Numerical manifold method for compression molding of granular materials

TY - JOUR

T1 - Numerical manifold method for compression molding of granular materials

AU - Zhai, Xuezhen

AU - Guo, Yuchen

AU - Zhang, Yongjia

AU - Yue, Rui

AU - Shu, Liuchen

AU - Ning, Youjun

AU - Chen, Pengwan

AU - Kang, Ge

N1 - Publisher Copyright: © 2026 Elsevier Ltd

PY - 2026/7

Y1 - 2026/7

N2 - Compaction molding of Granular materials are critical processes that govern the uniformity of density and the final mechanical properties of the material. However, the underlying mechanisms controlling particle evolution during densification remain poorly understood. To address this issue, a two-dimensional granular material compaction model was developed using the numerical manifold method (NMM). The entire densification process, from particle rearrangement and plastic deformation to crack initiation and fragmentation, was simulated based on realistic particle morphologies. Through model validation and mesoscale analysis, the evolution of particle breakage rate, crack length, and various failure modes during compaction was quantitatively characterized. The results indicate that the compaction of granular materials can be divided into four distinct stages: rearrangement, deformation, fragmentation, and densification. Within the strain range of 30%–45%, crack length increases rapidly, and the proportion of fractured particles rises from 10% to 80%, marking the most intense phase of energy dissipation and structural transformation. When strain exceeds 45%, crack propagation tends to saturate, leading to the formation of a stable interlocking structure. From the perspectives of structural evolution and damage development, this study elucidates the internal mechanisms governing density evolution and damage behavior in granular materials during compression molding, thereby providing a theoretical foundation for optimizing compaction processes and enhancing the quality of molded products.

AB - Compaction molding of Granular materials are critical processes that govern the uniformity of density and the final mechanical properties of the material. However, the underlying mechanisms controlling particle evolution during densification remain poorly understood. To address this issue, a two-dimensional granular material compaction model was developed using the numerical manifold method (NMM). The entire densification process, from particle rearrangement and plastic deformation to crack initiation and fragmentation, was simulated based on realistic particle morphologies. Through model validation and mesoscale analysis, the evolution of particle breakage rate, crack length, and various failure modes during compaction was quantitatively characterized. The results indicate that the compaction of granular materials can be divided into four distinct stages: rearrangement, deformation, fragmentation, and densification. Within the strain range of 30%–45%, crack length increases rapidly, and the proportion of fractured particles rises from 10% to 80%, marking the most intense phase of energy dissipation and structural transformation. When strain exceeds 45%, crack propagation tends to saturate, leading to the formation of a stable interlocking structure. From the perspectives of structural evolution and damage development, this study elucidates the internal mechanisms governing density evolution and damage behavior in granular materials during compression molding, thereby providing a theoretical foundation for optimizing compaction processes and enhancing the quality of molded products.

KW - Compression molding

KW - Crack evolution

KW - Densification evolution

KW - Force chain

KW - Granular materials

KW - Numerical manifold method

UR - https://www.scopus.com/pages/publications/105032381024

U2 - 10.1016/j.compgeo.2026.108048

DO - 10.1016/j.compgeo.2026.108048

M3 - Article

AN - SCOPUS:105032381024

SN - 0266-352X

VL - 195

JO - Computers and Geotechnics

JF - Computers and Geotechnics

M1 - 108048

ER -