)
Edges (Cleared)

2. From the Data panel, hide the two items under Geometries, every Cube and Particles Time Se-
lection User Processes and show Particles by clicking their respective eye icons.

The results shown below are for the last output time: [100] 1 s

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 Part B: Post-Processing

Now we will manually define the limits of the color scale and see how the surface wear changes over
time.

1. From the Data panel, under Color Scales, select Cumulative Shear Work (Custom).

2. From the Data Editors panel, set the Limits options as User Defined, and then click the Compute
limits in time range and set as "User defined" button.

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Tutorial - Mixing Tee

3. From the Calculate limits for the time range dialog, click OK.

4. Use the slider on the Time toolbar to see how the Cumulative Shear Work develops over time.

To get a better context of how the particles are interacting with the geometry, we can create a
Particles Trajectory process:

1. From the Time toolbar, set the output time to [80] 0.8 s.

2. Use the information in the table below to create a this Particles Trajectory process.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Particles Trajectory User Process
B User Processes Particle Update Particles Selection (button)
Trajectory
Particles
Coloring Edges (Enabled)
Trajectory
<01> Edges | Property Absolute Translational
Velocity

3. From the Data panel, make sure the Particles Trajectory <01> item is visible by enabling its eye
icon.

The results are shown below.

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 Part B: Post-Processing

As shown in the images below, most of the shear work happens on the bottom portion of the main
pipe.

Of the bottom portion of the main pipe, the regions of highest shear work are:

• The region right below the particles' inlet.

• The region of the stream separation.

As the shear work is more severe in these regions, they are the most susceptible to wear.

17.2.9. CONCLUSION
This completes Part B of this tutorial.

Rocky was used to post-process a simulation of a Mixing Tee.

During this tutorial, it was possible to:

• Use a Time Plot to identify a steady state for particle flow.

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Tutorial - Mixing Tee

• Use Cube and Particles Time Selection User Processes to measure the amount of particle mass
that flowed through the outlets.

• Analyze the particle size segregation between the outlets by using a Histogram.

• Visualize the cumulative shear work on the Mixing Tee geometry by using the Boundary Collision
Statistics data that was collected in Part A combined with the Particles Trajectory.

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 18: Tutorial - Ribbon Blender
(Part A) Set up and process a simulation that makes use of the Liquid Bridge Model external module,
which enables you to compute adhesive forces caused by the liquid film that involves the particles
when they are wet.

(Part B) Analyze the mixing performance using the Lacey Mixing Index (LMI).

(Part C) Analyze the liquid distribution during the mixing process.

18.1. Part A: Project Setup and Processing

18.1.1. OBJECTIVES
The main purpose of this tutorial is to learn to set up and process a Liquid Bridge simulation for
later mixing analysis.

• Part B will cover analyzing the mixing performance using the Lacey Mixing Index (LMI) and Part
C will cover analyzing the liquid distribution.

The scenario considered in this tutorial is evaluating the mixing performance of a Ribbon Blender
combining two different materials: one powder material (dry) and one additive material (wet).

Note:

Ribbon Blenders are commonly used in the food, chemical, and pharma industries.

You will learn how to:

• Install, enable, and then configure the Liquid Bridge adhesion model

And you will use these features:

• Liquid Bridge Model Module

18.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

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Tutorial - Ribbon Blender

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

To make use of the referenced external module, you must have Rocky 2025 R1 or later and your
version of Rocky must be the same as the SDK version in which the module was compiled.

18.1.3. EXTERNAL MODULE

For this tutorial, an external module will be installed and used.

External modules are not installed with the Rocky product by default; rather, they are downloaded
and installed separately.

To install the module, do the following:

1. Download the ready-to-use module Liquid Bridge Model for your operating system.

2. Open the folder that downloads and then extract its content.

3. Copy the 25.1.0 folder you previously extracted to one of the following locations:

a. Windows: %HOMEPATH% / Documents / Rocky / Modules

b. Linux: ~/.Rocky / Modules

4. Restart (or open if already closed) Rocky to refresh the module libraries.

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 Part A: Project Setup and Processing

18.1.4. GEOMETRIES

The geometries in this tutorial are composed of:

• (1) Tank

• (2) Ribbon

These two items will be imported as .stl files, which can be found in the tutorial directory.

18.1.5. PROJECT CREATION

To get started setting up this tutorial, do the following:

1. Download the dem_tut18_files.zip file .

2. Unzip dem_tut18_files.zip to your working directory.

3. Ensure Rocky 2025 R1 is open.

4. Create a new project.

5. Save the empty project to a location of your choosing.

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Tutorial - Ribbon Blender

18.1.6. MODULES DEFINITION

For the Modules step, we will be enabling the Liquid Bridge Model module.

• Liquid Bridge Model applies to particles an adhesion model that simulates what happens when
a wet particle gets close enough to another particle or boundary for their liquid films to touch or
"bridge".

• Because the default values already represent water, we will be leaving most of the Liquid Bridge
settings as default for this tutorial.

Tip:

More information about this module can be found in the Ansys Help by clicking the button
as shown.

18.1.7. LIQUID BRIDGE DEFINITION

First, let's turn on the Liquid Bridge Model module:

1. From the Data panel, select Modules.

2. From the Data Editors panel, enable the Liquid Bridge Model checkbox (as shown).

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 Part A: Project Setup and Processing

Tip:

If you do not see the Liquid Bridge Model listed here, ensure you have followed the steps
on EXTERNAL MODULE (p. 824).

To see the parameters you are able to set:

1. From the Data panel, under Modules, select the new Liquid Bridge Model entry.

2. From the Data Editors panel, view the following parameters:

• Liquid Viscosity: Defines the viscosity of the liquid film around particles.

• Liquid Density: Defines the density of the liquid film around particles.

• Surface Tension: Defines the surface tension of the liquid film around particles.

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Tutorial - Ribbon Blender

In addition to those listed in the module itself, additional Liquid Bridge parameters will be available
in other locations of the Rocky setup, including:

• Materials Interactions

• Inlets and Outlets

Note:

We will cover these later in the tutorial.

18.1.8. PROJECT SETUP

Now that the module is enabled, we can begin setting up other parts of the project.

1. Use the information in the table that follows to continue setting up the project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Data Entity Editors Location Parameter or Action Settings

A Study Study Study Name Mixer
B Physics Physics | Numerical Softening 0.1 [ - ]
Momentum Factor
C Geometries Import Wall Ribbon.stl and
Tank.stl with "m" for
Import Unit
Create Circular Surface
D Geometries Circular Surface Center Coordinates -0.005, 0.675, 0.315
[m]
Circular
Max Radius 0.13 [m]
Surface
<01>
E Motion Frames Create Motion Frame
F Motion Frame Name Rotor
Frames Relative Position 0.62, 0, 0 [m]
Frame … | Motions Add motion
<01> Type Rotation
Initial Angular Velocity 42, 0, 0 [rev/min]
G Geometries Wall Motion Frame Rotor

Ribbon

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Action Settings

H Materials Material Young's Modulus 1e+09 [N/m2]
Default
Boundary
I Materials Material Bulk Density 593 [kg/m3]
Default Young's Modulus 1e+07 [N/m2]
Particles
J Materials Create Solid Material
K Materials Material Name Additive
Use Bulk Density (Enabled)
Material Bulk Density 640 [kg/m3]
<04> Young's Modulus 1e+07 [N/m2]
L Materials … | Default Static Friction 0.2 [ - ]
Interactions Particles Dynamic Friction 0.2 [ - ]
Default
Particles
… | Additive Static Friction 0.2 [ - ]
Dynamic Friction 0.2 [ - ]
Additive
… | Default Static Friction 0.2 [ - ]
Particles Dynamic Friction 0.2 [ - ]
Additive

Earlier in the Modules step, we enabled the Liquid Bridge Model module.

Doing so turned on additional parameters in other parts of the Rocky UI, including for Materials Inter-
actions.

18.1.9. INTERACTION BETWEEN MATERIALS - LIQUID BRIDGE

The additional Liquid Bridge Model parameters that you can set for your Materials Interactions
pairs are as follows:

• Bridge Volume Fraction (fb): Defines the fraction of the liquid bridge volume that the particle pair
will each contribute to when they are close enough for their liquid films to form a bridge.

• Contact Angle (θ): Defines the angle between the surface of the liquid bridge and the particle
(and/or boundary) surfaces between which it formed.

• Minimum Separation Ratio: Defines the minimum separation ratio between the pair of colliding
particles below which the capillary and viscous liquid bridge forces will remain with a constant
value. The minimum separation distance (h) is computed as the minimum separation ratio times
the biggest particle radius.

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Note:

For this tutorial, we will be leaving these settings as default.

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 Part A: Project Setup and Processing

18.1.10. PARTICLES AND INLETS DEFINITIONS

For this tutorial, we will create one Volumetric Inlet with Dry powder particles and a Particle Inlet
with Wet additive particles.

In this way, we will have two distinct layers of particles to better analyze the mixing:

1. Use the information in the table that follows to continue setting up your simulation:

Step Data Entity Editors Location Parameter or Action Settings

A Particles Create Particle
B Particles Particle Name Dry Powder
Particle | Size (1) Size | Cumulative % 0.04 [m] @ 100%
Particle
<01>
C Particles Create Particle

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Step Data Entity Editors Location Parameter or Action Settings

D Particles Particle Name Wet Additive
Material Additive
Particle
<01> Particle | Size (1) Size | Cumulative % 0.03 [m] @ 100%
E Inlets and Outlets Create Particle Inlet
F Inlets and Particle Inlet Name Injection (Wet)
Outlets Entry Point Circular Surface
<01>
Particle
Inlet Particle Inlet | Add row (x1)
<01> Particles (1) Particle | Mass Flow Rate Wet Additive 72
[t/h]
… | Time Stop 1 [s]
… | Entry Stop All Inection at Stop (Enabled)
Time

Important:

The Particle Inlet Mass Flow Rate was set in a way that the Wet Additive mass will be 15%
of the total mass (Wet Additive + Dry Powder).

Earlier in the Modules step, we enabled the Liquid Bridge Model module, which turned on additional
parameters in other parts of the Rocky UI, including for Inlets and Outlets.

This additional parameter appears on a new Modules sub-tab for your Inputs:

• Liquid Mass: Defines the liquid mass that will be applied to each particle within the selected
Particle set.

Note:

The Particle set listed here is defined on the Particles sub-tab.

1. From the Modules sub-tab, define Liquid Mass.

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 Part A: Project Setup and Processing

Now, we'll create a Volumetric Inlet that injects the Dry Powder particles, and will finish setting up
the rest of our project.

Note:

We want the Dry Powder particles to be completely dry at the time of injection, so we
will leave the Liquid Mass setting as 0 (zero).

1. Use the information in the table that follows to finish setting up your project.

Step Data Editors Location Parameter or Action Settings

Entity
A Inlets and Outlets Create Volumetric Inlet
B Inlets Volumetric Inlet Name Volumetric Fill (Dry)
and Volumetric Inlet | Add row (x1)
Outlets Particles (1) Particle | Mass Dry Powder 113 [kg]
Volumetric Inlet | Seed Coordinates 0, -0.375, 0 [m]
Volumetric Region
Geometries | Ribbon (Enabled)
Inlet
<01> Geometries | Tank (Enabled)
Box bounds | Center 0, -0.414, 0 [m]
Coordinates
Box bounds | Dimensions 1.6, 0.296, 1.1 [m]

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Step Data Editors Location Parameter or Action Settings

Entity
C Solver Solver | Time Simulation Duration 10 [s]
Solver | General Simulation Target CPU

18.1.11. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

18.1.12. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

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Tutorial - Ribbon Blender

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

18.1.13. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a Ribbon Blender
simulation.

During this tutorial, it was possible to:

• Download, install, enable, and set up the Liquid Bridge Model module.

• Define new Materials and configure their module-specific Materials Interactions.

• Create multiple Inputs, and define module-specific parameters within them.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and/or Part C and post-process this project.

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 Part B: Post-Processing (LMI Analysis)

18.2. Part B: Post-Processing (LMI Analysis)

18.2.1. OBJECTIVES
The main purpose of this tutorial is to use the results of the simulation we set up and processed in
Part A to analyze the mixing efficiency using the Lacey Mixing Index (LMI).

As a reminder, the scenario considered in this tutorial is a Ribbon Blender mixing two different ma-
terials: one (dry) powder material and one (wet) additive material.

You will calculate the LMI by learning how to:

• Tag particles with a certain defined criteria

• Use Cylinder and Eulerian Statistics User Processes to define discrete cells

• Calculate properties statistics and Custom Properties using mathematical expressions

• Build property filters by using the Property User Process

• Calculate custom properties from other properties in a Time Plot

And you will use these features:

• Tagging Particle Calculations

• User Processes, including:

– Cylinder

– Eulerian Statistics

– Property

• Time Plots (including the Add Formula feature)

18.2.2. PREREQUISITES

Important:

Important: This ADVANCED tutorial contains fewer details, screenshots, and procedures
than other Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

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To make use of the external module referenced, you must have Rocky 2025 R1 or later and your
version of Rocky must be the same as the SDK version in which the module was compiled.

Tip:

If you are unsure which version of Rocky you have, check the Rocky About screen. (From
the Help menu, click About, and then view the Version information).

18.2.3. OPEN PROJECT

If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue from
where Part A left off.)

If you did not complete Part A, do all of the following:

• Download the dem_tut18_files.zip file .

• Unzip dem_tut18_files.zip to your working directory.

• Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1. If you
have an earlier version of Rocky, please upgrade Rocky to version Rocky 2025 R1, or
complete Part A from scratch.

• From the Rocky program, click the Open Project button, find the dem_tut18_files folder, then
from the tutorial_18_A_pre-processing folder, open the tutorial_18_A_pre-processing.rocky
file.

• Process the simulation. (From the Data panel, select Solver and then from the Data Editors panel,
click the Start button.)

With the processing complete, we can now start analyzing our results.

18.2.4. POST-PROCESSING
At any given time, Properties can be used to color the Particles in a 3D View window.

For example, you can do the following:

1. From the Particles entity, on the Properties tab, right-click Particle Group, point to 3D View
and then click Show in new 3D View.

Tip:

You might need to make the Tank geometry transparent (or hidden) to see the particles.

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 Part B: Post-Processing (LMI Analysis)

18.2.5. EVALUATION OF MIXING DEGREE

In order to evaluate the uniformity of mixing, we will divide the mixture into samples and will measure
the Mass Fraction of Additive Particles in each sample.

A good degree of mixing means that the mass fractions of the samples are approximately the same.

Each discrete volume (cell) will represent a different sample of our mixture.

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To compare the degree of uniformity between samples, we can calculate their Additive Mass Fraction
Variance.

The higher the variance, the more heterogeneous is the system, which means a poor degree of mixing.

The Lacey Mixing Index (LMI) is often used to evaluate the uniformity of mixing. It can be interpreted
as a normalization of the mass fraction variance, and will provide values ranging from 0 to 1.

• An index of 0 (zero) means that the mass fraction variance is the maximum theoretical value and
also means complete segregation (no mixing achieved).

• An index of 1.0 means that the mass fraction variance is the minimum theoretical value and also
means a completely random mixing (maximum mixing achieved).

• A "good" mixture can be defined as achieving an index between 0.75 - 1.0.

18.2.6. MIXING INDEX

The Lacey Mixing Index can be defined as:

(18.1)

The equation components are described below.

• Mass fraction variance:

(18.2)

• Variance of fully segregated (unmixed) system, the maximum theoretical value:

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 Part B: Post-Processing (LMI Analysis)

(18.3)

• Variance of fully mixed system, the minimum theoretical value:

(18.4)

• Additive Mass Fraction:

(18.5)

Where:

• : Number of cells (Eulerian Statistics Divisions)

• : Average Additive Mass fraction across cells

• : Additive Mass fraction of the whole system

• : Additive Mass fraction in the cell i

• : Average number of particles across cells

• : Additive Mass in the cell i

• : Main Product Mass in the cell i

18.2.7. FILTERING ADDITIVE PARTICLES

Particles Properties and Tagging Calculations will be used to filter the Wet Additive Particles.

Tagging allows you to define a Global value to particles that meet a specific criterion in a particular
Output Time.

To select a group of particles, we will create a new Property User Process that filters particles based
on their properties.

1. Filter the Particles by the Wet Additive Particle Group by using the information in the table below:

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Property User Process
B User Property Name Wet
Processes Additive
Property Particle
Group
Property
<01> Cut Value 1 [<ind>]

2. To see only the filtered particles, use the eye icons on the Data panel to hide the main Particles
entity and make the Wet Additive User Process visible.

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18.2.8. TAGGING ADDITIVE PARTICLES

In this tutorial, we will Tag the Wet Additive Particles with a value of 1, which will automatically
make all other untagged particle groups have a value of 0.

This separation will be needed later when we calculate the mass of the Wet Additive particles only.

1. Tag the Wet Additive particles using the information in the table below:

Step Data Entity Editors Parameter or Action Settings

Location
A Particles Create a Tagging calculation over the Wet
Additive entity
B Calculations Tagging Time Range Filter | Specific Time
Domain Range
Tagging (Wet
Time Range Filter | At 1 [s]
Additive)
time
{t=0[s], v=1} Tag Value 1 [s]

18.2.9. ADDITIVE MASS CALCULATION

Next, we will define a new property that multiplies the Tag value and the Particles Mass value, which
we will call Mass If Additive.

In this way, if the particle is a Wet Additive particle, the value of this new custom property is the
Particle Mass. Otherwise, the value will be zero.

1. Create a new Custom Property using the information in the table below:

Step Item Location Parameter or Action Settings

A Particles Properties Add new custom property (button)

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 Part B: Post-Processing (LMI Analysis)

Step Item Location Parameter or Action Settings

B Add new (dialog box) Name Mass if
Additive
Output unit kg
Inputs | Particle Mass (Enabled)
Inputs | Tagging (Wet Additive)... (Enabled)
C Custom Property (dialog box) Expression A*B

A new property called Mass If Additive (Custom) appears on the Properties tab for Particles.

18.2.10. SAMPLING
Now that we've defined the Mass If Additive property, we need to divide the Ribbon Blender tank
into samples.

For this step, we will create a Cylinder User Process and then apply Eulerian Statistics divisions to
the cylinder.

The Additive Mass Fraction will then be calculated for each individual cell by adding a new expression
defined as the Additive Mass divided by the Particle Mass.

1. Use the information in the table that follows to set up the processes.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Cylinder User Process
B User Processes Cylinder Size 1.1, 1.5, 1.1 [m]
Center 0, 0, 0 [m]
Cylinder <01>
Orientation | Angles
Method
Orientation | 0, 0, 90 [dega]
Rotation
C User Processes Create a Eulerian Statistics User Process

Cylinder <01>

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Step Data Entity Editors Parameter or Settings

Location Action
D User Processes Eulerian Radial Divisions 1[-]
Statistics Tangential Divisions 18 [ - ]
Eulerian Statistics
<01> Axial Divisions 8[-]

18.2.11. ADDITIVE MASS FRACTION

Next, we will calculate the Additive Mass Fraction in each cell.

First we need to calculate both the sum of all particles mass and the Wet Additive particle mass in
each cell.

1. Use the information in the table that follows to add two new Eulerian properties:

Step Item Location Parameter or Settings

Action
A User Processes Properties Add and edit properties for source entity
(button)
Eulerian Statistics
<01>
B Add or edit eulerian properties Add a new property
C Add new property (dialog box) Operation Sum
Particle Property Mass If Additive
(Custom)
Add Property
Operation Sum
Particle Property Particle Mass
Add Property

From the Properties tab of the Eulerian Statistics <01> entity, the two new custom properties appear.

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 Part B: Post-Processing (LMI Analysis)

The last step to visualize the mass fraction is to divide the Sum of Mass If Additive (Custom) by the
Sum of Particle Mass using a new Custom Property.

