Developing the design of the roller of a roll stone crusher by FEM simulation

Subject Areas : Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

Mohammad Sajjad Mahdieh ^{1 *} , Farshad Nazari ² , Haider Abdulhussein Rubaiawi ³

1 - Department of Mechanical Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran
2 - Mechanical Engineering Department, Shahid Chamran University of Ahvaz, Ahvaz, Iran
3 - Department of Mechanical Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran

Received: 2024-04-25 Accepted : 2025-09-29 Published : 2025-10-18

Keywords: FEM simulation, Stone crusher, Mining equipment, Roller design.,

Abstract :

Stone crushers are fundamental equipment in size reduction processes across metallurgical, mechanical, and other industrial applications. These machines are produced in a wide range of capacities, typically from 30 to 1000 tons per hour, and are categorized according to both the extent of material fragmentation and the type of force application mechanism. From a mechanistic standpoint, crushers are generally classified into three main types: roll crushers, jaw crushers, and impact crushers. Roll crushers, in particular, are widely utilized for medium- and small-scale stone processing due to their structural simplicity and operational effectiveness. This study focuses on the structural optimization of a roll crusher with an emphasis on its roller component, which plays a pivotal role in determining the system’s overall efficiency, performance, and operational cost. The subject of the case study is a roll crusher operating in an iron ore mine located in Yazd Province, Iran. The existing roller design is fully solid, which contributes to excessive weight, reduced mechanical efficiency, and elevated costs associated with maintenance and repair. In response, this research proposes a redesigned roller with reduced weight while ensuring that its mechanical integrity and operational functionality are preserved. The roller is modeled using computer-aided design (CAD) software and subsequently analyzed through Finite Element Method (FEM) simulations. To validate the numerical results, the FEM outputs are compared against the corresponding analytical solutions.

References:


[1] Mahdieh, M.S., Nazari, F. and Jawad, L. (2025) Evaluation of hydroforming parameters for motorcycle exhaust pipe production using fem simulation. Journal of Modern Processes in Manufacturing and Production. 14(1): 43-58.
[2] Mahdieh, M.S., Nazari, F. and Mane’, H.Y. (2025) Investigation of forming process of the floor of volvo truck’s body via fem simulation. Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering. 16(3): 19-26.
[3] Mahdieh, M.S., Nazari, F., Zayed, K.S. and Aghoun, F. (2024) Investigating of manufacturing of titanium hip prosthesis by cold forging process via fem analysis. Journal of Modern Processes in Manufacturing and Production. 13(3): 5-16.
[4] Mahdieh, M.S., Nazari, F. and Ghlaim, F.A. (2024) Design of forks and lifting system of a 10-ton forklift truck by fem simulation. Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering. 16(2): 59-67.
[5] Mahdieh, M.S., Nazari, F. and Khairullah, A.R. (2024). A study on the effects of different pad materials on brake system performance of a high-capacity elevator by fem simulation. International Journal of Advanced Design and Manufacturing Technology. 16(4): 61-68.
[6] Terefe, T.O. and Tefera, G.A. (2019) Design of impact stone crusher machine. Int. J. Sci. Eng. Res. 10: 904-909.
[7] Borse, C. D., Thete, P. V., & Yadav, R. P. V. J. S. Design and analysis of fixture for stone crusher body. International Journal of Research in Engineering and Technology, 4(6), 229-236.
[8] Joshi, A.J. and Modak, J.P. (2013) A generalized approach for kinematic synthesis and analysis of alternate mechanism for stone crusher using relative velocity method. International Journal of Engineering Research and Application. 3(2): 189-194.
[9] Munyasi, D. (2012) Assesment of stone crushing characteristics and development of a stone crusher for small scale entrepreneurs. Thesis.
[10] Mahdieh, M.S. (2020) The surface integrity of ultra-fine grain steel, electrical discharge machined using iso-pulse and resistance–capacitance-type generator. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications. 234(4): 564-573.
[11] Gurway, S. and Gadge, P. (2022) Optimizing processing parameters of stone crushers through taguchi method. Materials Today: Proceedings. 65: 3512-3518.
[12] Nanda, R.P., Das, A.K. and Moharana, N. (2010) Stone crusher dust as a fine aggregate in concrete for paving blocks. International Journal of Civil & Structural Engineering. 1(3): 613-620.
[13] Chaurasia, S., Singh, R., & Pathak, V. (2009). Environmental Study of Stone Crusher. Cough, 35(20), 15-57.
[14] Attri, G.K., Gupta, R.C. and Shrivastava, S. (2022) Sustainable precast concrete blocks incorporating recycled concrete aggregate, stone crusher, and silica dust. Journal of Cleaner Production. 362: 132354.
[15] Narkhede, V., Likhar, S. and Mishra, M.K. (2012) Morbidity profile of stone crusher workers with special reference to respiratory morbidity–a cross sectional study. National journal of community Medicine. 3(03): 368-371.
[16] Kim, S.-H., Kim, B.-G., Jung, D.-S., Choi, S.-B., Lee, J.-M. and Lee, K.-B. (2020) Vibration diagnosis of sand units in a stone crusher plant: An on-site field test. Applied Sciences. 10(12): 4327.
[17] Attri, G.K., Gupta, R. and Shrivastava, S. (2021) Effect of demolished concrete and stone crusher dust on properties of m− 40 grade paver blocks. Materials Today: Proceedings. 44: 4330-4336.
[18] Rumengan, M.R., Dundu, A.K. and Pratasis, P.A. (2017) Analisa kelayakan investasi alat berat stone crusher di kelurahan kumersot kota bitung. Jurnal Sipil Statik. 5(10):
[19] Lazić, V., Arsić, D., Nikolić, R., Mutavdžić, M. and Meško, J. (2016) Reparation by hard facing of the damaged secondary stone crushers. Manufacturing Technology. 16(2): 375-380.
[20] Farzana, S.Z., Biswas, B., Das, A. and Zafor, A. (2016) A study on cause and effects of noise pollution due to stone crusher machine at jaflong, sylhet. Int Res J Eng Technol. 3(8): 32-35.
[21] Rahul, J. (2022) Stone crusher dust and its impact: Accumulation efficiency of some woody tree species around the stone crusher plant (scp). Proc. Sustainable Energy-Water-Environment Nexus in Deserts: Proceeding of the First International Conference on Sustainable Energy-Water-Environment Nexus in Desert Climates. 621-627.
[22] Rahul, J. (2013) Effect of stone crusher dust on butea monosperma (lam.)(bastard teak). Int J Environ Sci Eng Res. 4: 976-37081.
[23] Sert, B., Bogrekci, I., Demircioglu, P. and Bacaksız, H. The design of roller screening machine.