Simulation Model and Performance Analysis of High-Pressure Grinding Rolls Based on DEM-MBD

High-pressure grinding rolls (HPGRs) are critical in mineral processing, making comprehensive research and analysis of their performance of great significance. This study focuses on the HPGR-3516 test prototype and develops an analytical model that combines the discrete element method (DEM) with multi-body dynamics (MBD). The influences of feed top size, roll speed, and specific press force on equipment performance were examined using analysis of variance (ANOVA) in conjunction with response surface methodology (RSM). A performance prediction model was established through regression analysis, followed by multi-objective optimization and experimental validation. The results indicate that increasing roll speed under high specific press force significantly reduces the roll gap, while the effect is negligible under low specific press force. Increasing roll speed improves throughput more substantially for fine feed than for coarse feed. The optimal process parameters were determined to be a feed top size of 8 mm, a roll speed of 0.37 m/s, and a specific press force of 4.84 N/mm2. In comparison to the original parameters, throughput increased by 15.81%, qualified particle size passing rate (QPR) improved by 7.85%, and roll gap decreased by 10.24%. This study offers valuable insights into predicting the dynamic performance of HPGRs and has significant engineering implications.