Numerical simulation and optimization of dry bead mill based on DEM

To decouple the effects of geometric and operational parameters on dry grinding performance, we resolved the single-phase particle field of a dry bead mill employing discrete element method simulations. Our investigation centered on a novel rotor configuration, specifically designed to probe how structural optimization and varying rotational velocities impact internal particle distribution and mill efficiency. The enhanced rotor paradigm facilitates elevated, localized particle velocities, significantly augmenting the collision frequency and energy transfer between zirconia balls. Moreover, it induces pronounced near-wall velocity gradients, which translate into a global amplification of grinding severity. Notably, we observed that within an optimal operational window, escalating the rotor speed preserves the fundamental characteristics of the internal particle field. Rather than disrupting the spatial distribution, increased rotor speed yields a strictly positive, linear enhancement in comminution intensity.