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Visual Animation Demonstration of Crusher Working Principles!

Jun 18, 2025

Visual Animation Demonstration of Crusher Working Principles!

Crushing equipment is an indispensable part of processes such as gravel crushing, sand making, and grinding. However, with a wide variety of crushers on the market currently, how can you select a suitable and satisfactory product? First, you need to have a thorough understanding of the applicable conditions, advantages, and disadvantages of several mainstream types of equipment! Before delving into crushers, it is necessary to have a brief understanding of the crushing methods:

Crushing Methods

The crushing methods of crushers can be classified into extrusion, splitting, breaking, shearing, impact, or striking, etc. Generally, a combination of multiple methods is used, and no crusher relies solely on a single method.

111 - Visual Animation Demonstration of Crusher Working Principles!

Extrusion Crushing

The working surfaces of the crushing machinery apply pressure to the material sandwiched between them. When the compressive stress on the material reaches its compressive strength limit, the material breaks. (Insert an animation here to show the process of two working surfaces gradually approaching and squeezing the material until it finally breaks.)

Splitting and Shearing Crushing

The edges of the crushing working surfaces wedge into the material, generating tensile stress inside it. When this value exceeds the material’s tensile strength limit, the material splits, and powder is generated locally at the contact point between the sharp edge and the material. (Insert an animation to present the scene where the edge wedges into the material and the material splits from the inside.)

Bending and Breaking Crushing

The material sandwiched between the working surfaces is like a simply supported beam or a multi – supported beam under concentrated force. The material mainly experiences bending stress, but splitting occurs at the contact points with the working surfaces. (Use an animation to demonstrate the process of the material breaking like a beam between two working surfaces.)

Extrusion and Shearing Crushing

It is a combination of extrusion crushing and shearing crushing. (The animation should reflect the effect of the material being both squeezed and sheared to some extent.)

Impact Crushing

Impact crushing includes the impact of a high – speed moving crushing body on the material to be crushed, the impact of high – speed moving material against a fixed wall, and the mutual impact of moving materials. (Insert animations for these three types of impact crushing respectively, such as a high – speed hammer impacting the material, the material hitting the fixed wall at high speed, and two high – speed moving materials colliding with each other.)

Analysis of the Crushing Mechanisms, Advantages, and Disadvantages of Different Crushers

Crushers can be divided into three major categories according to the feed size and product particle size:

Coarse Crushers: Crush materials from 1500 – 500mm to 350 – 100mm;

Medium Crushers: Crush materials from 350 – 100mm to 100 – 40mm;

Fine Crushers: Crush materials from 100 – 40mm to 30 – 10mm.

According to different working principles and structural features, crushers can be classified as follows:

1. Jaw Crushers

The operation of jaw crushers is intermittent. Crushing is achieved by the swinging of the fixed jaw and the movable jaw to squeeze the stone. Some friends left messages asking about simple pendulum jaw crushers some time ago. In fact, they are rarely used nowadays, and compound pendulum jaw crushers are mainly used. (Insert an animation of the operation of a compound pendulum jaw crusher to clearly show the swinging process of the movable jaw and the fixed jaw.)

jaw crusher - Visual Animation Demonstration of Crusher Working Principles!

Application: Suitable for a wide range of materials, both hard and soft, especially for the coarse and medium crushing of hard stones.

Advantages: Simple structure, reliable operation, relatively light weight, low price, small external dimensions, low configuration height, large feed opening size, easy adjustment of the discharge opening, simple maintenance, and economical operating costs.

Disadvantages: Liners are prone to wear, the content of flaky and needle – shaped particles in the product is relatively high, and generally, feeding equipment needs to be configured.

2. Cone Crushers

Cone crushers operate continuously. They crush the stone by the eccentric movement of the moving cone. Meanwhile, due to the tangential opposite movement between the moving cone and the fixed cone, the stone also undergoes shearing and grinding. Therefore, its working mechanism is a combination of extrusion, shearing, and grinding. (Insert an animation of the operation of a cone crusher, focusing on the eccentric movement of the moving cone and the stress process of the material in the crushing chamber.)

cone crusher - Visual Animation Demonstration of Crusher Working Principles!

Application: Mainly used for the medium or fine crushing of various stones. According to different structures (suspended – shaft type and supported – shaft type), it can also be used for the coarse crushing of stones (the suspended – shaft type is rarely used).

