Comprehensive Guide to Cone Crushers Working Principle, Components, Applications, Advantages, and Maintenance

Cone Crusher:

Cone crushers are one of the most commonly used types of crushers in mining and construction industries for reducing ore materials into smaller and uniform sizes. In this article, we will discuss in detail about cone crushers including their working principle, components, applications, advantages and maintenance.

Working Principle of Cone Crusher
Let's first understand how a cone crusher works. A cone crusher breaks rock by squeezing the rock between an eccentrically gyrating spindle which is covered by a wear resistant mantle and the enclosing concave hopper chamber positioned above it. As rock enters the top of the cone crusher, it becomes squeezed and crushed between the mantle line surface and the bowl liner.

The material is crushed by compression as the pieces squeeze together and fracturing as the compressed rock expands along natural fracture planes. The fractured rock is crushed until it can fall through the narrow opening at the bottom of the crushing chamber. Most cone crushers have a variegated manganese steel mantle to withstand impact and resist wear.

Major Components
The major components of a cone crusher includes mainframe and engine, transmission system, eccentric shaft, bevel pinion, manganese steel mantle, concave bowl liner, feed chute, output discharge chute etc. The transmission system uses belt and gear drives to rotate the eccentric mounted crusher body inside the crushing chamber under high torque. The crusher body hold the mantle which gyrates inside the bowl shell under centrifugal action to perform rock crushing.

Applications of Cone Crushers
Cone crushers are largely utilized for secondary and tertiary crushing applications in quarries and mining operations. Some common applications include:

- Crushing river gravel for construction aggregate.
- Crushing basalt and granite for road metal and construction aggregate.
- Crushing slag and fly ash for cement, concrete and road base construction.
- Crushing recycled concrete for base coarse and drainage fillers.
- Crushing ferrous and non-ferrous ores for recovery of metals like copper, cobalt etc.
- Crushing limestone for cement, aggregates and other building materials.

Advantages of Cone Crushers
Cone Crushers have certain advantages over conventional jaw crushers or impactor crushers. Some of the key advantages include:

- Sturdy construction for continuous operation in harsh environment.
- Unique crushing action suitable for reduction and shaping of soft to medium hard rocks and ores.
- Adjustable discharge setting to control particle size of crushed product.
- Easy maintenance with replaceable liner and manganese crush liners.
- Produce cubical particles with less fine generation compared to jaw crushers.
- Higher capacity with less power consumption than impact crushers.

Maintenance of Cone Crushers
Regular maintenance is important to ensure maximum productivity and longevity of cone crushers. Some key maintenance tasks include:

- Check wear resistance liners and replace mantle and concave bushings as required.
- Lubricate all transmission, bearings and pivot points regularly.
- Inspect drive belts and tighten fasteners periodically.
- Clean crusher chamber regularly to remove debris and damp surfaces.
- Check hydraulic system if fitted and replace hydraulic oil periodically.
- Inspect support structure and welding periodically to detect damage early.
- Service engine as per manufacturer prescribed schedule if direct drive crusher.

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