1. Use the information in the table that follows to create this new custom property.

Step Item Location Parameter or Action Settings

A User Properties Add new custom property (button)
Processes

Eulerian
Statistics
<01>
B Add new (dialog box) Name Additive Mass
Fraction
Output unit -
Inputs | Sum of Mass If (Enabled)
Additive
Inputs | Sum of Particle Mass (Enabled)

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Step Item Location Parameter or Action Settings

C Custom Property (dialog box) Expression A/B

Note:

For Step C, ensure the expression you enter represents Sum of Mass If Additive
(Custom) divided by Sum of Particle Mass.

The newly created property will be available on the Properties tab for the Eulerian Statistics <01>
entity.

1. Drag and drop the new Additive Mass Fraction (Custom) property onto a 3D View window.

2. By using the slider on the Time toolbar, you can see how the Mass Fraction is distributed in the
cells over time.

18.2.12. FILTERING
In order to evaluate the Lacey Mixing Index (LMI) unbiased, we'll select and analyze only those cells
with the highest amounts of particles, to ensure better representative samples.

For this step, we will filter the cells based on their mass.

1. Use the information in the table that follows to create a property process to filter those cells:

Step Data Entity Editors Location Parameter or Settings

Action
A User Processes Create a Property User Process

Eulerian Statistics <01>

B User Processes Property Name Sample LMI
Property Sum of Particle
Property <01>
Mass
Mode Select

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 Part B: Post-Processing (LMI Analysis)

Step Data Entity Editors Location Parameter or Settings

Action
Type Range
Minimum value 1 [kg]
Maximum value 10 [kg]

Important:

• Modifying the number of Eulerian Statistics divisions changes the total particle Mass
in each sample. Therefore, the mass range used to filter the samples through the
Property Process would be different.

• The range of Sum of Particle Mass defined through the Property Process above should
be adjusted based on the Property limits.

Tip:

You can view the limits by clicking the Load Limits button on the Property
tab when defining a Property User Process.

• The number of Eulerian Statistics cells (volume of samples) affect the calculated value
of Lacey Mixing Index. For example, a higher number of divisions would increase the
heterogeneity between samples and, therefore, their variance.

• A sensitivity analysis should be performed to find the optimum number of cells. For ex-
ample, coarser particles would require a greater volume of each sample (so, the particles
wouldn't be bigger than a cell), reducing the number of cells.

18.2.13. MIXING INDEX

1. From the Sample LMI entity, on the Properties tab, right-click Additive Mass Fraction (Custom),
point to Time Plot, point to Show in new Time Plot, and then click Variance. (Resulting plot
shown.)

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The plot represents , Additive Mass Fraction Variance, represented by:

(18.6)

Where is the number of cells, is the Additive Mass Fraction in the cell i and is the Additive
Mass Fraction Average (taken across Eulerian Statistics cells).

2. From the Sample LMI entity, on the Properties tab, right-click Number of Particles, point to
Time Plot, point to Show in selected Time Plot, and then click Average. (Resulting plot shown.)

If we recall from the setup in Part A, the System Additive Mass Fraction ( ) is 15%.

So next, we need to define and (see equations below) using the Add Formula feature in
the Time Plot window we already created.

• Variance of fully segregated (unmixed) system:

(18.7)

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 Part B: Post-Processing (LMI Analysis)

• Variance of fully mixed system:

(18.8)

3. Use the information in the table that follows to create formulas in the Time Plot:

Step Location Parameter or Settings

Action
A Time Plot | Add Formula
Table
B Add Curve Caption Fully
Expression Unmixed
Curve Expression 0.15*(1-0.15)
C Time Plot | Add Formula
Table
D Add Curve Caption Fully Mixed
Expression Curve Expression E1/C
E Time Plot | Add Formula
Table
F Add Curve Caption LMI
Expression Curve Expression (B-E1)/(E2-E1)

Note:

Make sure that the B column represents the Variance: Additive Mass Fraction (Custom)
calculation, the C column represents the Average: Number of Particles (Mixer - Sample
LMI), the E1 column represents the Fully Unmixed calculation and the E2 column
represents the Fully Mixed calculation.

If you switch to the Plot tab, you can now see how the Lacey Mixing Index (orange dashed line)
changes over time.

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Tip:

Change the Axes Layout to By Quantity to facilitate visualization.

We can see that the LMI reaches 0.99 (which we can consider "fully mixed") at 6.8s.

Note:

Your results might differ from the ones shown in this tutorial.

Tip:

Press and hold the Shift key and then left-click the curves with your mouse to see
specific values.

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 Part C: Post-Processing (Liquid Distribution Analysis)

It is also possible to see this result from the Table tab.

18.2.14. CONCLUSION
This completes Part B of this tutorial, in which Rocky was used to calculate the Lacey Mixing Index
(LMI) of the Ribbon Blender simulation we set up and processed in Part A.

During this tutorial, it was possible to:

• Use Tagging Particle Calculations to mark particles with a certain defined criteria.

• Use a Cylinder User Process to define an Eulerian Statistics User Process in order to calculate
properties statistics in discrete cells.

• Calculate Custom Properties using mathematical expressions.

• Build property filters using the Property User Process.

• Calculate custom curves from other curves in a Time Plot.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part C
and continue post-processing this tutorial.

18.3. Part C: Post-Processing (Liquid Distribution Analysis)

18.3.1. OBJECTIVES
The main purpose of this tutorial is to use the results of the liquid bridge simulation we set up and
processed in Part A to analyze the distribution of liquid during mixing.

As a reminder, the scenario considered in this tutorial is a Ribbon Blender mixing two different ma-
terials: one (dry) powder material and one (wet) additive material.

You will learn how to:

• Display liquid mass in a 3D View window

• Change the color-scale of a 3D View window

• Use a Property User Processes to analyze liquid distribution and dispersion

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And you will use these features:

• Liquid Mass Property

• User Processes, including:

– Property

• Time Plots

• Histograms

18.3.2. PREREQUISITES

Important:

Important: This ADVANCED tutorial contains fewer details, screenshots, and procedures
than other Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

To make use of the external module referenced, you must have Rocky 2025 R1 or later and your
version of Rocky must be the same as the SDK version in which the module was compiled.

Tip:

If you are unsure which version of Rocky you have, check the Rocky About screen. (From
the Help menu, click About, and then view the Version information).

18.3.3. OPEN PROJECT

If you completed Part A (and/or ) of this tutorial, ensure that Rocky project is open. (Part C will con-
tinue from where Part A (or Part B) left off.)

If you did not complete Part A (and/or Part B), do all of the following:

• Download the dem_tut18_files.zip file .

• Unzip dem_tut18_files.zip to your working directory.

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 Part C: Post-Processing (Liquid Distribution Analysis)

• Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1. If you
have an earlier version of Rocky, please upgrade Rocky to version Rocky 2025 R1, or
complete Part A from scratch.

• From the Rocky program, click the Open Project button, find the dem_tut18_files folder, then
from the tutorial_18_A_pre-processing folder, open the tutorial_18_A_pre-processing.rocky
file.

• Process the simulation. (From the Data panel, select Solver and then from the Data Editors panel,
click the Start button.)

With the processing complete, we can now start analyzing our results.

18.3.4. LIQUID DISTRIBUTION

Earlier in Part A we enabled the Liquid Bridge adhesion model, which performs the following functions
during processing:

• (1) Tracks liquid content in each particle

• (2) Calculates capillary and viscous forces

• (3) After particles separate (bridge ruptures), redistributes liquid

After processing the simulation, a new property is available for Particles:

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• Liquid Mass: Provides the mass of the liquid film around each individual particle.

Important:

The liquid mass is not included in the particle mass. For example, if the dry particle has
0.1 kg and you add 0.1kg of liquid, the particle mass will remain 0.1 kg.

We can use this new property to see how the dry particles were affected by the wet particles during
mixing.

1. From the Particles entity, on the Properties tab, right-click Liquid Mass, point to 3D View and
then click Show in new 3D View.

2. Make the Tank and Ribbon geometries transparent (or hidden) to see the particles.

The Liquid Mass of the particles is shown.

To change the color scale, do the following:

1. Right-click the color scale, and then select Edit.

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 Part C: Post-Processing (Liquid Distribution Analysis)

2. From the Data Editors panel, click the ... button next to Color-scale.

3. From the Color-scale dialog, click the ... button again, and then select the red-to-blue color scale
(as shown).

4. Below the red-to-blue Color-scale, double-click the red-colored dot and then from the Select
Color dialog, select the white color (as shown), and then click OK.

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Tutorial - Ribbon Blender

5. The Color-scale should now show white-to-blue.

6. Click OK to close the dialog.

7. From the Data Editors panel, under Limits, define Limit options, and then define the Limits
values (as shown).

Use the slider on the Time toolbar to see how the liquid from the Wet Additive (blue) is transferred
to the Dry Powder (white) over time.

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 Part C: Post-Processing (Liquid Distribution Analysis)

We can also plot the average Liquid Mass of both the dry and wet particles on a Time Plot.

But first, we need to separate the groups by creating two Property User Processes.

1. Filter the Particles by Particle Group by using the information in the following table.

Note:

If you completed Part B of this tutorial, you can skip steps A and B since you already
have the Wet Additive Property User Process.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Property User Process
B User Property Name Wet
Processes Additive
Property Particle
Group
Property
<01> Type Value
Cut Value 1 [<ind>]
C Particles Create a Property User Process
D User Property Name Dry Powder
Processes Property Particle
Group
Property Type Value
<01> Cut Value 0 [<ind>]

2. From the Data panel, under User Processes, multi-select both the Dry Powder and Wet Additive
items.

3. From the Data Editors panel, on the Properties tab, right-click Liquid Mass, point to Time Plot,
point to Show in new Time Plot, then click Average.

The resulting Time Plot shows that by the end of the simulation, the liquid that was initially only in
the wet particles is after mixing, evenly distributed throughout both the wet and dry particles.

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18.3.5. LIQUID DISPERSION

Now let's analyze the liquid dispersion, starting from the beginning of the simulation.

1. From the Time toolbar, move the slider back to [20] 1 s.

2. From the Data panel, under User Processes, multi-select both the Dry Powder and Wet Additive
items.

3. From the Data Editors panel, on the Properties tab, right-click Liquid Mass, point to Histogram,
and then click Show in new Histogram.

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 Part C: Post-Processing (Liquid Distribution Analysis)

4. Use the information in the table that follows to configure the histogram:

Step Item Parameter or Action Settings

A Histogram (window) Configure histogram (button)
B Configure Histogram (dialog Number of Bins 20 [ - ]
box) Percent Values (Enabled)
Properties | Liquid (Selected)
Mass
Limits User
Defined
Min 0 [kg]
Max 0.02 [kg]

The resulting Histogram (at 1 s) shows that at the very beginning of the simulation, 100% of the liquid
is concentrated on the wet additive.

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You can explore how the liquid spreads over time by moving the Time slider forward.

For example, a few seconds into the simulation, fewer particles remain completely dry than at the
beginning of the simulation. (Results shown at 3 s.)

By the end of the simulation, the liquid content is gathering around the average. (Results shown at
10 s.)

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 Part C: Post-Processing (Liquid Distribution Analysis)

18.3.6. CONCLUSION
This completes Part C of this tutorial, in which Rocky was used to analyze the liquid distribution
within the Ribbon Blender simulation we set up and processed in Part A.

During this tutorial, it was possible to:

• Understand the results of a Liquid Bridge simulation

• Display the Liquid Mass property in a 3D View window

• Change the colors and limits of a 3D View's Color-scale

• Use Property User Processes and a Time Plot to analyze liquid distribution

• Use Property User Processes and a Histogram to analyze liquid dispersion

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 19: Tutorial - Backhoe Loader
(Part A) Set up 2-Way Coupling abilities between Rocky and Ansys Motion, and then use Ansys Motion
to export pre-defined geometry movements into a Functional Mock-Up Unit (FMU) file.

(Part B) Use the FMU information exported earlier out of Ansys Motion to set up and process the 2-Way
Coupled simulation in Rocky.

19.1. Part A: Ansys Motion Coupling Setup

19.1.1. OBJECTIVE
The main purpose of this tutorial is to set up 2-Way Coupling abilities between Rocky and Ansys
Motion.

We will then use Ansys Motion to export pre-defined geometry movements into a Functional Mock-
Up Unit (FMU) file that will later be coupled with Rocky.

The scenario considered in this tutorial is evaluating the performance of a backhoe loader's bucket
as it scoops material out of a pit in the ground.

In Part A of this tutorial, you will learn how to:

• Download and install the Ansys Motion Coupling module

• Open an existing Subsystem file in Ansys Motion

• Export the motion FMU file out of Ansys Motion

Later in Part B you will learn how to import the FMU file into Rocky, and run the 2-Way coupled
simulation.

19.1.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine both of the following
programs:

• Ansys Motion 2025 R1.

Important:

Ansys Motion must be installed in the same installation folder as your other Ansys 2025
R1 products.

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Tutorial - Backhoe Loader

• Rocky 2025 R1.

Tip:

If you are unsure which version of Rocky you have, you can view the Version information
on the About Rocky screen. (From the Rocky Help menu, click About.)

Important:

This ADVANCED tutorial assumes that you are already familiar the following programs
and resources:

• The Rocky program.

– If this is not the case, it is recommended that you complete at least Tutorials 01 - 05
before beginning this tutorial.

• The Ansys Motion program.

– If that is not the case, please refer to the Ansys Motion user documentation for basic
introduction about Motion usage before beginning this tutorial.

19.1.3. GEOMETRIES

The geometries in this tutorial are composed of:

• (1) Boom, Arm, and Actuators (several components)

• (2) Bucket

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 Part A: Ansys Motion Coupling Setup

• (3) Ground and pit

Note:

The first two sets of geometries are included in the Ansys Motion setup file. The third
geometry is provided as an .stl file that will be imported into Rocky later.

19.1.4. MOTION COMPARISON

The primary benefits of 2-Way Coupling Rocky with Ansys Motion as compared to using the standard
Rocky Motion Frames method are explained in the table below.

19.1.5. FMU OVERVIEW

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Tutorial - Backhoe Loader

Ansys Motion Coupling enables you to use motions defined in Ansys Motion within the DEM simu-
lation you set up and run in Rocky.

Motions are exported into an "all-in-one" Functional Mock-Up Unit (FMU) file.

This FMU is then imported into Rocky, defining both geometries and motions.

Exporting and importing the FMU requires the installation of two modules' one for Ansys Motion and
one for Rocky.

Both are bundled into one .exe file that is available on the Ansys Customer Portal.

19.1.6. INSTALL MODULES

STEP 1: Download and install the Ansys Motion Coupling module.

1. Download the Ansys Rocky Installation Guide document and go to the Ansys Rocky Integrations
section to better understand the installation of the coupling with the Motion. You can find the
document on the link from the Ansys Customer Portal: https://download.ansys.com/Installa-
tion%20and%20Licensing%20Help%20and%20Tutorials. .

2. Download the Additional Package for Rocky and extract the content from ansys-rocky-motion-
coupling-bin-25.1.0-win64.exe file.

Tip:

We will not cover these additional resources in this tutorial but you can use them to
learn more about Ansys Motion Coupling with Rocky.

3. Open the .exe, and then follow the steps in the wizard, ensuring the following:

a. When you get to the User Information screen, do one of the following:

• If you are installing this module for someone else, enter their Windows Username in the
field provided.

Tip:

This step should only be necessary if you are logged in as an administrator and
the user for which you are installing the module does not have the proper install-
ation permissions.

• Otherwise, if you are installing this module for yourself, you can leave the Username field
blank.

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 Part A: Ansys Motion Coupling Setup

b. When you get to the Select Components screen, select both components listed (as shown).

c. On the Select Additional Tasks, enable the Ansys Motion 2025 R1 Module checkbox. Also
enable the checkbox for Mechanical (optional).

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Tutorial - Backhoe Loader

4. Follow the remaining steps in the wizard to complete the installation.

19.1.7. ANSYS MOTION SETUP - OPEN PROJECT

STEP 2: Open the Ansys Motion project you want to couple with Rocky.

1. Download the dem_tut19_files.zip file .

2. Unzip dem_tut19_files.zip to your working directory.

3. Open Motion Pre 2025 R1.

4. From the File menu, click the Setting button, go to Labs tab and enable the Legacy ACIS Kernel
based file support checkbox.

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 Part A: Ansys Motion Coupling Setup

5. From the File, menu, click Open.

6. From the Open dialog, from the All Available Files list, select All Files (as shown).

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Tutorial - Backhoe Loader

7. From the Open dialog, locate the ansys_motion_setup folder inside the dem_tut19_files folder
you downloaded, select the subsystem file Backhoe_loader.dfsub, and then click Open.

The backhoe loader model appears in the view (as shown).

19.1.8. ANSYS MOTION SETUP - PREPARE SUBSYSTEM

For Ansys Motion Coupling to work, we need to ensure that the gravity direction exactly matches
what we will use in Rocky.

To verify that gravity is set in the Y direction, do the following:

1. From the Properties panel, view the values for Gravity (as shown).

Tip:

To view this panel, from the main Home tab on the Window toolbar, click the Proper-
ties button.

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 Part A: Ansys Motion Coupling Setup

We also must ensure that the simulation time in Ansys Motion is equal to or greater than the one
we will use in Rocky.

Tip:

Because a stopped Ansys Motion Coupling simulation might not be able to be resumed,
extended, nor restarted in Rocky, it is recommended that you make the simulation time
in Ansys Motion longer than what you think you need.

We plan to have a 12s simulation in Rocky. Verify that the simulation time in Ansys Motion is greater
than this by doing the following:

1. From the main toolbar, review the simulation time (T) value (as shown).

19.1.9. ANSYS MOTION SETUP - EXPORT FILES

STEP 4: Export the files needed for Ansys Motion Coupling.

1. From the Co-Simulator tab, click the Generate Information button on the Rocky Coupling
toolbar (as shown).

This version of Ansys Motion Coupling supports particle interactions on only rigid bodies without
beam elements.

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Tutorial - Backhoe Loader

• Flexible bodies without beam elements are supported on the Ansys Motion side but will not interact
with particles in Rocky.

Note:

Choosing to include flexible bodies in your coupled simulation will increase processing
time.

Part of the exporting files step is choosing how body components are treated during coupling.
Specifically:

• Bodies marked as Output will have their motions shared with Rocky.

• Bodies marked as Input will collect forces and moments due to interactions with particles. This
data will then be used by the Ansys Motion solver during processing.

For this tutorial, we want all bodies to have motions in Rocky, but only the Bucket body to collect
particle forces.

1. From the Rocky Coupling dialog, do all the following (as shown):

a. From the Output column, enable the main checkbox to select all the bodies.

b. From the Input column, enable only the Bucket checkbox.

c. Click Export.

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 Part B: Rocky Setup and Processing

2. From the Save As dialog, enter the File name Backhoe_FMU, and then click Save.

The export can take several minutes. You will get a confirmation message when it completes.

3. Click OK to close the confirmation message, and then click Close to close the Rocky Coupling
dialog.

4. Save your project and then close Ansys Motion.

19.1.10. HELP
This completes Part A of this tutorial.

For further information on setting up your Ansys Motion project for coupling with Rocky, we suggest
reviewing the Rocky Ansys Motion Coupling Setup Guide, which provides more in-depth descriptions
of the settings and parameters.

Tip:

To gain access to this PDF, follow the instructions on INSTALL MODULES (p. 866).

For more information about Ansys Motion, please refer to the Ansys user documentation.

19.1.11. CONCLUSION
We used Ansys Motion to set up and export geometry movements that will later be coupled with
Rocky.

During this tutorial, it was possible to:

• Download and install the .exe file that contains the two Ansys Motion Coupling modules

• Open an existing subsystem file and then verify that is ready for Rocky coupling

• Generate and then export the motion FMU file out of Ansys Motion

What's Next? If you completed this part successfully, then you are ready to move on to Part B and
set up and process the Rocky portion of this coupled simulation.

