applied

sciences
Article
Dynamic Analysis and Parameter Optimization of the Cutting
System for Castor Harvester Picking Devices
Fanting Kong 1,2 , Defu Wang 1,3, *, Lei Shi 2 , Huinan Huang 3 , Qing Xie 2 , Teng Wu 2 , Yongfei Sun 2
and Changlin Chen 2

1 College of Engineering, Northeast Agricultural University, Harbin 150030, China

2 Nanjing Institute of Agricultural Mechanization, Ministry of Agriculture and Rural Affairs,
Nanjing 210014, China
3 College of Mechanical and Electrical Engineering, Henan Agricultural University, Zhengzhou 450046, China
* Correspondence: dfwang640203@163.com

Abstract: Our study aimed to identify a design which would reduce cutting resistance during the
harvesting of castor. This paper presents a theoretical study of the wave-type disc cutter, which plays
an important role in castor harvesting. Based on the SPH–FEM coupling algorithm, a combined
orthogonal rotation experiment was performed to study the effects of disc cutter thickness, edge angle,
disc cutter rotation speed, and feeding speed on the maximum cutting force. The response surface
method was used to achieve an optimal combination of all the test factors. Mathematical modeling of
the maximum cutting force and influencing factors was utilized to obtain the optimal parameters
for a cutting system consisting of wave-type disc cutters. The optimal results were obtained with a
computer-simulated disc cutter rotation speed of 844.2–942.1 r/min, a feeding speed of 0.89–1.01 m/s,
a disc cutter thickness of 2.71–3.15 mm, and an edge angle of 29.2–33.9◦ . Under these conditions, the
maximum cutting force was less than 50 N. Finally, the experimental data and numerical computer
simulation results were compared using cutting performance test verification. The analysis found
that the test results and simulation results were largely consistent. Therefore, the simulation model
was judged to be effective and reasonable.

Citation: Kong, F.; Wang, D.; Shi, L.;

Keywords: agricultural machinery; castor harvester; cutting system; SPH–FEM coupling method;
Huang, H.; Xie, Q.; Wu, T.; Sun, Y.;
Chen, C. Dynamic Analysis and
cutting force; parameter optimization
Parameter Optimization of the
Cutting System for Castor Harvester
Picking Devices. Appl. Sci. 2023, 13,
2116. https://doi.org/10.3390/ 1. Introduction
app13042116 Castor is a common crop, well known for its specific oil, which is widely used in the
Academic Editors: Mark J. Jackson chemical industry [1]. In addition, many castor extracts have significant pharmacological
and Roberto Romaniello activities [2,3]. Because the castor plant places low demands on the growing environment
and is simple to plant, with low input costs and high economic benefits, it is an important
Received: 16 December 2022 cash crop that enables farmers to increase their income. Castor production in India, China,
Revised: 26 December 2022
Brazil, and Mozambique accounts for nearly 88% of world production [4,5]. The key restric-
Accepted: 31 December 2022
tion of castor production is the largely manual harvesting required. Mechanized harvesting
Published: 7 February 2023
is an effective way to promote the development of the castor industry and it is, therefore,
necessary to study castor harvesting technology in order to solve the mechanization chal-
lenges, reduce the harvesting costs, and drive the sustainable development of the castor
Copyright: © 2023 by the authors.
industry.
Licensee MDPI, Basel, Switzerland. In recent years, scholars have designed and tested many types of castor harvester.
This article is an open access article Wu et al. [6] designed a castor harvesting device that used a set of wheel-saw cutters to
distributed under the terms and cut the main stalk and then transport it to the thresh rollers by means of an entanglement
conditions of the Creative Commons device. The test showed that the castor harvester achieved the designed functions, but the
Attribution (CC BY) license (https:// harvesting ratio was 67.1 ± 6.8%, indicating that the harvester still required improvement.
creativecommons.org/licenses/by/ Liu et al. [7] developed the 4BZ-4 self-propelled castor harvester and performed technical
4.0/). research in terms of the physical characteristics and harvesting process of castor beans.

