Torque Analysis of a Gyratory Crusher with the Discrete Element Method

Moncada, Manuel; Toledo, Patricio; Concha, F.; Rodríguez, Cristian

doi:10.3390/min11080878

Cited by 16 publications

(7 citation statements)

References 42 publications

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“…In studies carried out on crushers that have a conical structure rather than a beam structure, heat treatment [18] was applied on a cone crusher surface to increase the resistance to abrasion. Gyratory crusher torque analysis [19] was analyzed with discrete element method and found that large particles cause to decrease the crushing torque.…”

Section: Methodsmentioning

confidence: 99%

Effect of Crusher Arm Position and Surface Friction on the Mechanical Behaviour of a Crusher under Static Conditions

Yavuz

2024

Hittite Journal of Science and Engineering

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Crushers are utilized to break down or crush various components in industrial applications are subjected to high stresses. The crushing process is carried out by a crusher arm located on the crusher itself. The shape and length of the crusher arm influence the deformation on the arm and the efficiency of crushing process. During the crushing process, stress concentrations occur at the contact regions and especially at the connection location of the crusher arm and the drive shaft. This study examined the connection of the crusher arm at various positions on the shaft and explored variations in stress. Finite element analysis was used in the analyses. The used material is standard steel that behaved elastically. The stresses changed in a way that was not proportional to the movement of the tangential crusher arm towards the center of the shaft. The d=8 mm and d=24 mm locations are the most suitable places to move the crusher arm rather than the tangential position (d=40 mm). The highest stresses occurred at the corners where the shaft and crusher arm connected and formed a stress concentration. The friction effects on the contact surface were also examined and the increased friction coefficient slightly reduced the stress values of the crusher system, but increased the stresses on the crushed object. Only maximum stress levels that are observed at the surface of the beam are mainly considered. The results regarding the crusher arm are discussed in detail.

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Section: Methodsmentioning

confidence: 99%

Effect of Crusher Arm Position and Surface Friction on the Mechanical Behaviour of a Crusher under Static Conditions

Yavuz

2024

Hittite Journal of Science and Engineering

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“…To the knowledge of the authors, there has been no solution reported for online wear monitoring of gyratory crusher liners. Recent advancements in discrete element modelling (DEM) have enabled the simulation of industrial-scale gyratory crushers [15][16][17]. Particle breakage models were developed and incorporated into DEM to study the size reduction process of rock.…”

Section: Introductionmentioning

confidence: 99%

“…Additionally, the liner's wear life also largely relies on its material selection. Materials with higher abrasion wear resistance, such as high manga- Recent advancements in discrete element modelling (DEM) have enabled the simulation of industrial-scale gyratory crushers [15][16][17]. Particle breakage models were developed and incorporated into DEM to study the size reduction process of rock.…”

Section: Introductionmentioning

confidence: 99%

Modelling of Gyratory Crusher Liner Wear Using a Digital Wireless Sensor

Ou,

Chen

2023

Sensors

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A gyratory crusher is a key mineral processing asset in a comminution circuit. Monitoring and predicting the crusher liner wear is essential to ensure the throughput and product quality are maintained during production. This study developed a digital sensor and a discrete element modelling (DEM)-coupled methodology to monitor and reconstruct the gyratory crusher concave liner wear pattern. The developed digital sensor was able to track and report the live thickness of the specific installation point on a concave liner during operation. A wear reconstruction model was then developed based on the wear intensity obtained using the DEM and digital sensor results. The wear reconstruction model predictive results were subsequently compared with site measurements after 95 days of operation. The results indicated that the wear reconstruction model showed good agreement with measured results in terms of wear zone distribution as well as quantitative wear rate prediction. The outcome of this study can be potentially utilised in the mineral processing industry for plant monitoring and automation.

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“…Different methods such as ignoring particle shapes (using only spherical particles), particle upscaling, coarse grain modeling, and periodic simulations have been proposed to reduce the related complexity and computational cost. For example, Moncada et al [19] successfully developed and validated a DEM model to predict the performance of a gyratory crusher. The validation was performed in terms of throughput, crushed particle size, and crushing power and the effects of particle size on power consumption, torque force, and equipment fatigue were investigated.…”

Section: Introductionmentioning

confidence: 99%

“…For example, Moncada et al [ 19 ] successfully developed and validated a DEM model to predict the performance of a gyratory crusher. The validation was performed in terms of throughput, crushed particle size, and crushing power and the effects of particle size on power consumption, torque force, and equipment fatigue were investigated.…”

Section: Introductionmentioning

confidence: 99%