19.2. Part B: Rocky Setup and Processing

19.2.1. OBJECTIVE
The purpose of this tutorial is to use the information we exported out of Ansys Motion in Part A to
set up and process the 2-Way Coupled simulation in Rocky.

• We will make use of the Functional Mock-Up Unit (FMU) file we created in Part A.

• As a reminder, the scenario considered in this tutorial is the analysis of how well the bucket part
of a backhoe loader holds up to its material load after scooping particles from a pit in the ground.

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In Part B of this tutorial, you will learn how to:

• Enable the Multibody Dynamics FMU Coupling module in Rocky

• Use the FMU file to import both motions and geometries

• Define a pre-filled particle bed with a custom input

• Process and post-process the coupled simulation in Rocky

19.2.2. PREREQUISITES
To complete this tutorial, you are required to have on a Windows machine both of the following
programs:

• Ansys Motion 2025 R1.

Important:

Ansys Motion must be installed in the same installation folder as your other Ansys 2025
R1 products.

• Rocky 2025 R1.

Tip:

If you are unsure which version of Rocky you have, you can view the Version information
on the About Rocky screen. (From the Rocky Help menu, click About.)

In addition, you must have already downloaded and installed the Ansys Motion Coupling module.

Tip:

Refer to Part A of this tutorial for installation details.

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• If you do not already have a good level of familiarity with the most common setup and
post-processing tasks in Rocky, it is recommended that you complete at least Tutorials
01 - 05 before beginning this one.

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 Part B: Rocky Setup and Processing

19.2.3. GEOMETRIES

As a reminder, the geometries in this tutorial are composed of:

• (1) Boom, Arm, and Actuators (several components)

• (2) Bucket

• (3) Ground and pit

Note:

The first two sets of geometries are included in the Ansys Motion FMU file. The third geo-
metry is provided as an .stl file. All will be imported into Rocky in this tutorial.

19.2.4. PROJECT SETUP

Whether or not you completed Part A of this tutorial, do the following:

1. Download the dem_tut19_files.zip file .

2. Unzip dem_tut19_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

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6. Use the information in the table that follows to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Data Editors Location Parameter or Action Settings

Entity
A Study Study Study Name Backhoe Loader
B Physics Physics | Rolling Resistance Model Type C: Linear Spring
Momentum Rolling Limit
Numerical Softening 0.1 [ - ]
Factor

19.2.5. TURN ON MODULES

For the Modules step, we will be enabling the Ansys Motion Coupling functionality and turning on
the collection of boundary-related collision data.

1. Use the information in the table that follows to start setting up your modules.

Step Data Entity Editors Location Parameter or Action Settings

A Modules Modules Multibody Dynamics FMU (Enabled)
Coupling
Boundary Collision Statistics (Enabled)
B Modules Boundary Collision Stresses (Enabled)
Statistics
Boundary
Collision
Statistics

Stresses: Rocky will collect the normal and tangential stress values measured by each individual
geometry triangle. This can be useful for analyzing the distribution of load due to particle collisions
on a geometry.

19.2.6. IMPORT MOTIONS

We will use the first module to import the FMU file we exported out of Ansys Motion in Part A. As a
reminder:

• A single FMU file contains all the geometries, motion definitions, and motion solver information
Rocky needs for coupling.

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 Part B: Rocky Setup and Processing

• We will use this same FMU file to import geometries in a separate step later.

Important:

To avoid errors during geometry import later, an FMU file should NOT be manually renamed
after it is generated.

1. From the Data panel, under Modules, select Multibody Dynamics FMU Coupling.

2. From the Data Editors panel, do the following:

a. Leave the Communication step size control as Automatic. (For each Ansys Motion timestep,
Rocky computes 100 timesteps.)

b. Click the FMU filename: button (as shown).

3. From the Select file to import dialog, do one of the following:

• If you completed Part A, find and select the FMU file that you exported as part of that tutorial.

• If you did not complete Part A, find the dem_tut19_files folder you downloaded, find the
geometry folder, and then select the Backhoe_FMU.fmu file.

4. Click Open.

Once the Select file to import dialog closes without error, this indicates that the FMU file was suc-
cessfully imported.

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19.2.7. FMU GEOMETRY IMPORT

For the Geometries step, we will import the exact same FMU file that we used earlier.

Important:

To ensure correct motions, use the same FMU file in both the Multibody Dynamics FMU
Coupling module and for importing geometries.

Because we want to analyze particle forces on the Bucket component later, we must also refine its
mesh.

And lastly, we'll import the ground and pit geometry as an .stl file.

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Location Parameter or Settings

Action
A Geometries Import Wall Backhoe_FMU.fmu with "m" for
Import Unit
B Geometries Wall | Transform Triangle Size 0.05 [m]

Bucket
C Geometries Import Wall Ground.stl with "mm" for
Import Unit

19.2.8. MATERIAL DEFINITION

For the Materials step, we will:

• Modify the Default Particles material.

• Create a new material representing the Ground based on the Default Boundary Material.

• Use the Default Boundary Material for the excavator geometries.

Note:

The values for this last Material will be left as default.

1. Use the information in the table that follows to continue setting up your Rocky project.

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 Part B: Rocky Setup and Processing

Step Data Entity Editors Location Parameter or Settings

Action
A Materials Material Bulk Density 1500
[kg/m3]
Default Particles
B Materials Duplicate Material

Default Boundary
C Materials Material Name Ground

Default Boundary
<01>
D Geometries Wall Material Ground

Ground
E Materials Interactions … | Default Particles Static Friction 1[-]
Dynamic Friction 1[-]
Ground
… | Default Particles Static Friction 1[-]
Dynamic Friction 1[-]
Default Particles

19.2.9. PARTICLE GROUP DEFINITION

For the Particles step, we will create a sphere-shaped particle group with some added rolling resistance.

For the Inlets and Outlets step, we will create a Particle Custom Inlet and import a .csv file that
defines an already-filled pit of particles.

Note:

There is no need to set the particle size here because it will be defined in the Custom Inlet
file.

1. Use the information in the table that follows to finish setting up your Rocky project.

Step Data Entity Editors Location Parameter or Settings

Action
A Particles Create Particle
B Particles Particle | Movement Rolling 0.35 [ - ]
Resistance
Particle
<01>
C Inlets and Outlets Create Particle Custom Inlet

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Step Data Entity Editors Location Parameter or Settings

Action
D Inlets and Particle Custom Particle Particle <01>
Outlets Inlet Load File
Particle Select file to custom_input_sphere.csv
Custom import
Inlet <01>
E Solver Solver | Time Simulation 12 [s]
Duration
Solver | General Simulation CPU
Target

19.2.10. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

19.2.11. SIMULATE PROJECT

1. Ensure that your Ansys license is active.

2. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

Important:

Do not press Stop or lose access to your Ansys license while the simulation is processing.
You might not be able to Resume the coupled simulation once it is stopped.

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 Part B: Rocky Setup and Processing

19.2.12. FORCE ANALYSIS - CURVES

After processing is complete, we can analyze the particle forces on the bucket component.

For example, we can plot the Instantaneous Force in the Y direction:

1. From the Data panel, under Geometries, select Bucket.

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2. From the Data Editors panel, select the Curves tab, right-click Force : Y : Instantaneous, and
then click Show Curve in new Plot.

Results show the reaction force of the particles over the bucket surface during the ground digging
phase (1-3 s) and the weight of the scooped material until the unloading phase (3-10 s).

19.2.13. EVALUATING BUCKET MASS

Let's next evaluate the draw efficiency of the bucket by using a Cube User Process and a Time Plot
to analyze the carried Particle Mass.

1. From the Time toolbar, choose a time when the bucket is full and the material is relatively stable.
(For example, at [160] 8 s.)

2. Use the information in the table below to create the Cube.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create a Cube User Process
B User Cube Center -2.2, 0.7, -1.2
Processes [m]
Magnitude 1.8, 1.5, 1.7
Cube
[m]
<01>

This results in a Cube (blue outline, as shown) encompassing the full bucket.

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 Part B: Rocky Setup and Processing

19.2.14. OUTPUT VALUE

Now, let's use Output variables to view the max value at 8 s.

1. Use the information in the table below to create and modify the output variable.

Step Item Location Parameter or Settings

Action
A Tools (menu) Show Expressions/Variables
B Expressions/Variables Select Output tab
C User Processes Properties | Particle Drag and drop to Output tab
Mass
Cube <01>

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Step Item Location Parameter or Settings

Action
D Expressions/Variables Output | Particle_Mass Edit (button)
E Edit Properties (dialog box) Property to Curve sum
Domain Range Specific Time
At Time 8 [s]

The updated value shows that the Particle Mass in the Bucket reaches about 750 kg before it is
dumped.

Note:

Your values might differ slightly from this tutorial.

19.2.15. STRESS ANALYSIS

You can also visualize stresses on the Bucket geometry in a 3D View window:

1. From the Window menu, click New 3D View.

2. From the Data panel, under Geometries, multi-select all components except for the Bucket
component, and then click the eye icon to hide all but the bucket from the view (as shown).

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3. Repeat this process to hide the main Particles entity.

Only the Bucket geometry should be visible now (as shown).

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4. From the Data panel, select the Bucket component.

5. From the Data Editors panel, select the Properties tab, and then click and drag Stress : Tangential
to the 3D View window.

6. Use the Time slider to change the output when the bucket is actively scooping (for example, 3
s, as shown).

7. Adjust the limit of the color scale to optimize the mapping (for example, from 0 to 10000 Pa, as
shown).

This analysis shows the shear stress caused by the interactions between particles and the bucket
geometry, and therefore identifies zones that are prone to wear.

Extension: You can extend this analysis even farther by creating a Time Statistics Property on the
Bucket and then plotting a contour of wear.

19.2.16. HELP - SETUP GUIDE

This completes Part B of this tutorial.

For further information on Ansys Motion Coupling with Rocky, we suggest searching the Ansys Motion
Coupling Setup Guide. To access it, do the following:

1. From the Data panel, under Modules, select Ansys Motion Coupling.

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 Part B: Rocky Setup and Processing

2. From the Data Editors panel, on the main Ansys Motion Coupling tab, click the Open this
Module's Help File icon (as shown). The PDF manual opens.

19.2.17. CONCLUSION
Rocky was used to set up, process, and post-process a simulation of a backhoe loader with movements
defined in Ansys Motion.

During this tutorial, it was possible to:

• Enable the Multibody Dynamics FMU Coupling module in Rocky

• Use the FMU file we created in Part A to import both motions information and geometries

• Define a pre-filled particle bed by using a custom input .csv file

• Process and post-process the coupled simulation in Rocky

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 20: Tutorial - Fertilizer Spreader
(Part A) Set up and run a simulation that uses the 1-Way Constant CFD Coupling method.

(Part B) Use multiple, nested user processes to create a Cumulative Mass Field in order to understand
how the fertilizer particles are distributed by the spreader.

20.1. Part A: Project Setup and Processing

20.1.1. OBJECTIVES
The main purpose of this tutorial is to learn how to set up a simulation that uses the 1-Way Constant
CFD Coupling method.

• The scenario considered is evaluating the performance of a crop spreader, such as those used for
broadcasting seed or fertilizer onto fields.

You will learn how to:

• Define a rotation motion

• Set up CFD Coupling using the 1-Way Constant method

• Set custom domain limits

And you will use these features:

• Motion Frames

• CFD Coupling

• Domain Settings

20.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

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Tutorial - Fertilizer Spreader

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

20.1.3. GEOMETRY

The geometries in this tutorial are composed of:

• (1) Spreader

• (2) Walls

In the tutorial directory, the .stl files can be found.

Note:

Due to the relatively high particle count expected for this tutorial, no geometry representing
the ground will be included.

This allows us to speed up processing by reducing the amount of particles that remain
active in the simulation while still allowing us to see the full spreading effects.

20.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut20_files.zip file .

2. Unzip dem_tut20_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

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 Part A: Project Setup and Processing

5. Save the empty project to a location of your choosing.

6. Use the information in the tables that follow to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials to find the detailed in-
structions you need.

Step Data Entity Editors Parameter or Action Settings

Location
A Study <01> Study Study Name Spreader
B Geometries Import Wall Spreader.stl and Wall.stl
with "m" for Import Unit
Create Rectangular Surface
C Geometries Rectangular Center Coordinates -0.11, 0.15, 0 [m]
Surface Length 0.05 [m]
Rectangular Width 0.04 [m]
Surface
<01>
D Motion Frames Create Motion Frame
E Motion Frames Frame Name Rotation Motion
Add motion
Frame
<01> Motions | Type Rotation
… | Initial Angular 0, 810, 0 [rev/min]
Velocity
F Geometries Wall Motion Frame Rotation Motion

Spreader
G Materials Material Young's Modulus 1e+08 [N/m2]
Default
Boundary
H Materials Material Use Bulk Density (Cleared)
Density 1000 [kg/m3]
Default
Particles Young's Modulus 1e+06 [N/m2]
I Particles Create Particle
J Particles Particle Name 3mm
Size 0.003 [m] @ 100%
Particle
<01>
K Particles Create Particle

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Tutorial - Fertilizer Spreader

Step Data Entity Editors Parameter or Action Settings

Location
L Particles Particle Name 4mm
Size 0.004 [m] @ 100%
Particle
<01>
M Inlets and Outlets Create Particle Inlet
N Inlets and Particle Inlet Entry Point Rectangular Surface <01>
Outlets
Particle Inlet Add row (x2)
Particle
| Particles (1) Particle | Mass Flow 3mm 0.6 [t/h]
Inlet <01>
Rate
(2) Particle | Mass Flow 4mm 1.2 [t/h]
Rate

20.1.5. CFD COUPLING - 1-WAY CONSTANT

For this tutorial, we want the particles to be spread over the domain in the presence of still (non-
moving) air.

In this case, the particles will experience air resistance when launched.

The images below show how important is to consider air resistance in this scenario.

A simulation without air resistance results in particles spreading much farther than when air resist-
ance is considered in the project.

To represent this behavior, we will make use the 1-Way Constant CFD coupling method, which has
the following key benefits:

• Useful in cases where you have a known, unchanging fluid field.

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 Part A: Project Setup and Processing

• Does not require a separate CFD program. (The functionality is included in Rocky.)

• Enables you to define constant values for density, velocity, viscosity and (optional) thermal properties.

Define this coupling method by doing the following:

1. From the Data panel, select CFD Coupling.

2. From the Data Editors panel, select Constant (Fluid > Particle) under 1-Way from the Coupling
Mode list (as shown).

3. From the Data panel, select the newly created 1-Way Constant item.

4. From the Interactions tab, select the 3mm item from the Particle list (as shown).

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Tutorial - Fertilizer Spreader

The CFD Laws that can be set for the selected particle group will appear.

For this tutorial, the CFD Laws for both particle groups will be left as they were set by default.
(No changes.)

5. Select the Fluid Flow tab.

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 Part A: Project Setup and Processing

Since we want to simulate still air and the default values already represent this condition, no
changes will be made.

20.1.6. CONTINUE PROJECT SETUP

1. Use the information in the table that follows to continue setting up your Rocky project.

Step Data Entity Editors Parameter or Action Settings

Location
A Domain Domain Use Boundary Limits (Cleared)
Settings Settings Min Values -3,-1, -1
[m]
Max Values 7, 1, 9
[m]
B Solver Solver | Time Simulation Duration 2 [s]
Solver | Output Settings | Time 0.005 [s]
General Interval
Simulation Target CPU

20.1.7. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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Tutorial - Fertilizer Spreader

20.1.8. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

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Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

20.1.9. CONCLUSION
This completes Part A of this tutorial, during which Rocky was used to set up and process a Fertilizer
Spreader simulation.

During this tutorial, it was possible to:

• Use Motion Frames to set up a rotation motion.

• Set up the 1-Way Constant method of CFD Coupling.

• Define custom Domain Settings limits.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

20.2. Part B: Post-Processing

20.2.1. OBJECTIVES
The main purpose of this tutorial is to learn how to use multiple, nested user processes to understand
how the fertilizer particles are distributed by the spreader we simulated earlier in Part A.

• Part B will continue from where Part A left off.

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 Part B: Post-Processing

You will learn how to:

• Layer multiple, nested User Processes to achieve a specific result.

• Create a custom property for Eulerian Statistics.

And you will use these features:

• User Processes, including:

– Cube

– Property

– Particles Time Selection

– Eulerian Time Statistics

20.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01- 05 before beginning this one.

20.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that project is open in Rocky. The Part B will
continue from where Part A left off.

2. If you did not complete the project from Part A, do all of the following:

a. Download the dem_tut20_files.zip file .

b. Unzip dem_tut20_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade Rocky to the latest
version, or complete Part A from scratch.

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Tutorial - Fertilizer Spreader

d. From the Rocky program, click the Open Project button, find the dem_tut20_files folder,
then from the tutorial_20_A_pre-processing folder, open the tutorial_20_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Solver entity, click the Start button.)

20.2.4. POST PROCESSING - CUMULATIVE MASS FIELD

Once the simulation finishes processing, you are ready to start Part B.

• In this tutorial, we want to understand how the Fertilizer Spreader distributes the particle mass
throughout the domain.

• To do that, we will create a Cumulative Mass Field to see how different regions of the domain
receive different amounts of particle mass.

To evaluate the performance of the spreader, it is useful to measure the fertilizer distribution across
the entire crop area.

The Cumulative Mass Field that results from the spreader operating at steady-state as simulated in
this tutorial can be used to extrapolate the mass distribution across the entire crop field.

To accomplish the cumulative mass field, we will need to layer different User Processes on top of
each other.

We will make use of four User Processes to do this:

• (1) Particles Time Selection

• (2) Cube (on top of Particles Time Selection)

• (3) Eulerian Statistics (on top of Cube)

• (4) Filter (on top of Eulerian Statistics)

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 Part B: Post-Processing

20.2.5. POST PROCESSING - PERIOD SELECTION

But before we create our first layer, we need to choose a period of time for the analysis. Specifically:

• We will choose a period of time in which the system is in a steady-state.

• In other words, the amount of particles being injected is approximately the same amount of particles
leaving the domain.

We can obtain that information by plotting the Particles Count and then selecting a period of time
in which the curve is stable.

1. From the Particles entity, on the Curves tab, right-click Particles Count, and then click Show
curve in new Plot.

2. Press the Shift key while left-clicking the top of the Curve to see the values (as shown).

We can see that steady-state is reached after about 0.7 (s).

We now know that for our analysis, we want to select a time period after this point.

20.2.6. LAYER 1 - PARTICLES TIME SELECTION

We want to analyze how the particles would be distributed on the ground.

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Tutorial - Fertilizer Spreader

However, to speed up the processing time in Part A, we did not include a geometry representing
the ground; therefore, the particles in this tutorial leave the domain soon after they fall far enough
in the Y direction.

In a case like this, a good approach is to analyze the mass distribution in a layer right before the
particles leave the domain.

To accomplish this, we will define a Particles Time Selection, which in this case, will record the last
position of every particle that passed inside the domain within a particular time range.

Note:

A Particles Time Selection can also be applied to a particular region, such as a Cube or
Cylinder.

Furthermore, the particles that left the domain due to the absence of a ground geometry will be re-
corded very close to the bottom of the domain. This is similar to where the particles would be if they
were actually on the ground.

20.2.7. LAYER 1 - PARTICLES TIME SELECTION

Now, we are going to select all the particles that passed through the domain during the 1s to 2s
period. (Based upon earlier measurements, we know this is during steady state.)

1. Use the information in the table below to create the first layer of this analysis.

Step Data Entity Editors Parameter or Action Settings

Location
A Particles Create a Particle Times Selection User Processes
B User Processes Time Selection Domain Range Time Range
Initial 1 [s]
Particles Time
Selection <01> Final 2 [s]

2. Open a 3D View by pressing Ctrl+D.

• By default, particles are displayed in Automatic/Rich mode, which displays the fully-rendered
particles at their original size.

• At this domain view, the particles are much too small to see, so we will change to Simple mode,
which will render the particles as fixed-sized points instead.

