HighlightsA discrete element simulation model was used to improve the performance of a corn silage crushing and throwing device.Feed rate, crushing speed, and dial speed were used as the test factors, and the average cutting force and average energy loss were used as the evaluation indexes in orthogonal testing.The order of significance of the factors was crushing speed > feed rate > dial speed for average cutting force and crushing speed > dial speed > feed rate for average energy loss.Abstract. To improve the performance of a corn silage crushing and throwing device and address the problems of low crushing quality and high power consumption, a discrete element simulation model of a corn silage crushing and throwing device and granular straw was established based on discrete element theory using EDEM, a general-purpose CAE software program designed with modern discrete element model technology to simulate and analyze particle processing and production operations. The average cutting force and average energy loss of the particles were the evaluation indexes, and the influence of feed rate, crushing speed, and dial speed on the evaluation indexes was analyzed using single-factor simulation tests. The order of significance was crushing speed > feed rate > dial speed for the average cutting force and crushing speed > dial speed > feed rate for the average energy loss. Using multi-objective optimization, the optimal combination of feed rate, crushing speed, and dial speed was 3.52 kg s-1, 892.06 rpm, and 1502 rpm, respectively. With the optimal parameters, the average cutting force was 58.20 N and the average energy loss was 0.85 J. To verify the feasibility of the EDEM simulation, field tests were conducted using a trial-produced device, with the acceptability of straw crushing and power consumption as the test indicators. During the field tests, the feed rate, crushing speed, and dial speed were set to 3.52 kg s-1, 890 rpm, and 1500 rpm, respectively. The field tests showed that the acceptability of straw crushing and the power consumption were 93.60% and 6.73 kW·h, respectively, with the optimal parameters, which satisfied the corn silage crushing standard and provides a theoretical and scientific basis for the design and optimization of the device. Keywords: Corn silage, Crushing and throwing device, Discrete element simulation, Motion simulation, Multi-objective optimization method.
HIGHLIGHTS The mechanism of straw smashing was analyzed. Factors such as the speed of the cutter shaft, the number of blades, the thickness, and the inclination angle had a greater impact on the theoretical length of the straw section after crushing. Based on the straw crushing mechanism, the structure of the crushing chamber was designed. The corn stalk crushing and sending device was trial-produced and field experiments were carried out. ABSTRACT . In order to further improve the crushing quality of corn stalks, this research designs a corn stalk crushing and throwing device. First, it introduced the overall structure and working principle, and analyzed the crushing mechanism of corn stalks to obtain the main factors affecting its crushing performance. Then, the crushing blade in the crushing chamber was designed to determine that the number of crushing blades was 10. Kinematics and dynamic balance analysis, and the establishment of a mathematical model, the speed range of the crushing cutter shaft was 530~900 r/min. On this basis, the ADAMS motion simulation software was used to measure the change curves of the restraint force, runout, and acceleration of the shaft end with different speeds of the crushing cutter shaft. The simulation analysis finally determined that when the speed of the crushing knife shaft was 700 r/min, and the working performance of the device was better and meets the requirements of dynamic balance. Finally, the verification test was carried out, and the result shows: when the speed of the crushing knife shaft was 700 r/min, the qualified rate of corn stalk crushing length was 93.65%. Compared with the original silage corn crushing and throwing device, the performance had increased by 4.78%. It meets the standard of corn stalk crushing operation, which can provide a theoretical basis and scientific basis for the design and optimization of corn stalk crushing and returning equipment. Keywords: Crushing mechanism, Dynamic balance, Motion simulation, Silage corn.
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