Optimization Design Of Large Gyratory Crusher Chamber Shape And DEM Simulation For Its Performance

This article was based on the National Key Technology R&D Program(Development of semi-continuous mining equipment–The Mobile CrushingScreening Station used in glory-hole (NO.2012AA062002)) focusing on theperformance optimization of the large gyratory crusher assembled on the station. Fourmain chapters were represented in this paper: theory of rock breakage, analysis ofcrusher performance, optimization of the crusher chamber shape and the crusherperformance simulation with EDEM.Research status on design of gyratory crusher was firstly introduced as well as itsbasic structure and operation theory. Then the design feature and advantages ofgyratory crusher were summarized. Besides, the optimization theory for the chambershape and the application of EDEM on simulating the performance of crushers wereoverviewed.The gyratory crusher manipulation model of hematite, which could be described asthree functions: the crushing function, the selection function and the crushing forcedistribution function was built based on the inter-particle breakage theory. Adeveloped computing method was raised for determining the reasonable speed rangebased on the kinematic analysis of the main shaft. Moreover, the location of eachbroken layer was calculated so that the force distribution along the main shaft and thechock position was confirmed. The distribution of velocity and size of particle inchock level were calculated to gain both the theoretical and practical productivity ofthe gyratory crusher. What’s more, the impact of motion parameters on theperformance of gyratory crusher was analyzed and based on which the chamber shapewas optimized in order to gain the maximum theoretical productivity with theeffective particle rate, the number of crushing and the geometry of the crusher meetthe constraints.The DEM method was applied to simulate the practical performance of either theoriginal or the optimized chamber shape with the software of EDEM to prove theaccuracy and the correctness of the manipulation model as well as the kinematicanalysis of the main shaft. The simulation result indicated that there exists asignificant improvement in the optimized gyratory crusher chamber shape.The manipulation model and the iterative algorithm for calculating the chockposition base on the kinematic analysis of the main shaft had a certain academicsignificance while the optimization of the chamber shape had an obvious engineeringsignificance. The application of EDEM for crusher performance simulation offered areference method in crusher output prediction.