The choke-level is one of the key factors that influence the falling process of the granular materials which is closely related to the crushing efficiency in the cone crusher. In this paper the motion characteristics of the particles near the choke-level have been analyzed and the phenomenon of single particle breakage below the choke level is pointed out. Based on the multi-zone method, an improved particle shape prediction model is established. In this model, the compound breaking behavior which includes the single particle breakage under the choke-level effect and the inter-particles breakage under the fill-feed, the transformation of particle shape and the particle size distribution in each crushing zone are considered. Tests on the PYG-B1735 cone crusher are conducted in order to validate the improved model. The improved model provides a theoretical foundation for the productivity estimation and the performance optimization.

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