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M.J. Adams
Unilever Research, Port Sunlight Laboratory, Quarry Road East, Bebington, Wiral, Memyside L63 3JW (UK)
Abstract
In order to measure the strength of an agglomerated product it is convenient to compress a bed of the agglomerates
using a piston in a rigid cylinder; this is known as a confined uniaxial compression test. A simple first-order
lumped-parameter analysis of this compression process is presented, treating the system as purely dissipative
and applying the Mohr-Coulomb macroscopic failure criterion. This enables average single agglomerate strengths
to be deduced from the initial deformation behaviour of the bed under comparatively low loads. Agglomerates
with a range of strengths have been formed from quartz sand using varying amounts of a polyvinylpyrrolidone
binder. These have been tested both in the uniaxial compression test and individually, by compression between
parallel platens. The results show agreement with the proposed theory over an order of magnitude in single
particle crushing load. The load-deformation curve for the compression experiments is also consistent with
Kawakita’s equation and it is shown that, over a certain range of strain, the load-deformation equation developed
here and that due to Kawakita take approximately the same form; the agreement enables a physical interpretation
to be made of one of the parameters in Kawakita’s equation.
nevertheless enables average single agglomerate failure Eventually, as the applied pressure is increased, the
stresses to be deduced from simple uniaxial compression single particles lose their separate identities and bulk
experiments, which has obvious practical advantages. deformation occurs. Much work on compaction has
Heckel[2] adopted the above approach and was able concentrated on this final stage of the process, because
to describe the pressure-volume relationship of metal this is of most importance in tableting. The work
powders in terms of two lumped parameters. He sub- presented here focuses upon the initial deformation
sequently demonstrated that one of these parameters under low loads, because it is this region of the load/
was directly related to the yield stress of the particles porosity relationship which yields most information
[3]. The application of this work to a wide range of about single particle properties.
powders has been undertaken by many workers with The approach taken here is a macroscopic one.
perhaps the most comprehensive study being carried Therefore, it should be stated at the outset that it is
out by Roberts and Rowe [4]. They greatly extended not possible to deduce anything in detail about the
the value of the technique by introducing the effects strength of the particles in terms of a fracture mechanics
of particle ductility, particle size and deformation. How- analysis. The authors are engaged in a parallel study
ever, they and others have observed that there are of the fracture mechanics of individual agglomerates;
significant deviations from the Heckel relationship for the details of this work are described elsewhere [lO-121.
brittle materials. While this does limit the value of the It is argued below that the breakdown of agglomerates
technique for agglomerates with solid binders, a more due to the compressive stress fields experienced in
serious concern is that the failure stress for a brittle uniaxial compression is most appropriately prescribed
porous material in compression is a function of the by conditions on a failure surface which may be defined,
principal stresses acting on its periphery. For example, for example, by eqn. (1).
the failure surface for a sandstone rock has recently
been proposed to be of the following form [5]: Theory
fracture mechanics concepts have to be modified to where A* = k,nA and n is the total number of active
take account of inelastic processes occurring at the or load-bearing columns.