• We will also reduce the size of the points in the view for better visibility.

3. From the Data Editors panel, select the Coloring tab, and then do both of the following (as
shown):

a. Ensure Visible is enabled.

b. From the Level of Detail list, select Simple.

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 Part B: Post-Processing

c. Under Nodes, define the Point size as 2.

The 3D View now shows all the particles that passed through the domain from 1s to 2s.

Each particle was recorded in its last position either just prior to its leaving the domain or wherever
it was at the last timestep, including any particles that were still traveling through the air at that time.

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Tutorial - Fertilizer Spreader

20.2.8. LAYER 2 - CUBE

We want to generate a Mass Field to analyze the distribution of particles on the ground. Thus, we
must exclude the particles that were still traveling through the air during the last time step.

Therefore, we are going to create a Cube user process over Particles Time Selection <01> to select
only the layer of particles closest to the ground.

1. Use the information in the table below to create the second layer of this analysis.

Step Data Entity Editors Parameter or Settings

Location Action
A User Processes Create a Cube User Process

Particles Time Selection

<01>
B User Cube Center 2, -0.95, 4
Processes [m]
Magnitude 20, 0.1, 20
Cube
[m]
<01>
Coloring Level of Detail Simple
Nodes | Point Size 2[-]

2. From the Data panel, hide Particles Time Selection <01> from the view.

The 3D View now shows the particles of the Particles Time Selection <01> that are next to the
ground, inside the Cube <01>.

20.2.9. LAYER 3 - EULERIAN STATISTICS

In order to generate a Mass Field from these selected particles, we need to create a Eulerian Statistics
User Process over the Cube we just created.

1. Use the information in the table below to create the third layer in this analysis.

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 Part B: Post-Processing

Step Data Entity Editors Parameter or Settings

Location Action
A User Processes Create a Eulerian Statistics User Process

Cube <01>
B User Processes Eulerian Width Divisions 20 [ - ]
Statistics Heigth Divisions 1[-]
Eulerian Statistics
<01> Depth Divisions 20 [ - ]

Next, to compute the particle mass in each Eulerian Statistics cell, we must add a new property,
derived from Particles.

1. Use the information in the table below to continue with this analysis.

Step Item Location Parameter or Action Settings

A User Processes Properties Add and edit properties for source entity
(button)
Eulerian
Statistics <01>
B Add or edit eulerian properties (dialog Add property (button)
box)
C Add new property (dialog box) Operation Sum
Particle Property Particle Mass
Add property (button)

2. From the Data Editors panel, on the Properties tab, drag-and-drop the newly created Sum of
Particle Mass onto the 3D View.

Tip:

You may need to use the eye icons on the Data panel to hide the other User Processes.

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Tutorial - Fertilizer Spreader

20.2.10. LAYER 4 - FILTER

Now we will filter the resulting Cumulative Mass Field to show only where the particle mass is above
a specific value.

To achieve that, we are going to apply a Filter User Process over the Eulerian Statistics.

1. Use the information in the table below to create the fourth layer in this analysis.

Step Data Entity Editors Parameter or Settings

Location Action
A User Processes Create a Filter User Process

Eulerian Statistics <01>

B User Property Property Sum of Particle
Processes Mass
Mode Cut
Filter
<01> Type Range
Minimum Value 0.001 [kg]
Maximum Value 1 [kg]

1. From the Filter <01> entity, select the Properties tab, select Sum of Particle Mass, and then
drag-and-drop it onto the 3D View. (Results shown.)

Tip:

Hide Eulerian Statistics <01> by using its Data panel eye icon.

We can then smooth out the faces visualization of the property by enabling Show on Node option.

1. From the Data Editors panel, select the Coloring tab, enable the Show on Node? checkbox, and
then clear the Edges checkbox.

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 Part B: Post-Processing

20.2.11. CUMULATIVE MASS FIELD - EXTENSIONS

Instead of simulating distribution across the entire crop field, which might require running costly
simulations using millions of particles, simulating a steady-state field like we have done in this tutorial
can be used to reduce computational time.

Additional analyses can be achieved in the following ways:

• Superpose this same field along several points of the trajectory to generate the mass distribution
across the entire crop field.

• Use the PrePost Scripting functionality to extract the values of each cell and then develop a Python
script that computes the trajectory and superposed computations.

20.2.12. CONCLUSIONS
This completes Part B of this tutorial, which makes use of Rocky to analyze how a Fertilizer Spreader
distributes particles throughout the domain.

During this tutorial, it was possible to:

• Layer multiple User Processes to achieve a specific result.

• Create a custom property for Eulerian Statistics.

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 21: Tutorial - Bottling Line
(Part A) Set up and process a simulation that makes use of Custom Inputs, which enables you to define
specific positions, release times, and orientations for particles.

(Part B) Analyze the bottle transportation to identify stuck and tipped over bottles, and pin-point possible
sources of bottle damage due to impact.

21.1. Part A: Project Setup and Processing

21.1.1. OBJECTIVES
The main purpose of this tutorial is to learn to set up and process a simulation that makes use of
Particle Custom Inlets, which enables you to define specific positions, release times, and orientations
for particles.

The scenario considered in this tutorial is a Bottling Line operation that transports filled champagne
bottles while also consolidating them into a single line.

You will learn how to:

• Use a Particle Custom Inlet to inject particles in specific positions, times, and orientations.

• Define custom Center of Mass and Moments of Inertia for a particle shape.

And you will use these features:

• Particle Custom Inlet

• Particle Mass Center and Moment of Inertia Properties

21.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

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Tutorial - Bottling Line

21.1.3. GEOMETRIES

The geometries in this tutorial are composed of:

• (1) Rail (single component)

• (2) Conveyor Belts (13 separate components)

These 14 items will be imported as .stl files, which can be found in the tutorial directory.

21.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut21_files.zip file .

2. Unzip dem_tut21_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the table that follows to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Data Entity Editors Location Parameter or Action Settings

A Study Study Study Name Bottling Line

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 Part A: Project Setup and Processing

Step Data Entity Editors Location Parameter or Action Settings

B Physics Physics | Momentum Numerical Softening 0.1 [ - ]
Factor
C Modules Modules Inter-particle Collisions (Enabled)
Statistics
D Modules Inter-particle Normal Impact Velocity (Enabled)
Collisions Statistics

Inter-particle
Collisions
Statistics
E Geometries Import Wall Rail.stl (one file)
and from
Belt_01.stl to
Belt_13.stl
(thirteen files)
with "mm" for
Import Unit

21.1.5. MOTION FRAMES

To achieve the goals of both safely transporting the bottles and consolidating them into a single line,
the 13 conveyors must increase in velocity while the rail lines up the bottles.

For the Motion Frames step, we will create one motion frame for each conveyor belt.

1. Use the information in the table that follows to set up your first motion frame.

Step Data Entity Editors Parameter or Settings

Location Action
A Motion Frames Create Motion Frame
B Motion Frame Name Belt Velocity
Frames <01>
Keep in Place Global
Frame
<01> Add motion
Velocity 0.1676, 0, 0 [m/s]
C Geometries Geometry Motion Frame Belt Velocity
<01>
Material Default Belt
Belt_01

2. Repeat the previous steps for all twelve remaining conveyors using one of the following two
methods:

• Manual Method: Use the values in the table below to create and assign these additional Motion
Frames to their respective belts manually.

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Tutorial - Bottling Line

• Automatic Method: To save setup time, use a script that completes this step for you. To make
use of the script, do the following:

a. From the Tools menu, ensure that the Python Shell checkbox is enabled.

b. Navigate to the dem_tut21_files folder that you previously downloaded, find the script
folder, and then open the tutorial_21_script.txt file.

c. In the text reader, press Ctrl+A to select all the content, and then copy and paste it into
the Python Shell panel (as shown). The commands run automatically.

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 Part A: Project Setup and Processing

All the thirteen Motion Frames should now be created and assigned to their respective belts.

In addition, each belt should have their Material correctly set to Default Belt.

21.1.6. CONTINUE PROJECT SETUP

Now that the Motion Frames are defined, we can continue setting up our project.

1. Use the information in the table that follows to define Materials Interactions, and import a Custom
Particle shape.

Step Data Editors Location Parameter or Settings

Entity Action
A Materials … | Default Particles Static Friction 0.4 [ - ]
Interactions Dynamic Friction 0.4 [ - ]
Default Belt
… | Default Particles Static Friction 0.1 [ - ]
Dynamic Friction 0.1 [ - ]
Default Boundary
… | Default Particles Static Friction 0.1 [ - ]
Dynamic Friction 0.1 [ - ]
Default Particles
B Particles Create Particle
C Particles Particle Name Bottle
Shape Custom Polyhedron
Particle Select file to import Bottle.stl with "m" for
<01> Import Unit

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Tutorial - Bottling Line

21.1.7. CONVEX AND CONCAVE DETECTION

1. From the Convert to Convex? dialog, select 1 - Keep the shape as is., and then click OK (as
shown).

In this case, we want Rocky to treat the particle as Concave in order to preserve its shape.

Otherwise, it would convert the geometry to Convex and we would lose some of the Bottle's details.

Tip:

For further information about Convex and Concave detection, refer to Tutorial - Tablet
Coater (p. 485).

21.1.8. PARTICLE GROUP DEFINITION

To properly represent the behavior of a Filled Bottle, we must the change the Center of Mass and
the Moments of Inertia of the particle.

1. From the Data Editors panel, select the Movement sub-tab.

2. Enable the Change Mass Properties checkbox.

In Rocky, the Center of Mass Offset is expressed as a percentage of the particle size in each dir-
ection.

For this tutorial, we consider that the Center of Mass Offset for a filled Bottle is 5% (of the
height) lower than the empty Bottle.

3. Set the Center of Mass Offset (as shown).

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 Part A: Project Setup and Processing

In Rocky, the custom Moments of Inertia are expressed in second moments of volume (length5)
relative to the Principal axes, assuming a sieve size of 1.

Tip:

You may compute these values using CAD software.

4. Set also the Principal Moment of Inertia.

Note:

We'll leave the X, Y and Z directions as default since our Bottle is already approximately
aligned with its principal axes.

5. From the Size tab, ensure Sieve Size is selected for Size Type and then enter the Size (as shown).

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Tutorial - Bottling Line

It is important that we ensure the volume produced by this sieve size matches the real-life volume
of the bottle (353ml). We will do this by using the values on the Info tab.

6. From the Info tab, verify the Volume value.

7. Now that the size is set, it is important to View the Particles Details window and note the min-
imum Y-coordinate (as shown).

This value will be used later to prescribe the desired Particle Custom Inlet position.

Note:

In this particle view, the Geometric Center (orange dot) is in (0,0,0) position, relative to the
local coordinate system of the particle; and the Center of Mass (blue dot) is located a little
below it due to the Center of Mass Offset we defined earlier.

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 Part A: Project Setup and Processing

21.1.9. PARTICLE CUSTOM INLET DEFINITION

For this tutorial, we want the Bottles to be injected at given positions and times.

In Rocky, this is possible by using the Particle Custom Inlet feature, which uses an imported .csv file
to define each particle's injection properties.

Within the .csv file, the particle properties are defined as header columns, and each particle is set on
a separate row.

The particle properties (and their respective units) you can define in your .csv file are explained on
the next slide.

Property columns you can define in a Particle Custom Inlet .csv file:

• x, y, and z (required) are the global coordinates (in meters (m)) in which the given particle's
Geometric Center will be placed.

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Tutorial - Bottling Line

• size (optional) is the Sieve Size (in meters (m)) of the injected particle.

• release (optional) is the time (in seconds (s)) when the particle is injected. If there is any obstruction
at the given time, the injection will be delayed and a warning will be displayed in the Simulation
Log panel.

• angle, nx, ny, and nz (optional) define the rotation of each particle around a unit vector (nx, ny,
nz). The angle is defined in radians (rad) and the vector is defined in meters (m).

• temperature (required only if Thermal Modeling is enabled) is the temperature (in Kelvin (K)) of
the particle.

• ux, uy, and uz (optional) are the initial velocities of the particle in each direction, as measured in
meters per second (m/s).

• wx, wy, and wz (optional) are the initial angular velocities of the particle in each direction, as
measured in radians per second (rad/s).

For this tutorial we have provided you with a .csv file (as shown) that will inject rows of bottles in
the Bottling Line inlet.

Note that only the x, y, z, and release properties are necessary for our purposes in this tutorial.

Important:

When creating your own .csv file, ensure that it uses commas as a separator.

21.1.10. INPUT DEFINITION

Now, we'll create a Particle Custom Inlet to inject the particles into the domain.

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 Part A: Project Setup and Processing

1. Use the information in the table that follows to set up your inlet.

Step Item Location Parameter or Settings

Action
A Inlets and Outlets Create Particle Custom Inlet
B Inlets and Outlets Custom Input Particle Bottle
Load File
Particle
Custom Inlet
<01>
C Select file to import (dialog box) File name custom_bottle_injection.csv

Under File Info, we can verify summarized info, such as the Number of Particles and the Min and
Max values of the various Properties that were defined inside the .csv we loaded.

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Tutorial - Bottling Line

Note:

The min (0.063) and max (0.063) values of the y property indicate that all the particles will
be injected 0.063m above the conveyors. If you recall, this is approximately the distance
between the geometric center and the bottom of the bottle, that we noted earlier on slide
15.

21.1.11. CONTINUE PROJECT SETUP

In this tutorial, the height of the bottles is higher than the Rail height (as shown)

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 Part A: Project Setup and Processing

As a consequence, a portion of the particles would be outside of the domain if we use the geometries
limits as boundaries.

Therefore, we will set the boundary limits manually.

1. Use the information in the table that follows to finish setting up your project.

Step Data Entity Editors Parameter or Action Settings

Location
A Domain Domain Use Boundary Limits (Cleared)
Settings Settings Min Values -0.1, 0, -0.3
[m]
Max Values 5.4, 0.5, 1
[m]
B Solver Solver | Time Simulation Duration 40 [s]
Output Settings | Time 0.01 [s]
Interval
Solver | Simulation Target CPU
General

21.1.12. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

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Tutorial - Bottling Line

21.1.13. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

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Tutorial - Bottling Line

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

21.1.14. CONCLUSION
This completes Part A of this tutorial.

Rocky was used to set up and process a Bottling Line simulation.

During this tutorial, it was possible to:

• Import a Custom Polyhedron particle shape and define a custom Center of Mass and Moments
of Inertia.

• Create a Particle Custom Inlet injection method.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

21.2. Part B: Post-Processing

21.2.1. OBJECTIVES
The purpose of this tutorial is to use the results from the simulation we set up and processed in Part
A to analyze the bottle transportation on the various conveyors.

You will learn how to:

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 Part B: Post-Processing

• Identify different periods of operation.

• Verify if there are obstructions or stuck bottles in the line.

• Verify if any bottles fell or flipped during transport.

• Identify bottles and zones with the highest velocity of impact.

And you will use these features:

• Particle Properties and Curves

• Time Plots

• 3D View Windows

21.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

21.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that project is open in Rocky. (Part B will continue
from where Part A left off.)

2. If you did not complete the project from Part A, do all of the following:

a. Download the dem_tut21_files.zip file .

b. Unzip dem_tut21_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade to the latest version,
or complete Part A from scratch.

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Tutorial - Bottling Line

d. From the Rocky program, click the Open Project button, find the dem_tut21_files folder,
then from the tutorial_21_A_pre-processing folder, open the tutorial_21_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Solver entity, click the Start button.)

• Once the simulation is finished processing, you are ready to start Part B.

21.2.4. PARTICLES COUNT

A simple way to identify if there are any major obstructions somewhere inside the domain is to plot
the Particles Count for each output.

1. From the Particles entity, on the Curves tab, right-click Particles Count, and then click Show
curve in new Plot.

The time plot shows that between approximately 13s (when the first bottle exits the domain) and
23s (when the last bottle is injected), the amount of particles inside the domain remains stable.

This analysis proves that there is no obstruction preventing the bottles from exiting the domain.

21.2.5. RESIDENCE TIME

The Residence Time of a particle is the amount of time it spends inside the domain.

In a period of continuous operation, all the particles should spend approximately the same amount
of time within the domain.

Therefore, the Maximum Residence Time of a given timestep should be stable. Let's verify:

1. From the Particles entity, on the Properties tab, right-click Residence Time, point to Time Plot,
point to Show in selected Time Plot, and then click Max.

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 Part B: Post-Processing

The maximum Residence Time curve shows that during the continuous operation period, each particle
spent around 14s inside the domain.

21.2.6. BOTTLE ORIENTATION

Now we will check if there are any bottles that fall or flip during transport, which is an undesired
outcome. We can make use of the particles Y-coordinate to analyze this.

Note:

(a) The bottle Geometric Center (GC) coordinate is (0, 0, 0) (see the image below).

(b) The distance between the bottom of the bottle and the GC is 0.0628m.

(c) The bottle maximum radius is 0.032 m. (As shown)

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Tutorial - Bottling Line

Considering that the Y-coordinate for the particles into the simulation domain is measured from the
bottom (as shown below), we can assume that:

• A fully upright bottle has a Y-coordinate of 0.0628 m.

• A bottle lying on the rail has a Y-coordinate of 0.032 m.

To perform this analysis, do the following:

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 Part B: Post-Processing

1. From the Particles entity, on the Properties tab, right-click Coordinate : Y, point to Time Plot,
point to Show in new Time Plot, and then click Min.

Note:

You may get different results from the ones presented in this tutorial due to the sens-
ibility of this simulation.

Tip:

If your plot is showing any peak or valley with values with a relevant difference if
compared with the initial ones, you can check which bottle(s) fell in the rail at the time
that the peak or valley ocurred in a 3D View.

The resulting plot shows that the minimum particle Coordinate : Y is approximately the expected
value for all outputs, which indicates that all the bottles remained upright.

21.2.7. BOTTLE IMPACT VELOCITY

Another source of possible damage to the bottles is during impact with other bottles or conveyor
components.

To measure the amount of impact, we will use the Relative Average Velocity data that is collected
during collisions.

The higher the Relative Average Velocity of a collision, the higher the impact energy (and the more
likely for damage).

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Tutorial - Bottling Line

As a reminder, we already enabled the collection of this data in Part A of this tutorial when we turned
on the Inter-particle Collision Statistics module and enabled the Normal Impact Velocity component.

To start this analysis, do the following:

1. From the Particles entity, on the Properties tab, right-click Velocity : Impact : Normal : Mean,
point to Time Plot, point to Show in new Time Plot, and then click Max.

2. To see the exact time in which that impact happens, select the Table tab (as shown).

The table shows that the maximum velocity impact occurs at 25.19 s.

Note:

Your results may differ from these ones. Select the Time properly.

1. Identify which bottles have this impact velocity and where it happens by using the information
in the table below to create a 3D View window.

Step Item Location Parameter or Settings

Action
A Time Toolbar Time 25.19 s

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 Part B: Post-Processing

Step Item Location Parameter or Settings

Action
B Particles | Velocity : Impact : Normal : Show in new 3D View
Mean

The view shows that the highest impact velocity occurs near the final "S-curve" of the rails, when the
bottles are conveyed by the fastest belt.

Besides that collision, if we move the slider to investigate times around this point, we see that most
of the highest impact velocities occur near this same location.

21.2.8. CONCLUSION
This completes Part B of this tutorial.

Rocky was used to post-process a simulation of a Bottling Line.

During this tutorial, it was possible to:

• Use the Particle Count curve to identify different periods of operation and detect a possible major
obstruction.

• Use the Residence Time property to identify if any bottles got stuck during transport.

• Use the Particle Coordinate : Y property to identify bottles that did not remain fully upright.

• Use the Inter-particle Collision Statistics we collected in Part A to analyze where and when the
highest Impact Velocities occurred.

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 22: Tutorial - Lawn Mower
(Part A) Set up and process a simulation that makes use of Custom Fibers, defined by a .csv file. Use a
Particle Custom Inlet together with Custom Fibers and Frozen Segments, to set the grass Fiber positions.

