Innovative Spiral Vibrating Screen for High-Quality Cubical Crushed Stone: Design and Validation

Efficient production of high-quality cubical crushed stone is critical for road construction and concrete manufacturing. Conventional vibrating screens suffer from low cubicality and high energy consumption, limiting their applicability. We developed a novel spiral vibrating screen featuring a helical screening surface and adjustable oscillation parameters. Experimental studies were conducted on granite aggregates (5–20 mm) at vibration frequencies of 16–26 Hz and amplitudes of 1.5–4.0 mm to evaluate cubicality, screening efficiency, throughput, and energy consumption. Under optimal operating conditions (22 Hz, 3.0 mm amplitude), the prototype achieved 84–86% cubical particles, 93–95% screening efficiency, and specific energy consumption of 1.20 ± 0.05 kWh/t. Compared with conventional flat and drum screens, cubicality improved by 8–12 percentage points, while energy consumption decreased by up to 12%. The developed screen offers a scalable solution for producing high-quality cubical aggregates with lower energy demand and reduced clogging risks. These findings provide practical guidance for improving aggregate processing technologies.