A cone crusher crushes rock by repeatedly compressing it between a moving mantle and a fixed bowl liner, also called a concave. An eccentric drive makes the mantle gyrate, opening and closing the space through which the material moves. The closest gap—called the closed-side setting (CSS)—helps determine the product size and influences capacity and power draw.
What does a cone crusher do?
A cone crusher reduces rock and other suitable feed material into smaller pieces. In aggregate and mining plants, it is commonly used for secondary, tertiary, and quaternary crushing; Metso also describes use in recycling. A cone crusher can serve as the first crushing stage when naturally small feed does not require a traditional primary crusher. Its place in a plant depends on the feed and the rest of the circuit, not just the machine itself. Metso’s cone crusher overview describes these applications.
How does a cone crusher crush rock?
The moving and fixed crushing surfaces
The crushing chamber is the space between two wear surfaces. The mantle is fitted to the moving head and main shaft; the bowl liner, or concave, forms the fixed outer surface. A gear and pinion rotate an eccentric shaft, which causes the main shaft and mantle to gyrate. The mantle does not simply spin against the bowl liner: its motion makes the gap between the surfaces vary through each cycle. Metso’s overview explains this arrangement.
Compression breaks the material
As material descends through the chamber, it is compressed when the mantle moves closer to the concave. Larger pieces may be crushed against the wear surfaces; smaller pieces can also break through contact with neighboring rock. Metso’s GP-series application guide calls this multi-layer crushing and notes its contribution to product shape and wear-part life. The material continues through the chamber until it can pass through the discharge opening. Metso’s GP-series wear-parts application guide describes the process.
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What are CSS and OSS, and why do they matter?
Because the mantle gyrates, the distance between the mantle and concave changes around the cycle. The closed-side setting (CSS) is the closest clearance; the open-side setting (OSS) is the widest opening. CSS is a key operating setting, but it is not a guarantee of one exact product size: feed characteristics, chamber design, operating conditions, and the plant circuit also affect the resulting gradation.
Metso’s GP application guidance says CSS affects reduction ratio, product gradation, capacity, and power draw. In that guide’s general relationship, a larger setting produces a coarser product and can increase capacity while reducing power draw. This is guidance for GP-series applications, not a universal instruction for every cone crusher or material. Use the limits and adjustment procedure for the specific machine. Metso’s GP operating guidance covers setting effects.
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How are cone crusher settings adjusted?
Adjustment arrangements vary by design. Metso describes systems that reposition the outer wear part by rotating the bowl, as well as designs that change the setting by raising or lowering the main shaft. Hydraulic systems can facilitate adjustment, but the mechanism and permitted settings depend on the crusher model. Do not treat a general description as an adjustment procedure; consult the relevant machine manual. Metso’s cone crusher overview and crusher types overview describe these design approaches.
What affects product size, shape, and throughput?
CSS is only one part of the operating picture. Chamber profile, speed, feed, material properties, and the surrounding plant all matter. Metso’s chamber-selection guidance describes general tendencies: higher speed can produce finer gradation and better product shape, while lower-range speed can increase cavity volumetric throughput and produce fewer fines. These are not settings to apply without considering the machine, feed, and target product.
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- Feed: Size and gradation, evenness of distribution, moisture, clay content, bulk density, and crushability can affect capacity and loading.
- Chamber profile: Available chamber options suit different feed sizes and setting ranges; the choice should match the application.
- Target product: Desired gradation and shape influence the chamber and setting choices.
- Operating conditions: Speed, power draw, throughput, and model-specific setting limits constrain the operating envelope.
- Plant circuit: Feeders, screens, conveyors, recirculation, and upstream or downstream stages affect how the crusher performs as part of the plant.
Metso’s chamber-selection article discusses chamber and speed tendencies; its GP application guide covers feed and operating factors.
Why is even, choke feeding recommended?
Choke feeding means keeping the crushing chamber full as appropriate for the crusher and application. Metso’s GP-series guide states: “The crusher should be choke fed so that the crushing chamber is full all the time.” The same guide recommends stable, evenly distributed feed and warns that segregated, oversize, or unsuitable material can reduce capacity or create unnecessary loads. This is GP-series application guidance, not a substitute for the manual or operating limits for another machine. Metso’s GP application guide provides the guidance.
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What should operators check before choosing a setting or chamber?
There is no universally correct CSS, speed, or chamber profile. The appropriate choice depends on the required product and the conditions in which the crusher operates. For a configuration or operating decision, assess:
- Feed size and gradation, moisture, clay, bulk density, and material crushability.
- Required product size, gradation, and shape.
- Crusher model, available chamber profiles, setting range, speed, throughput, and power constraints.
- Feeding, screening, recirculation, and the other stages in the plant circuit.
- Wear-part condition and the model-specific maintenance and safety requirements.
Operating limits, startup and shutdown steps, clearing procedures, and maintenance requirements are model- and installation-specific. Metso’s training material covers operating and safety rules, startup and shutdown, maintenance, and troubleshooting for the product families it lists; it is not a replacement for the manual and procedures applicable to a particular installation. Metso’s cone crusher training brochure describes that training scope.
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