A conical crusher cavity type parameter optimization method based on EDEM

Abstract

This invention discloses a method for optimizing the cavity parameters of a cone crusher based on EDEM (Edge Analyzer Model). The specific steps include establishing an assembly model of the moving and fixed cone liners of the cone crusher, constructing an EDEM-based simulation of the crushing process, and analyzing the simulation results to determine the crushing efficiency and liner wear rate under different cavity parameters, thereby optimizing the cavity parameters of the cone crusher. This invention utilizes EDEM software to optimize the cavity parameters of the cone crusher, using the fracture of bonded joints to reflect the crushing efficiency, analyzing the required strength of the liner material through the pressure distribution on the surfaces of the moving and fixed cones, and comparing the pressure changes on the surfaces of the moving and fixed cone liners under different cavity parameters to reflect the liner wear rate. This allows for the acquisition of optimal cavity parameters, continuously improving crushing efficiency, and providing an intuitive and reliable method for optimizing the cavity parameters of a cone crusher.

Description

Technical Field

[0001] This invention belongs to the field of cone crusher design technology, specifically relating to a method for optimizing cone crusher cavity parameters based on EDEM. Background Technology

[0002] Cone crushers, as key equipment in mining material crushing, are mainly used in the medium and fine crushing stages of ores. With the increasing promotion of "crushing instead of grinding," the application of cone crushers has become more widespread. The moving and fixed cone liners of a cone crusher are constantly subjected to grinding and impact from the ore during service, resulting in harsh working conditions and making them the most significant consumable parts in the crushing process. The moving and fixed cone liners constitute the main working space of the cone crusher, namely the crushing chamber. Therefore, effectively controlling the chamber shape parameters is crucial for improving crushing quality, uniformizing ore particle size, and increasing crusher production efficiency. Research shows that the working state of a cone crusher can be simulated using EDEM discrete element simulation software, thereby reflecting the service status of the moving and fixed cone liners, thus improving the crushing efficiency of the cone crusher and reducing liner wear. EDEM mainly consists of a Creator, a Simulator, and an Analyst. Creator is the pre-processing tool, handling the import of geometric models, the creation of particle models, and the setting of material parameters. Simulator is the solver, used to simulate the motion of the particle system. Analyst is the post-processing module, exporting and analyzing results based on the problem being studied. Typically, the Bond Particle Model (BPM) method is used to construct the particle crushing model during simulation. This method accurately reflects the characteristics of the ore to be crushed (its motion, stress, and crushing behavior within the crushing chamber). In EDEM, small particles are filled into the ore model (large particles), and then these small particles replace the ore model, generating bonds between the small particles to maintain the ore shape. The particle replacement method involves writing a particle replacement API file and importing it into EDEM. The method for generating bonds involves selecting the Hertz-Mindlin with bonding model as the particle-to-particle contact model in EDEM and setting the corresponding parameters. The Hertz-Mindlin with bonding model is commonly used to simulate material crushing and fracture problems.

[0003] Due to the complex operating conditions of cone crushers, and the large number of cone crusher models currently in use, the cavity parameters of cone crushers are often calibrated based on experience accumulated during actual production, lacking a direct and effective calibration method. Reference 1 (Lü Ning, 2020; Master's Thesis, Huaqiao University) reports that, based on the theory of layered crushing and the material motion law, the curves of the moving and fixed cones were optimized, and the optimized cavity curves were plotted using MATLAB simulation. Reference 2 (Pan Weiqiao, 2020; Master's Thesis, Taiyuan University of Science and Technology) reports that, through MATLAB numerical simulation, the cavity curves achieved optimal matching with the structural and performance parameters of the cone crusher. Chinese invention patent CN110020481A discloses a multi-gradient structure reinforced cone crusher liner and its design method. The multi-gradient structure reinforced cone crusher liner includes a moving cone liner and a fixed cone liner. Multiple sets of cast alloy are provided on the working surface facing the crushing chamber. The design method provides a basis for determining the distribution density, maximum size of the exposed surface and specific shape of the cast alloy based on the particle size distribution difference and the wear characteristic curve of the liner.

