Particle morphology has great influence on mechanical behaviour and hydro/thermal/electrical conductivities of granular materials. Surface reconstruction and mesh generation are critical to consider realistic particle shapes in various computational simulations. This study adopts the combined finite- discrete element method (FDEM) to investigate single particle crushing behaviour. Particle shapes were reconstructed with spherical harmonic (SH) in both spherical and Cartesian coordinate systems. Furthermore, the reconstructed surface mesh qualities in two coordinate systems are investigated and compared. Although the efficiency of the two SH systems in reconstructing star-like shapes is nearly identical, SH in Cartesian coordinate system can reconstruct non-star-like shapes with the help of surface parameterisation. Meanwhile, a higher triangular mesh quality is generated with spherical coordinate. In single particle crushing tests, the low mesh quality produces more fluctuations on load–displacement curves. The particles with more surficial mesh elements tend to have a lower contact stiffness due to more contact stress concentrations induced by complexity of morphology features and more volumetric tetrahedral elements. The fracture patterns are also influenced by mesh quality and density, e.g. a particle with fewer mesh elements has a simpler fragmentation pattern. This study serves as an essential step towards modelling particle breakage using FDEM with surface mesh directly from SH reconstruction.

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Keywords: Numerical modelling, Particle morphology, Particle crushing/crushability, Particle-scale behaviour, Sands