Abstract
Segregation of granular materials is often induced by differences in size, density, shape and surface properties. Density and size-induced mixing and segregation of binary mixtures of glass beads and/or resin particles in the FT4 powder rheometer are investigated experimentally using a new FT4 methodology. The proposed methodology allows for quantification of mixing and segregation of components based on a mixing index. It is observed that the mixing index increases with increasing density and size ratio. Variation of flow energy and torque is related to the mixing and segregation of the mixture components, thus demonstrating that the FT4 powder rheometer may be used as a predictive tool for the tendency of mixture components to segregate under various stress conditions. Numerical analysis by DEM shows that for non-cohesive systems mixing and segregation occur by sifting of fines through interstitial gaps formed between coarse particles in the dilated region. For the non-cohesive system, higher blade tip speeds reduce the rate of mixing and minimise the segregation of different-sized components. Increasing the interfacial energy reduces the rate of mixing and alleviates the segregation of particles. For the cohesive systems, mixing occurs by rupture of cohesive fine clusters with the mixing index increasing with increasing blade tip speed owing to the higher shear stresses that break the agglomerates.
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•Mixing and segregation of binary mixtures in the FT4 were investigated.•A new FT4 methodology was developed to quantify mixing and segregation.•Effects of size and density ratios and surface energy were investigated.•Mechanisms governing mixing and segregation were evaluated.•Mixing and segregation rates were related to FT4 flow energy.