DEM simulation and characterization of copper and iron powders fabricated by ball milling

In this study, the particle morphology, and size changes in copper and iron powders were investigated by using a high-energy ball mill under the same experimental conditions. The particle sizes and morphologies of the powders were examined using a particle size analyzer and scanning electron microscopy (SEM). We also used the discrete element method (DEM) to analyze the ball impaction and the shear energy during the ball milling process. It was discovered that the quantity of milling balls and rotational speed had a major impact on energy dissipation through heat and plastic deformation as well as milling efficiency. The characteristic (particle morphology and size) of the iron and copper powder were differently changed under the same experimental conditions, shear energy, and ball impaction. When the particle sizes of copper and iron powder were compared under the same experimental conditions, the copper particle size increased from 21.6 μm to 280 μm, resulting in particle agglomeration, while the iron powder particle size decreased from 154 μm to 4.35 μm.