The Three Stages of the Layer-Pressure Crushing Process in a Cone Crusher

Based on experimental research and analysis, the layer-pressure crushing process can be divided into three stages:

1. Compaction Stage:  

At the beginning of the test, due to the high porosity between materials and the relatively low pressure applied, materials are not significantly compressed or crushed. As pressure increases, the density between materials grows, reducing volume and forming multiple reliable contact points;

2. Crushing Stage:  

As the material continues to be compressed, the pressure it undergoes also increases. The higher the density between particles and the lower the porosity, the greater the force on the contact points. When these forces exceed the strength of a particular point in the material, it breaks, accompanied by the sound of breaking and the oscillation of the pressure gauge pointer.

This phenomenon occurs because the pressure on the material increases significantly before crushing. When the material is crushed, the stress suddenly decreases, causing the material to be recompacted;

3. Agglomeration stage:

When the material is compressed to a certain extent by the press, the stress increases rapidly, causing the material to be compacted and produce a large amount of powder, leading to agglomeration.

During the crushing process, the total electrical energy consumed by grinding is nearly four times that of crushing, yet its production efficiency is far lower than that of a crusher. Therefore, in actual production, it is advisable to use a crusher instead of a grinder, which is of great significance for reducing electrical energy consumption.

Materials crushed using the layer compression crushing principle result in more uniform material, with a higher proportion of cubic-shaped particles and a higher content of fine-grained material, thereby better aligning with the ‘more crushing, less grinding’ theory.

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