How Asphalt Simulation Technology Provides Powerful Insights

Simulation is an engineering tool for virtually exploring and testing new ideas. By investigating new concepts virtually, engineers can test more ideas faster and at much less cost than traditional prototyping

Astec has been using simulation for decades to solve engineering problems, improve product quality and provide value to its customers.

“Astec’s pioneering use of simulation has contributed to our recognition as a technology leader, not just in our industry but more broadly in the simulation space,” explained Andrew Hobbs, PhD and Head of Simulation & Modeling for Astec.

“Simulation begins with a concept and then a computer assisted design (CAD) model. With a virtual representation of the concept, different simulations are then performed and the results analyzed. Based on the findings, changes to the concept or CAD may be introduced and the process looped through until the design is ready for physical testing.”

The process Hobbs describes is used in new product development (NPD), as well as towards continuous improvement of existing products and customer support.

Computational fluid dynamics (CFD) combustion simulation of an Astec Power Flame burner

Provided by Astec Industries

“We can investigate everything from burner combustion, engine cooling, fans and air filtration using computational fluid dynamics (CFD), rock crushing, mixing, and drying using discrete element method (DEM) and ensure robust structural integrity using finite element analysis (FEA).” Hobbs said.

Here are some of the ways Hobbs and his team use simulation to help Astec bring value to their customers:

Particle simulation of the Astec Double Barrel showing particles colored by velocity

Provided by Astec Industries

1. IMPROVED PRODUCT

QUALITY

Quality at Astec is measured in reliability, safety, and robustness. Simulation is used to eliminate potential issues early in the design cycle.

“In a recent NPD project, we ran numerous unique simulations in the design phase and identified several potential failures,” Hobbs said. “By fixing those problems before any steel was cut or welded, we drastically reduced the overall development time as well as reduced the risk of customer downtime and costly rework or warranty repair.”

2. IMPROVED PRODUCT

PERFORMANCE TO

MAXIMIZE ROI

From crushing rocks to paving roads, Astec customers expect products that will help them run an efficient and successful business.

Simulation is used across Astec’s product line to maximize equipment throughput and improve performance all with an eye on the final product to make sure customers get the best results from the equipment they invest so much of their resources in.

3. IMPROVED

SUSTAINABILITY

Simulation aids sustainability in a number of ways. On the production end, thermal efficiency in Astec’s mixing equipment means less fuel consumed, less waste and lower emissions. This goes a long way towards the industry's goal of net-zero carbon emissions over the next few decades. But simulation also aids in improving the recycling and reuse of old material. Greater Reclaimed Asphalt Pavement (RAP) capacity in the company’s asphalt plants allows for more recycled asphalt, saving resources and reducing the environmental impact of road construction. Competition for road work projects is at an all-time high, and sometimes the RAP mix and usage is the factor that makes all the difference between getting a job and it going to a competitor.

“To increase RAP usage in a sustainable manner requires thermally efficient mixing equipment,” Hobbs said. “Simulation can help improve equipment design if models can capture the physics relevant to RAP heating at industrial scale. Astec has developed their modeling methods to improve RAP heating and mixing in our equipment.”

4. GREATER INSIGHT AND

UNDERSTANDING

The data from simulation gives a unique window inside equipment. Things that are usually impossible to observe in actual equipment can be “seen” in a new way. This technological advantage gives us a better understanding for how the equipment operates.

“Astec is on the cutting edge of leveraging technologies like AR and VR to gain greater understanding of our equipment functions,” Hobbs said. “This is a great tool for communicating the benefits of Astec technology to customers.”

5. ACCELERATED

INNOVATION

Simulation allows for the in-depth investigation of more ideas at a much faster pace than physical prototyping possibly could. Instead of a handful of designs, simulation technologies can work through hundreds of different variations to indentify the optimum results or solutions at an incredibly efficient speed.

“Working on a computer to analyze hundreds of designs allows us to move more quickly to eliminate bad ideas,” said Hobbs. “We like to say, ‘fail early and fail often until you land on a product that works.’”

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Particle simulation of the Astec Shuttle Buggy SB-3000 filling a RP-175 paver with particles colored to show lateral mixing.

Provided by Astec Industries

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A Correction For Outdated Information

Asphalt Contractor regrets publishing details from an old report on density technology

In last month’s issue, we covered technology that can be used to measure asphalt density. We were made aware that some information in the article was from a report that was written several years ago.

As we know, technology in our industry changes rapidly and the information reported in the piece was outdated and therefore inaccurate with today's devices.

The report indicated that concerns were raised about the accuracy of non-nuclear density gauges,but that technology has greatly improved since then.

This table is a copy of the precision data from ASTM D2950 Standard Test Method for Density of Bituminous Concrete in Place by Nuclear Methods and ASTM D7113 Standard Test Method for Density of Bituminous Paving Mixtures in Place by the Electromagnetic Surface Contact Methods. It shows a better range of results in all categories from the non-nuclear gauge.

Both ASTM D7113 and AASHTO T343-12 have detailed and accepted practices for the calibration procedures for a non-nuclear density gauge.

The part of the article written on the non-nuclear density gauge does not make any attempt to highlight some fundamental advantages of this technology over the use of nuclear density gauges. The three used as illustrations are: • PORATABILITY: a non-nuclear gauge is less than 1/3 the weight of a nuclear gauge making it much more portable. • QUICK RESULTS: the non-nuclear method produces results in less than 3 seconds in comparison to a nuclear gauge in 60 seconds. • VIRTUALLY NON DESCRUCTIVE: the non-nuclear density gauge is non-invasive so there for 100% non-destructive.

We apologize for the error as we commit to provide relevant and accurate information to the industry and our readers.