Application of EDEM in Hammer Crushing

Simulating the Hammer Crushing Process with Altair ® EDEM™
to Support the Design of Hammer Crushers

【 Industry 】

       Heavy Machinery

【 Challenges 】

       A hammer crusher primarily consists of an upper housing, lower housing, hammer head, rotor, pulley, and adjustment components. The motor drives the rotor to rotate at high speed inside the crushing chamber. Material enters through the top feed inlet and is crushed by the high-speed hammer through impact, collision, shearing, and grinding. Key design considerations include hammer wear, maximum material throughput (processing capacity), and overall crushing performance, which serve as important structural design criteria for hammer crushers.

 【 Solution 】

• Using EDEM to simulate the crushing process, analyze breakage behavior, evaluate crushing performance, assess hammer wear, and provide guidance for early-stage crusher design.

• Leveraging EDEM and MotionSolve co-simulation to analyze hammer crusher operation. MotionSolve provides motion conditions, while the Tavares breakage model—implemented through the EDEM API—enables evaluation of hammer wear, processing capacity, and crushing effectiveness.

• Coupling EDEM with MotionSolve enables efficient structural connection and motion definition for the crusher system. Using the Tavares model, particle breakage can be accurately simulated. With EDEM’s Analyst tool, crushed particle size distribution can be evaluated, enabling assessment of discharge characteristics and overall crushing effectiveness, providing valuable data to improve crusher efficiency.

• By analyzing machine throughput, the system can determine whether capacity requirements are met; wear analysis helps identify high-wear areas for improvement or reinforcement.

【 Advantages 】

• Accurate breakage prediction based on test-calibrated models

• Reduced wear and improved cost efficiency

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