Simulation of solid particle erosion wear using discrete element method: Comparison of experimental and analysis results--颗粒学报PARTICUOLOGY

a Mechanical Engineering Department, Faculty of Engineering and Natural Sciences, Konya Technical University, Konya, 42250, Türkiye
b Akören Ali Rıza Ercan Vocational School, Department of Computer Technologies, Selcuk University, Konya, 42060, Türkiye

10.1016/j.partic.2025.10.003

Volume 107, December 2025, Pages 134-156

Received 21 August 2025, Revised 7 October 2025, Accepted 9 October 2025, Available online 17 October 2025, Version of Record 25 October 2025.

E-mail: mbagci@ktun.edu.tr; meh_bagci@yahoo.com

Highlights

• Solid particle erosion of St37 steel was systematically studied via experiments and DEM simulations.

• Weight loss tests at 30°, 60°, 90° with 1–3 kg particles were conducted to determine erosion rates.

• DEM simulations using Hertzian spring-damper and Coulomb friction models were validated experimentally.

• ANOVA showed impact angle as the dominant erosion factor, while particle quantity had limited effect.

• Comparisons indicate DEM predicts erosion well at high angles, but drift abrasion increases deviation at low angles.

Abstract

The Discrete Element Method (DEM) stands out as an effective computational tool for modeling complex mechanical wear processes such as solid particle erosion. The DEM method offers significant advantages in terms of providing realistic results, particularly when it comes to examining particle and surface interactions over time and predicting surface deformations. In this study, the effectiveness of DEM in determining the solid particle erosion wear behavior was evaluated by comparing it with experimental data. In the experimental phase, aluminum oxide (Al₂O₃) particles were impacted onto St37 structural steel samples at different impact angles (30°, 60°, 90°) and different quantities (1, 2, 3 kg) to calculate erosion rates. DEM based simulation analyses were performed using the same parameters, and surface deformations were modelled. When compared with experimental data, the simulation results showed high convergence, particularly at high impact angles such as 60° and 90° (5–15 % deviation). However, deviations increased at low impact angles such as 30°. While DEM analyses can successfully predict surface embedment deformations, they have not been able to adequately reflect damage caused by ductile behavior such as sliding. The surface embedment effect has shown a similarity of around 5 % at high impact angles compared to experimental data. In addition, ANOVA tests were applied to the erosion rates found in experiments and simulations to statistically evaluate the results. The test results statistically revealed that the most effective variable on the erosion rate was the angle of impact (p < 0.0001). The results demonstrate that the discrete element method is a reliable approach for modeling solid particle erosion wear behavior and, when used in conjunction with experimental data, can provide effective solutions for predicting and preventing erosion-induced damage during the design phase in systems such as jet engine turbines, space applications, and dust particle interaction engineering problems.

Graphical abstract

Keywords

Discrete element method; ANOVA; Solid particle erosion wear; Surface damage; Impact angle

文章导读