Flexible Pouch Filling (ABP)

This Application Best Practice (ABP) offers a concise guide to simulating flexible pouch filling using Ansys Rocky™ particle dynamics simulation software. It covers mesh creation, particle injection, and post-processing techniques to predict headspace and solid fraction, helping optimize product design. The approach uses simplified modules to improve simulation stability and performance and scripting to facilitate post-processing, making it ideal for anyone with basic DEM and Ansys Rocky software PrePost knowledge.

Learning Outcomes:

Following completion of this Application Best Practice (ABP), you will be able to:

• Understand the pouch filling process and its challenges in simulating solid material behavior within flexible packaging.
• Set up and execute simulations using Ansys Rocky software, including particle injection, and module configuration.
• Apply performance-enhancing techniques such as particle scaling and freeze modules to improve simulation stability and efficiency.
• Analyze simulation results to calculate headspace and bulk material solid fraction using custom properties and Python scripting.
• Recognize the importance of validation by comparing simulation outputs with experimental data to ensure model accuracy.

Prerequisites:

• Rocky Tutorial Guide, Chapter 1: Tutorial - Transfer Chute
• Rocky Tutorial Guide, Chapter 23: Tutorial - Solver SDK
• Introduction | Ansys Developer Forum
• Introduction to Ansys Workbench Meshing Software for FEA

Please note: These training materials were developed and tested in the 2025R2 release.

Application Best Practices (ABPs) outline engineering design goals for specific applications and provide guidance for how to achieve those goals using Ansys simulation software. It is important to note that a Geometry File or other Input Files are not always available. ABPs, as opposed to the official training-material workshops/tutorials, are not meant to be a step-by-step instruction document. ABPs are a link between product-based training courses and application specific tutorials, educating on the "how" and "why" of the best modeling approach, highlighting best practices and workflows for a particular application.