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On the formation of super-stable granular heaps

Published online by Cambridge University Press:  03 January 2025

H.A. Lloyd
Affiliation:
Department of Mathematics and Manchester Centre for Nonlinear Dynamics, University of Manchester, Oxford Road, Manchester M13 9PL, UK
E.S.F. Maguire
Affiliation:
Department of Mathematics and Manchester Centre for Nonlinear Dynamics, University of Manchester, Oxford Road, Manchester M13 9PL, UK
D. Mistry
Affiliation:
Department of Mathematics and Manchester Centre for Nonlinear Dynamics, University of Manchester, Oxford Road, Manchester M13 9PL, UK
G.K. Reynolds
Affiliation:
Oral Product Development, Pharmaceutical Technology and Development, AstraZeneca, Macclesfield SK10 2NA, UK
C.G. Johnson
Affiliation:
Department of Mathematics and Manchester Centre for Nonlinear Dynamics, University of Manchester, Oxford Road, Manchester M13 9PL, UK
J.M.N.T. Gray*
Affiliation:
Department of Mathematics and Manchester Centre for Nonlinear Dynamics, University of Manchester, Oxford Road, Manchester M13 9PL, UK
*
Email address for correspondence: nico.gray@manchester.ac.uk

Abstract

A super-stable granular heap is a pile of grains whose free surface is inclined above the angle of repose, and which forms when particles are poured onto a plane that is confined laterally by frictional sidewalls that are separated by a narrow gap. During continued mass supply, the heap free surface gradually steepens until all the inflowing grains can flow out of the domain. As soon as the supply of grains is stopped, the heap is progressively eroded, and if the base of the domain is inclined above the angle of repose, then all the grains eventually flow out. This phenomenology is modelled using a system of two-dimensional width-averaged mass and momentum balances that incorporate the sidewall friction. The granular material is assumed to be incompressible and satisfy the partially regularized $\mu (I)$-rheology. This is implemented in OpenFOAM$^{\circledR}$ and compared against small-scale experiments that study the formation, steady-state behaviour and drainage of a super-stable heap. The simulations accurately capture the dense liquid-like flows as well as the evolving heap shape. The steady uniform flow that develops along the heap surface has non-trivial inertial number dependence through its depth. Super-stable heaps are therefore a sensitive rheometer that can be used to determine the dependence of the friction $\mu$ on the inertial number $I$. However, these flows are challenging to simulate because the free-surface inertial number is high, and can exceed the threshold for ill-posedness even for the partially regularized theory.

Information

Type
JFM Papers
Creative Commons
Creative Common License - CCCreative Common License - BY
This is an Open Access article, distributed under the terms of the Creative Commons Attribution licence (http://creativecommons.org/licenses/by/4.0), which permits unrestricted re-use, distribution and reproduction, provided the original article is properly cited.
Copyright
© The Author(s), 2025. Published by Cambridge University Press.
Figure 0

Figure 1. Conical pile formed from the $710\unicode{x2013}750\,\mathrm {\mu }{\rm m}$ green glass spheres used in the super-stable heap experiments. The angle of repose is approximately $22^{\circ }$.

Figure 1

Figure 2. Experimental set-up for the super-stable heap. Two 10 mm thick perspex front and back confining walls are separated by 3 mm perspex bars across the left and bottom boundaries (as well as a perspex spacer along part of the top boundary) to form a $600\,{\rm mm} \times 300\,{\rm mm}$ rectangular domain. A silo with a funnel is attached to the top, with a ‘double gate’ mechanism to control the mass-inflow rate and open and close the inlet. Material exits the domain through the right-hand side of the rectangular domain and lands on a balance. This measures the mass accumulation as a function of time. The left-hand stand adjusts the inclination angle of the system, whilst the right-hand stand has a fixed height, allowing for in-plane rotation.

Figure 2

Figure 3. Photographs of the (a) experimental formation and (b) draining of the super-stable heap, for slope angle $\theta = 29.2^\circ$ and mass-inflow rate $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$. The inlet is opened at $t_{exp} = 0$, and the photos of the filling are taken at $t_{exp} = 6$, 12, 20, 43, 83 and $321$ s. Photo (a vi) shows the steady state, with the earlier free-surface profiles superimposed for comparison. The inlet is cut off at $t_{exp} = 340.5$ s. The draining images are at times $t_{exp} = 341$, 344, 346, 370, 398 and 424 s. For comparison, the free-surface shapes during the draining phase are superimposed on the first of these images. All of the material leaves the domain at $t_{exp} = 429.5$ s. Movie 1 of the supplementary material shows the growth and decay of a closely similar super-stable heap for a mass-inflow rate $Q = 0.0060\,{\rm kg}\,{\rm s}^{-1}$.

