Medal win for bulk materials handling thesis

An engineering student has won James Cook University’s (JCU’s) annual Charles (CN) Barton Medal for his fourth-year thesis, an in-depth investigation into improving the efficiency of bulk materials handling.

Thomas Bainbridge, a Bachelor of Engineering (Mechanical) Honours student, has won the prize for this thesis: Development of a Bulk Material Handling Scale Test Facility, Phase 1: Scale Testing Proof of Concept.

The thesis investigated the effect of dozer blade scale on excavation forces and the feasibility of a scale testing facility to improve design efficiencies.

“With the growing dependence of modern society on bulk materials, improved design efficiencies of handling systems are paramount,” Bainbridge said.

“Bulk material handling systems such as excavators, hopper or silo storage and transportation including train, road and ships exist locally in a typical coal mine to ship process.

“It is recognised that scaled testing may be a powerful tool in design and could optimise current design methods dramatically, reducing both costs and carbon footprints currently experienced in industry.”

To explore the feasibility of a bulk material scale testing facility, Bainbridge investigated and analysed coal excavation forces on four dozer blades of various scaled dimensions.

“Using experimental, numerical and empirical techniques, an investigation was conducted to investigate if dozer blade scale and excavation force relationships exist,” Bainbridge said.

“The aim of my thesis was to explore whether a mathematical relationship could be obtained that would allow small-scale test results to be scaled up. Such relationships could replace the need for full-scale tests currently used in industry.”

He found that an approximately cubic relationship between longitudinal excavation force and excavation dimensions exists.

“Experiment results largely match numerical predictions; however, empirical methods were found to be inaccurate. Coal force versus scale relationships are consistent with those found in a parallel study on blade excavation in sand.

“This thesis looked only at a finite dozer blade scale range; however, undeniably, scale relationships in the excavation of coal and sand are present. This shows promise to the concept of using scaled testing as a design tool.

“However, more work is required before the feasibility of a bulk material handling scale testing facility and its position in the design process can be assessed.”

The Charles (CN) Barton Medal is awarded each year to the student who presents the best fourth-year engineering thesis seminar at the School of Engineering & Physical Sciences at JCU. Bainbridge was one of four students vying for the prize.