[0004] The shortcomings of the methods described in the above-mentioned literature and patents are as follows: 1) The method of optimizing the grinding zone curve of the moving cone liner and fixed cone liner of the cone crusher based on MATLAB numerical simulation is relatively cumbersome and lacks intuitiveness; 2) Most of the invention patents of the same type describe a certain shape change of the moving cone liner and fixed cone liner of the cone crusher, rather than a universally applicable optimization method for various models of moving cone liner and fixed cone liner of the cone crusher, and there is a lack of relevant research results in this regard. Summary of the Invention

[0005] The purpose of this invention is to provide a method for optimizing the cavity shape parameters of a cone crusher based on EDEM. The key technical problem to be solved is to study the crushing efficiency and service condition of the liner for different cone crusher models, optimize the cavity shape of the cone crusher liner, and improve economic efficiency.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] The present invention provides a method for optimizing the cavity parameters of a cone crusher based on EDEM, characterized by comprising the following steps:

[0008] Step 1: Establishing the assembly model of the moving cone and fixed cone liner of the cone crusher. The specific steps are as follows:

[0009] S1.1 Adjust and combine the cavity parameters of the cone crusher, the height difference h between the top surfaces of the moving cone and the fixed cone and the precession angle γ0. Use CAD drawing software to assemble the moving cone liner and the fixed cone liner. Measure the parallel zone length l, the minimum value a of the tight side and the minimum value b of the wide side of the cone crusher crushing cavity under different cavity parameter combinations.

[0010] S1.2. Based on the actual crushing requirements in production, determine the minimum tight side value a and the minimum wide side value b of the cone crusher under different combinations of the height difference h between the top surfaces of the moving cone and the fixed cone and the precession angle γ0. Select the cavity parameter combination that best meets the crushing requirements and use SOLIDWORKS 3D modeling software to establish the assembly model of the moving cone and fixed cone liner of the cone crusher.

[0011] Step 2: Constructing the simulation model of the cone crusher crushing process based on EDEM. The specific steps are as follows:

[0012] S2.1 Set material property parameters and interaction coefficients and add particles.

[0013] In the EDEM software, two types of ore materials and liner materials are added. The material property parameters of the ore and liner materials are set according to the material characteristics of the ore and liner in the actual crushing process. The interaction coefficient between the ore and liner is also set, with the interaction coefficients being the same for both ore materials and the interaction coefficients of the liner material on both ore materials being the same. A single large spherical particle is added under one type of ore material, and the radius of the large spherical particle is set according to the actual size of the ore. A single small spherical particle is added under the other type of ore material, and the radius and contact radius of the small spherical particle are set according to the particle size of the crushed ore.

[0014] S2.2 Import the assembly model of the moving cone and fixed cone liner of the cone crusher and establish the pellet plant.

[0015] Import the assembly model of the moving cone and fixed cone liner of the cone crusher from step 1 into EDEM. Set the material of the assembly model of the moving cone and fixed cone liner of the cone crusher to the liner material. Set the rotation speed of the moving cone liner according to the actual working conditions. Then set an annular pellet plant above the crusher. Large spherical particles will be randomly generated in the pellet plant and enter the crushing chamber under the action of gravity.

[0016] S2.3. Write and import the particle replacement API file to replace the large spherical particles with small spherical particles. The specific steps are as follows:

[0017] Write the position coordinates of the small spherical particles after replacement into the Particle_Cluster_Data.txt text file, and write the names of the large spherical particles to be replaced and the small spherical particles used for replacement, as well as the start time of replacement, into the Particle_Replacement_prefs.txt text file. The ParticleReplacement.dll application extension file can be directly read by EDEM. Place these three files in the same root directory of the simulation, and then import the ParticleReplacement plugin into EDEM's PluginFactories and add ParticleReplacement in the particle volume forces. This plugin will call the contents of Particle_Cluster_Data.txt and Particle_Replacement_prefs.txt. Under the action of particle volume forces, the large spherical particles are removed, and the small spherical particles take their place, thus completing the particle replacement.

[0018] S2.4. Forming adhesive bonds between the replaced small spherical particles.

