.. _model-bingham: Bingham Plastic =============== Quick Reference --------------- - **Use when:** Rigid below yield stress, Newtonian flow after yielding - **Parameters:** 2 (:math:`\sigma_y`, :math:`\eta_p`) - **Key equation:** :math:`\tau = \tau_y + \eta_p \dot{\gamma}` for :math:`|\tau| > \tau_y` - **Test modes:** Flow (steady shear) - **Material examples:** Cement pastes, drilling muds, mayonnaise, ketchup, toothpaste Overview -------- The **Bingham Plastic** model describes **viscoplastic materials** that behave as **rigid bodies below a yield stress** (:math:`\tau_y`) and **flow linearly** with a plastic viscosity (:math:`\eta_p`) once yielded. Named after Eugene Bingham (1922), this is the simplest model capturing yield-stress behavior—materials that require a minimum stress to initiate flow. The Bingham model is foundational for understanding **cement pastes, drilling muds, slurries, toothpaste, mayonnaise, and suspensions** whose post-yield flow curves are approximately Newtonian. The model represents a critical transition in non-Newtonian fluid mechanics: below :math:`\tau_y`, the material acts as an **elastic or rigid solid**; above :math:`\tau_y`, it flows as a **shear-thinning or Newtonian liquid**. This behavior arises from **microstructural networks** (particle contacts, hydrogen bonds, electrostatic interactions) that must be broken before flow can occur. Notation Guide -------------- .. list-table:: :widths: 15 85 :header-rows: 1 * - Symbol - Meaning * - :math:`\tau` - Shear stress (Pa) * - :math:`\tau_y` - Yield stress (Pa). Minimum stress for flow initiation. * - :math:`\dot{\gamma}` - Shear rate (s\ :sup:`-1`) * - :math:`\eta_p` - Plastic viscosity (Pa·s). Post-yield slope. * - :math:`\eta_{app}` - Apparent viscosity (Pa·s) = :math:`\tau/\dot{\gamma}` * - :math:`Bi` - Bingham number = :math:`\tau_y L / (\eta_p U)`. Ratio of yield to viscous stress. Physical Foundation ------------------- **Microstructural Origin of Yield Stress:** The yield stress :math:`\tau_y` arises from: 1. **Particle Networks**: Colloidal particles forming space-spanning structures (e.g., clay suspensions, cement) 2. **Attractive Interactions**: Van der Waals, electrostatic, or depletion forces creating particle bridges 3. **Entangled Structures**: Fiber networks, polymer chains, or droplet clusters 4. **Jamming Transitions**: Dense suspensions where particles cage each other **Post-Yield Flow:** Once :math:`\tau > \tau_y`, the network breaks and particles/droplets flow past each other with a constant viscosity :math:`\eta_p` (plastic viscosity), analogous to Newtonian flow but offset by the yield stress. Governing Equations ------------------- **Constitutive Equation:** .. math:: \tau = \begin{cases} \tau_y \operatorname{sgn}(\dot{\gamma}) & \text{if } |\tau| \le \tau_y \text{ (unyielded)}, \\ \tau_y + \eta_p \dot{\gamma} & \text{if } |\tau| > \tau_y \text{ (yielded)}, \end{cases} where: - :math:`\tau` = shear stress (Pa) - :math:`\dot{\gamma}` = shear rate (s\ :sup:`-1`) - :math:`\tau_y` = yield stress (Pa), :math:`\tau_y \geq 0` - :math:`\eta_p` = plastic viscosity (Pa·s), :math:`\eta_p > 0` **Apparent Viscosity:** .. math:: \eta(\dot{\gamma}) = \frac{\tau_y}{|\dot{\gamma}|} + \eta_p \qquad \text{for } |\dot{\gamma}| > 0 The apparent viscosity **diverges** as :math:`\dot{\gamma} \to 0` (infinite viscosity at very low shear rates). **Flow Curve Interpretation:** Plot :math:`\tau` vs :math:`\dot{\gamma}`: - **Intercept**: :math:`\tau_y` (extrapolation to :math:`\dot{\gamma} = 0`) - **Slope**: :math:`\eta_p` (linear post-yield region) Parameters ---------- .. list-table:: Parameter summary :header-rows: 1 :widths: 24 24 52 * - Name - Units - Description / Constraints * - ``sigma_y`` - Pa - Yield stress; ≥ 0. Sets the plateau torque required to initiate motion. Typical range: 1-500 Pa. * - ``eta_p`` - Pa·s - Plastic viscosity governing the linear post-yield segment; > 0. Typical range: 0.001-10 Pa·s. Material Examples ----------------- **Cement and Construction Materials** (:math:`\tau_y \approx 10-200` Pa, :math:`\eta_p \approx 0.1-5` Pa·s): - **Cement pastes** (water-cement ratio dependent) - **Concrete slurries** (fresh concrete) - **Mortar** and **grouts** - **3D printing inks** (cementitious) **Drilling and Mining Fluids** (:math:`\tau_y \approx 5-50` Pa, :math:`\eta_p \approx 0.01-0.5` Pa·s): - **Bentonite drilling muds** - **Barite-weighted fluids** - **Oil well drilling fluids** **Food Products** (:math:`\tau_y \approx 10-100` Pa, :math:`\eta_p \approx 0.1-5` Pa·s): - **Mayonnaise** (:math:`\tau_y \approx 80-150` Pa) - **Ketchup** (:math:`\tau_y \approx 20-50` Pa) - **Mustard** (:math:`\tau_y \approx 30-70` Pa) - **Chocolate** (molten, :math:`\tau_y \approx 5-20` Pa) **Personal Care and Pharmaceuticals** (:math:`\tau_y \approx 50-300` Pa): - **Toothpaste** (:math:`\tau_y \approx 100-200` Pa) - **Lotions and creams** - **Ointments** and **gels** **Suspensions and Slurries** (:math:`\tau_y \approx 1-100` Pa): - **Clay suspensions** (kaolin, montmorillonite) - **Mineral slurries** (tailings, coal slurries) - **Activated sludge** (wastewater treatment) Experimental Design ------------------- **Flow Curve (Controlled Shear Rate):** 1. **Shear rate sweep**: 0.001-1000 s\ :sup:`-1` (log-spaced, 10 points/decade) 2. **Pre-shear**: High shear rate (100 s\ :sup:`-1`, 60 s) to erase history 3. **Rest period**: 2-5 min to allow structure recovery 4. **Ramp protocol**: Low → high or bidirectional to check thixotropy 5. **Geometry**: **Vane or serrated plates** to minimize wall slip **Yield Stress Determination Methods:** 1. **Flow Curve Extrapolation**: - Linear regression of :math:`\tau` vs :math:`\dot{\gamma}` in post-yield region - Intercept at :math:`\dot{\gamma} = 0` → :math:`\tau_y` - **Caution**: Sensitive to fitting range selection 2. **Controlled Stress Ramp**: - Apply increasing stress, monitor strain rate - :math:`\tau_y` = stress where :math:`\dot{\gamma}` jumps from ~0 to finite value - More reliable for materials with sharp yielding 3. **Vane Method** (ASTM D4648): - Insert vane into sample, rotate at constant speed - Peak torque → :math:`\tau_y` (accounts for 3D geometry) - Minimizes wall slip artifacts **Avoiding Common Artifacts:** - **Wall slip**: Use roughened surfaces, vane geometry, or serrated plates - **Sedimentation**: Short measurement times, homogenize before test - **Evaporation**: Solvent trap, short test duration - **Thixotropy**: Control rest time, use consistent pre-shear protocol Physical Foundations -------------------- Microstructural Origin of Yield Stress ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ The yield stress :math:`\tau_y` arises from: 1. **Particle Networks**: Colloidal particles forming space-spanning structures (e.g., clay suspensions, cement) 2. **Attractive Interactions**: Van der Waals, electrostatic, or depletion forces creating particle bridges 3. **Entangled Structures**: Fiber networks, polymer chains, or droplet clusters 4. **Jamming Transitions**: Dense suspensions where particles cage each other Post-Yield Flow ~~~~~~~~~~~~~~~ Once :math:`\tau > \tau_y`, the network breaks and particles/droplets flow past each other with a constant viscosity :math:`\eta_p` (plastic viscosity), analogous to Newtonian flow but offset by the yield stress. Validity and Assumptions ------------------------ When Bingham Model Applies ~~~~~~~~~~~~~~~~~~~~~~~~~~~ The Bingham model is appropriate when: 1. **Clear yield stress exists**: Material does not flow below a critical stress. The stress-strain rate curve shows a stress intercept at zero rate. 2. **Newtonian post-yield behavior**: After yielding, the material follows linear flow with constant plastic viscosity. 