A Dynamic Model of Inertia Cone Crusher Using the Discrete Element Method and Multi-Body Dynamics Coupling

Abstract

The cone crusher is an indispensable equipment in complex ore mineral processing and a variant of the cone crusher is the inertia cone crusher. A real-time dynamic model based on the multibody dynamic and discrete element method is established to analyze the performance of the inertia cone crusher. This model considers an accurate description of the mechanical motions, the nonlinear contact, and the ore material loading response. Especially the calibration of ore material simulated parameters is based on the Taguchi method for the Design of Experiments. For model verification, the industrial-scale experiment was conducted on a GYP1200 inertia cone crusher. Two different drive speeds were included in the experiments, and the testing devices were used to acquire crusher performances, for instance, displacement amplitude, power draw, product size distribution, and throughput capacity in order to accurately compare simulation results. The preliminary model can be qualitatively evaluated the flow pattern of particles and quantitatively evaluated the crushing force distribution in the concave. Furthermore, the simulation predicts the variety of crusher performances using the drive speed and the fixed cone mass as input variables. The simulation model provides novel insight regarding the improvement of linings wear period, lowering manufacturing cost, and obtaining optimal operation parameters.

Influence of Two Mass Variables on Inertia Cone Crusher Performance and Optimization of Dynamic Balance

“…The BPM consists of bonding a packed distribution of particles, forming a breakage cluster [19]. As shown in Figure 2, a parallel bonding beam is created between each particle in contact, so the forces (torques) on the bonding beam are calculated from Equation (8) and Equation (9). BPM has been used in simulating the crushing behavior of particles [13,20,21].…”

“…However, these simulation methods do not have the ability to take into account the effect of inertia parameters (fixed cone and moving cone mass) on operation performance (crushing force, amplitude and average power) for an inertia cone crusher. Cheng et al [9] provided a powerful method whereby the coupling multi-body dynamics (MBD) [10,11] and discrete element method (DEM) [12,13] simulate the crushing behavior response for an inertia cone crusher. Currently no research using coupled MBD-DEM dynamic models for an inertia cone crusher has been published, except for our publication [9].…”

“…Cheng et al [9] provided a powerful method whereby the coupling multi-body dynamics (MBD) [10,11] and discrete element method (DEM) [12,13] simulate the crushing behavior response for an inertia cone crusher. Currently no research using coupled MBD-DEM dynamic models for an inertia cone crusher has been published, except for our publication [9]. Barrios et al [14] and Chung et al [15], regarding coupled MBD-DEM models, provided useful attempts for high-pressure grinding rolls (HPGR).…”

An Improved Capacity Model of the Cone Crushers Based on the Motion Characteristics of Particles Considering the Influence of the Spatial Compound Motion of the Mantle

“…Chen et al [24] discussed the influence of the concave curve radius, eccentric angle, and mantle shaft speed of the gyratory crusher on the crushing chamber performance based on the DEM analysis model. Cheng et al [25] established a real-time dynamic model based on the multibody dynamic and discrete element method, and the paths of particles in the inertia cone crusher with sliding, free-fall, and squeezing were obtained visually. However, in the existing research of the capacity model of the cone crusher, the particularity of the structure of the cone crusher is not considered, the influence of the spatial compound motion of the mantle on the motion characteristics of the particles is ignored, and the velocity variation along the radial direction when the particles pass through the choke-level is not investigated.…”

Torque Analysis of a Gyratory Crusher with the Discrete Element Method

“…Their results provided good agreement with experiments for throughput with a relative error of 9.6, 10.4, and 37.9% for the three cases presented, but the findings reported a deviation up to a 50% for specific energy and product size. A multibody dynamic and discrete element method was presented to analyze the performance of the GYP1200 inertia cone crusher, and it was contrasted with experimental data, obtaining a 4% of relative error in both power draw and throughput for the 400 rpm case, 11% error in power draw, and a 22% error in throughput for the 600 rpm case [19]. Complete research of comminution modeling was presented by Cleary et al, focusing on recent advances in particle-based modeling of crushing [20].…”