[0019] In EDEM, the contact model between small spherical particles is set as the Hertz-Mindlin with bonding model. Then, based on the radius of the small spherical particles and the properties of the ore material, the normal and tangential stiffness coefficients per unit area, the critical normal and tangential stresses are calculated. The start time of bond formation and the bonding radius are set. The start time is generally 10 seconds later than the particle replacement time. -3 s, the bonding radius is generally 1.5 times the radius of the small spherical particles;

[0020] S2.5. Set the simulation parameters and start the simulation.

[0021] The total simulation time of EDEM is set according to the actual speed of the crusher to ensure that the moving cone rotates at least once. The time step is adjusted within a certain range to allow the bonding bonds to be generated and kept stable. The mesh size is set to 2 to 3 times the minimum spherical particle radius, and then the simulation is started.

[0022] Step 3: Analyze the results of EDEM simulation and determine the advantages and disadvantages of different crusher crushing efficiency and liner wear rate under different cavity parameters. The specific steps are as follows:

[0023] S3.1. Export the bond fracture data over time from the EDEM to determine the crushing efficiency of the crusher under different cavity parameters. The specific operation is as follows:

[0024] In the Analyst interface, select Create Graph. Then, in the Line option, select bond, switch the Type to small spherical particles, set the X-axis to time, and the Y-axis to Number of intact bonds. Click Create Graph. Export a graph showing the number of bond bonds changing over time under different assembly conditions. By analyzing the breakage of bond bonds, determine the crushing efficiency of the crusher under different cavity parameters.

[0025] S3.2. Export the curves of surface pressure on the moving and fixed cone liners over time from the EDEM, analyze the required strength of the liner material, and determine the advantages and disadvantages of different liner wear rates under different cavity parameters. The specific operation is as follows:

[0026] In the Analyst interface, select Create Graph. Then, in the Line option, select Geometry. Switch the Sections to Moving Cone Liner and Fixed Cone Liner, set the X-axis to Time, the Y-axis to Pressure, and the Component to Maximum. Then click Create Graph. Export the curves showing the maximum pressure on the surfaces of the Moving and Fixed Cone Liners under different assembly conditions as a function of time. By analyzing the changes in the pressure on the liner surfaces, determine the basic mechanical properties of the liner material and assess the advantages and disadvantages of different liner wear rates under different cavity parameters.

[0027] Compared with the prior art, the advantages of the present invention are as follows:

[0028] (1) This invention uses EDEM software to optimize the cavity parameters of a cone crusher, uses the fracture of the bond to reflect the crushing efficiency of the crusher, analyzes the required strength of the liner material by the pressure distribution on the surface of the moving and fixed cones, compares the changes in surface pressure of the moving and fixed cones under different cavity parameters, and thus reflects the wear rate of the liner, thereby obtaining the optimal cavity parameters and continuously improving the crushing efficiency. This provides an intuitive and reliable method for optimizing the cavity parameters of a cone crusher.

[0029] (2) The method for optimizing the cavity shape parameters of the cone crusher liner of the present invention is applicable to all crusher models and has universality.

[0030] (3) The cone crusher optimization method described in this invention is intuitive and easy to operate. Attached Figure Description

[0031] Figure 1 This is a flowchart illustrating the structure of the present invention.

[0032] Figure 2 is a three-dimensional model of the assembly of the moving cone and the fixed cone of the present invention:

[0033] (a) When the height difference between the top surfaces of the moving cone and the fixed cone is 0 mm and the precession angle is 1°, the moving cone and the fixed cone are assembled into a model.

[0034] (b) When the height difference between the top surfaces of the moving cone and the fixed cone is 10 mm and the precession angle is 1.5°, the moving cone and the fixed cone are assembled into a model;

[0035] (c) When the height difference between the top surfaces of the moving cone and the fixed cone is 25mm and the precession angle is 2°, the moving cone and the fixed cone are assembled into a model.

[0036] Figure 3 This is a flowchart illustrating the process of writing and importing the particle replacement API file for this invention.

