design thesis cone crusher

# Thesis Proposal: Design and Optimization of a Cone Crusher

## Title
“Design, Analysis, and Performance Optimization of a Cone Crusher for Enhanced Crushing Efficiency”

## Abstract
Cone crushers are widely used in the mining and aggregate industries for secondary and tertiary crushing of hard and abrasive materials. Despite their efficiency, challenges such as uneven wear, power consumption, and product size inconsistency persist. This thesis aims to design an improved cone crusher by optimizing key parameters such as crushing chamber geometry, eccentric speed, and liner profile. Computational simulations (e.g., Finite Element Analysis – FEA) and experimental validation will be conducted to enhance crushing efficiency, reduce energy consumption, and extend component lifespan.

## 1. Introduction
1.1 Background
– Importance of cone crushers in mineral processing and aggregate production.
– Common challenges: wear on liners, power inefficiency, inconsistent particle size distribution.

1.2 Problem Statement
Current cone crushers suffer from inefficiencies due to suboptimal design parameters leading to excessive wear, high energy consumption, and poor product gradation.

1.3 Objectives
– Develop a geometrically optimized crushing chamber for better material flow.
– Analyze the effect of eccentric speed on crushing performance.
– Improve liner design to reduce wear and extend service life.
– Validate findings through simulation (DEM – Discrete Element Method & FEA) and experimental testing.

## 2. Literature Review
– Review of existing cone crusher designs (Symons, Metso HP series, Sandvik CH).
– Previous studies on crushing dynamics and liner wear mechanisms.
– Advances in computational modeling (DEM & FEA) for crusher optimization.

## 3. Methodology

3.1 Conceptual Design Approach
– Selection of key design parameters: mantle/concave geometry, eccentric throw, speed, closed-side setting (CSS).

3.2 Analytical Modeling
– Crushing force calculations based on compressive strength of rocks.
– Power consumption analysis using Bond’s Law & empirical models.

3.3 Computational Simulation (FEA & DEM)
– Finite Element Analysis (FEA) for stress distribution in liners & structural components.
– Discrete Element Method (DEM) for particle flow & breakage simulation (using EDEM or Rocky DEM).

3.4 Prototype Testing & Validation
– Laboratory-scale