Figure 3

Figure 4. Steady-state super-stable heaps for mass-inflow rates $Q = 0.0020$, $0.0046$ and $0.0060\,{\rm kg}\,{\rm s}^{-1}$, and box inclination angle $\theta = 29.2^\circ$. The pile size increases with increasing mass-inflow rate. It is useful to define three coordinate systems. The $(X,Z)$ coordinate system is used to represent the horizontal and gravity-aligned vertical, the $(\tilde {x},\tilde {z})$ system is aligned with the rectangular domain at angle $\theta$ to the horizontal, and the $(x,z)$ system is aligned with the steady uniform flowing layer at angle $\zeta$ to the horizontal. For the flow rates given, the heap inclination angles are $\zeta =41.63^\circ$, 49.35$^\circ$ and 49.8$^\circ$, respectively.

Figure 4

Figure 5. (a) Accumulated mass and (b) the mass-outflow rate as functions of time for mass-inflow rates $Q=0.0020$, $0.0046$ and $0.0060\,{\rm kg}\,{\rm s}^{-1}$, and the box inclination angle $\theta =29.2^\circ$. The mass-outflow rate is calculated by taking the time derivative of the accumulated mass data. The inlet is opened at $t=0$ s, and the plateaus in total accumulated mass in (a) show where all of the material has drained from the system. The linear dot-dashed lines in (a) and the horizontal dot-dashed lines in (b) indicate the steady-state super-stable heap regime, when the mass-inflow rate equals the mass-outflow rate.

Figure 5

Figure 6. Panel (a) and movie 2 of the supplementary material show a $1000 \times 120$ pixel high-speed photo/image sequence of the grains flowing down the inclined free surface at mass-inflow rate $Q=0.0046\,{\rm kg}\,{\rm s}^{-1}$. The camera is inclined at $48.9^\circ \pm 0.1^\circ$ to the horizontal. One thousand of these images are used to construct the velocity field (b) using the PIVlab package (Thielicke & Stamhuis 2014). Green velocity vectors are obtained from particle image velocimetry (PIV) analysis, and the red ones are interpolated from the surrounding field. (c) The time-averaged velocity magnitude in $(x,z)$ coordinates, which lie at an angle $\zeta = 49.34^\circ$ to the horizontal. The white line is the horizontally averaged velocity magnitude $|{\boldsymbol {u}}|$ through the flow depth. Note that the velocity scale is aligned with the colour bar for the contour map.

Figure 6

Figure 7. Steady uniform velocity profiles measured using PIV for mass-inflow rates $Q = 0.0020$, $0.0046$ and $0.0060\,{\rm kg}\,{\rm s}^{-1}$, which generate slopes at $\zeta =41.63^\circ$, 49.35$^\circ$ and 49.8$^\circ$ to the horizontal, respectively. The $z$ coordinate lies perpendicular to the inclined free surface, which is defined at $z = 0$. The dot-dashed lines represent velocity data that have been removed to ensure that the mass-inflow rates agree with that measured at the outlet. Since the solids volume fraction is very small in this region, this is not a large discrepancy.

Figure 7

Figure 8. The friction $\mu$ as a function of $I$ is shown in (a,b) for the original function (1.3) of Jop et al. (2006) (red curve) and the partially regularized function (3.19) of Barker & Gray (2017) (blue curve) using the parameter values in table 1. The red and blue dots highlight the values of $\mu$ when $I=0$ in the two models. Different horizontal scales are needed to show the extent of the well-posed regions for (a) the original (light red shading) and (b) the partially regularized theories (light blue shading). The well posedness condition $C$ of $I$, defined in (3.18), is shown for (c) the original and (d) the partially regularized theory. The black dots indicate the points where $C = 0$. It is these points that set the boundaries of the well-posed regions in (a,b).

Figure 8

Table 1. Material parameters taken from Barker et al. (2021).

