Workshop 08 - Cone Crusher

Workshop 08 – Cone Crusher
(Breakage)
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OBJECTIVES
The two main purposes of this workshop are to a) learn how to define
the mantle and shaft movements required for a Cone Crusher
simulation, and b) how to set up breakage parameters.
You will learn how to: And you will use these features:
Define mantle and shaft movements Cone Crusher Frame
for a cone crusher simulation
Breakage
Set up breakage parameters
Histograms
Tag specific particles and fragments User Processes, including:
for locations tracking
Cylinder
Cube
Divisions Tagging Particle Calculations
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PREREQUISITES
This workshop assumes that you are already familiar with the Rocky
user interface (UI) and with the project workflow.
If this is not the case, please refer to Workshop 01 – Transfer Chute
for a basic introduction about Rocky usage before beginning this
workshop.
AGENDA
Part 1: Project Setup and Part 2: Post-Processing

Processing Verifying the Particle Size Distribution
Geometry Introduction and Project using a Histogram
Creation Using Divisions Tagging to identify
Project Details and Physics Setup where in the hopper a set of fragments
originated
Geometry Import and Inlet Definitions
Accessing the User Manual
Setting Up, Previewing, and Assigning
Cone Crusher Motions Conclusion
Materials Definitions and Interactions
Particle Groups, Breakage, and Inputs
Solver Setup and Processing
PART 1: PROJECT SETUP
AND PROCESSING
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GEOMETRY
(1) The geometry in this tutorial is

composed of:
1) Feed Hopper (Choke Feed)
2) Housing
(5)
(2) 3) Transmission Axis
4)
(6) 5) Mantle Shaft
6) Concave
(3)
(4)
In the workshop directory the
*.stl files can be found.
PROJECT CREATION
Ensure you have downloaded and extracted the WS 08 – Input Files

zip folder that was provided along with this PDF.
Open Rocky 4. Look for Rocky 4 in Program Menu or use the desktop
shortcut. Click on the New Project button, or from the File menu, click
New Project (Ctrl+N).
New Project Save Project
PROJECT DETAILS
The first step of the setup is to define any

useful information of the project.
From the Data panel, click Study 01 and
then enter the information as shown.
PHYSICS DEFINITION
From the Data panel, select Physics.

From the Gravity tab, you can define the
gravity components and the time during which
it is applied in the project.
For this workshop, use all default Physics

values.
GEOMETRY IMPORT The Geometries step enables you to either
create or import geometries.
For this case we will import geometry files
in *.stl format. Right-click Geometries,
point to Import, and then click Custom
Geometry.
Select all of the following files:
All parts will be imported using “mm” as

Import Unit and with the option Convert Y
and Z Axes unchecked.
INLET DEFINITION
After the geometries are imported, an inlet must be defined in order to

release particles into the domain.
From the Data panel, right-click Geometries, point to Create, and then
click Inlet.
Under Geometries, select the newly created Inlet <01>.

From the Data Editors panel, select the Inlet tab, and then edit the
parameters as shown on the next slide.
INLET DEFINITION
From the Geometry sub-tab, define: Type, Center Coordinates, and

Max Radius (as shown).
From the Simulation Configuration sub-tab, define: Stop Time (as
shown).
MOTION FRAME
Vertical Mantle The Mantle rotates eccentrically

Axis Axis around the vertical axis pressing
the particles on the Concave,
promoting breakage. At the
same time, it is free to rotate
around the Shaft.
The intersection between the
Pivot Mantle Axis (green) and the
Point Vertical Axis (blue)
characterizes the Pivot Point.
It is important to have your
mantle geometry rotated by the
desired Mantle Angle and to
Mantle know in which direction this is
Angle done to properly set up the
Cone Crusher movement!
MOTION FRAME
To add motions specific to the cone crusher,

from the Data panel right-click Motion
Frames, and then select Create Cone
Crusher Frame.
A new frame called Cone Crusher 01

appears in the Motion Frames list.
To visualize the new created frame, click
Motion Frames and then click Preview.
A new window will appear showing the
geometry and the created frame.
You can also adjust the frame size by
changing the Default axes size parameter.
MOTION FRAME – CONE CRUSHER
When the new Cone Crusher 01 frame is selected, the following

options are available in the Data Editors panel:
Pivot Point: Coordinate of the point around which the Mantle and Shaft will pivot.
Rotation Axis: The axis around which the Mantle and Shaft are rotated.
Rotational Velocity: The angular velocity along the Rotation Axis.
Initial Orientation: The vector about which the Mantle and Shaft begin their
rotation.
Start/Stop Time: Time in which the motion starts and stops.
The Cone Crusher 01 frame automatically creates two separate
motions that are designed to be applied to the appropriate geometries,
as follows:
Cone Crusher 01 (Mantle) for the Mantle Cone geometry.
Cone Crusher 01 (Shaft) for the Mantle Shaft geometry.
MOTION FRAME
From the Data panel, under