(Part B) Use Particle Mass to view how a Fiber breaks, calculate the Mower Blades’ Power and Torque
and identify which regions of the blades are most susceptible to wear.

22.1. Part A: Project Setup and Processing

22.1.1. OBJECTIVES
The main purpose of this tutorial is to learn to set up and process a simulation that makes use of
Custom Fibers defined with Frozen Segments.

The scenario considered in this tutorial is a Lawn Mower cutting grass, where the individual grass
plants are represented by Custom Fibers with Frozen Segments where the fibers attach to the
ground.

You will learn how to:

• Define a Custom Fiber particle shape using a .csv file

• Export a particle shape to an .stl file

• Use a Particle Custom Inlet, together with Custom Fibers and Frozen Segments, to set the grass
Fiber positions

• Attach the grass Fibers to a Motion Frame

And you will use these features:

• Particle Custom Inlet

• Custom Fiber Particle Shape

• Multi-Element (Flexible) Particles

• Frozen Fibers

• Joint Breakage

• Particle Shape Export

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Tutorial - Lawn Mower

22.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

22.1.3. GEOMETRIES

The geometries in this tutorial are composed of:

• (1) Mower

• (2) Blades

• (3) Ground

These 3 items will be imported as .stl files, which can be found in the tutorial directory.

22.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut22_files.zip file .

2. Unzip dem_tut22_files.zip to your working directory.

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 Part A: Project Setup and Processing

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

6. Use the information in the tables that follow to start setting up your Rocky project.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory
Tutorials and Advanced Tutorials) to find the detailed instructions you need.

Step Data Entity Editors Parameter or Action Settings

Location
A Study Study Study Name Lawn Mower
B Physics Physics | Numerical Softening 0.1 [ - ]
Momentum Factor
C Modules Modules Boundary Collision (Enabled)
Statistics
D Modules Boundary Intensities (Enabled)
Collision
Boundary Statistics
Collision
Statistics
E Geometries Import Wall blades.stl, ground.stl
and mower.stl with
"mm" for Import Unit
F Geometries Wall | Translation 0, 0.005, 0 [m]
Transform Triangle Size 0.01 [m]
blades
G Motion Frames Create Motion Frame
H Motion Frames Frame Name Translation
Add motion
Frame
<01> Velocity -0.17, 0, 0 [m/s]
I Geometries Wall Motion Frame Translation

ground
J Motion Frames Create Motion Frame
K Motion Frames Frame Name Rotation
Relative Position 0.185, 0, 0 [m]
Frame
<01> Add motion
Type Rotation
Initial Angular Velocity 0, -30, 0 [rad/s]

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Tutorial - Lawn Mower

Step Data Entity Editors Parameter or Action Settings

Location
L Geometries Wall Motion Frame Rotation
M Materials Material Bulk Density 439 [kg/m3]
Default Young's Modulus 1e+07 [N/m2]
Particles

22.1.5. PARTICLE GROUP DEFINITION

For the Particles step, we will create a Custom Fiber, which is defined in a .txt or .csv file and then
imported into Rocky.

• Custom Fiber shapes are made up of separate but connected Segments, which the positions are
defined by the coordinates of each starting and ending Nodes.

• Other properties can be defined per Segment, including its Diameter and whether or not the
Segment will be considered Frozen.

In this tutorial, we will create a Custom Fiber with four segments of different diameters, which the
bottom segment is Frozen (as shown).

The structure of the .csv file we will use to define this shape is shown below:

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 Part A: Project Setup and Processing

Each row beneath the header defines a separate segment where:

• x1, y1 and z1 are the coordinates of the node that starts the segment.

• x2, y2 and z2 are the coordinates of the node that ends the segment.

• diameter is the segment's diameter.

• k_multiplier (optional) is the Young's modulus multiplier for the segment.

• frozen (optional) indicates whether the segment will be treated as frozen (1) or unfrozen (0).

Note:

Segments of a multi-element Fiber defined as frozen will "stick" to a certain location and
have only the unfrozen segments of the Fiber respond to interactions from other objects
in the simulation.

Let's now create a Custom Fiber and import the .csv file that defines it.

1. Create a new Particle.

2. From the main Particle tab, enter the Name, and then define the Shape as Custom Fiber.

3. From the Select file to import dialog, navigate to the geometry folder and open the grass.csv
file.

4. From the Import File Info dialog, click OK.

5. From the Size sub-tab, set the Size Type.

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Tutorial - Lawn Mower

6. From the Data Editors panel, click the View button.

The particle shape representing a Grass Fiber is shown in a Particle Details window.

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 Part A: Project Setup and Processing

22.1.6. PARTICLE SHAPE EXPORT

Because we designed this Custom Fiber shape in a .csv file, we don't have a copy of it we can use in
a CAD program if, for any reason, we needed to.

Luckily, Rocky enables us to export Particle shapes to .stl files. Let's try it:

1. From the Data panel, under Particles, right-click Grass Particle, point to Export and then click
Rendered Shape.

2. From the Select output unit dialog, click OK.

3. From the Select target STL file dialog, choose a location and enter a File name for your file, and
then click Save.

You now have an .stl copy of your grass Fiber shape.

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Tutorial - Lawn Mower

22.1.7. PARTICLE GROUP DEFINITION

For this tutorial, we want the grass Fibers to have a random orientation around the vertical axis:

1. From the Data Editors panel, select the Orientation sub-tab.

2. Enable the Random Angle checkbox and set the Half Angle (x,y,z).

In this way, we have defined the Y-angle limit within which Rocky will randomly orient each individual
particle within the Particle set.

For this tutorial, we want the grass Fiber to be both flexible in its movements and allow for the mower
blades to cut (break) it on contact.

We will enable both these features by composing the Fiber of Multiple Elements.

• By default, a Fiber is defined as a Single Element. This results in a rigid shape that cannot be
broken.

• In order to support both flexibility and breakage, Fibers must be composed of Multiple Elements,
which divides each Segment into one or more Elements.

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 Part A: Project Setup and Processing

– The number of Elements is (roughly) controlled by the Target Number of Elements number,
and can be verified on the Info tab.

• Flexibility and breakage both happen at the Joints that connect the Elements to each other.

For this tutorial, we want the number of Elements equal to the number of Segments making up the
Fiber (4), so we will set the Target to a value less than or equal to this number.

1. From the Data Editors panel, select the Composition sub-tab, and then from the Composition
list, select Multiple Elements.

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Tutorial - Lawn Mower

2. We can then verify the number of Elements Rocky will calculate on the Info tab. From the Info
sub-tab, view the Elements value (as shown).

For Multi-Element particles, Rocky provides five model options for joint breakage:

• Shear Stress Criterion

• Griffith Surface Energy

• Tensile Stress Criterion

• Tensile or Shear Stress Criterion

• von Mises Stress Criterion

Tip:

Further information on these models can be found in the Rocky DEM Technical
Manual.

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 Part A: Project Setup and Processing

3. From the Data Editors panel, select the Breakage sub-tab, and then define the Model and Shear
Stress Limit (as shown).

22.1.8. INPUT DEFINITION

For this tutorial, we'll create a Particle Custom Inlet to exactly position the grass Fibers in a lawn-
like pattern.

• By previously defining the bottom Segment of our grass Fiber as frozen, we will ensure that the
particles we position will stay stuck to the ground and upright, as if rooted.

• If we had not taken this step, the grass Fibers would fall over soon after placement due to gravity
and/or contacts with the mower.

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Tutorial - Lawn Mower

1. To define the custom input, use the following information:

Step Data Entity Editors Parameter or Action Settings

Location
A Inlets and Outlets Create Particle Custom Inlet
B Inputs Custom Input Particle Grass Particle
Load File grass_position.csv
Particle
Custom Inlet Motion Frame Translation
<01>

Because we are using multi-element Frozen Fibers, we can choose to attach them to a Motion
Frame. Doing this enables the "frozen" part of the particles to move along with the assigned motions.

For this tutorial, we will assign the Translation Motion Frame, which will move the grass along with
the ground towards the mower blades.

Important:

When you attach a Motion Frame to a Particle Custom Inlet, the release property in the
.csv file must be set to zero for all particles or omitted all together.

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 Part A: Project Setup and Processing

Under File Info, we can verify summarized info of the Properties that were defined inside the .csv
we imported (as shown).

Note:

The ux property set in the .csv file, which defines the initial velocity in the X-direction, was
defined with the same velocity as our translation motion frame.

Doing this ensures all the Fiber's Segments start the simulation with the same velocity;
otherwise, only the Frozen Segments would have the motion frame's velocity at 0s.

22.1.9. SOLVER DEFINITION

1. Use the information in the table that follows to define solver parameters and finish setting up
your project.

Step Data Entity Editors Location Parameter or Action Settings

A Solver Solver | Time Simulation Duration 3 [s]
Output Settings | Time 0.005 [s]
Interval
Breakage | Start 0 [s]

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Tutorial - Lawn Mower

Step Data Entity Editors Location Parameter or Action Settings

Breakage | Delay After 0 [s]
Release
Solver | General Simulation Target CPU

22.1.10. SETUP CONFIRMATION

With a 3D View window opened, your Data panel and Workspace should look similar to the below
image.

22.1.11. SIMULATE PROJECT

1. From the Solver entity, click Start.

The Simulation Summary screen appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

Tip:

You can use the Auto Refresh checkbox to view in a 3D View window the results during
processing.

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Tutorial - Lawn Mower

22.1.12. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a Lawn Mower
simulation.

During this tutorial, it was possible to:

• Understand how a Custom Fiber particle shape is composed.

• Import a Custom Fiber particle shape that was defined with Frozen Segments.

• Export a particle shape to an .stl file.

• Set an appropriate Joint Breakage model for the Custom Fiber.

• Assign a Motion Frame to a Particle Custom Inlet.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

22.2. Part B: Post-Processing

22.2.1. OBJECTIVES
The purpose of this tutorial is to use the results from the simulation we set up and processed in Part
A to analyze the performance of the Lawn Mower.

You will learn how to:

• Use Particle Mass to view how a Fiber breaks

• Calculate the Mower Blades' Power and Torque

• Identify which Mower Blade regions are most susceptible to wear

And you will use these features:

• Geometries Properties and Curves

• Time Plots

• Output Variables

22.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

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 Part B: Post-Processing

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

22.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that project is open in Rocky. (Part B will continue
from where Part A left off.)

2. If you did not complete the project from Part A, do all of the following:

a. Download the dem_tut22_files.zip file .

b. Unzip dem_tut22_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade to the latest version,
or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut22_files folder,
then from the tutorial_22_A_pre-processing folder, open the tutorial_22_A_pre-pro-
cessing.rocky file.

e. Process the simulation. (From the Solver entity, click the Start button.)

22.2.4. VIEW INDIVIDUAL ELEMENTS

1. Use the information in the table below to see the effects of the blade geometry colliding with
the grass Fibers.

Reminder: If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials (via the Introductory Tutorials and
Advanced Tutorials) to find the detailed instructions you need.

Step Item Location Parameter or Settings

Action
A Window (menu) Create a New 3D View
B Particles Coloring Nodes (Enabled)
Property Particle
Mass

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Tutorial - Lawn Mower

Initially, at 0 s into the simulation, each grass Fiber is whole (unbroken).

By moving the slider on the Time toolbar, you can observe how the mower blades cut the grass
particles into fragments.

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 Part B: Post-Processing

Note:

For the Fibers that broke, only the frozen Segment of the Fiber remains upright.

22.2.5. TORQUE AND POWER

In this tutorial we will estimate the Mower Blades torque according to:
(22.1)

Where:

• is the torque (Nm)

• is the Power (W)

• is the angular frequency (Hz)

22.2.6. TORQUE AND POWER

1. Use the information in the table below to create a Custom Curve for Torque.

Step Item Location Parameter or Action Settings

A Geometries Curves Add new custom curve (button)

blades
B Add new (dialog box) Name Torque
Output Unit N.m
Inputs | Power (Enabled)
Inputs | Velocity : Rotational (Enabled)
:Y

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Tutorial - Lawn Mower

Step Item Location Parameter or Action Settings

C Custom Curves (dialog box) Expression A/(2*3.1416*B)

Note:

For Step C, ensure the expression you enter represents:

For this tutorial, we will assume that selecting the right size engine for our Lawn Mower requires us
to know the following values:

• Minimum Torque

• Average Torque

• Maximum Power

• Average Power

We could create four separate Time plots and locate this information on each plot. However, this
becomes more difficult when comparing values across multiple simulations.

An easier method is to use Output Variables, which distills a set of Property or Curve data into a
single value in one easy-to-find location.

Let's use Output Variables to create the four single values we need for this analysis.

To create the Output Variables, do the following:

1. From the Tools menu, ensure that Expressions/Variables is enabled.

2. From the Data Editors panel, drag-and-drop the newly created Torque (Custom) Curve onto the
Output tab. Repeat for the Power Curve.

3. From the Output tab, select the newly added Power entry, and then click the Edit button.

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 Part B: Post-Processing

4. From the Edit Properties dialog, enter the Name, and then click OK.

5. Repeat for the Torque_Custom_ entry, entering the Name and defining the Operation on Curve.

Note:

As the blade spins counter-clockwise, the minimum Torque value will be the maximum
absolute value.

Now we want the Average values.

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Tutorial - Lawn Mower

6. From the Data Editors panel, drag-and-drop the Torque (Custom) Curve and the Power Curve
onto the Output tab again.

7. Select the newly added Power entry, and then click the Edit button.

8. From the Edit Properties dialog, enter the Name, define the Operation on Curve (as shown),
and then click OK.

9. Repeat for the Torque_Custom_ entry, entering the Name and defining the Operation on Curve.

10. Press Ctrl+T to open a Time Plot.

11. From the Data Editors panel, drag-and-drop the newly created Torque (Custom) curve and the
Power onto the Time Plot.

Now we have exactly the right Torque and Power values we need to choose an appropriate engine
for our Lawn Mower.

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 Part B: Post-Processing

22.2.7. INTENSITY AND WEAR

In Rocky, you are able to compute the wear effects using surface wear modification.

The wear law used in that feature takes into account the shear work on the geometry surface to
compute how it will wear down over time.

However, for the case we are studying in this tutorial, the surface modification of the mower blades
would not be noticeable due to the short simulation time.

Instead, we can compute the total work done by the shear forces on each triangle surface and then
verify which regions of the blades have the highest shear work.

You might recall that in Part A, we enabled the collection of Intensities data for Boundary Collision
Statistics. We can use that data to perform the shear work analysis.

22.2.8. INTENSITY AND WEAR

A good approximation of it would be:

(22.2)

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Tutorial - Lawn Mower

Where:

• (J) is the work

• (W/m2) is the Intensity : Shear, both of which act on the triangle,

• (m2) is the Area : Cell, which is the area of the triangle is the time (s)

• (s) is the time between 2 outputs, which is dictated by the Time Interval

1. Use the data in the following tables to add a new custom property that calculates the shear work
in the blades:

Step Item Location Parameter or Action Settings

A Geometries Properties Add new custom property (button)

blades
B Add New (dialog box) Name Instantaneous Shear
Work
Output Unit J
Inputs | Area : Cell (Enabled)
Inputs | Intensity : Shear (Enabled)
C Custom Property (dialog box) Expression A*B*OUTPUT_FREQUENCY
D Geometries Properties Add and edit time statistics properties (button)

blades
E Edit time statistics properties Add time statistics properties (button)
(dialog box)
F Add time statistics properties Start time 1 [s]
(dialog box) Stop time 3 [s]
Operations | Sum (Enabled)
Properties | Instantaneous (Enabled)
Shear Work (Custom)

2. From the Properties tab, right-click the newly created Sum of Instantaneous Shear Work (Cus-
tom) property, point to 3D View, and then select Show in new 3D View.

3. From the Data panel, under Geometries, hide all but the blades component. Hide also the main
Particles entity.

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 Part B: Post-Processing

22.2.9. CONCLUSION
This completes Part B of this tutorial.

Rocky was used to post-process a simulation of a Lawn Mower cutting grass.

During this tutorial, it was possible to:

• Use Particle Mass to view how a Fiber breaks.

• Compute the mower blades' Torque by creating Custom Curves.

• Use Output Variables to distill the mower blades' Torque and Power Curves into single, easy-to-
locate values.

• Compute total shear work done by the grass particles to the blades by creating Custom Properties
and Time Statistics Properties.

What's Next? If you completed this tutorial successfully, then you are ready to move on to next tu-
torial.

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Chapter 23: Tutorial - Solver SDK
(Part A) Learn how to install and configure the working environment for the Rocky Solver SDK (Software
Development Kit).

(Part B) Learn how to use the Rocky Solver SDK and working environment we set up in Part A to build
a simple custom module.

23.1. Part A: Working Environment Setup

23.1.1. OBJECTIVE
The purpose of this tutorial is to learn how to install and configure the working environment for the
Rocky Solver SDK.

• The Rocky Solver SDK includes the runtime libraries, simulation information, and compilation
mechanisms you need to create your own custom modules

• Custom modules are separate pieces of code, built using the Solver SDK, that attach to the solver
code in Rocky and expand its capabilities

• For example, you can create custom modules that apply unique models, laws, and other special
functionality to your Rocky simulations

In Part A of this tutorial, you will learn how to:

• Download and install the Rocky Solver SDK package

• Obtain the tools and settings necessary for working with the Solver SDK files

• Make other recommended settings for best usage

Later in Part B you will learn how to use the Solver SDK to make your own example module.

23.1.2. PREREQUISITES
Before you begin this ADVANCED tutorial, ensure that you have satisfied the following prerequisites:

• You are familiar with the Rocky 2025 R1 user interface (UI), have a good understanding of the
common setup and post-processing tasks, and grasp firmly the concept of Modules.

– If you do not already have this level of familiarity, it is recommended that you complete at least
Tutorials 01- 05 before beginning this one.

• You have working knowledge of both the Python and C++ programming languages.

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Tutorial - Solver SDK

• The system upon which you intend to use the Rocky Solver SDK has at least one of the following
supported operating systems installed:

– 64-bit Windows 10 or 11

– 64-bit Linux (Rocky 8.10 or 9.4, Red Hat 8.10 or 9.4, SLES 15 and Ubuntu 20.04 or 22.04)

23.1.3. INSTALLATION COMPONENTS

The first step to building your own custom modules is to install the necessary files and set up the
required components, which are defined below:

1. Rocky Solver SDK Files: A package of libraries that translates the module code including what
values are entered into the module UI by the Rocky end user to the solver. This simplifies the
custom code development and compilation.

Important:

The Rocky Solver SDK you use must have the same release version as the Rocky program
you intend the modules to be run upon. This means that if you intend to create modules
for Rocky 2025 R1, for example, you must install the 2025 R1 Rocky Solver SDK.

2. Solver SDK Files Environment Variable: Points to the folder location of the unzipped Solver SDK
files.

3. CUDA Toolkit: Provides the development environment necessary for GPU processing compatibility.

Note:

This toolkit is required whether or not you plan on using GPUs for processing simulations
that will make use of the custom modules.

4. CUDA Files Environment Variable: Points to the folder location of the installed CUDA Toolkit
files. For Windows, this variable is created automatically; for Linux, we will create it manually.

5. Build Tools: The tools required for compiling the C++ scripts. For Windows, Visual Studio build
tools will be used; for Linux, we will use Miniconda 3 (or Miniforge 3) to install some packages.

In addition to the required steps, the following steps are also recommended:

6. (OPTIONAL) Creating a separate folder for working on your custom modules.

7. (OPTIONAL) Setting an environment variable to point to the folder location of your compiled
module.

Instructions for all setup items will be detailed in this tutorial, separated by the type of operating
system you are using:

• For Windows instructions, proceed to the next section.

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 Part A: Working Environment Setup

• For Linux instructions, skip ahead to Working Environment Setup for Linux 64-bit (p. 964).

