Optimizing the liner of cone crusher based on orthogonal experiments and numerical simulations

Abstract To improve the efficiency of existing cone crushers, this study proposes a moving cone liner optimization method: wedge grooves are arranged on the moving cone surface, and the gap between the grooves and the fixed cone wall enables combined compression-shear crushing, overcoming the limitation of the traditional single-compression mode. Based on EDEM numerical simulation, 25 groups of 4-factor-5-level orthogonal experiments are designed to investigate the effects of moving cone rotation speed, wedge groove angle, upper depth, and lower depth on crushing performance. Using the average crushing ratio as the core index, Minitab-based statistical analysis clarifies the parameter influence weights. The optimal parameters are determined as follows: upper depth of 50 mm, lower depth of 9 mm, wedge groove angle of 60°, and moving cone rotation speed of 390 r/min. Compared with the traditional groove-free structure, the optimized liner increases the qualified product rate by 12.27% and productivity by 4.49%, reduces P80 specific energy consumption by 23.7%, increases the passing rate of particles smaller than 15 mm by 13.5%, and reduces moving cone liner wear by 48.1%, thus realizing the synchronous improvement of crushing efficiency, product quality, and equipment durability.