Simulation of random packing of spherical particles with different size distributions

A numerical model for a loose packing process of spherical particles is presented. The simulation model starts with randomly choosing a sphere according to a pre-generated continuous particle-size distribution, and then dropping the sphere into a dimension-specified box, and obtaining its final position by using dropping and rolling rules which are derived from similar physical process of spheres dropping in the gravitational field to minimize its gravity potential. Effects of three different particle-size distributions on the packing structure were investigated. Analysis on the physical background of the powder-based manufacturing process is additionally applied to produce optimal packing parameters of bimodal and Gaussian distributions to improve the quality of the fabricated parts. The results showed that higher packing density can be obtained using bimodal size distribution with particle-size ratio from 1.5 to 2.0 and the mixture composition around n2:n1=6:4. For particle size with a Gaussian distribution, the particle radii should be limited in a narrow range around 0.67 to 1.5.