Design and parameter optimisation of a cotton straw crushing device based on DEM-MBD Article Swipe
YOU?
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· 2025
· Open Access
·
· DOI: https://doi.org/10.1016/j.atech.2025.101584
· OA: W4415628907
To address the problems of structural complexity and unsatisfactory crushing qualification rate in existing integrated machines for straw crushing and film recovery, a cotton straw crushing device suitable for a split-type film recovery machine was designed. Parameter optimisation of key components was carried out using a coupled DEM–MBD simulation approach. The device adopts a novel 2L+1 straight-knife rotor configuration, consisting of 132 L-shaped blades and 66 straight blades arranged in a double-helical pattern to enhance crushing performance. A dynamic analysis of the longitudinal cutting, follow-up motion and chopping phases of the straw was conducted to identify the factors that influence the crushing qualification rate. A machine–straw–soil coupled discrete element model was developed, and single-factor tests were conducted through EDEM–RecurDyn co-simulations. The optimal operating ranges were identified as follows: machine forward speed of 6–8 km/h, rotary shaft speed of 2200–2400 r/min and blade length of 155–165 mm. A three-factor, three-level orthogonal test was designed using the Box–Behnken method based on these ranges. Response surface methodology was applied to determine the optimal combination of the operating parameters: forward speed of 7.88 km/h, rotary shaft speed of 2280.5 r/min and blade length of 160.24 mm. Field validation showed that the straw crushing qualification rate reached 91.82 % under these parameters, meeting regional agronomic requirements. The proposed split-type crushing unit effectively meets the operational needs for cotton straw processing in the Xinjiang region, providing a practical solution to the challenges of mechanical complexity and maintenance difficulty in combined straw crushing and film recovery systems.