[0037] Figure 4 The graph shows the change in the number of bonding bonds over time under different assembly conditions of this invention:

[0038] Figure 5 The graph shows the maximum pressure on the liner surface versus time under different assembly conditions according to the present invention:

[0039] (a) Curve of maximum pressure on the liner surface over time when the height difference between the top surfaces of the moving cone and the fixed cone is 0 mm and the precession angle is 1°;

[0040] (b) Curve of maximum pressure on the liner surface over time when the height difference between the top surfaces of the moving cone and the fixed cone is 10 mm and the precession angle is 1.5°;

[0041] (c) The curve of the maximum pressure on the liner surface over time when the height difference between the top surfaces of the moving cone and the fixed cone is 25 mm and the precession angle is 2°.

[0042] Figure 6 shows the curves of maximum pressure on the surface of the moving cone and fixed cone liner plates under different assembly conditions of the present invention as a function of time:

[0043] (a) Curves showing the change of maximum pressure on the surface of the moving cone liner under different assembly conditions over time;

[0044] (b) Curves showing the maximum pressure on the surface of the fixed cone liner plate under different assembly conditions as a function of time. Detailed Implementation

[0045] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0046] Example

[0047] like Figure 1 As shown in Figure 6, the present invention provides a method for optimizing the cavity parameters of a cone crusher based on EDEM, characterized by comprising the following steps:

[0048] Step 1: Establishing the assembly model of the moving cone and fixed cone liner of the cone crusher. The specific steps are as follows:

[0049] S1.1 Adjust and combine the cavity parameters of the cone crusher, the height difference h between the top surfaces of the moving cone and the fixed cone and the precession angle γ0. Use CAD drawing software to assemble the moving cone liner and the fixed cone liner. Measure the parallel zone length l, the minimum value a of the tight side and the minimum value b of the wide side of the cone crusher crushing cavity under different cavity parameter combinations.

[0050] Based on the actual structural parameters of the moving cone liner and the fixed cone liner, the range of values ​​for the height difference h between the top surfaces of the moving cone and the fixed cone and the precession angle γ0 can be obtained as follows:

[0051] 0≤h≤30mm

[0052] 1°≤γ0≤2.2°

[0053] The moving cone liner and fixed cone liner of the cone crusher were assembled in CAD. The parallel zone length l, the minimum value of the tight side a, and the minimum value of the wide side b of the crushing chamber were measured respectively. The specific data are shown in Table 1.

[0054] Table 1: Assembly Dimensions of Cone Crusher

[0055]

[0056] S1.2. Based on the actual crushing requirements in production, determine the minimum tight side value a and the minimum wide side value b of the cone crusher under different combinations of the height difference h between the top surfaces of the moving cone and the fixed cone and the precession angle γ0. Select the cavity parameter combination that best meets the crushing requirements and use SOLIDWORKS 3D modeling software to establish the assembly model of the moving cone and fixed cone liner of the cone crusher.

[0057] Based on the actual production process, the average particle size of the ore before crushing is 75mm, and the target particle size for crushing is 20mm. Therefore, three assembly dimensions were selected to establish the moving cone and fixed cone assembly models. These are:

[0058] ① When the height difference between the top surfaces of the moving cone and the fixed cone is 0mm and the precession angle is 1°, the simplified number is 0-1;

[0059] ② When the height difference between the top surfaces of the moving cone and the fixed cone is 10mm and the precession angle is 1.5°, the simplified number is 10-1.5;

[0060] ③ When the height difference between the top surfaces of the moving cone and the fixed cone is 25mm and the precession angle is 2°, the simplified number is 25-2;

[0061] Use SOLIDWORKS to create assembly models of the moving cone and fixed cone liner of the above three cone crushers, and export the .STL model file.

