Discrete Element-Based Optimization Parameters of an Experimental Corn Silage Crushing and Throwing Device

Highlights A 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.