23.1.4. Working Environment Setup for Windows 10/11 64-bit

23.1.4.1. SOLVER SDK FILES SETUP (WINDOWS)

STEP 1: Download and unzip the SDK and Modules package for the operating system and Rocky
version for which you want to create custom modules.

Tip:

The SDK and Modules package contains the 2025 R1 Solver SDK and modules, and
is available in Ansys Customer Portal.

1. Download the SDK and Modules package for Windows.

Reminder: The Solver SDK version you install allows you to make modules only for the same
version of the Rocky product. This means that modules made from the 2025 R1 Solver SDK, for
example, will work only in Rocky 2025 R1.

2. Extract the files, and copy (or cut) and paste the sdk folder into a folder of your choice. (For
example, within your %HOMEPATH%/Documents/Rocky/Modules folder.)

23.1.4.2. SDK VARIABLE CREATION (WINDOWS)

STEP 2: Create an environment variable called RockySDK_DIR

1. From the Windows Search bar, type Edit the system environment variables, and then open
the Control Panel result that appears.

2. From the System Properties dialog, on the Advanced tab, click the Environment Variables...
button.

3. From the Environment Variables dialog, from the System variables box, click the New...
button.

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Tutorial - Solver SDK

4. From the New System Variable dialog, define the Variable name as RockySDK_DIR and the
Variable value with the folder path of the SDK subdirectory (as shown), and then click OK.

Note:

The folder path should be the folder were the SDK files were extracted in Step 1.

The environment variable will now be listed in the System variables section.

23.1.4.3. CUDA TOOLKIT SETUP (WINDOWS)

STEP 3: Install and configure the CUDA Toolkit 11.7.

Important:

The 2025 R1 (and later) versions of the Rocky Solver SDK are compatible only with ver-
sion 11.7 of the CUDA toolkit.

1. Open the CUDA Toolkit 11.7 Archive page from the NVIDIA official website and download the
installer for your operational system.

2. Open the downloaded *.exe, and then extract the installation files as instructed.

3. Follow the NVIDIA Installer using the Custom (Advanced) options.

4. On the Custom installation options step, under the CUDA component, ensure that the Runtime,
Development and Visual Studio Integration checkboxes are selected.

5. Follow the installer instructions to complete the installation.

23.1.4.4. ENSURE CUDA VARIABLE CREATION (WINDOWS)

STEP 4: Ensure that an environment variable called CUDA_PATH_V11_7 was created.

1. Confirm the location of the installed CUDA Toolkit on your system.

Tip:

This is typically C:/Program Files/NVIDIA GPU Computing Toolkit/CUDA/v11.7

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 Part A: Working Environment Setup

2. Follow the instructions on SDK VARIABLE CREATION (WINDOWS) (p. 961) to ensure that a
CUDA_PATH_V11_7 environment variable was automatically created and correctly defines the
path to the installed CUDA Toolkit.

23.1.4.5. BUILD TOOLS SETUP (WINDOWS)

STEP 5: Download and install Visual Studio Build Tools.

1. Go to Microsoft | Visual Studio official website and download Build Tools for Visual Studio
2022 LTSC 17.6.17.

a. From the Microsoft official website, access the Visual Studio 2022 page.

b. On the page that opens, roll down until you find Visual Studio downloads list, and access
the Tools for Visual Studio drop-down list and click the long term servicing baselines
(LTSCs) link.

c. From the page that opens, access the Release History for version 17.6.

d. From the Fixed version bootstrappers list, find the 17.6.17 Version (click Ctrl + F and
search for 17.6.17) and click the link to download the .exe installer for the Build Tools.

2. Open the downloaded .exe.

3. From the Installing screen:

• Select Desktop development with C++ (under Desktop & Mobile on the Workloads tab)

• Ensure that build tools, Windows SDK and C++ CMake tools for Windows (under Optional
on the Installation details panel) .

4. Click Install and finish installation accordingly.

5. Go to the C:\Program Files\NVIDIA GPU Computing Toolkit\CUDA\v11.7\extras\visual_stu-

dio_integration\MSBuildExtensions folder and copy its files.

6. Go to the C:\Program Files (x86)\Microsoft Visual Studio\2022\BuildTools\MSBuild\Mi-

crosoft\VC\v170\BuildCustomizations folder and paste the files you just copied.

23.1.4.6. WORKING FOLDER SETUP (WINDOWS)

STEP 6: (OPTIONAL) Create a Working Folder for your custom modules.

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Tutorial - Solver SDK

1. Create a new folder where you will work on your custom modules. (For example,
%HOMEPATH%/Documents/Rocky/Compiled_Modules)

Note:

Your custom module will be compiled in your working folder.

However, to display the module within the Rocky UI, the compiled files must reside in
the %HOMEPATH%/Documents/Rocky/Modules folder.

To have Rocky to recognize your module after it is compiled, you can do either of the
following:

• Copy and paste the compiled files out of your working folder and into the
%HOMEPATH%/Documents/Rocky/Modules folder each time you make an update.

• Create an environment variable called ROCKY_PLUGINS_PATH that defines the path

to the compiled files. (PLUGIN VARIABLE SETUP (WINDOWS) (p. 964))

23.1.4.7. PLUGIN VARIABLE SETUP (WINDOWS)

STEP 7: (OPTIONAL) Create an environment variable called ROCKY_PLUGINS_PATH

1. Follow the instructions on SDK VARIABLE CREATION (WINDOWS) (p. 961) to create a new
ROCKY_PLUGINS_PATH environment variable that points to the folder location where the
compiled module files will be created. (For this tutorial, it is the %HOMEPATH%/Docu-
ments/Rocky/Compiled_Modules folder.)

Note:

Later in Part B, we will take steps to ensure that the compiled files are created in this
location.

23.1.5. Working Environment Setup for Linux 64-bit

23.1.5.1. SDK FILES SETUP (LINUX)

STEP 1: Download and unzip the SDK and Modules Package for the operating system and Rocky
version for which you want to create custom modules.

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 Part A: Working Environment Setup

1. Download the package for Linux.

Reminder: The Solver SDK version you install allows you to make modules only for the same
version of the Rocky product. This means that modules made from the 2025 R1 Solver SDK, for
example, will work only in Rocky 2025 R1.

2. Extract the files into a folder of your choice (for example, within your ~/.Rocky/Modules folder).

23.1.5.2. SDK VARIABLE CREATION (LINUX)

STEP 2: Create an environment variable called RockySDK_DIR in the bashrc file.

1. From the terminal, enter sudo vi /.bashrc

2. From the vi editor that opens, press the a key to edit and define the environment variable (as
shown).

3. Press the esc key and then type :wq to save and exit (as shown).

4. To refresh your environment variables, enter source /.bashrc

5. Enter env to print the environment variables. The variable you just defined will be listed (as
shown).

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23.1.5.3. CUDA TOOLKIT SETUP (LINUX)

STEP 3: Install and configure the CUDA Toolkit 11.7.

Important:

The 2025 R1 (and later) versions of the Rocky Solver SDK are compatible only with ver-
sion 11.7 of the CUDA toolkit.

1. Open the CUDA Toolkit 11.7 Archive page from the NVIDIA official website and download the
installer for your operational system.

2. Run the following commands:

$ bash {INSTALLERFILENAME} --silent --nox11 --override --no-man-page --toolkit
--toolkitpath={INSTALLATIONPATH}cuda/v11.7
$ echo "export CUDA_PATH_V11_7={INSTALLATIONPATH}cuda/v11.7" >> $HOME/.bashrc
$ source $HOME/.bashrc

where {INSTALLERFILENAME} is the name of the downloaded file and {INSTALLATIONPATH}

is the desired installation path.

23.1.5.4. BUILD TOOLS SETUP (LINUX)

STEP 5: Download and install Miniconda 3 or Miniforge 3 and enable the required make, cmake,
and gxx_linux-64 packages.

1. Download Miniconda 3 or Miniforge 3.

2. Navigate to the folder where you downloaded the installer, open a terminal and execute it as
in the example below, and continue the installation.

bash -Miniforge3-Linux-x86_64.sh

3. Activate the environment, as in the example below.

source ~/miniforge3/bin/activate

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4. Install the three required packages by entering the following commands:

conda install -c anaconda make

conda install -c anaconda cmake

conda install -c anaconda "gxx_linux-64>=11,<12".

The conda prompt now contains a minimum set of tools required to build Rocky modules.

23.1.5.5. WORKING FOLDER SETUP (LINUX)

STEP 6: (OPTIONAL) Create a Working Folder for your custom modules.

1. Create a new folder where you will work on your custom modules. (For example,
~/.Rocky/Compiled_Modules)

Note:

Your custom module will be compiled in your working folder.

However, to display the module within the Rocky UI, the compiled files must reside in
the ~/.Rocky/Modules folder.

To have Rocky to recognize your module after it is compiled, you can do either of the
following:

• Copy and paste the compiled files out of your working folder and into the
~/.Rocky/Modules folder each time you make an update.

• Create an environment variable called ROCKY_PLUGINS_PATH that defines the path

to the compiled files. (Shown below)

23.1.5.6. PLUGIN VARIABLE SETUP (LINUX)

STEP 7: (OPTIONAL) Create an environment variable called ROCKY_PLUGINS_PATH

1. Follow the instructions on SDK VARIABLE CREATION (LINUX) (p. 965) to create a new
ROCKY_PLUGINS_PATH environment variable in the bashrc file that points to the folder location
where the compiled module files will be created. (For this tutorial, it is the /user/.Rocky/Com-
piled_Modules folder.)

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Tutorial - Solver SDK

Note:

Later in Part B, we will take steps to ensure that the compiled file are created in this
location.

23.1.6. HELP - SOLVER SDK MANUAL

This completes Part A of this tutorial.

For further information about setting up your working environment for the Rocky Solver SDK, we
suggest searching the Rocky Solver SDK Manual.

To access it, from Rocky Help menu, point to Manuals, and then click Solver SDK Manual.

23.1.7. CONCLUSION
During this tutorial, it was possible to:

• Download and install the Rocky Solver SDK, CUDA Toolkit, and build tools for both Windows and
Linux machines.

• Define required and optional environment variables to make compiling the custom modules easier.

What's Next?

• Now that you have successfully set up your working environment, you are ready to move on to
Part B and learn how to use the Solver SDK to create an example module.

23.2. Part B: Building a Custom Module

23.2.1. OBJECTIVE
The main purpose of this tutorial is to learn how to use the Rocky Solver SDK and working environment
we set up in Part A to build a simple custom module.

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 Part B: Building a Custom Module

The module we will create enables end users to define a region of spherical shape inside the simulation
domain and then mark all particles located inside this region with a custom property.

In Part B of this tutorial, you will:

• Review files that define the module, which includes:

– Understanding each file's purpose and role in the module's function

– Learning how and when to make use of the Rocky Solver SDK

– Seeing how custom code communicates with the Rocky solver

• Compile the module (separate Windows and Linux instructions provided)

• Test the module in the Rocky User Interface (UI)

23.2.2. PREREQUISITES
Before you begin this ADVANCED tutorial, ensure that you have satisfied the following prerequisites:

• You are familiar with the Rocky 2025 R1 user interface (UI), have a good understanding of the
common setup and post-processing tasks, and grasp firmly the concept of Modules.

– If you do not already have this level of familiarity, it is recommended that you complete at least
Tutorials 01- 05 before beginning this one.

• You have correctly configured your working environment to build custom modules through the
Rocky Solver SDK. If this is not the case, please refer to either of the following resources:

– Part A of this tutorial

– The 1.1 Prerequisites section of the Rocky Solver SDK Manual

• You have working knowledge of both the Python and C++ programming languages.

23.2.3. ROCKY SOLVER SDK OVERVIEW

Based upon on the core processes of a standard DEM simulation, you can add or modify Rocky be-
havior through the different Solver SDK models included in the Rocky Solver SDK.

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23.2.4. EXAMPLE MODULE OVERVIEW

We will make use of the Custom Scalars API for our example module, called Spherical Region.

The main purpose of the Spherical Region module is to:

• [Setup]: Allow users to define a region of spherical shape inside the simulation domain. They will
accomplish this by defining the X Y Z coordinate values of the sphere's center point, as well as the
sphere's radius.

• [Processing]: For each individual timestep, instruct Rocky to mark any particles that come within
that spherical region.

• [Post-Processing]: Enable users to isolate those marked particles at any given timestep using a
new particle variable called Inside Sphere Flag, which will have a value of 1.0 when the particle
is inside the region, and 0.0 otherwise.

We will use this example as a framework for understanding how to make best use of the Rocky
Solver SDK.

The first step is to understand the files required for defining a custom module.

23.2.5. Get and Review Files that Define the Module

23.2.5.1. FILES OVERVIEW

A custom module is composed of five files, each one having a specific objective as explained below:

• Info file (.plugin): Exposes the name and other relevant information about the custom module
to the Rocky UI.

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 Part B: Building a Custom Module

• Python file (.py): Responsible for linking the custom module to the Rocky user interface (UI) and
also for making Rocky aware of the Dynamic Link Library (DLL).

• CUDA file (.cu): The core of the module. All the calculations and loop instructions are located
here. It is coded in C++.

• CMake file (.txt): Contains all instructions necessary for compiling the custom module. Basically,
the compilation process consists of pointing the CUDA file (.cu) to the compiler. A DLL (for Win-
dows) or a .so (for Linux) will be generated as a result of this process.

• PDF file (.pdf): This is an optional Help file for the modules. If you choose to include it, this file
will be accessible via the module's interface in the Rocky UI.

23.2.5.2. STEP 1: GET FILES

To start building your Spherical Region module, you need to create a special folder to use as your
preferred working directory.

Reminder: In Part A, we created a working folder for this purpose called Compiled_Modules.

Tip:

The SDK and Modules package contains the 2025 R1 SDK and modules, and is
available in Ansys Customer Portal.

1. From the package files you downloaded, go to the Source Codes folder, and then to the Simple
Modules one.

2. Extract the contents from the spherical_region-1.0.0-sdk... folder.

3. Then within your working directory, paste the spherical_region folder. Your folder structure
should now look similar to the screenshot below.
spherical_region/
CMakeLists.txt
spherical_region.cu
spherical_region.pdf
spherical_region.plugin
spherical_region.py

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Tutorial - Solver SDK

23.2.5.3. STEP 2: REVIEW INFO FILE

Your module's Info file (spherical_region.plugin) enables you to define the following kinds of in-
formation:

• Name: Specifies the name of the module as you want it to appear in the Rocky UI.

• Module: Lists the name of the module's compiled library file.

Note:

We will cover how to generate this artifact later in the tutorial.

The items under [Documentation] will be displayed in the UI on the Info tab for the module:

• Author and Website: Specifies the company information you want associated with the module.

• Version and Description: Provides further identifying information for the module.

Note:

If you want to make a multiline Description you must indent the lines after the first
one (as shown).

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23.2.5.4. STEP 3: REVIEW PYTHON FILE

Your module's Python file (spherical_region.py) specifies which are the module parameters that
must be displayed in the Rocky UI.

From this file, Rocky extracts the following two primary instructions:

• The initial value and location of custom user input parameters.

• Whether or not the module should override any of Rocky's built-in models.

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 Part B: Building a Custom Module

All the information within this file is organized through various methods and classes that offer dif-
ferent functionality depending upon the module's purpose.

Tip:

All available methods and classes are described in the Rocky Solver SDK Manual.

Key parts of this file are explained below.

• [Lines 2-6] Import the Solver SDK utilities necessary for specifying the module data.

• [Line 9] Defines the name of the module that Rocky must show in the UI.

• [Lines 12-22] Define the auxiliary class SphericalRegionModel, which includes the definition of
the module parameters. The Rocky Solver SDK provides a special class called Quantity for this
purpose, which includes the capability of associating units to each variable.

• [Line 26] Defines the SphericalRegionSpecs class, which itself defines the specifications of the
module. This function is used to tell the Rocky UI which components are affected and/or replaced
by the module, such as contact models or material interaction properties.

• [Line 31] The module's name (name).

• [Line 34] The components affected (model), which in this case includes only the specification
of the parameters previously included in the SphericalRegionModel class.

• [Lines 38-39] The module's path (CreateAddin method), which handles the loading of the
compiled library file for the module when the simulation starts.

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• [Line 43] Includes the SphericalRegionModule class, which defines the module as a new Rocky
plugin and hooks the module specifications to Rocky.

• [Lines 44-45] Implement only one method in this class, get_addin_specs, which makes available
all the specifications made previously in the file.

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 Part B: Building a Custom Module

23.2.5.5. STEP 4: REVIEW CUDA FILE

Your module's CUDA file (spherical_region.cu) includes all the C++ code that implements the
module's intended functionality during the simulation.

The functions defined in this file must be connected or hooked into the solver at strategic points
during simulation processing (see also ROCKY SOLVER SDK OVERVIEW (p. 969)) by using one or more
of the following types of hooks:

• Start/Termination Hooks: These are called only once during the simulation: either when the
simulation initializes or when it terminates.

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Tutorial - Solver SDK

• Iteration Hooks: These are called once per iteration during the simulation loop (a loop is where
motions and models are solved, and the state of particles is updated as a result, for a new time
level. The iteration of many loops makes a full simulation).

Important:

All iteration hooks of this type requires to include a function call to finalize the
hook: {function name}_END()

Tip:

The full list of hooks is provided in Chapter 3 of the Solver SDK Manual.

Key parts of this file are explained below.

• [Line 7] ROCKY_CUDA_API: Enables the execution of the module in single or multi-GPU config-
urations.

• [Lines 11-16] struct ModuleData: Creates a structure to save the user parameters defining the
spherical region.

• [Line 19] ROCKY_PLUGIN(): Initializes the plugin, defining the name and version. This is a man-
datory definition.

• [Lines 23-37] ROCKY_PLUGIN_CONFIGURE(): Hook used to acquire the inputs for the module
that will appear in the Rocky UI, the definition of which includes:

• [Line 26] An instance of the custom struct ModuleData is allocated and the corresponding
pointer is named module_data.

• [Lines 29-33] Recover the values of module variables entered through the Rocky UI, as defined
in the SphericalRegionModel class in the python file (STEP 3: REVIEW PYTHON FILE (p. 974)).
Those values are assigned to the corresponding variables in ModuleData.

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 Part B: Building a Custom Module

• [Line 36] This pointer is converted to a void pointer in order to assign it to the function argument
data, which Rocky will store and make available in the subsequent stages of the simulation.

• [Lines 39-47] ROCKY_PLUGIN_SETUP(): Hook used to allocate resources for the simulation,
which in this case defines only a particle scalar variable that will be used to mark particles inside
the spherical region. Specifically:

• [Line 43] In order to have access to the data stored previously, the void pointer must be converted
back into a ModuleData pointer.

• [Line 46] The object that handles operations with particle scalars is defined.

• [Line 47] The custom particle scalar is specified. The two arguments in the add function are the
label that must be associated to the particle scalar in the Rocky UI, and the unit.

• [Lines 51-61] ROCKY_PLUGIN_NON_DIMENSIONALIZE(): Hook used to nondimensionalize all

the custom parameters previously defined, in order to use them in operations involving data
coming from the Rocky solver, which are dimensionless.

– In this example module, all parameters are lengths, which means they are nondimensionalized
using the length factor provided by the corresponding method of the model argument.

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• [Lines 64-72] ROCKY_PLUGIN_INITIALIZE_CUDA(): Hook used to copy module data to the GPU.
This kind of operation is mandatory when a module is intended for execution in single or multi-
GPU configurations.

• [Lines 76-98] ROCKY_PLUGIN _POST_MOVE_PARTICLES(): Hook executed inside a loop (time

iterative) over the active particles in the simulation, after the position and velocities of the particles
were updated in Rocky.

• [Lines 88-91] The distance between the centroid of the current particle and the center of the
spherical region is calculated.

• [Lines 94-97] Sets the variable Inside Sphere Flag to 0.0 or 1.0 depending upon whether the
distance is higher or lower than the radius of the sphere region.