[0062] Step 2: Constructing the simulation model of the cone crusher crushing process based on EDEM. The specific steps are as follows:

[0063] S2.1 Set material property parameters and interaction coefficients, and add particles. The specific steps are as follows:

[0064] In the EDEM software, two types of ore materials and liner materials are added. The material property parameters of the ore and liner materials are set according to the material characteristics of the ore and liner in the actual crushing process. The interaction coefficients between the ore and liner are also set, with the interaction coefficients between the ore materials being the same, and the interaction coefficients of the liner material on both ore materials being the same. Specific data are shown in Tables 2 and 3. Then, a single large spherical particle is added under Ore Material 1, with its radius set to 37.5 mm based on the actual size of the ore. A single small spherical particle is added under Ore Material 2, with its radius set to 5 mm based on the particle size of the crushed ore. The "Edit Contact Radius" option is checked, and the contact radius is set to 8 mm.

[0065] Table 2: Material Property Parameters

[0066]

[0067] Table 3: Interaction coefficients between materials

[0068]

[0069] S2.2 Import the assembly model of the moving cone and fixed cone liner of the cone crusher and establish the pellet plant. The specific operation is as follows:

[0070] Import the .STL model file from step 1 into Geometries in EDEM, and set the material of the cone crusher's moving cone and fixed cone liner assembly model to the liner material. Based on actual working conditions, set the rotational speed of the moving cone liner to 2 rpm. Then, add an annular particle plant above the crusher, setting the particle plant type to static, starting generation from 0s, setting the total number of generated particles to 50, and selecting ore material 1 as the particle material. At the start of the simulation, 50 large spherical particles will be randomly generated in the particle plant and enter the crushing chamber under the influence of gravity.

[0071] S2.3. Write and import the particle replacement API file to replace the large spherical particles with small spherical particles. The specific sub-steps are as follows:

[0072] S2.3.1. Import large spherical particles. The specific steps are as follows:

[0073] Create a new EDEM file and import the ore model, i.e., a large spherical particle with a diameter of 75mm, into the Geometries module. Set the type of the large spherical particle to Virtual and use Translation to move the center of the ore model, i.e., the large spherical particle, to coincide with the origin of the EDEM.

[0074] S2.3.2 Fill with small spherical particles. The specific operation is as follows:

[0075] Add a Box using Add Geometry, setting its type to Physical (solid), to fill it with small spherical particles with a diameter of 10mm. Once the small spherical particles completely submerge the ore model and reach a stable state, change the type of the large spherical particles to Physical, confirm the corresponding material, and change the Box type to Virtual; continue the simulation until, except for the small spherical particles in the ore model, other small spherical particles gradually leave the computational domain under the influence of gravity.

[0076] S2.3.3 Exporting the coordinates of small spherical particles, the specific steps are as follows:

[0077] In the Analyst interface of EDEM, use the shortcut Ctrl+E to enter the Export Result Data interface. Uncheck "All" under "Time Steps" in General to export only the coordinates at a specific time. In Queries, select the variables you want to export. Taking the X-coordinate of a small spherical particle as an example, add a new Queries entry Q01, select "Position" under "Particle," set the Component to "X," select "Small Spherical Particle" as the particle type, and click "Export" to export the data.

[0078] S2.3.4. Write the API file. The specific steps are as follows:

[0079] Multiply the exported coordinates of the small spherical particles by 10. -3 After unifying the units, copy them to the Particle_Cluster_Data.txt file and save it. In Particle_Replacement_prefs.txt, write the name of the particle to be replaced as the name of the large spherical particle, write the name of the particle to be replaced as the name of the small spherical particle, and set the start time of replacement to 0.500s.

[0080] S2.3.5. Import the API file. The specific steps are as follows:

[0081] Place Particle_Replacement.dll, Particle_Cluster_Data.txt, and Particle_Replacement_prefs.txt in the same simulation directory. The Particle_Replacement.dll application extension file can be directly read by the discrete element analysis software. Import the ParticleReplacement plugin into the EDEM's Plugin Factories and add ParticleReplacement to the particle volume forces. This plugin will call the contents of Particle_Cluster_Data.txt and Particle_Replacement_prefs.txt. Under the action of particle volume forces, large spherical particles are removed, and small spherical particles replace them, thus completing the particle replacement.

