Optimization of a Jaw Crusher Using DEM

  • Sousani, Marina (ANSYS INC)

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The process of crushing is essential for reducing the size of aggregates used in construction while it is important to minimize energy consumption and machine wear while improving the crushing efficiency. Jaw crushers are a century old design with a relatively simple four bar mechanism that produces a complex motion of the moving jaw. The four-bar mechanism is responsible for moving the jaw plate that compresses aggregate particles against a stationary surface and the kinematics of the jaw depends on the dimensions and position of the mechanism as well as the speed of the shaft. Simulation offers the potential to optimize the design and motion improve performance as well as energy efficiency. This study aims to understand the complex motion and its impact on material behavior as well as understanding energy usage and optimizing the simulation workflow for a range of kinematics. The material behavior is modelled using DEM polyhedral particles and the Tavares Breakage Model [1,2], which is an advanced stochastic replacement method that reproduces the fragments resulting from particle collisions. The model shows both catastrophic particle breakage and their weakening from non-breakable events while capturing the material flow of highly irregular shapes and provides the distribution of the fragments.