Figure 9

Figure 9. (a) Exact solutions for the down-slope velocity $u$ as a function of $z$ at inclination angles $\arctan (\mu _d - 0.15) = 36.87^\circ$ and $\arctan (\mu _d + 0.15) = 46.40^\circ$ using the parameters in table 2. The solutions are shown for the original (red lines) and partially regularized (black lines) forms of the $\mu (I)$-rheology (GDR MiDi 2004; Jop et al.2006; Barker & Gray 2017). The circular and diamond-shaped markers show the height $z=z_{st}$ at which the material falls below yield. The grey-shaded markers correspond to the $46.40^\circ$ case. The dashed line in the inset indicates that on the $46.40^\circ$ slope, the velocity $u\rightarrow \infty$ at a finite depth for the original friction law (1.3). This corresponds to the height where the friction is $\mu \rightarrow \mu _d$. (b) The inclination angle $\zeta$ as a function of the mass-inflow rate $Q$ for the partially regularized (black line) and the original (red line) laws using the same parameters. The coloured triangles indicate the experimental cases from § 2, while the diamond and circular markers indicate the solutions in (a). The dashed line and star show the maximum mass-inflow rate for which a solution to the Jop et al. (2006) model exists.

Figure 10

Table 2. Rheological parameters for the partially regularized $\mu (I)$-rheology, and wall friction, used in § 4 to fit the experimental steady-state velocity profiles in figure 10 and the inclination angle as a function of mass-inflow rate in figure 9(b). A summary is also included of the measured steady super-stable-heap angles $\zeta _1^{exp}$, $\zeta _2^{exp}$ and $\zeta _3^{exp}$ for the experimental mass-inflow rates $Q = 0.0020$, $0.0046$ and $0.0060\,{\rm kg}\,{\rm s}^{-1}$. Using these parameters, the one-dimensional exact solution produces slope inclination angles $\zeta _1^{fit}$, $\zeta _2^{fit}$ and $\zeta _3^{fit}$, for the same mass-inflow rates. Note that $\mu _s$ is determined from the angle of repose in figure 1.

Figure 11

Figure 10. (a) The experimental down-slope velocity profiles with $z$ (dot-dashed lines) for the three mass-inflow rates in § 2, and the corresponding fitted profiles (solid lines) using the parameters in table 2. For mass-inflow rates $Q = 0.0020$, $0.0046$ and $0.0060\,{\rm kg}\,{\rm s}^{-1}$, the resulting slope angles are $\zeta ^{fit}=43.3769^\circ$, 47.9899$^\circ$ and 49.5276$^\circ$, whereas the experimental angles were $\zeta ^{exp}=41.63^\circ$, 49.35$^\circ$ and 49.8$^\circ$, respectively. (b) The corresponding exact solution for the inertial number through the flow depth. The black dashed line indicates the upper limit of the well-posed region of the partially regularized $\mu (I)$-rheology. This is equal to 1.0297 for the parameters in table 2.

Figure 12

Figure 11. Numerical simulation of a free-falling jet using the the partially regularized $\mu (I)$-rheology in the absence of wall friction and interface-sharpening forces. (a) The volume fraction of granular material in the free-falling jet, and (b) the velocity magnitude. (c) The blue circles represent the computed width-averaged flow rate through the jet at each $z$ coordinate, while the red line represents the flow rate input by the boundary conditions, i.e. $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$.

Figure 13

Figure 12. Contours of the simulated velocity magnitude $|{\boldsymbol {u}}|$ for a mass-inflow rate $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$ during (a) the growing phase and (b) the draining phase. The simulation times from (a i) to (a vi) are $t_{sim} = 7.2$, 12.4, 16.8, 30.8, 56, 150 s (steady), while for (b i) to (b vi), $t_{sim} = 151.2$, 155.2, 174.4, 202, 252, 297.6 s. Movie 3 of the supplementary material shows the full time-dependent evolution. The heap shapes are compared with the experimental free surfaces (magenta lines) when the granular areas are approximately equal. The areas are (a) $A = 0.02$, 0.045, 0.065, 0.11, 0.15, 0.175 m$^2$, and (b) $A = 0.175$, 0.16, 0.11, 0.08, 0.04, 0.01 m$^2$. The experimental data are taken at $t_{exp} = 6$, 12, 20, 43, 83, 321 s (steady) and $t_{exp} = 341$, 344, 346, 370, 398, 424 s.

Figure 14

Figure 13. Contours of the simulated pressure $p$ for a mass-inflow rate $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$ during (a) the growing phase and (b) the draining phase. The simulation times are the same as those in figure 12. Movie 4 of the supplementary material shows the full time-dependent evolution.

Figure 15

Figure 14. Contours of the base ten logarithm of the inertial number $I$ for a mass-inflow rate $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$ during (a) the growing phase and (b) the draining phase. The simulation times are the same as those in figure 12. Movie 5 of the supplementary material shows the full time-dependent evolution. The viscosity cap (5.10) is active below the white dashed line.

