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A formal approach to the modelling of a cone crusher is presented. The emphasis is on predicting the final output of a cone crusher using only the physical mechanisms which are occurring. Each of these mechanisms are clearly identified and mathematical formulations are provided for each. Rock breakage characterisation is examined in several ways including the use of the Hopkinson Pressure Bar (HPB). The HPB is applied in a novel manner to the assessment of breakage in crushing. In addition the HPB is used to examine energy application, breakage and damage in both compression and impact environments. It is believed that the HPB is demonstrated to be a highly useful device in the assessment of comminution breakage. The final output of the crusher is successfully predicted in terms of the throughput, the product size distribution and the power drawn in crushing the rock material. The strength of this approach is that it provides a design model for either new or existing cone crushers for a complete range of rock types and operating conditions.
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