[0082] S2.4. Generate bonding bonds between the replaced small spherical particles. The specific steps are as follows:

[0083] In the EDEM physics options, the contact model between the small spherical particles was set to the Hertz-Mindlin with bonding model, specifying the generation of adhesive bonds between the small spherical particles. Then, based on the radius of the small spherical particles and the properties of the ore material, the normal and tangential stiffness coefficients per unit area, and the critical normal and tangential stresses were calculated. The start time for adhesive bond generation was set to 0.501s, and the bonding radius was set to 8mm. Specific data are shown in Table 4.

[0084] Table 4: Parameters of the Hertz-Mindlin with bonding model

[0085]

[0086] S2.5. Set the simulation parameters and start the simulation. The specific steps are as follows:

[0087] In the EDEM Simulator interface, set the total simulation time to 30s so that the moving cone can rotate one revolution. Adjust the time step to 1.5% so that the bond can be generated and remain stable. Set the mesh size to 3Rmin, and then start the simulation.

[0088] Step 3: Analyze the results of EDEM simulation and determine the advantages and disadvantages of different crusher crushing efficiency and liner wear rate under different cavity parameters. The specific steps are as follows:

[0089] S3.1. Export the bond fracture data over time from the EDEM to determine the crushing efficiency of the crusher under different cavity parameters. The specific operation is as follows:

[0090] In the EDEM Analyst interface, select Create Graph. Then, in the Line options, select bond, switch the Type to small spherical particles, set the X-axis time range to 0–30 seconds, and the Y-axis to Number of intact bonds. Click Create Graph. Export a graph showing the number of bonded bonds over time under different assembly conditions. Figure 4 .

[0091] S3.2. Export the curves of surface pressure on the moving and fixed cone liners over time from the EDEM, analyze the required strength of the liner material, and determine the advantages and disadvantages of different liner wear rates under different cavity parameters. The specific operation is as follows:

[0092] In the EDEM Analyst interface, select Create Graph. Then, in the Line options, select Geometry, and switch the Sections to Moving Cone Liner and Fixed Cone Liner respectively. Set the X-axis time range to 0–30 s, the Y-axis to Pressure, and the Component to Maximum. Then click Create Graph. Export the curves showing the maximum pressure on the surfaces of the Moving and Fixed Cone Liners under different assembly conditions as a function of time. See [link to relevant documentation]. Figure 5 .

[0093] 1) Analysis and determination of crushing efficiency of crusher under different cavity parameters

[0094] from Figure 4 It can be seen that after 30 seconds, the number of bonding bonds is the lowest in the case of 25-2, while the number of bonding bonds decreases slightly in the case of 0-1, and the number of bonding bonds hardly changes in the case of 10-1.5. This indicates that the ore breaking efficiency is: 25-2>0-1>10-1.5.

[0095] The results are interpreted by considering the movement of particles within the crusher and the dimensional table of the cone crusher assembly results from step 1:

[0096] ①0-1: During the operation of the cone crusher, due to the narrow distance of the wide side inlet, the particles cannot enter the crushing chamber further during the rotation of the moving cone. As a result, a large number of particles accumulate in the upper part of the crushing chamber, causing a "material jamming" phenomenon. Therefore, the ideal crushing effect cannot be achieved. However, due to the close overall distance between the moving and fixed cones, some bonding bonds on the particle surface break during the crushing process.

[0097] ②10-1.5: The overall stress state of the particles is similar to that of 0-1, but because the distance between the moving and fixed cones is slightly greater in this case, the material pile position is slightly lower than that of 0-1, and the compaction effect is weaker. Therefore, the number of bond breakages is further reduced compared to 0-1.

[0098] ③25-2: In case 25-2, because the distance between the wide sides is large enough, the particles can enter the crushing chamber during the oscillation of the moving cone and be crushed under the compression of the moving and fixed cones, i.e., lamination crushing is performed. However, because the minimum distance between the wide sides is too large and the rotation speed of the moving cone is relatively slow, some particles roll off the wide sides without being crushed, resulting in a decrease in the crushing effect.

[0099] Therefore, as can be seen from the above analysis, the minimum width of the crushing chamber should not be too large, as this can easily cause material leakage, nor should it be too small, otherwise it can easily cause material accumulation. Therefore, when optimizing the chamber shape, the minimum width should be kept within a suitable range so that the ore can enter the crushing chamber further and is not discharged prematurely.

