Discrete Element Method-Based Simulation for Rice Straw Comminution and Device of Parameter Optimization

To mitigate the entanglement, agglomeration, and unstable conveying of high-moisture rice residues during stubble crushing for field incorporation, a discrete element method (DEM)-based modeling and optimization framework was developed to enhance the performance of a stubble-crushing device under wet paddy-field conditions. The device structure and kinematics were first analyzed, and the physical and mechanical properties of the residues were obtained through field measurements. A hollow wet–flexible straw model was then proposed to account for both mechanical breakage and moisture-induced adhesive interactions. Key contact and material parameters were calibrated using DEM simulations coupled with laboratory shear and three-point bending tests, showing good agreement with experimental trends. The validated model was subsequently extended to the device scale to characterize the cyclic capture–acceleration–throwing behavior of residues inside the crushing chamber. The individual and interactive effects of rotor speed, forward speed, and throwing-chamber clearance on comminution efficiency and conveying stability were investigated. A multi-objective response surface optimization identified an optimal parameter combination of 2000 rpm rotor speed, 0.87 m s−1 forward speed, and 10.5 cm clearance. Under these conditions, the comminution rate reached 96.94%, and the coefficient of variation in throwing uniformity was 8.71%. Field validation further confirmed the reliability of the simulation results, with relative errors below 6%. Overall, the proposed framework provides an effective tool for the design optimization and parameter selection of wet-residue comminution equipment.