A Rotational Drum Wear DEM simulation is a computer model used to see how equipment wears out in industries like mining and cement production. A Rotary Drum Wear DEM Rocky simulation helps engineers understand why this happens and how to prevent it. Using the Discrete Element Method (DEM) in Rocky software, we can watch every single particle move inside the drum. This analysis of particle flow dynamics shows us where the particles hit and rub against the walls. This is critical for bulk material handling simulation and helps predict wear in equipment like industrial mixers and grinding mills. We use the famous Archard’s wear model to calculate how much material is lost over time.

Figure 1: A rotary drum schematic where interaction of particles and wear matters

Simulation Process: Rocky DEM Setup, Particle Physics and Wear Modeling

For this Drum Wear DEM Rocky simulation, we configured the model with precise settings to get realistic results. We used spherical particles with standard material properties. We turned on particle rotations because rolling and sliding are the main causes of wear. A rolling resistance of 0.35 was set to correctly model the energy used when particles roll.

For the physics, we used specific contact models. The Hysteretic Linear Spring model was used for the normal force (head-on collisions), and the Linear Spring Coulomb Limit was used for the tangential force (sliding friction). We did not use an adhesive force. The most important model for this study is the wear model. We used Shear Work Proportionality, also known as Archard’s Law. This is the best model for predicting abrasive wear. It uses a wear coefficient, which we set to 5e-06 m³/J. To make sure the results were accurate, we let the particles settle for 2.5 seconds before the simulation started calculating wear.

Post-processing: DEM Analysis, Correlating Particle Dynamics to Power and Wear

This abrasive wear simulation connects the power and particle motion to the final wear pattern on the drum wall. The drum wear contour is a professional visual that shows where material is being removed. The areas of highest wear (green and yellow) are not random; they are located exactly where the cascading particles slide and crash into the drum’s surface. The simulation uses Archard’s Law to translate every particle impact and slide into a tiny amount of predicted material loss. By adding up millions of these events over time, it creates a wear map. The particles’ Y-velocity, which ranges from -1.06 m/s (falling) to 0.44 m/s (being lifted), confirms this high-energy impact zone. The most important achievement of this simulation is its ability to directly link the measured power consumption to a specific, predictable wear pattern on the drum wall, giving engineers a powerful tool to reinforce critical areas and optimize drum speed to maximize equipment life.

Figure 2: Particle Distribution and Radial Displacement Patterns

The particle distribution provides a professional visual that acts as a diagnostic map of the material flow. From an engineering standpoint, this shows the classic “kidney” shape of a tumbling load inside a rotary drum. The particles are lifted by the rotating wall and then cascade down the other side. This motion is directly linked to the power consumption plot. The plot shows an initial power spike to about 0.061 kW, which is the energy needed to get the entire particle bed moving. After this, the power stays steady at around 0.058 kW. This steady power is the energy required to continuously lift the material against gravity, and it is a direct measure of the forces causing friction and impacts inside the drum.

Figure 3: Power Consumption and Drum Wall Wear Analysis