• [Line 100] ROCKY_PLUGIN_POST_MOVE_PARTICLES_END(): Mandatory function to be defined

after ROCKY_PLUGIN_POST_MOVE_PARTICLES(). Similar close-out functions are required for
any hooks executed during the time iterative loop.

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 Part B: Building a Custom Module

• [Lines 103-107] ROCKY_PLUGIN_TEAR_DOWN(): Performs any end-of-simulation actions required,

such as to de-allocate memory or output any final/cumulative values.

• [Lines 110-114] ROCKY_PLUGIN_TEAR_DOWN_CUDA(): In this hook the module must free the
memory allocated for custom data in the GPU devices during the execution of ROCKY_PLU-
GIN_INITIALIZE_CUDA().

• [Line 117] ROCKY_PLUGIN_END: Mandatory for finalizing the module's declaration.

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23.2.5.6. STEP 5: REVIEW PDF FILE

Your module's (optional) PDF file (.pdf) enables you to provide usage instructions and/or technical
references for the module's end users.

Note:

The placeholder .pdf file (spherical_region.pdf) is provided for tutorial illustration pur-
poses only.

If added, the PDF will be automatically linked to the module in the Rocky UI and can be opened
by clicking a question mark icon (as shown).

After you create the PDF, it is required that you save the file with the same name as the module's
folder, and place it in the same folder as the .plugin and .py files.

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 Part B: Building a Custom Module

23.2.5.7. STEP 6: REVIEW CMAKE FILE

The purpose of your module's CMake file (CMakeLists.txt) is to manage the module's build process.

It includes all the instructions regarding the location of the Rocky Solver SDK and CUDA files.

Key parts of this file are explained below.

23.2.5.8. STEP 6: REVIEW CMAKE FILE

• [Line 4] Package name of module is defined. This variable needs to be updated according to the
module's name.

Important:

It is assumed that all files (.py, .plugin, .cu, .pdf ) have been named the same as the
module.

• [Line 10] The default installation folder is defined by the ROCKY_PLUGINS_PATH environment
variable that we created earlier in Part A.

– Because this environment variable points directly to the working directory, and we've set the
module's files to be compiled there, the Rocky UI will automatically know about this new
module whenever it is compiled.

– If you want the module to be installed in another folder, for any other reason, uncomment
this line and set a location manually.

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23.2.6. ENABLE AUTO-COMPLETE FOR MODULES DEVELOPMENT (WINDOWS

- OPTIONAL)
When developing a module with Solver SDK functions, you can enable auto-complete in Visual Studio
Code for editing your CUDA files. This feature will help you quickly access function suggestions,
making module development faster and more efficient.

1. Ensure you have Visual Studio Code installed, open it and open your module folder (in this example,
the spherial_region).

2. Click Ctrl + Shift + P and select C/C++: Edit Configurations (JSON). It will create a .vscode folder
and a c_cpp_properties.json file inside your working directory.

3. From this new .json file, include the path to Rocky SDK ("${env:RockySDK_DIR}/include",)
inside IncludePath option, as shown.

4. If there is a configurationProvider option, delete the line and save the file.

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 Part B: Building a Custom Module

5. Click Ctrl+Shift+P and select Reload Window.

The auto-complete is configured.

23.2.7. COMPILATION OVERVIEW

Now we are going to compile our custom module, which involves all of the following steps:

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1. Execute the build commands: For Windows, this will be done using a special Visual Studio
command prompt or in Visual Studio Code; in Linux, this will be done using the terminal.

2. Verify the compiled files: During compilation, Rocky will within the working directory, automat-
ically make a folder named with the Rocky version and then within that new folder, place the
resulting module.

Separate build instructions will be provided for each operating system.

23.2.8. STEP 1: EXECUTE BUILD COMMANDS (WINDOWS)

1. From the Windows Search bar, type x64 Native Tools Command Prompt for VS, and then open
the App result that appears.

2. From the x64 Native Tools Command Prompt for VS window, navigate to your working directory
(as shown).

3. Within the command prompt, execute separately the following three commands:
cmake -DCMAKE_GENERATOR_PLATFORM=x64 spherical_region
cmake --build . --config Release
cmake -P cmake_install.cmake

Tip:

You can configure the Visual Studio Code to build modules (no need to type the
three commands every time).

To set the environment to compile your modules through Visual Studio Code, follow the procedure
below:

1. Ensure you have Visual Studio Code installed and open it.

2. From the Extensions panel, search for the CMake Tools extension and install it.

3. Access the Extension Settings and enable the Status bar visibility (make visible).

4. Open your working directory (from File | Open Folder... open the module folder, for example
spherical_region).

The CMake Tools status bar will show up in the bottom of the screen with the options you need
to set up, as described below.

5. For the active kit, select the amd64 version.

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 Part B: Building a Custom Module

6. For the build variant, select Release.

7. Change the default build target from ALL_BUILD to install.

8. Click Build.

Note:

For the opened directory, settings will be saved, but when opening a different one,
you must follow the steps 5-7 again before compiling the module.

23.2.9. STEP 1: EXECUTE BUILD COMMANDS (LINUX)

1. Using the terminal, navigate to your working directory.

Note:

This tutorial defines the working directory as ~/user/Documents/Rocky/Compiled_mod-

ules

2. Execute separately the following two commands:

cmake spherical_region
make install

23.2.10. STEP 2: VERIFY COMPILED FILES

1. Using the file structure below as a guide, navigate through your working folder to verify that the
compiled content of the spherical_region module is now available in the version folder that
matches the Solver SDK you have installed (For example, the 25.1.0 folder).

Note:

On Windows machines, compilation will generate two new files (*.dll and *.lib). On
Linux machines, only one new file will be generated (*.so).

Windows:
25.1.0/
spherical_region/
spherical_region.dll
spherical_region.lib
spherical_region.pdf
spherical_region.plugin
spherical_region.py

Linux:
25.1.0/
spherical_region/
spherical_region.pdf

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spherical_region.plugin
spherical_region.py
spherical_region.so

23.2.11. TEST THE MODULE

23.2.11.1. OPEN ROCKY

The easiest way to check if your module built correctly is to just open Rocky, and then start a new
project.

Tip:

If Rocky was open while you were compiling, you must close Rocky and open it again
to refresh the Modules folder.

When you select Modules from the Data panel, a checkbox for your new module should appear
in the Data Editors panel (as shown).

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 Part B: Building a Custom Module

After you select that checkbox and then expand the Modules entity on the Data panel, you can
select your new module, and then see the parameters you can set for it in the Data Editors panel
(as shown).

23.2.11.2. USE THE MODULE IN A PROJECT

To test setting the module's parameters, you can use the simulation example presented in Tutorial
- Transfer Chute (p. 23).

Tip:

If you have not yet completed this tutorial, you can download and extract the
dem_tut01_files.zip folder from .

Then from the tutorial_01_A_pre-processing folder, open tutorial_01_A_pre-pro-

cessing.rocky.

Enable the new Spherical Region module (as specified on OPEN ROCKY (p. 988)) and then define
the parameters (as shown).

Process the simulation as usual.

After the simulation completes, you will be able to visualize what particles are inside the defined
region by viewing the Inside Sphere Flag property on a 3D View window.

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All the particles that enter the spherical region specified by the Spherical Region module will be
assigned with Inside Sphere Flag equal to 1.

23.2.12. HELP - SOLVER SDK MANUAL

This completes Part B of this tutorial.

For further information about the Solver SDK structure and its usage, refer to the Rocky Solver SDK
Manual.

To access it, from Rocky Help menu, point to Manuals, and then click Solver SDK Manual.

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 Part B: Building a Custom Module

23.2.13. CONCLUSION
During this tutorial, it was possible to:

• Understand the files involved in building a custom module

• Learn how and when to make use of the Rocky Solver SDK

• See how custom code communicates with the Rocky solver

• Compile the module

• Test the module in the Rocky User Interface (UI)

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to next tutorial.

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Chapter 24: Tutorial - Dam Break
(Part A) Project Setup and Processing

(Part B) Post-Processing

Note:

This is an advanced tutorial.

24.1. Part A: Project Setup and Processing

24.1.1. OBJECTIVES
The main purpose of this tutorial is to introduce SPH entity parameters and to process a fluid-only
simulation in Rocky.

The scenario considered is a dam break.

You will learn how to:

• Configure fluid material

• Collect fluid collision data

• Create a fluid inlet

And you will use these features:

• SPH

• SPH Boundary Interaction Statistics

• Eulerian Solution

• Inlets and Outlets

24.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than
other Rocky tutorials.

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Tutorial - Dam Break

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky
user interface (UI), and already have a good understanding of the common setup
and post-processing tasks.

• If you do not already have this level of familiarity, it is recommended that you
complete at least Tutorials 01- 05 before beginning this one.

24.1.3. GEOMETRY INTRODUCTION

The wall geometries in this tutorial are composed of:

• (1) container

• (2) gate

• (3) column

In the tutorial directory each .stl file can be found.

24.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut24_files.zip file .

2. Unzip dem_tut24_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

5. Save the empty project to a location of your choosing.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar
with, please refer to the Rocky User Manual and/or other Tutorials to find the
detailed instructions you need.

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 Part A: Project Setup and Processing

24.1.5. INITIAL SETUP

1. Use the information in the table that follows to start setting up your Rocky project.

Step Data Entity Editors Parameter or Action Settings

Location
A Study 01 Study Study Name Dam Break
B Modules Modules SPH Boundary Interaction (Enabled)
Statistics
C Modules SPH Boundary Boundary Properties | (Enabled)
Interaction Nodal Forces
SPH
Boundary Curves | Force (Enabled)
Boundary
Interaction
Statistics
D Geometries Import Wall column.stl,
container.stl and
gate.stl with "m" for
Import Unit

Note:

By enabling the checkboxes from Step C, the module will collect force interaction data
for the boundaries.

• The Boundary Properties field enables values for each boundary triangle for each
timestep, that you can make operations with.

• The Boundary Curves field enables average values that correspond to the referred
boundary for each timestep.

Make the three imported walls transparent to make the visualization better.

24.1.6. MOTION FRAMES

For this tutorial, one Translation movement will be created for the gate in order to release the water
that will be filling the space limited by the container and gate.

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Tutorial - Dam Break

To create and assign the Motion Frame for the gate, follow the table below.

Step Data Entity Editors Parameter or Settings

Location Action
A Motion Frames Create Motion Frame
B Motion Frame Name Gate
Frames Opening
Add Motion
Frame
<01> Motions | Start 0.5 [s]
Time
… | Stop Time 0.9 [s]
… | Velocity 0, 1, 0 [m/s]
C Geometries Wall Motion Frame Gate
Opening
gate

To visualize the gate movement, preview it in a Motion Preview window (from Motion Frames, click
the Preview button).

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 Part A: Project Setup and Processing

24.1.7. FLUID DEFINITION

For the Materials step, default values for the boundaries (Default Boundary) will be used and we will
set the Fluid Material to represent Water.

1. From the Data panel, under Materials, select Default Fluid and define the Name in the Data
Editors panel.

24.1.8. SPH PARAMETERS

The SPH step allows you to define the SPH Solver, Kernel, Boundary Conditions and other fluid related
properties.

Note:

This tutorial case is set with the default SPH Solver WCSPH (Weakly Compressible SPH).
Depending on your application, it is also possible to use the IISPH (Implicit Incompress-
ible SPH) or DFSPH (Divergence-free SPH), that can lead to performance enhancement
in various scenarios.

For this tutorial, default options for the Fluid Dynamics, Wall Boundary Conditions, Positions
Correction and every Advanced fields will be used and we will set the Kernel | Element Size.

1. From the Data panel, select the SPH entity, and from the Data Editors, on the Model Parameters
tab, define the Sound Speed and Element Size.

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Tutorial - Dam Break

Tip:

Refer to the User Manual for more information about Sound Speed. For this tutorial,
we change the default value by a reasonable value in order to have consistent results
and reduce the simulation time.

2. With a 3D View opened, set your preference color for the fluid (SPH elements) from the Coloring
tab on Node color section.

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 Part A: Project Setup and Processing

24.1.9. INLET DEFINITION

The Inlets and Outlets step enables you to create two kinds of inlets for fluids:

• The Volumetric Inlet, that works for Fluid in the same way that it does for particles.

• The Fluid Inlet, that injects fluid at a constant rate through an associated Geometry at a defined
Time.

For this tutorial, we will create a Volumetric Inlet to fill part of the container with Water.

1. Follow the steps in the table below in order to create and define the inlet.

Step Data Entity Editors Location Parameter or Action Settings

A Inlets and Outlets Create Volumetric Inlet
B Inlets and Volumetric Inlet Name Water Fill
Outlets Volumetric Inlet | Mass 800 [kg]
SPH
Volumetric … | Region Seed Coordinates 0.2, 0.15, 0.305
Inlet [m]
<01> Box Bounds | Center 0.2, 0.15, 0.305
Coordinates [m]
… | Dimensions 0.4, 0.3, 0.61 [m]

In a 3D View it is possible to visualize the region to be filled when Water Fill Inlet is selected.

Note:

You can also set the dimensions and center of the region with the mouse by clicking and
dragging the slider handles attached to each face or to the center of the cubic region (for
this tutorial, please keep the values you just defined).

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Tutorial - Dam Break

24.1.10. DOMAIN SETTINGS

For the Domain Settings step, we will define a custom boundary box that exceeds the limits of our
wall geometries.

Doing this will allow Rocky to compute the elements that possibly escape above the container region
(splash from the collision with the column or container).

• By default Rocky automatically creates a Domain box based upon the boundary limits of the Walls.

• Any element that leaves those limits is eliminated from the simulation.

• These default settings would not work for the dam break simulation as the water splashes over
the container region.

24.1.11. DOMAIN AND SOLVER

1. Use the information in the table that follows to set the Domain and Solver.

Step Data Entity Editors Parameter or Action Settings

Location
A Domain Domain Use Boundary Limits (Cleared)
Settings Settings Min Values 0, 0, 0 [m]
Max Values 1.6, 0.75. 0.61
[m]
B Solver Solver | Time Simulation Duration 3.5 [s]
Output Settings | Time 0.01 [s]
Interval
Solver | Simulation Target GPU
General

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 Part A: Project Setup and Processing

You can check the resulting Domain in a 3D View.

Note:

The GPU is preferred in this case, but the simulation can also be run with a CPU.

24.1.12. SETUP CONFIRMATION

With a 3D View opened, your Data panel and Workspace should look similar to the below image.

24.1.13. SIMULATION SUMMARY

1. From the Solver entity, click Start.

The Simulation Summary appears, then processing begins.

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Tutorial - Dam Break

24.1.14. CONCLUSION
This completes Part A of this tutorial, in which Rocky was used to set up and process a Dam Break
simulation.

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 Part B: Post-Processing

During this tutorial, it was possible to:

• Enable a Module.

• Define a Fluid and a Fluid Inlet.

• Visualize SPH parameters.

• Define a Domain.

What's Next?

• If you completed this tutorial successfully, then you are ready to move on to Part B and post-process
this project.

24.2. Part B: Post-Processing

24.2.1. OBJECTIVES
The purpose of this tutorial is to analyze a fluid (SPH) simulation after you have processed it. We will
continue from where we left off in Part A.

You will learn how to:

• Create a fluid surface

• Visualize SPH Properties in a 3D View Window

• Analyze the Eulerian Solution

And you will use these features:

• Animation panel

• Eulerian Solution

• Time plot

• User Process - Cube

• User Process - Plane

24.2.2. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut24_files.zip file .

b. Unzip dem_tut24_files.zip to your working directory.

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Tutorial - Dam Break

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025
R1 or later. If you have an earlier version of Rocky, please upgrade to the latest
version, or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut24_files
folder, and then from the tutorial_24_A_pre-processing folder, open the tu-
torial_24_pre-processing.rocky file.

e. Process the simulation. (From the Simulation toolbar, click the Start button.)

24.2.3. COLORING FLUID ELEMENTS

Let's start by coloring our fluid elements by velocity.

1. From the Data panel, select SPH and then from the Data Editors panel, select the Properties
tab.

2. Select Velocity and then drag and drop it onto the 3D View window.

24.2.4. EULERIAN SOLUTION VIEW

To represent SPH data as continuous fluid, let's use the Eulerian Solution to continue the post-pro-
cessing.

We will first color the cells by Velocity, in order to compare the results we had by coloring the SPH
elements.

1. From the Data panel, on the SPH field, select Eulerian Solution and then from the Data Editors
panel, select the Coloring tab.

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 Part B: Post-Processing

2. Expand Faces and then select Velocity from the drop down list as Property.

3. Use the eye icons to make Eulerian Solution visible and hide everything else but the Velocity
color scale.

Note:

You will view only data from the most external cells from the domain. To see results
from an specific area, you can create a cube, cylinder or a plane User Process from
the Eulerian Solution entity and follow the same procedure.

24.2.5. DISCRETE AND CONTINUOUS FLUID VIEWS

In this tutorial, we are interested in analyzing the region where Water collides with the column
(middle of the container).

We will create a Plane in order to visualize this region with the Eulerian Solution (continuous data).

Let's also create a Cube to see the elements in this region with the SPH (discrete) entity.

1. Follow the steps in the table below to create both User Processes.

Step Item Location Parameter or Settings

Action
A Eulerian Solution Create a Plane User Process

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Tutorial - Dam Break

Step Item Location Parameter or Settings

Action
B User Plane Angle 90 [dega
Processes Plane Normal 0, 1, 0 [ - ]
Plane Coloring Edges (Cleared)
<01> Faces | Property Velocity
C Windows (Panel) Create a new 3D View
D SPH Create a Cube User Process
E User Cube Center 0.8, 0.38, 0.305
Processes [m]
Magnitude 1.6, 0.75, 0.02
Cube
[m]
<01>
Coloring Nodes (Enabled)
Nodes | Property Velocity

Finally, let's visualize and compare the fluid views between SPH (discrete) and Eulerian Solution
(continuous) data.

1. From the Windows panel, select the 3D View <01> and use the eye icons to hide everything but
the Plane <01>, column and Velocity color scale.

2. Select the (recently created) 3D View <02> and use the eye icons to hide everything but the
Cube <01>, column and Velocity color scale.

3. On the Data panel, from Color Scales, select Velocity, and from the Data Editors panel, ensure
Limits options is defined as Automatic PER View.

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 Part B: Post-Processing

4. Use the mouse to adjust the views in a way you can compare them (as shown).

Tip:

If you are using a full screen in the workspace, use the button located on the upper
right in order to make the window adjustable.

5. Use the slider from the time bar to choose the timestep you want to analyze.

24.2.6. WATER SURFACE - WEIGHT PROPERTY

We will also make use of a Filter User Process in order to visualize a fluid surface.

To represent it, we will restrict Eulerian Solution data based upon a value for a property defined as
Weight.

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Tutorial - Dam Break

• The value of the properties (velocity, density, etc.) for each node of the interpolation grid is based
on an interpolation, using the kernel function*, of the values of the SPH elements inside the kernel
radius.

• The Weight property gives the summation of the weight of all SPH elements that affect each grid
node.

• This property can be used to define the fluid surface as it is related to the concentration of SPH
elements around the nodes.

– If the region has no SPH elements, the Weight returns 0.

– When the region is full of elements, the function tends to return a value close to 1.

* Refer to SPH Technical Manual to learn more about SPH Kernel functions.

To better understand how the Weight is calculated, see the images below.

• Point A: Weight (approximately) 1

• Point B: Weight = 0

• Point C: 0 < Weight < 1

– As the volume around C is half empty, half full of elements, Weight tends to return 0.5. (see the
Color Scale in the reproduced scheme into Rocky below)

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 Part B: Post-Processing

24.2.7. WATER SURFACE

1. Follow the steps in the table below to create a weight based isosurface.

Step Data Entity Editors Parameter or Settings

Location Action
A Eulerian Solution Create a Filter User Process
B User Property Name Water
Processes Surface
Property Weight
Filter
<01> Mode Cut
Cut Value 0.5 [ - ]
Coloring Transparency (Enabled)
Faces | Property Velocity
Edges (Cleared)

Tip:

Ensure that Faces checkbox is enabled and the other ones are disabled for Property
<01> | Coloring.