Motion Frames, click Cone
Crusher 01.
From the Data Editors panel,
define (as shown):
Pivot Point
Rotational Velocity
Initial Orientation
Start Time
Vertical
Axis Mantle
Axis
MOTION FRAME
Once the frame has been configured, the motions can then be assigned
to their respective geometries.
From the Data panel under

Geometries, select Mantle Cone
<01> and then from the Custom
Boundary tab, select Cone
Crusher 01 (Mantle) from the
Motion Frame drop-down list (as
shown).
Repeat for the Mantle Shaft
<01> geometry, assigning to it
the Cone Crusher 01 (Shaft)
motion (as shown).
At this point, the movement can be previewed using the Motion Preview
window. (Tip: Make the geometries transparent to see the motion.)
Note: The motion will change when the particles are introduced.
The Timestep toolbar (in yellow) is used for the results display.
MATERIAL DEFINITION
In this workshop two materials will be used: one for all geometry parts
(Default Boundary) and other for the particles (Default Particle).
Default values will be used for the Default Boundary material (as
shown).
For Default Particles, clear the Use Bulk Density checkbox and edit
the Density value (as shown).
INTERACTION BETWEEN MATERIALS
To set the interaction properties, click

Material Interactions in the Data panel.
In this simulation we have two materials,

so we need to define two separate
interactions using the left and right drop-
down lists (shown above):
Default Particles x Default Particles
Default Particles x Default Boundary
Adjust the parameters for each
combination according to the values
shown on the next slide.
INTERACTION BETWEEN MATERIALS
Static Friction: 0.7

Dynamic Friction: 0.7
Default
Coefficient of Restitution: 0.1
Boundary
Adhesive Distance: 0.0001
Force Fraction: 0
Default
Particles
Static Friction: 0.7

Dynamic Friction: 0.7
Default
Coefficient of Restitution: 0.3
Particles
Adhesive Distance: 0.0001
Force Fraction: 0
Note: Particle x Particle interaction

values are left default for this
workshop.
PARTICLE GROUP DEFINITION
To create a new particle group, right-click

Particles in the Data panel and then select
Create Particle.
A new particle group is created under

Particles.
Select the newly created Particle <01> entry
to begin editing its parameters.
From the Data Editors panel, in the Geometry sub-tab, define Shape
Type, Vertical/Horizontal Aspect Ratio and Number of Corners (as
shown).
To visualize the newly created particle, click Preview. A new Particles
Preview window will appear showing the particle geometry.
From the Breakage sub-tab, define Enable Breakage, Minimum Size,

Reference Size, Minimum Specific Energy, and Selection Function
Coefficient (as shown).
In the Size Distribution sub-tab, click the green plus button (Add) until
you have four size distribution rows. Define Size and Cumulative % (as
shown).
MASS FLOW DEFINITION
To create a new particle mass flow, from the

Data panel, right-click Input and then select
Create Particle Input.
A new entry is created under Input.

Select the newly created Particle Input <1>
and then from the Data Editors panel,
modify the parameters as specified on the
following slide.
MASS FLOW DEFINITION
From the Entry Point drop-down list, select Inlet <01>.

Click the green plus button to create an entry row.
Select Particle <01> from the drop down list and define the Tonnage
(as shown).
SOLVER DEFINITION
From the Data panel, select Solver, and then from the Data Editors
panel, select the Solver tab.
From the Time Configuration sub-tab, define the calculation Start and
Delay times (as shown).
In the General Settings sub-tab, select CPU (or GPU/Multi GPU) as
Simulation Target, and then set the Number of Processors (or Target
GPU(s)). For this workshop, CPU will be fastest due to the low particle
count.
Click Start Simulation.
SOLVER DEFINITION
The Simulation Summary dialog appears.
Click OK for Rocky to begin processing the simulation.
SIMULATION
From the Windows menu, click New 3D

View. (Tip: To see the particles and motions,
make the geometries transparent.)
Click the Refresh button (or use the
Auto Refresh checkbox) to see the
results during processing.
The speed of the simulation depends
on various factors such as:
Number of mesh elements used to
define the geometry
Number of contacts in the simulation
domain at any time
Smallest particle size and material stiffness
The particle shape and the number of vertices used
to define the shape
Frequency of file output
PART 2: POST-PROCESSING
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POST PROCESS – PSD HISTOGRAM
Once processing is complete, you can verify that all particles were broken
under 0.075 m by using a Particle Size Distribution (PSD) Histogram.
From the Data panel right-click Particles, point to Show in new, point to
Histogram, and then select Particle Size.
From the upper-left corner, click the Configure histogram button and then
change the Number of Bins, enable both the Cumulative Bins and
Percent Values features, and modify the Limits values (as shown).
POST PROCESS - DIVISIONS TAGGING
In the last Timestep of the