crack tip. The analytical procedures involved to de- Note that as the compression proceeds and agglom-
termine the critical value of K at fracture, the ‘critical erates fail, the columns of which they form a part may
stress intensity factor’, K,, for agglomerates have been become inactive (in the load-bearing sense) only to be
described elsewhere [21]. In short, Kc is a measure of reactivated at a higher strain. However, in this simple
the stress at which fracture occurs by crack propagation approach, the failure load F of each column is the
and is therefore an intrinsic material property. same, so that any increment in load implies an increase
For an isolated column or agglomerate, failure in in the total number of load-bearing columns, n. Thus,
uniaxial compression occurs by tensile crack opening
dP=7dA* (6)
[22], as in the well-known ‘Brazilian test’. In the ‘column
model’ of confined uniaxial compaction described here, or
however, local crack opening within a single agglomerate
resulting from the major principal stress acting in the dP=rdA*lA, (7)
axial direction would be constrained by the radial where dP is the increment in nominal pressure and A0
principal stress induced by neighbouring columns. Under is the cross-sectional area of the bed. The number of
these conditions, the particles would be constrained to load-bearing columns must increase with the applied
fail in oblique shear. Such failure is common in the strain - dhlh in order to support the load. The simplest
fracture of stone columns under a compressive load. assumption is then that the increment in new fracture
This was first recognised by Coulomb [23] who related area is directly proportional to the strain. This may be
the shear failure stress, 7, to the sum of the cohesive written in the following form in order to render the
strength r0 and the frictional stress Crp’ acting at the constant of proportionality, ka, dimensionless:
failure planes, thus
7=70+& (3) dA*=k* $A,,
as
+*=d*
s
PO
-=-
dlJ
Tb+a'P s
.h dh
ho
T (14)
12 1.0 2580 3.1 f 0.9 4.7 f 1.4 Fig. 5. Comparison of values of calculated and measured single
particle fracture loads.
4 2.0 1850 5.7+0.8 16.7 k 2.3
3 2.0 6.9 + 1.9 14.5 rt4.0
5 2.0 2580 7.4* 1.3 11.1*2.0 to describe compression of a mass of powder. One of
11 3.2 1440 6.2* 1.1 29.9 f 5.3
the most widely used of these equations is that due
10 3.2 1850 6.9k1.8 20.2 + 5.3 to Kawakita and co-workers [7, 261:
9 3.2 2180 10.8 of:2.0 22.7 of:4.2
8 3.2 2580 14.0 f 2.9 21.Ok4.4 v,-v
-=- abl'
(18)
v, l+bP
(F/d:) should remain constant with changes in ag- where V, is the initial volume of the bed, V is the
glomerate size providing that the binder concentration current volume, P is the applied pressure and a and
remains unchanged. In fact, it is apparent from the b are constants. It is clear from eqn. (18) that as P
data of Table 2 that (F/&*) decreases somewhat with becomes large so that bP> 1,
increase in agglomerate size, suggesting, unsurprisingly,
that factors in the agglomeration process reduce the vo-v..
strength of the agglomerates as they become larger. a=V,
That the TV’values in Table 1 follow a similar trend where V, is the volume of the particles alone. Kawakita
is further evidence to support the analysis presented et al. [26] found that the values of the parameter a
above. they obtained from fitting eqn. (18) to experimental
Figure 5 compares values of (kZ/k3)FCALCderived data were in good agreement with the initial porosity
from the confined compression test and the measured of the powder bed. Combining eqns. (18) and (19) we
single particle fracture load. Despite the considerable have
scatter in the single agglomerate fracture loads, the
experimentally-determined value of the single particle p(!c-$)~$k$) (20)
crushing load is seen to be approximately proportional
to the single agglomerate failure load inferred from
the uniaxial confined compression test. which is one of the forms of his equation which Kawakita
recommends in order to obtain a value for the constant
b. Figure 6 shows a plot of a typical set of data from
Discussion the sand/PVP agglomerates, illustrating good agreement
with eqn. (20). Kawakita er al. [26] suggested that the
It is of interest to compare the predictions of eqn. constant (l/b), which has dimensions of pressure, is
(16) with those of the empirical equations often used related to the yield stress of the individual powder
11
Thus,
P v-v,
or
!c
p=$
a’ (1v
From Kawakita’s eqn. (20):
r-1
v, - v
indeed proportional over certain ranges of void fraction.
VO
For V, lV,,= 0.44, for example, the two terms are ap-
Fig. 6. Kawakita plot for 2 360-2 800 Frn sand agglomerates (1.0%
proximately equal in the range 0.9 > V/V,,> 0.6 if CY’= 4;
binder; run 12).
as the value of a’ increases, the range of void fraction
over which the two expressions are proportional de-
creases, so that for (Y’=20
(25)
over the range 0.98 > V/V, > 0.92. In this work, (Y’varied
between 10 and 30, but strains were confined to less
than lo%, so that eqn. (24) may be used, leading to
Tb= 0.7/b (26)
which is shown in Fig. 7, giving good agreement with
the data for this value of V,/V,.
