Evaluating the performance of cone crushers under various feeding conditions using DEM and coupled DEM-MBS simulations

Cone crushers are used in both the construction and mining industries for the production of aggregates and extraction of ores. Aggregates are used when building for example houses, roads and railways, hence the cone crushers are a vital part of modern society. To ensure the performance of the cone crusher, it is important to properly adjust the feeding conditions. Using computational methods to virtually analyze the performance of the crushers is a more time and cost efficient solution compared to physical testing. This thesis was divided into two parts, where the main objective of the first part was to use the discrete element method (DEM) to analyze the segregation in cone crushers. Three different methods were developed, which later were utilized to compare the segregation for four different feeding conditions. Two of the analysis methods only considered the segregation in the feed hopper, whilst the third method aimed to give an understanding ofthe segregation inside the crushing chamber. The two first methods could successfully be used to compare how segregated the feed material was for the four feeding conditions, however, the third method proved to be both hard to validate and highly dependent on proper material flow inside the crushing chamber. The main objective during the second part of the thesis was to investigate the possibility of running the DEM simulations coupled to a multibody simulation (MBS) software. The simulation routine was then used to compare the foundation loads for the same four feeding conditions as in the first part. The subframe was later modeled as a flexible body to analyze and compare the stresses the subframe was subject to during operation for the same four feeding conditions. Setting up and running the coupled simulation was successful. Different simulation settings were tested, anda general guideline on how those settings should be defined was set up. The actual impact the coupling had on the foundation loads and stresses in the subframe was however almost non-existent. This could probably be directly related to the fact that the crushing forces in EDEM are known to be many times smaller than what they have been measured to in experiments. This also meant that changing the feeding conditions to alter the segregation did not have a noticeable effect on the results