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Tutorial - Dam Break

You can visualize the resulting surface for all timesteps in a 3D View.

24.2.8. FLUID ANIMATION

Let's create an animation to visualize the fluid behavior with the created surface.

Tip:

Hide everything but the Geometries and Water Surface.

1. Follow the steps in the table below to create a video of your simulation.

Step Item Parameter or Action Settings

A Tools Enable Animation Panel
(menu)
B Animation FPS 100 [ - ]
Time (0s) Add Key Frame
(button)
Frame | Number of 350 [ - ]
Frames
Time (3.5s) Add Key Frame
(button)

2. Click the Play button to preview it, and the Export Animation button to save the movie to an
AVI file.

24.2.9. FLUID FORCES

In a dam break simulation, the magnitude of fluid forces in wall geometries is a result of interest.

In this tutorial we will analyze the resulting fluid force in the column in the X (fluid flow) direction
for all timesteps.

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 Part B: Post-Processing

We will also visualize the maximum fluid force in a column triangle in order to see where it occurs
in the wall.

1. Follow the steps in the table below to create a Time Plot with both force values .

Step Data Editors Parameter or Action Settings

Entity Location
A Geometries Curves SPH : Force : X Show curve in new Plot
Properties SPH : Force : Nodal : Show in selected Time Plot by
X Max
column

The resulting plot is shown below.

24.2.10. PROPERTY VISUALIZATION

By inspecting the plot values, it is possible to see that the maximum force value in a column triangle
occurs at 0.84 s.

Note:

Your results may differ slightly from the ones presented in this tutorial.

1. Follow the table to color the column by nodal forces in a 3D View in order to visualize the region
of the wall that the force is occurring.

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Tutorial - Dam Break

Step Data Editors Parameter or Settings

Entity Location Action
A Geometries Coloring Transparency (Disabled)
Faces (Enabled)
coloring Faces | Property SPH : Force : Nodal :
X

2. With a 3D View opened, from the Time Toolbar, select the time that the maximum force occurs
(in this tutorial, 0.84 s).

You can visualize the point where the maximum fluid force occurs in the 3D View by hiding everything
but the column and the SPH : Force : Nodal : X Color Scale.

Note:

The maximum force occurs when the water first collides with the column, in the base
of the column. You can use the shortcut Shift+X to see the face in a normal view.

24.2.11. CONCLUSION
This completes Part B of this tutorial.

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 Part B: Post-Processing

Rocky was used to analyze a dam break.

During this tutorial, it was possible to:

• Set up a fluid-only simulation

• Visualize Properties in a 3D View window

• Use post-processing tools to filter data and visualize water surface

• Create an animation of a SPH simulation

• Plot Curves and Properties

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Chapter 25: Tutorial - Slurry Mill
(Part A) Set up and process a simulation with coupled SPH and DEM.

(Part B) Learn how to analyze the power supply of the system and the influence of the slurry filling.

25.1. Part A: Project Setup and Processing

25.1.1. OBJECTIVES
The main purpose of this tutorial is to:

• Set up and process an SPH-DEM coupled simulation.

The scenario considered in this simulation is a Slurry Mill.

• In wet milling, the presence of slurry (fluid mixture) can affect the supplied power.

You will learn how to:

• Set up a SPH-DEM case

• Use the same Volumetric inlet to inject both DEM and SPH

• Enable the collection of SPH Boundary Interaction Statistics

And you will use these features:

• SPH

• Modules

• Inlets and Outlets - Volumetric Inlet

• Cartesian Periodic Domains

25.1.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

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Tutorial - Slurry Mill

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one (especially Tutorial - SAG Mill (p. 247),
which has the same context of this one but without fluid injection).

25.1.3. GEOMETRY

The geometry in this tutorial is composed of:

• Mill slice

In the tutorial directory, the .stl file can be found.

25.1.4. PROJECT CREATION

To get started with this tutorial, do the following:

1. Download the dem_tut25_files.zip file .

2. Unzip dem_tut25_files.zip to your working directory.

3. Open Rocky 2025 R1.

4. Create a new project.

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 Part A: Project Setup and Processing

5. Save the empty project to a location of your choice.

Tip:

If you run into settings or procedures in these tables that you are not yet familiar with,
please refer to the Rocky User Manual and/or other Tutorials to find the detailed in-
structions you need.

25.1.5. INITIAL SETUP

Let's begin our setup by defining Physics and Modules parameters.

1. Use the information in the table that follows to start setting up your Rocky project.

Step Data Entity Editors Location Parameter or Action Settings

A Study Study Study Name Slurry Mill
B Physics Physics | Rolling Resistance Model Type C: Linear
Momentum Spring Rolling
Numerical Softening 0.1 [ - ]
Factor
C Modules Modules Boundary Collision (Enabled)
Statistics
SPH Boundary (Enabled)
Interaction Statistics
D Modules Boundary Collision Intensities (Enabled)
Statistics
Boundary
Collision
Statistics
E Modules SPH Boundary Power (Enabled)
Interaction
SPH Statistics
Boundary
Interaction

Note:

By enabling the checkboxes from Steps D and E, the modules will collect interaction data
(with the particles and fluid) for the boundaries that we will use later to calculate the power
draw of the Mill.

25.1.6. MOTION FRAMES

For this tutorial, start up and steady state Rotation motions within the same Frame will be created
for the Mill.

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Tutorial - Slurry Mill

1. Follow the steps in the table below to import the mill slice geometry and create the Motion Frame
that will be attached to it later.

Step Data Entity Editors Parameter or Settings

Location Action
A Geometries Import Wall Mill.stl with "mm" for Import
Unit
B Motion Frames Create Motion Frame
C Motion Frame Name Rotation Motion
Frames Add motion
Frame Stop Time 3 [s]
<01> Type Rotation
Angular Acceleration 0, 0, 200 [rev/min]
Add motion
Start Time 3 [s]
Type Rotation
Initial Angular 0, 0, 10 [rev/min]
Velocity

25.1.7. MILL SETUP

Next, we will assign the created Motion Frame to the Mill.

We will also set the Triangle Size in order to be refined but not excessively fine to balance resolution
with computational time.

1. Use the information in the table below to continue your setup.

Step Data Editors Parameter or Settings

Entity Location Action
A Geometries Wall Motion Frame Rotation
Motion
Mill
… | Transform Triangle Size 0.5 [m]

To visualize the Mill movement, preview it in a Motion Preview window.

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 Part A: Project Setup and Processing

25.1.8. MATERIALS
For the Materials step, default values for the boundaries (Default Boundary) will be used, we will
create two new materials for Rock and Steel particles that will be inputed later and we will use the
Default Fluid to represent the Slurry.

Note:

In practice, the slurry properties can vary depending on which components are added to
the water. In this tutorial, for simplicity, we will use default (water) properties.

1. Use the information in the following tables to set up the Materials and Materials Interactions steps.

Step Data Entity Editors Location Parameter or Settings

Action
A Materials Create Solid Material
B Materials Material Name Rock
Material
Material <04>
Density 2800 [kg/m3]
C Materials Material Name Steel
Material
Material <05>
Density 7800 [kg/m3]
D Materials Fluid Material Name Slurry
Material
Default Fluid
E Materials Rock Material - Rock Static Friction 0.8 [ - ]
Interactions Material Dynamic Friction 0.8 [ - ]
Restitution 0.5 [ - ]
Coefficient
Rock Material - Steel Static Friction 0.5 [ - ]
Material Dynamic Friction 0.5 [ - ]
Restitution 0.5 [ - ]
Coefficient

25.1.9. PARTICLES
We will create two particles sets to represent Rock Particles and Steel Particles.

1. Use the information in the table below to create both particle sets.

Step Data Entity Editors Parameter or Settings

Location Action
A Particles Create Particle (x2)

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Tutorial - Slurry Mill

Step Data Entity Editors Parameter or Settings

Location Action
B Particles Particle Name Rock Particles
Material Rock Material
Particle Particle | Size Add row (x2)
<01> Size | Cumulative % 0.3 [m] @ 100
[%]
Size | Cumulative % 0.25 [m] @ 70
[%]
Size | Cumulative¨% 0.2 [m] @ 20 [%]
… | Movement Rolling Resistance 0.35 [ - ]
C Particles Particle Name Steel Particles
Material Steel Material
Particle Particle | Size Size | Cumulative % 0.35 [m] @ 100
<02> [%]
… | Movement Rolling Resistance 0.35 [ - ]

25.1.10. SPH - FLUID SETUP

For the SPH step, we will use default values for every parameter but the Element Size.

1. From the Data panel, select SPH, and from Data Editors panel, ensure the Fluid Material is
defined as Slurry Material.

2. From the Kernel field, define the Element Size.

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 Part A: Project Setup and Processing

The Element Size is roughly 1/3 of the smallest Particle to ensure proper interaction between the
SPH and DEM physics.

Refer to SPH Technical Manual for more information.

25.1.11. INLET DEFINITION

For this tutorial, we will create a single Volumetric Inlet to inject the Particle groups and SPH ele-
ments into the simulation.

1. Follow the steps in the table below in order to create and define the inlet.

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Tutorial - Slurry Mill

Step Data Editors Location Parameter or Action Settings

Entity
A Inlets and Outlets Create Volumetric Inlet
B Inlets and Volumetric Inlet | Add row (x2)
Outlets Particles Particle | Mass Rock Particles @32000
[kg]
Volumetric Particle | Mass Steel Particles @ 8000
Inlet [kg]
<01> Volumetric Inlet | Mass 8300 [kg]
SPH
… | Region Seed Coordinates 0, -4, 0 [m]
Geometries | Mill (Enabled)
Use Geometries to (Enabled)
Compute

In a 3D View it is possible to visualize the Region to be filled (white box) and the Seed (blue sphere)
when the Inlet is selected.

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 Part A: Project Setup and Processing

25.1.12. DOMAIN AND SOLVER

For the Domain Settings step, we will define a Cartesian Periodic Domain to recycle particles and
fluid that leave one side of the mill slice back into the simulation on the opposite side.

• The same procedure for the Domain step is followed in the Tutorial 04. Refer to the tutorial and/or
to the Rocky User Manual for more details about Periodic Domains.

For the Solver step, we will prefer to use a GPU in order to reduce the simulation time.

1. Follow the steps in the table below to set your Domain and Solver.

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Tutorial - Slurry Mill

Step Data Entity Editors Parameter or Action Settings

Location
A Domain Domain Periodic Domain | Periodic Domain Cartesian
Settings Settings Type
Periodic Domain | Periodic Direction | (Cleared)
X
Periodic Domain | Periodic Direction Z (Enabled)
B Solver Solver | Time Simulation Duration 25 [s]
Output Settings | Time Interval 0.1 [s]
Solver | Simulation Target GPU
General

25.1.13. SETUP CONFIRMATION

With a 3D View opened, your Data panel and Workspace should look similar to the image below.

25.1.14. SIMULATION SUMMARY

1. From the Solver entity, click Start.

The Simulation Summary appears (as shown), then processing begins.

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 Part A: Project Setup and Processing

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Tutorial - Slurry Mill

25.1.15. HELP - USER MANUAL

This completes Part A of this tutorial, in which Rocky was used to set up and process a Slurry Mill
simulation.

During this tutorial, it was possible to:

• Enable Modules.

• Define an Inlet for both particles and fluid.

• Define a Periodic Domain.

What's Next? If you completed this tutorial successfully, then you are ready to move on to Part B
and post-process this project.

25.2. Part B: Post-Processing

25.2.1. OBJECTIVES
The purpose of this tutorial is to analyze an SPH-DEM simulation of a Slurry Mill after you have pro-
cessed it. We will continue from where we left off in Part A.

You will learn how to:

• Evaluate mill Slurry Filling

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 Part B: Post-Processing

• Evaluate mill supplied power

• Analyze pooling effects

And you will use these features:

• Custom Properties

• Expressions/Variables

• Time Plot

25.2.2. PREREQUISITES

Important:

This ADVANCED tutorial contains fewer details, screenshots, and procedures than other
Rocky tutorials.

• An ADVANCED tutorial is designed for users who are more familiar with the Rocky user
interface (UI), and already have a good understanding of the common setup and post-
processing tasks.

• If you do not already have this level of familiarity, it is recommended that you complete
at least Tutorials 01 - 05 before beginning this one.

25.2.3. OPEN PROJECT

1. If you completed Part A of this tutorial, ensure that Rocky project is open. (Part B will continue
from where Part A left off.)

2. If you did not complete Part A, do all of the following:

a. Download the dem_tut25_files.zip file .

b. Unzip dem_tut25_files.zip to your working directory.

c. Open Rocky 2025 R1.

Important:

To make use of the Rocky project file provided, you must have Rocky 2025 R1 or
later. If you have an earlier version of Rocky, please upgrade to the latest version,
or complete Part A from scratch.

d. From the Rocky program, click the Open Project button, find the dem_tut25_files folder, and
then from the tutorial_25_A_pre-processing folder, open the tutorial_25_pre-pro-
cessing.rocky file.

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Tutorial - Slurry Mill

e. Process the simulation. (From the Simulation toolbar, click the Start button.)

25.2.4. SLURRY FILLING

Our main interest in this tutorial is to evaluate the Supplied Power and analyze how it varies according
to the Slurry Filling.

The Slurry Filling ( ) is the ratio between the volume of slurry loaded to the volume of particle
interstices available within the bed at rest, and it can be calculated using the following expression:

(25.1)

Where:

• is the static porosity of the bed of particles (≈ 0.360 - 0.42 on average)

• is the mill volume fraction occupied by all particles (including the interstices)

Note:

represents the volume of particle interstices.

For this tutorial, we will assume = 0.4, as in reference paper [1] (p. 1036).

The Slurry Filling can be analyzed so that:

• = 0: No slurry

• 0< < 1: Interstices partially filled

• = 1: Interstices filled

• > 1: Slurry amount enough to fill the Interstices and left over

The parameters we need to calculate the Slurry Filling ( and ) can be obtained in Rocky
(discussed below).

• : is the sum of the volumes of SPH elements.

Note:

The volume for a single SPH element is equal to Element Size cubed.

• : is the sum of the volumes of the Particles (Particle Volume property) divided by the ratio
between material Bulk Density and Density (to consider the interstices), that is 0.6 in Rocky by
default (typical for spherical particles).

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 Part B: Post-Processing

25.2.5. SLURRY FILLING CALCULATION

Let's calculate the Slurry Filling for our project.

Note:

In the Part A of this tutorial, the Element Size and SPH Mass (thus, the ) were inten-
tionally chosen so that reaches approximately the unity ( ≈ 1).

1. Follow the steps in the table below to obtain the necessary parameters and calculate .

Step Item Location Parameter or Settings

Action
A SPH Properties Add new custom property
B Add new (dialog box) Name SPH Element
Volume
Output unit m3
C Custom Property (dialog box) Expression (2/30)**3
D SPH Properties | SPH Element Show in new Time Plot by Sum
Volume (Custom)
E Particles Properties | Particle Show in selected Time Plot by Sum
Volume
F Time Plot Table Add Formula
<01>

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Tutorial - Slurry Mill

Step Item Location Parameter or Settings

Action
G Add Expression (dialog box) Curve Caption Slurry Filling
Curve Expression B/(0.4*(C/0.6))

Note:

For Step G, ensure B refers to SPH Element Volume (Custom) and C to Particle Volume.

25.2.6. SLURRY FILLING - RESULT

You can visualize the resulting Slurry Filling in the Table tab from Time Plot <01>.

Note:

The Slurry Filling depends on the static porosity of the bed ( ), that must be evaluated
with the bed of particles at rest.

Also note that for constant, the only parameter that would change the Slurry Filling value
in a simulation without fluid/particle inlets or outlets is the volume of slurry, due to fluid
compressibility, and these variations are not significant.

This way, Slurry Filling should be roughly constant for this simulation.

Tip:

This analysis can be convenient when your simulation has slurry inlets or outlets.

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 Part B: Post-Processing

25.2.7. POWER ANALYSIS

Next we will evaluate and analyze the Supplied Power.

Note:

The Supplied Power corresponds to the necessary energy for the Mill to maintain the
prescribed rotational velocity. It accounts for the additional work to lift particles and fluid.

Tip:

The Supplied Power has contributions from the fluid (SPH : Power) and Particles (Power),
that have to be summed to represent it.

1. Follow the steps in the tables below to plot both the separated contributions and the Supplied
Power.

Step Item Location Parameter or Settings

Action
A Geometries Curves Add new custom curve

Mill
B Add new (dialog box) Name Supplied
Power
Output Unit W
Inputs | Power (Enabled)
Inputs | SPH : (Enabled)
Power
C Custom Curves (dialog box) Expression A+B
D Geometries Curves | Power Show curve in new plot
Curves | SPH : Power Show curve in selected plot
Mill
Curves | Supplied Power Show curve in selected plot
(Custom)

2. On the Plot tab, make the Axes Layout By Quantity so you can easily visualize the difference
between the Slurry and Particles influence in Supplied Power (results shown below).

25.2.8. SLURRY FILLING - RESULT

The resulting plot is shown below. The black line represents the Supplied Power.

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Tutorial - Slurry Mill

Note:

The green line represents the portion of power consumed by the slurry.

Tip:

If this curve becomes negative, it means that the slurry is contributing to the mill rotation.
In this tutorial, we will see when it happens and how to analyze it. It will occur for some
conditions with > 1.

25.2.9. POWER ANALYSIS

In order to have a reference value for comparison purposes, lets calculate the average value for the
Supplied Power with the mill at steady state.

Note:

Later in this tutorial, results for different values of will be presented, and the procedures
to get them are the same of the ones presented in the following table.

1. Follow the steps in the table below to create a variable for the Supplied Power.

Step Item Location Parameter or Action Settings

A Menu Tools Enable Expression/Variables
B Geometries Curves | Supplied Power Drag and drop to Expressions/Variables |
(Custom) Output
Mill

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 Part B: Post-Processing

2. From the Expressions/Variables panel, select Supplied_Power_Custom and click Edit.

3. Define the Name, Operation on Curve and Domain Range.

4. Click OK and see the resulting value on the Output tab.

25.2.10. POWER ANALYSIS - POOLING

An interesting phenomenon that starts to happen with a certain amount of Slurry in the Mill is
pooling.

In this context, pooling is the formation of a slurry pool separated from the particles that contributes
for the mill rotation by changing the center of gravity of the system.

Note:

Therefore, it should be noted a Supplied Power reduction with the presence of pooling.

In the next section, we will visualize the slurry behavior for different values of and check for which
value the pooling starts for our setup.

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Tutorial - Slurry Mill

• Example of pooling ( = 3)

25.2.11. SLURRY BEHAVIOR

Take a moment to analyze the slurry behavior for different Slurry Filling values (this and next section).

Note:

These (07) 3D View results were obtained from the same setup of this tutorial for the last
output, varying only the SPH Mass (slurry mass), indicated below each view.

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 Part B: Post-Processing

25.2.12. POWER ANALYSIS

By following the procedures from POWER ANALYSIS (p. 1032) for these 07 cases, it is possible to plot
the Supplied Power as function of the Slurry Filling.

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Tutorial - Slurry Mill

It is possible to see that the Supplied Power starts to reduce for > 1.5 as pooling takes place.

25.2.13. CONCLUSION
This completes Part B of this tutorial.

Rocky was used to analyze a Slurry Mill.

During this tutorial, it was possible to:

• Set up a DEM-SPH simulation

• Plot Curves and Properties

• Visualize a comparison for different setups within the same mill

25.2.14. BIBLIOGRAPHY

Bibliography
[1] * Mulenga, F. K. and Moys, M.H.. Effects of slurry filling and mill speed on the net power draw of a
tumbling ball mill. Minerals Engineering. 56. 45–56. 2014.

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1036 of ANSYS, Inc. and its subsidiaries and affiliates.