.. , , , , , , , Conclusions
0
0 2 L 6
AGGLOMERATE SHEAR STRENGTH 7; (MRI Uniaxial confined compression of the agglomerates
Fig. 7. Comparison of Kawakita parameter, b, with agglomerate considered here is a purely dissipative process in which
shear strength, TV’, for all confined compaction experiments; eqn. strain can only be accommodated as the result of
(26). individual agglomerate failure. Here, the Mohr-
Coulomb macroscopic stress criterion is applied to the
particles. Values of l/b from this work are plotted in failure of individual agglomerates. The modelling prob-
Fig. 7 against values of TV’, obtained by fitting eqn. lem then reduces to describing (i) the way in which
(16) to the experimental data. The excellent linear the effective area over which failure occurs varies with
correlation confirms the link between Kawakita’s con- the extent of the overall deformation (i.e. the strain)
stant and the yield stress of the particles, which may and (ii) the way in which single agglomerate failure is
initially seem surprising because of the apparently dif- affected by the local normal stresses on the failure
ferent forms of eqns. (16) and (18). plane. In this analysis, extremely simple assumptions
Developing the comparison further, at large values have been made in each case, leading nevertheless to
of strain, eqn. (16) reduces to an expression for the load-deformation relationship
which is a good approximation to experimental be-
In P= ln(T,‘/a’) + a’6 (21) haviour. Moreover, this simple theory provides a means
Since E is here the natural strain it may be replaced by which the average shear strength of a single ag-
by ln(V,,lV), using the notation of eqn. (16). glomerate can be obtained by experiments on a bed
12
of agglomerates, and this value is related to the single kl, k2,k, proportionality constants, -
particle crushing strength through a single empirical number of active columns (eqn. (5)), -
proportionality factor. ;: pressure, stress, Nme2
The form of any expression for the load-deformation P’ local value of normal stress on failure plane,
relationship under confined uniaxial compaction must Nmp2
include some measure of the strength of the individual V bed volume, m3
particles (in this case, agglomerates) being compressed. vo initial bed volume, m3
The analysis presented here clearly shows that the V/, final bed volume (eqn. (19)), m3
constant b in Kawakita’s equation is to be interpreted
as proportional to the reciprocal of the single particle Greek letters
failure stress, which is in agreement with the qualitative a parameter in Mohr-Coulomb failure cri-
arguments put forward by Kawakita et al. [26]. terion (eqn. (3)), -
ff’ =k,a (eqn. (13)), -,
E void fraction, -
% mean tensile strength (eqn. (2)), Nme2
Acknowledgements 7 failure stress, Nmp2
70 strength of agglomerate at zero normal load,
This work was carried out as part of a project Nmp2
sponsored under the Particulate Technology Specially rb =(k2/k3)~o (eqn. (12)), Nme2
Promoted Programme (S.P.P.) of the Science and En-
gineering Research Council. The grant-holder (Dr J.P.K.
Seville) wishes to acknowledge the assistance of Mr
L.J. Ford, the S.P.P. Coordinator. The authors also
wish to thank Professor R. Clift, Dr J.G. Petrie and References
Dr U. Ti.izi,in for useful discussions during the prep-
aration of this paper, and Dr C. Thornton of the C. Thornton and D.J. Barnes, Acta Mechanicu, 64 (1986) 45.
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Department of Civil Engineering of Aston University
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607.
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234.
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A area of failure surface, m2 61.
A* =k+4, m2 8 R.P. Seelig and J. Wulff, Trans. Am. Inst. Min. Metall. Eng.,
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A0
9 A.R. Cooper and L.E. Eaton, J. Am. Ceram. Sot., 45 (1962)
a,, 4, a2 parameters in eqn. (l), -
97.
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J2
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Nme2
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13
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