Particle morphology change and different experimental condition analysis during composite fabrication process by traditional ball milling with discrete element method (DEM) simulation were investigated. A simulation of the three dimensional motion of balls in a traditional ball mill for research on the grinding mechanism was carried out by DEM simulation. We studied the motion of the balls, the ball behavior energy and velocity; the forces acting on the balls were calculated using traditional ball milling as simulated by DEM. The effect of the operational variables such as the rotational speed, ball material and size on the flow velocity, collision force and total impact energy were analyzed. The results showed that increased rotation speed with interaction impact energy between balls and balls, balls and pots and walls and balls. The rotation speed increases with an increase of the impact energy. Experiments were conducted to quantify the grinding performance under the same conditions. Furthermore, the results showed that ball motion affects the particle morphology, which changed from irregular type to plate type with increasing rotation speed. The evolution was also found to depend on the impact energy increase of the grinding media. These findings are useful to understand and optimize the particle motion and grinding behavior of traditional ball mills.

The research develops the calculation steps of Z sigma level, process capability index(PCI) and process performance index(PPI) applicable to the discrete process in the service industry. The paper presents three following topics used related process indexes according to the precision and accuray in the continuous process. The contents include diverse process indexs for nonconformities by SPC attribute control charts and bias coefficient. The same technique of the nonconformites is also used in the nonconforming units. The practical examples are provided to help easier understanding for users.