simulation, you can observe
that some Particles are
accumulating in an open space
of the transmission housing (as
shown).
Using the Divisions Tagging
Calculation of the Particles in
the hopper, we can identify
from what section of the
hopper these particles are
coming from, which is helpful
information for improving the
equipment design.
Concerning accumulation
For this case, a Cylinder will be created at a Timestep far enough into the
simulation that the Hopper is full of particles.
From the Time toolbar, select the Timestep at 2.0 s.
From the Data panel, right-click Particles, point to Processes, and the click
Cylinder.
From the Data Editors panel, select the Cylinder tab, and then edit the Center
and Size coordinates, and adjust the Final Arc Angle value (as shown).
With the Cylinder set up, right-click Particles, point to Calculations,

point to Divisions Tagging, and then click Cylinder <01>.
This will generate divisions within the cylinder that was selected.
From the Data panel, under Particles Calculations, select the new
Divisions Tagging (Cylinder <01>)… entry.
From the Data Editors panel, select the Tagging tab and then define
Domain Range, Initial and Tangential Divisions (as shown).
From the Coloring tab, enable Transparency (as shown).
Color Particles using the newly added Property: Divisions Tagging

(Cylinder <01>)…
From the Data panel, select Particles and then from the Data Editors panel, select the
Coloring tab; under Nodes, change the Property to Divisions Tagging (Cylinder
<01>)…
Tip: Use the eye icon next to
Cylinder (under User Processes in
the Data panel) to hide the Cylinder
coloring and show only the
Particles coloring.
Display the final Timestep. You
should now see all of the following:
Hopper divided in 12 circular sectors.
Particles and Fragments colored by the
division they started in.
The accumulated Fragments colored
by their original position in the hopper.
Lastly, a Cube will be added to separate the accumulated Fragments

from the rest of the Particles.
From the Data panel, right-click Particles, point to Processes, and
then select Cube.
From the Data Editors panel, select the Cube tab and then define the
coordinates for Center and Magnitude (as shown).
Another Histogram will be created

to show the hopper region from
which the accumulated Fragments
are originating.
With the Cube <01> entry still
selected in the Data panel, select
the Properties tab in the Data
Editors panel, right-click Divisions
Tagging (Cylinder <01>)…, point to
Histogram, and then click Show in
new Histogram.
From the upper left corner of the plot
window, click the Configure
histogram button, and then change
the Number of Bins and Limits
values (as shown).
From the Histogram, it can be seen that most of the accumulated

Fragments are coming from bins 3, 4, and 5 of the hopper.
This information may not have been obvious before the Divisions
Tagging analysis. Now an appropriate solution can be devised if this
particular result is undesirable.
(8) (9) (10)
(7) (11) (3)
(6)
(12) (4)
(5)
(5) (1)
(4) (2)
(3)
HELP – USER MANUAL
For further information on any topic presented, we suggest searching

the User Manual, which provides in-depth descriptions of the tools and
parameters.
To access it, from the main Toolbar click Help, point to Manuals, and
then click User Manual.
HELP – USER MANUAL
In the User Manual, use the Search tab to quickly find the topic you are
interested in:
CONCLUSION
Rocky was used to study the case of a cone crusher.
During this workshop, it was possible to:

Use the specialized Cone Crusher Frame to easily set up and apply specific mantle
and shaft motions.
Model Breakage phenomena.
Use Histograms to plot PSD and processing results.
Track specific particles and fragments through the equipment using Divisions
Tagging Particle Calculations.
What’s Next?
If you completed this workshop successfully, then you are ready to move on to
Workshop 09 – Tablet Coating.

Workshop 08 - Cone Crusher

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Workshop 08 – Cone Crusher

Part 1: Project Setup and Part 2: Post-Processing

(1) The geometry in this tutorial is

Ensure you have downloaded and extracted the WS 08 – Input Files

New Project Save Project

The first step of the setup is to define any

From the Data panel, select Physics.

For this workshop, use all default Physics

Select all of the following files:

All parts will be imported using “mm” as

After the geometries are imported, an inlet must be defined in order to

Under Geometries, select the newly created Inlet <01>.

From the Geometry sub-tab, define: Type, Center Coordinates, and

Vertical Mantle The Mantle rotates eccentrically

To add motions specific to the cone crusher,

A new frame called Cone Crusher 01

When the new Cone Crusher 01 frame is selected, the following

From the Data panel, under

From the Data panel under

To set the interaction properties, click

In this simulation we have two materials,

Static Friction: 0.7

Static Friction: 0.7

Note: Particle x Particle interaction

To create a new particle group, right-click

A new particle group is created under

From the Breakage sub-tab, define Enable Breakage, Minimum Size,

To create a new particle mass flow, from the

A new entry is created under Input.

From the Entry Point drop-down list, select Inlet <01>.

The Simulation Summary dialog appears.

Click OK for Rocky to begin processing the simulation.

From the Windows menu, click New 3D

In the last Timestep of the

With the Cylinder set up, right-click Particles, point to Calculations,

Color Particles using the newly added Property: Divisions Tagging

Lastly, a Cube will be added to separate the accumulated Fragments

Another Histogram will be created

From the Histogram, it can be seen that most of the accumulated

For further information on any topic presented, we suggest searching

Rocky was used to study the case of a cone crusher.

During this workshop, it was possible to:

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