3. **Steady-state flow**: Material reaches equilibrium at each shear rate (no thixotropy or aging during measurement). 4. **No slip at walls**: The material shears uniformly without wall slip. When to Use Alternatives ~~~~~~~~~~~~~~~~~~~~~~~~~ .. list-table:: Model Selection :widths: 35 30 35 :header-rows: 1 * - Observation - Issue - Better Model * - Post-yield shear-thinning/thickening - Non-linear flow beyond yield - :doc:`herschel_bulkley` (:math:`n \neq 1`) * - Fitted :math:`\tau_y` ≈ 0 - No yield stress - :doc:`power_law` or :doc:`carreau` * - Thixotropic hysteresis - Time-dependent structure - Fluidity models, DMT * - Stress overshoot in startup - Viscoelastic effects - Saramito EVP, SGR Fitting Guidance ---------------- Initialization ~~~~~~~~~~~~~~ 1. **From flow curve**: Linear fit of high shear rate region → slope = :math:`\eta_p`, intercept = :math:`\tau_y` 2. **From controlled stress**: Stress at flow onset → :math:`\tau_y` 3. **Robust estimation**: Median of multiple yield determinations Optimization ~~~~~~~~~~~~ - **Use Huber loss** to down-weight noisy pre-yield data - **Weighted least squares**: Higher weights on post-yield region where :math:`\dot{\gamma}` is reliable - **Constrain** :math:`\tau_y \geq 0` and :math:`\eta_p > 0` - **Verify**: Residuals should be random in post-yield region Handling Pre-Yield Data ~~~~~~~~~~~~~~~~~~~~~~~~ - **Option 1**: Exclude data below :math:`\dot{\gamma} < 0.01` s\ :sup:`-1` (noisy, not truly rigid) - **Option 2**: Fit only post-yield region (:math:`\tau > 1.1 \tau_y`) - **Option 3**: Use robust loss (Huber, Tukey) to reduce influence of outliers Troubleshooting ~~~~~~~~~~~~~~~ .. list-table:: :header-rows: 1 :widths: 30 35 35 * - Problem - Cause - Solution * - Negative :math:`\tau_y` estimates - Noisy sub-yield data dominating fit - Use robust loss (Huber), exclude low :math:`\dot{\gamma}` points, or constrain :math:`\tau_y \geq 0` * - Poor fit quality despite linear appearance - Thixotropic hysteresis (up-ramp ≠ down-ramp) - Use consistent pre-shear protocol or fit up/down separately * - Apparent viscosity shows curvature - Material exhibits shear-thinning beyond yielding - Use :doc:`herschel_bulkley` (:math:`n < 1`) or Casson model * - Scatter at low shear rates - Instrument torque resolution, slip, or structural recovery - Use vane geometry, faster ramp rate, or exclude :math:`\dot{\gamma} < 0.01` s\ :sup:`-1` Usage ------------- .. code-block:: python from rheojax.core.jax_config import safe_import_jax jax, jnp = safe_import_jax() from rheojax.models import Bingham # Generate synthetic data (toothpaste) gamma_dot = jnp.logspace(-2, 2, 80) # 0.01 - 100 s⁻¹ tau_exp = 120.0 + 2.5 * gamma_dot + jnp.random.normal(0, 3, size=gamma_dot.shape) # Initialize and fit model = Bingham() model.parameters.set_value('sigma_y', 120.0) model.parameters.set_value('eta_p', 2.5) model.fit(gamma_dot, tau_exp, loss="huber", ftol=1e-6) # Inspect fitted parameters print(f"Yield stress: {model.parameters.get_value('sigma_y'):.2f} Pa") print(f"Plastic viscosity: {model.parameters.get_value('eta_p'):.3f} Pa·s") # Predict and plot tau_pred = model.predict(gamma_dot) Model Comparison ---------------- **Bingham vs Herschel-Bulkley:** - **Bingham**: Linear post-yield (:math:`n = 1`) - **Herschel-Bulkley**: Power-law post-yield (:math:`\tau = \tau_y + K\dot{\gamma}^n`) - Use