Advantages: Large crushing ratio, high efficiency, low energy consumption, less dust, uniform product particle size, stable operation, low failure rate, and not prone to over – crushing.

Disadvantages: Complex structure and maintenance, high body height, high price.

3. Gyratory Crushers

Gyratory crushers perform continuous crushing. They adopt the principle of inter – particle lamination crushing, and the crushing process occurs continuously along the circular crushing chamber. (Insert an animation of the operation of a gyratory crusher to show the crushing chamber and the continuous crushing and discharging process of the material inside.)

Application: Mainly used for the first – stage coarse crushing of various hardness materials, but not suitable for crushing sticky ores.

Advantages: Large crushing ratio, high production capacity, can be fed fully, and can be directly fed without the need for additional feeding equipment.

Disadvantages: Complex structure, high body height, large volume, requiring a high – rise factory building, large capital investment in infrastructure, heavy machine, inconvenient to move, and high price.

4. Roller Crushers

Roller crushers operate continuously. The stones are located between two parallel cylindrical rollers moving towards each other. The stones are drawn into the rollers by the friction between the stones and the rollers. For smooth – surface rollers, the stones are extruded, while for toothed rollers, the stones are crushed by splitting and extrusion. (Insert an animation of the operation of a roller crusher to clearly present the process of the material being drawn into the rollers and crushed.)

roller crusher - Visual Animation Demonstration of Crusher Working Principles!

Application: Mainly used for the medium and fine crushing of medium – hardness stones such as coal and limestone (compressive strength below 100MPa). Roller crushers are not used in road surface gravel processing.

Advantages: Simple structure, compact, low investment, easy adjustment, and can be used to crush sticky materials.

Disadvantages: Low production efficiency, unable to crush hard materials.

5. Impact Sand Making Machines

Impact sand making machines operate continuously. They crush materials by the high – speed movement of materials hitting iron, mutual impact, and friction between materials. There are two crushing methods: “stone – on – stone” and “stone – on – iron”. (Insert animations of the operation of impact sand making machines for the “stone – on – stone” and “stone – on – iron” methods respectively, highlighting the movement and crushing of materials under different crushing methods.)

Application: The “stone – on – stone” method is suitable for medium – hard and above materials with high abrasiveness. The finished product has a better particle shape but a slightly higher powder content. The “stone – on – iron” method is suitable for medium – hard and below materials with low abrasiveness. It has a higher crushing efficiency, but the wear cost of the peripheral guard plates is higher, and the finished product particle shape is slightly worse.

Advantages: Low energy consumption, high output, large crushing ratio, small equipment size, simple operation, convenient installation and maintenance, has a shaping function, the product is cubic, large bulk density, and the wear of the impact plate during operation is very small.

Disadvantages: Complex and costly maintenance, generally, the maximum feed size does not exceed 60mm, suitable for fine crushing and sand making.

6. Hammer Crushers

Hammer crushers also operate continuously. They crush stones by the high – speed rotating hammers on the rotor. (Insert an animation of the operation of a hammer crusher to show the scene of the rotor rotating at high speed and the hammers hitting the materials.)

hammer crusher - Visual Animation Demonstration of Crusher Working Principles!

Application: Suitable for the medium and fine crushing of medium – low hardness and non – abrasive stones (compressive strength less than 100MPa). When equipped with grids, it can also be used for sand making, but this application is less common nowadays.

Advantages: Large crushing ratio, high output, and more fine materials.

Disadvantages: Hammers wear quickly and need to be replaced frequently, high dust generation during operation, and materials with a moisture content greater than 12% cannot pass through effectively.

7. Impact Crushers

Impact crushers are machines that use impact energy to crush materials. By adjusting the gap between the impact frame and the rotor, the particle size and shape of the discharged materials can be changed. (Insert an animation of the operation of an impact crusher, focusing on the collision of materials with the impact frame and the process of adjusting the discharge particle size.)

impact crusher - Visual Animation Demonstration of Crusher Working Principles!

Application: Mainly used for the medium and fine crushing of medium – hardness and below stones. The crushed stones have a better shape.

Advantages: Small volume, simple structure, uniform product particle size, selective crushing effect, and high output.

Disadvantages: The hammers and impact plates are particularly prone to wear, especially when crushing hard rocks, and need to be replaced frequently. Not suitable for crushing plastic and sticky materials.

The above seven types of crushers are the most commonly configured in gravel crushing and sand making production lines. If you want to know more about products, feel free to leave a message for consultation!