[0100] 2) Analysis and determination of the required strength of the liner material and the wear rate of the liner under different cavity parameters.

[0101] Depend on Figure 5 The curve shows the variation in pressure on the surfaces of the moving and fixed cone liners. This pressure reflects the basic mechanical properties and wear of the liner materials. Data indicates that the pressure on the moving cone liner surface is significantly higher than that on the fixed cone under all conditions. Therefore, the wear on the moving cone is greater than that on the fixed cone, which is consistent with the actual operation of the cone crusher, where the moving cone always fails first. To further analyze the pressure variations on the surfaces of the moving and fixed cone liners under different assembly conditions, the moving and fixed cones are analyzed separately. The dashed line represents the average pressure under three conditions, as shown in Figure 6. From the average values, the pressure on the moving cone liner surface is: 10⁻¹.5 > 0⁻¹ > 25⁻², and the pressure on the fixed cone liner surface is: 10⁻¹.5 > 25⁻² > 0⁻¹. The wear rate of the moving cone is: 10⁻¹.5 > 0⁻¹ > 25⁻².

[0102] Based on the analysis of the three sets of simulation results, it can be concluded that the cone crusher achieves the best crushing efficiency and the slowest wear on the moving cone liner when the distance between the top surfaces of the moving and fixed cones is 25mm and the precession angle is 2°. If the material remains in the crushing chamber without being crushed, it will not only accelerate the wear of the liner but also seriously affect the efficiency of the crusher. The average surface pressure of the moving cone is above 300MPa, while the average surface pressure of the fixed cone is only 100MPa. This difference in surface pressure between the moving and fixed cones may be due to "material accumulation." To prevent liner deformation and failure, the yield strength of the liner material should be above 300MPa.

Claims

1. A method for optimizing the cavity parameters of a cone crusher based on EDEM, characterized in that, Includes the following steps: Step 1: Establishment of the assembly model of the moving cone and fixed cone liner of the cone crusher; The specific steps for establishing the assembly model of the moving cone and fixed cone liner of the cone crusher are as follows: S1.1 Adjust and combine the cavity parameters of the cone crusher, the height difference h between the top surfaces of the moving cone and the fixed cone, and the precession angle γ0. Use CAD drawing software to assemble the moving cone liner and the fixed cone liner. Measure the parallel zone length l, the minimum tight side a, and the minimum wide side b of the crushing cavity of the cone crusher under different cavity parameter combinations. S1.

2. Based on the actual crushing requirements in production, determine the minimum tight side value a and the minimum wide side value b of the cone crusher under different combinations of the height difference h between the top surfaces of the moving cone and the fixed cone and the precession angle γ0. Select the cavity parameter combination that best meets the crushing requirements and use SOLIDWORKS 3D modeling software to establish the assembly model of the moving cone and fixed cone liner of the cone crusher. Step 2: Construction of EDEM-based simulation of the cone crusher crushing process; S2.1 Set material property parameters and interaction coefficients and add particles; S2.2 Import the assembly model of the moving cone and fixed cone liner of the cone crusher and establish the pellet plant; S2.

3. Write and import the particle replacement API file to replace the large spherical particles with small spherical particles; S2.

4. Generate bonding bonds between the replaced small spherical particles; S2.

5. Set the simulation parameters and start the simulation; Step 3: Analyze the results of EDEM simulation and determine the advantages and disadvantages of crushing efficiency and liner wear rate of crusher under different cavity parameters; S3.

1. Export the bond fracture over time from EDEM to determine the crushing efficiency of the crusher under different cavity parameters; S3.

2. Export the curves of surface pressure on the moving cone and fixed cone liner plates as a function of time from the EDEM, analyze the required strength of the liner plate material, and determine the advantages and disadvantages of the liner plate wear rate under different cavity parameters.

2. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, In step S2.1, setting material property parameters and interaction coefficients and adding particles involves adding two types of ore materials and liner materials in the EDEM software. The material property parameters of the ore materials and liner materials are set according to the material characteristics of the ore and liner in the actual crushing process. The interaction coefficients between the ore and liner are also set, with the interaction coefficients between the ore materials being the same, and the interaction coefficients between the liner materials and the two types of ore materials being the same. A single large spherical particle is added to one type of ore material, and the radius of the large spherical particle is set according to the actual size of the ore. A single small spherical particle is added to the other type of ore material, and the radius and contact radius of the small spherical particle are set according to the particle size of the crushed ore.

3. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, In step S2.2, import the assembly model of the moving cone and fixed cone liner of the cone crusher and establish a pellet mill. Import the assembly model of the moving cone and fixed cone liner of the cone crusher from step 1 into EDEM, set the material of the assembly model of the moving cone and fixed cone liner of the cone crusher to the liner material, and set the rotation speed of the moving cone liner according to the actual working conditions. Then, set an annular pellet mill above the crusher. Large spherical particles will be randomly generated in the pellet mill and enter the crushing chamber under the action of gravity.

4. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, S2.3, writing and importing the particle replacement API file to replace the large spherical particles with small spherical particles, the specific operation is as follows: Write the position coordinates of the small spherical particles after replacement into the Particle_Cluster_Data.txt text file, and write the names of the large spherical particles to be replaced and the small spherical particles used for replacement, as well as the start time of replacement, into the Particle_Replacement_prefs.txt text file. The ParticleReplacement.dll application extension file can be directly read by EDEM. Place these three files in the same root directory of the simulation, and then import the ParticleReplacement plugin into EDEM's PluginFactories and add ParticleReplacement in the particle volume forces. This plugin will call the contents of Particle_Cluster_Data.txt and Particle_Replacement_prefs.txt. Under the action of particle volume forces, the large spherical particles are removed, and the small spherical particles take their place, thus completing the particle replacement.

5. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, In step S2.4, bonding bonds are generated between the replaced small spherical particles. In the EDEM, the contact model between the small spherical particles is set to the Hertz-Mindlin with bonding model. Then, based on the radius of the small spherical particles and the properties of the ore material, the normal and tangential stiffness coefficients per unit area, and the critical normal and tangential stresses are calculated. The start time for bonding bond generation and the bonding radius are set; the start time is generally 10 seconds later than the particle replacement time. -3 The bonding radius is generally 1.5 times the radius of the small spherical particles.

6. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, In step S2.5, set the simulation calculation parameters and start the simulation. Set the total simulation time of EDEM according to the actual speed of the crusher to ensure that the moving cone rotates at least once. Adjust the time step within a certain range to enable the bonding bonds to be generated and kept stable. Set the mesh size to 2 to 3 times the minimum spherical particle radius, and then start the simulation.

7. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, S3.1, exporting the bond fracture status over time from EDEM to determine the crushing efficiency of the crusher under different cavity parameters, is specifically operated as follows: Enter the Analyst interface and select Create Graph. Then, in the Line option, select bond, switch the Type to small spherical particles, set the X-axis to time, and set the Y-axis to Number of intact bonds. Then click Create Graph. Export the curve of the number of bonded bonds changing over time under different assembly conditions. By analyzing the breakage of bonded bonds, determine the crushing efficiency of the crusher under different cavity parameters.

8. The method for optimizing the cavity parameters of a cone crusher based on EDEM according to claim 1, characterized in that, S3.2 involves exporting the curves of surface pressure on the moving and fixed cone liners over time from the EDEM, analyzing the required strength of the liner material, and determining the advantages and disadvantages of the liner wear rate under different cavity parameters. The specific operation is as follows: In the Analyst interface, select Create Graph. Then, in the Line option, select Geometry. Switch the Sections to Moving Cone Liner and Fixed Cone Liner. Set the X-axis to Time and the Y-axis to Pressure. Select Maximum for Component. Then, click Create Graph to export the curves showing the maximum pressure on the surfaces of the Moving Cone and Fixed Cone Liners under different assembly conditions as a function of time. By analyzing the changes in the pressure on the liner surface, determine the basic mechanical properties of the liner material and the advantages and disadvantages of the liner wear rate under different cavity parameters.

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