Figure 16

Figure 15. Comparison between the experimental (red solid line) and computed (blue solid line) accumulated mass at the outlet as a function of time for a mass-inflow rate $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$. The experimental data are the same as in figure 5, while the numerical curve is computed from the simulations. Both systems start filling at $t = 0$ s and run until steady state is reached, during which the accumulated mass rises linearly in time. However, in the computations, the inflow is shut off at $t=150$ s, which is shorter than in the experiments that shut off at $t_{exp}=340.5$ s. To account for this, the computed steady-state regime has been extended (blue dashed line) so that the draining phase can be compared directly with the experimental data. Both systems therefore begin draining at $t = 340.5$ s. The inset shows a close-up of the early-time behaviour.

Figure 17

Figure 16. Comparison of the steady-state heap shape for the experiment (solid heaps) and the numerical simulations for mass-inflow rates $Q = 0.0020$ (yellow line), $0.0046$ (red line) and $0.0060\,{\rm kg}\,{\rm s}^{-1}$ (blue line). The experimental heaps are identical to those in figure 4.

Figure 18

Figure 17. (a) Computed velocity magnitude $|{\boldsymbol {u}}|$ measured perpendicular to the free surface and taken at a series of positions down the right-hand face of the pile. The colour of the profile corresponds to the position of the slice in (b). The inset in (b) is a close-up of the free-surface flowing layer; the colour map for the velocity magnitude is the same as that in figure 12. The opacity is used to show the transition between the excess air phase (white) and the region occupied by grains, which is at full saturation.

Figure 19

Figure 18. Comparison of the computed (coloured lines), measured (grey dashed) and exact (black dot-dashed) steady uniform velocity profiles through the flow depth for mass-inflow rates (a) $Q = 0.0020$, (b) $0.0046$, (c) $0.0060\,{\rm kg}\,{\rm s}^{-1}$.

Figure 20

Figure 19. Numerical simulation of the system with inflow rate $Q = 0.0046\,{\rm kg}\,{\rm s}^{-1}$ and no sidewall friction; all other parameters of the system remain the same as in table 2. The close-up shows that the material develops a steady uniform Bagnold velocity profile (B2), sufficiently far down the inclined section of the chute.

Figure 21

Figure 20. Down-slope velocity profiles $u$ as a function of $z$, calculated from two-dimensional periodic box simulations (circles) and by solving (4.12) for the profile in a steady uniform flow. The light to dark blue curves correspond to angles $\zeta = 41^\circ$, 47$^\circ$, 51$^\circ$, 54$^\circ$, 57$^\circ$ and 59$^\circ$, which generate volume flow rates $Q = 0.1051$, 0.5007, 1.2047, 2.2171, 3.9787 and $5.8308\,{\rm m}^2\,{\rm s}^{-1}$. The gap width is assumed to be $W = 0.04$, the wall friction coefficient $\mu _w = 0.277$, and the rest of the rheological parameters are summarized in table 1.

Figure 22

Figure 21. Down-slope velocity profiles $u$ as a function of $z$, calculated from two-dimensional periodic box simulations (circles) and by solving (4.12) for the profile in a steady uniform flow at $\zeta = 28^\circ$. The light to dark blue curves correspond to gaps $W = 0.18$, 0.45, 1, 3 and 500 m. The red dashed line represents the Bagnold profile (B2). All remaining parameters are as defined in table 1.

Supplementary material: File

Lloyd et al. supplementary movie 1

Experimental movie showing the formation and collapse of a super-stable granular heap of 710-750µm glass beads in a perspex channel inclined at θ=29.2 degrees and with a 3 mm gap between the transparent sidewalls. The mass flow rate is Q=0.0060 kg/s.
Download Lloyd et al. supplementary movie 1(File)
File 9.2 MB
Supplementary material: File

Lloyd et al. supplementary movie 2

High speed (1000 x 120 pixel) image sequence showing the steady-uniform flow of 710-750µm glass beads down the free surface of the super-stable heap for a mass flow rate of Q=0.0046 kg/s. The heaps is inclined at ζ=49.34 degrees to the horizontal.
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File 3.8 MB
Supplementary material: File

Lloyd et al. supplementary movie 3

Simulated velocity magnitude |u| for a mass-inflow rate of Q = 0.0046 kg/s during the growth and collapse of the super-stable heap.
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File 6.9 MB
Supplementary material: File

Lloyd et al. supplementary movie 4

Simulated pressure p for a mass-inflow rate of Q = 0.0046 kg/s during the growth and collapse of the super-stable heap.
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File 11.9 MB
Supplementary material: File

Lloyd et al. supplementary movie 5

Simulated inertial number I for a mass-inflow rate of Q = 0.0046 kg/s during the growth and collapse of the super-stable heap.
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File 13.3 MB