Application of Multibody Dynamics and Bonded-Particle GPU Discrete Element Method in Modelling of a Gyratory Crusher

The gyratory crusher is one of the most important mineral processing assets in the comminution circuit, and its production performance directly impacts the circuit throughput. Due to its higher energy utilisation rate for rock breakage than semi-autogenous (SAG/AG) milling, it is a common practice in operations to promote and optimise primary crushing before the downstream capacity can be enhanced. This study aims to develop a discrete element modelling (DEM) and multibody dynamics (MBD) cosimulation framework to optimise the performance of the gyratory crusher. An MBD model was initially established to simulate the gyratory crusher's drivetrain system. A GPU-based DEM was also developed with a parallel bond model incorporated to simulate the particle breakage behaviour. Coupling of the MBD and GPU-based DEM resulted in a cosimulation framework based on the Function Mock-up Interface. An industrial-scale gyratory crusher was selected to test the developed numerical framework, and results indicated that the developed method was capable of modelling normal and choked working conditions. The outcome of this study enabled more realistic gyratory crusher improvement and optimisation strategies for enhanced production.