Bingham when post-yield flow is Newtonian; HB for shear-thinning/thickening **Bingham vs Casson:** - **Bingham**: :math:`\tau = \tau_y + \eta_p \dot{\gamma}` - **Casson**: :math:`\sqrt{\tau} = \sqrt{\tau_y} + \sqrt{\eta_{\infty} \dot{\gamma}}` - Casson better for **blood** and **chocolate**; Bingham for suspensions **Bingham vs Carreau:** - **Bingham**: Discontinuous yielding - **Carreau**: Smooth shear-thinning without yield - Combine for materials with both yield stress and gradual thinning Limitations ----------- 1. **Pre-yield behavior**: Assumes rigid solid; real materials show viscoelastic creep 2. **Sharp yielding**: Real yield is gradual transition, not instantaneous 3. **Newtonian post-yield**: Cannot capture shear-thinning/thickening beyond yield 4. **No thixotropy**: Static model, ignores structural evolution 5. **Wall slip**: Requires careful geometry selection What You Can Learn ------------------ This section explains how to translate fitted Bingham parameters into material insights and actionable knowledge for both research and industrial applications. Parameter Interpretation ~~~~~~~~~~~~~~~~~~~~~~~~ **Yield Stress (** :math:`\tau_y` **)**: The yield stress reveals the strength of the material's internal network: - **Low yield stress (< 10 Pa)**: Weak structure. Material flows easily under gravity or light handling. Examples: dilute suspensions, low-fat mayo. - **Moderate yield stress (10–100 Pa)**: Functional structure for most applications. Sufficient to prevent sedimentation and sagging, yet dispensable with reasonable force. - **High yield stress (> 100 Pa)**: Strong network requiring significant force to initiate flow. Examples: toothpaste, heavy-duty grease, cement paste. *For graduate students*: The yield stress scales with microstructural parameters. For colloidal suspensions: :math:`\tau_y \propto \phi^2 G_p / a` where :math:`\phi` is volume fraction, :math:`G_p` is particle modulus, and :math:`a` is particle size. For attractive systems, :math:`\tau_y` increases exponentially with interparticle attraction strength. *For practitioners*: Use :math:`\tau_y` to assess shelf stability. A mayonnaise needs :math:`\tau_y > 50` Pa to prevent oil separation; a paint needs :math:`\tau_y > 5` Pa to avoid sagging on vertical surfaces. **Plastic Viscosity (** :math:`\eta_p` **)**: The plastic viscosity governs post-yield energy dissipation: - **Low** :math:`\eta_p` **(< 0.1 Pa·s)**: Thin flow once yielded. Good for easy pumping but may cause splashing or poor coating uniformity. - **Moderate** :math:`\eta_p` **(0.1–5 Pa·s)**: Balanced flow. Typical for most applications requiring controlled spreading or mixing. - **High** :math:`\eta_p` **(> 5 Pa·s)**: Viscous flow requiring sustained energy input. Common in heavy pastes and slurries. *For graduate students*: The plastic viscosity includes contributions from the continuous phase viscosity, hydrodynamic interactions between particles, and the rate of network breakdown. For concentrated suspensions: :math:`\eta_p \approx \eta_s (1 - \phi/\phi_m)^{-2}` where :math:`\phi_m` is the maximum packing fraction. *For practitioners*: The pumping power scales with :math:`\eta_p`. Reducing particle size or concentration lowers :math:`\eta_p` and pumping costs, but may also reduce :math:`\tau_y` and shelf stability. Material Classification ~~~~~~~~~~~~~~~~~~~~~~~ .. list-table:: Bingham Fluid Classification :header-rows: 1 :widths: 20 20 30 30 * - :math:`\tau_y / \eta_p` Ratio - Behavior - Typical Materials - Process Implications * - Low ratio (< 10 s\ :math:`^{-1}`) - "Thick and easy" - Light sauces, thin lotions - Easy pumping, gravity flow possible * - Moderate (10–100 s\ :math:`^{-1}`) - Balanced plasticity - Mayonnaise, drilling mud - Standard processing equipment * - High ratio (> 100 s\ :math:`^{-1}`) - "Stiff paste" - Toothpaste, cement - High pressure extrusion needed The ratio :math:`\tau_y / \eta_p` has units of shear rate and indicates the characteristic rate where yield stress and viscous stress are comparable. Engineering Applications ~~~~~~~~~~~~~~~~~~~~~~~~ **Pipe Flow Design**: The Buckingham-Reiner equation predicts pressure drop: .. math:: \frac{\Delta P}{L} = \frac{8 \eta_p Q}{\pi R^4} \left[1 + \frac{1}{3} Bi - \frac{4}{3} Bi^{-3} \right]^{-1} where :math:`Bi = \tau_y R / (\eta_p \bar{v})` is the Bingham number. For :math:`Bi > 3`, plug flow dominates and pressure scales with :math:`\tau_y/R`. **Coating and Spreading**: For gravity-driven leveling on an inclined surface: - Material will not flow if :math:`\tau_y > \rho g h \sin\theta` - Use this to size layer thickness :math:`h` for sag prevention **Mixing Power**: Anchor or helical impellers are preferred. Power requirement scales as: .. math:: P \propto \tau_y V + \eta_p (\dot{\gamma}_{avg}) V where :math:`V` is vessel volume and :math:`\dot{\gamma}_{avg}` is average shear rate in the mixer. Diagnostic Indicators ~~~~~~~~~~~~~~~~~~~~~ Warning signs in fitted parameters: - :math:`\tau_y` **→ 0**: Material is Newtonian or nearly so. Check if yield stress model is appropriate; consider using :doc:`carreau` instead. - :math:`\tau_y` **negative**: Fitting artifact from noisy low-rate data. Constrain to :math:`\tau_y \geq 0` or use robust fitting. - :math:`\eta_p` **unexpectedly low**: Check for wall slip or instrument calibration issues. - **Strong correlation between** :math:`\tau_y` **and** :math:`\eta_p`: Insufficient data range. Extend measurements to higher shear rates for better separation. - **Systematic residuals**: If residuals curve, the material shows shear-thinning post-yield. Use :doc:`herschel_bulkley` instead. Application Examples ~~~~~~~~~~~~~~~~~~~~ **Quality Control for Food Products**: Monitor :math:`\tau_y` as primary QC metric. A 20% drop in :math:`\tau_y` indicates batch problems (wrong emulsifier ratio, insufficient homogenization). **Drilling Mud Formulation**: Target :math:`\tau_y = 5-15` Pa for cuttings suspension with :math:`\eta_p` < 0.1 Pa·s for easy circulation. The API recommends reporting both 6 rpm and 300 rpm readings for Bingham analysis. **Cement Mix Design**: Fresh concrete workability correlates with Bingham parameters. Self-compacting concrete requires :math:`\tau_y < 60` Pa and :math:`\eta_p < 50` Pa·s. Fitting Guidance ---------------- Initialization ~~~~~~~~~~~~~~ 1. **From flow curve**: Linear fit of high shear rate region → slope = :math:`\eta_p`, intercept = :math:`\tau_y` 2. **From controlled stress**: Stress at flow onset → :math:`\tau_y` 3. **Robust estimation**: Median of multiple yield determinations Optimization ~~~~~~~~~~~~ - **Use Huber loss** to down-weight noisy pre-yield data - **Weighted least squares**: Higher weights on post-yield region where :math:`\dot{\gamma}` is reliable - **Constrain** :math:`\tau_y \geq 0` and :math:`\eta_p > 0` - **Verify**: Residuals should be random in post-yield region Handling Pre-Yield Data ~~~~~~~~~~~~~~~~~~~~~~~~ - **Option 1**: Exclude data below :math:`\dot{\gamma} < 0.01` s\ :sup:`-1` (noisy, not truly rigid) - **Option 2**: Fit only post-yield region (:math:`\tau > 1.1 \tau_y`) - **Option 3**: Use robust loss (Huber, Tukey) to reduce influence of outliers Troubleshooting ~~~~~~~~~~~~~~~ .. list-table:: :header-rows: 1 :widths: 30 35 35 * - Problem - Cause - Solution * - Negative :math:`\tau_y` estimates - Noisy sub-yield data dominating fit - Use robust loss (Huber), exclude low :math:`\dot{\gamma}` points, or constrain :math:`\tau_y \geq 0` * - Poor fit quality despite linear appearance - Thixotropic hysteresis (up-ramp ≠ down-ramp) - Use consistent pre-shear protocol or fit up/down separately * - Apparent viscosity shows curvature - Material exhibits shear-thinning beyond yielding - Use :doc:`herschel_bulkley` (:math:`n < 1`) or Casson model * - Scatter at low shear rates - Instrument torque resolution, slip, or structural recovery - Use vane geometry, faster ramp rate, or exclude :math:`\dot{\gamma} < 0.01` s\ :sup:`-1` Tips & Best Practices ---------------------- 1. **Pre-shear consistently**: Erase mechanical history before each measurement 2. **Use vane geometry**: Minimizes wall slip for yield stress materials 3. **Bidirectional sweeps**: Check for thixotropic hysteresis 4. **Robust fitting**: Huber or Tukey loss to handle pre-yield noise 5. **Validate yield stress**: Compare flow curve, stress ramp, and vane methods 6. **Temperature control**: :math:`\tau_y` and :math:`\eta_p` are temperature-sensitive (±0.1°C) 7. **Avoid evaporation**: Use solvent trap for aqueous systems References ---------- .. [1] Bingham, E. C. *Fluidity and Plasticity*. McGraw-Hill, New York (1922). The original description of the Bingham plastic model. .. [2] Barnes, H. A. "The yield stress—a review or 'παντα ρει'—everything flows?" *Journal of Non-Newtonian Fluid Mechanics*, 81, 133–178 (1999). https://doi.org/10.1016/S0377-0257(98)00094-9 .. [3] Coussot, P., and Ancey, C. "Rheophysical classification of concentrated suspensions and granular pastes." *Physical Review E*, 59, 4445–4457 (1999). https://doi.org/10.1103/PhysRevE.59.4445 .. [4] Larson, R. G. *The Structure and Rheology of Complex Fluids*. Oxford University Press, New York (1999). ISBN: 978-0195121971 .. [5] Coussot, P. *Rheometry of Pastes, Suspensions, and Granular Materials: Applications in Industry and Environment*. Wiley (2005). https://doi.org/10.1002/0471720577 .. [6] Balmforth, N. J., Frigaard, I. A., and Ovarlez, G. "Yielding to stress: Recent developments in viscoplastic fluid mechanics." *Annual Review of Fluid Mechanics*, 46, 121–146 (2014). https://doi.org/10.1146/annurev-fluid-010313-141424 .. [7] Cheng, D. C.-H. "Yield stress: A time-dependent property and how to measure it." *Rheologica Acta*, 25, 542–554 (1986). https://doi.org/10.1007/BF01774406 .. [8] Macosko, C. W. *Rheology: Principles, Measurements, and Applications*. Wiley-VCH, New York (1994). ISBN: 978-0471185758 .. [9] Mewis, J., and Wagner, N. J. *Colloidal Suspension Rheology*. Cambridge University Press (2012). ISBN: 978-0521515993 .. [10] Møller, P. C. F., Mewis, J., and Bonn, D. "Yield stress and thixotropy: On the difficulty of measuring yield stresses in practice." *Soft Matter*, 2, 274–283 (2006). https://doi.org/10.1039/b517840a See Also -------- Related Flow Models ~~~~~~~~~~~~~~~~~~~ - :doc:`herschel_bulkley` — generalizes Bingham with power-law post-yield slope (:math:`n \neq 1`) - :doc:`power_law` — zero-yield limit for simple shear-thinning/thickening fits - :doc:`carreau` — smooth transition between Newtonian plateaus without yield - :doc:`../fractional/fractional_zener_sl` — combines fractional relaxation with elastic plateau Transforms ~~~~~~~~~~ - :doc:`../../transforms/smooth_derivative` — differentiate torque signals for stress calculation - :doc:`../../transforms/mutation_number` — monitor structural breakdown during yielding Examples ~~~~~~~~ - :doc:`../../examples/flow/01-bingham-fitting` — step-by-step Bingham parameter estimation - :doc:`../../examples/advanced/02-yield-stress-comparison` — comparing Bingham, HB, and Casson