Evaluation of particle models of corn kernels for discrete element method simulation of shelled corn mass flow

•A single-sphere particle shape with certain associated corn physical properties was found to produce bulk density and angle of repose predictions that matched closely to values used as references.•Even though multi-sphere particles better represented the true shape of a corn kernel, the computation times for DEM simulation with such particles were long.•For simplicity and shorter computations times, single-sphere particle models are preferred. Bulk handling behavior of grains can be studied experimentally, but large-scale investigations of grain flow especially at the commercial scale are expensive, time consuming, and are therefore limited in the treatment factors that can be evaluated in any one study. Recent research has demonstrated the potential of discrete element method (DEM) in simulating grain flow in handling operations. However, application of DEM for simulating grain flow, requires development of appropriate particle models for each grain type. In this study, particle models comprised of one to four overlapping spheres were developed for shelled corn and tested. With these models, measurement of bulk properties, namely bulk density and angle of repose, both involving bulk flow were simulated using EDEM™ software with published data of material and interaction properties of shelled corn as inputs associated with each particle shape. Predicted time for the complete outflow from the bulk density test hopper (hopper emptying time), designated as simulation time in the study, was also recorded as another discriminant for model selection. Variable inputs into the simulation modeling were material properties particle shape, particle size distribution, Poisson's ratio, shear modulus, and density and interaction properties particle coefficients of restitution, static friction, and rolling friction. Computation time is critical in DEM modeling so single sphere particle models were emphasized over multi-sphere particles in the research even though multi-sphere particles represent the corn kernel shape more precisely because their simplicity can provide markedly reduced computation times to complete simulations. Predicted results for hopper emptying time, bulk density, and angle of repose were compared to experimental results or published data to select the most appropriate particle models for simulating bulk behavior of corn kernels in free-flowing grain applications using DEM. From the study, the most appropriate particle model (particle shape/physical