Abstract: On the basis of analyzing the structure and abrasion of a traditional gyratory crusher's chamber profile, its crushing capacity was defined by computing the flux ratio of every section along the chamber height. The chamber profile was geometrically described by means of a thrice spline curve. The chamber profile target function was built with productivity and nip angle as constraint conditions, then the gyratory crusher's chamber profile was designed and its curves were protracted. A test scheme was set down to meet the aluminum ore crushing demand. After the crushing test of aluminum ore with the optimized chamber profile and new linings, it is shown that the crushing capacity, the certified ratio of crushing products and the working life of linings are better than those with the traditional chamber profile.