Development and wear characteristics analysis of a layered wear model for cone crusher liners

To investigate the wear mechanisms of cone crusher liners, this study developed a layered wear prediction model for the CC 100 single-cylinder cone crusher used in a Jiangxi concentrator. The crushing chamber was divided into discrete zones, and the model integrated extrusion force experiments, particle size distribution analysis, and abrasion theory to simulate wear patterns across liner sections. Ultrasonic thickness measurements validated the model’s accuracy in predicting wear distribution. Using this model, the influence of eccentric speed, feed particle size, and precession angle on liner wear was systematically analyzed. Results revealed that peak wear occurs in the mid-lower region of the crushing chamber due to exponential pressure increases caused by narrowing cavity gaps. While overall wear trends showed minimal sensitivity to operational parameters, intra-layer analysis indicated that wear severity increases with decreasing eccentric speed, increasing feed size, and larger precession angles. Specifically, lower speeds prolong material compression cycles, larger particles induce localized pressure spikes and forced sliding abrasion, and larger precession angles intensify horizontal shear forces and friction paths. Wear rate uniformity exhibited a parabolic relationship with eccentric speed, suggesting an optimal rotational velocity for minimizing uneven wear. Conversely, reducing precession angle and feed size improved wear distribution homogeneity across the liner surface.