This paper on "Finite Element Rolling Simulation for Saturated Fibro-Porous Materials - Blanket Thickness and Extraction Energy Investigations" was presented at the NAFEMS World Congress on The Evolution of Product Simulation From Established Methods to Virtual Testing & Prototyping - 24-28 April 2001, The Grand Hotel, Lake Como, Italy.

Summary

A number of manufacturing industries utilise rolling as the primary method for dewatering saturated fibrous-porous materials, where the materials usually consist of comminuted organic plant matter. Historically, the design and operation of rolling mills has been largely empirical, with the two primary areas of focus being maximum processing rate and maximum liquid extraction.
This paper describes a fully coupled, two-dimensional plane strain Lagrangian finite element simulation of the rolling process for saturated fibro-porous materials. Darcy's law and the generalised Biot formulation are used to describe liquid flow through the fibro-porous solid skeleton, and a nonlinear elasto-plasticity model describes the constitutive response of the porous solid phase itself. The interaction between solid and liquid phases is fully coupled, and contact between the process material and the rolls is simulated using a multi-variate finite sliding friction algorithm.
The finite element model is used to simulate sugar cane crushing between a pair of rolls, and the predicted effect of feed blanket thickness on key rolling parameters is investigated. The simulation results provide valuable information regarding internal blanket stresses and liquid flow patterns, and allow consideration of the individual extraction energy dissipation mechanisms occurring during the rolling process.