Appl. Sci. 2023, 13, 2116. https://doi.org/10.3390/app13042116 https://www.mdpi.com/journal/applsci

Appl. Sci. 2023, 13, 2116 2 of 16

Stefanoni et al. [8] compared the effectiveness, machinery performance, and seed loss from
the impact and cleaning systems of two combine harvesters equipped with a sunflower
header and a cereal header, respectively, for harvesting castor beans. They observed that
a disc cutter was more suitable for use in cutting systems for castor picking and that the
structure of castor harvesters with disc cutters was much simpler than other types of
cutting system, making it easier to automate castor harvesting. In the process of cutting,
friction and wear between the cutter and the crops, soil, and, in particular, stone debris
may lead to blade passivation and reduced cutting performance. Rostek et al. [9] studied
the relationship between cutter life and the bending strength, ductility, and wear resistance
of matrix materials. Song et al. [10] carried out a series of studies concerning tool self-
sharpening technology. Momin et al. [11] established evaluation indexes, such as root
damage degree, residual height, and blade quality change, and evaluated the cutting
performance of cutters with different structural forms and surface treatment processes.
In terms of material properties, it was recommended that the hardness of the quenched
zone should be 48-60HRC and that the hardness of the non-quenched zone should not
exceed 35HRC [12]. However, there exist few innovative designs for the structure of the
key cutting components, and studies concerning the relationship between the structure
of key components and the performance of castor cutting systems are limited. Therefore,
further study of cutting systems for castor harvester picking devices is required.
With the improvement of computer processing technology, the use of numerical analy-
sis is becoming increasingly common in agricultural engineering. Considering accuracy
and economical calculation, the finite element method is one of the best ways to study the
factors affecting castor harvesting. Numerical simulation technology was used to simulate
the crop stalk cutting process. This approach could provide a research tool and theoret-
ical basis for the design of a castor harvester and reduce the time and cost involved in
machinery research and development. In recent years, LS-DYNA simulation software has
been widely used to study the results of material deformation or failure in the agricultural
field. Huang et al. [13] used ANSYS/LS-DYNA to conduct numerical calculations and
simulations on a finite element model composed of different cutting angles and speeds
in the sugarcane cutting process. Meng et al. [14] used ANSYS/LS-DYNA to simulate a
circular saw blade model under different conditions for the cutting of mulberry branches
and determined the optimal parameters for the circular saw blade. Based on a Box–Behnken
design experiment, Xie et al. [15] established models for the sugarcane cutting process
which simulated the cutting resistance and stress distribution of blades and sugarcane
under different factors. These models were used to determine the optimization param-
eters according to sugarcane cutting quality and the average maximum cutting power
consumption. Cao et al. [16] used LS-DYNA software to simulate the picking process of
a carp-clip safflower picking device and revealed the relationship between the different
structural and working parameters of the picking device and the safflower movement type.
Souza et al. [17] carried out finite element analysis of the interaction between harvester
rods and coffee branches using ANSYS/LS-DYNA software and tested the samples with
plagiotropic coffee branches. Ibrahmi et al. [18] studied the dynamic impact of the apple
using the finite element method and carried out the apple collision tests.
The FEM method involves the encryption of the mesh of the contact part, focusing on
material failure and damage in the cutting process. This simulation method is generally
based on element deletion technology, which ignores conservation and, to a certain extent,
affects the accuracy of the cutting force analysis. The SPH algorithm does not have the
mesh distortion and element failure problems and, in comparison with other methods,
has very significant advantages in terms of failure types [19–21]. However, because of
the algorithm differences, the computational efficiency of the SPH method is low and
boundary conditions are difficult to solve. For this reason, some scholars have proposed
the SPH–FEM coupling method [22–24]. The FEM algorithm is used to solve the low-speed
deformation region in the model analysis, and the SPH algorithm is used to solve the high
deformation, high speed, and difficult FEM calculation region. The advantages of the two
Appl. Sci. 2023, 13, x FOR PEER REVIEW 3 of 17

SPH–FEM coupling method [22–24]. The FEM algorithm is used to solve the low-speed
Appl. Sci. 2023, 13, 2116 deformation region in the model analysis, and the SPH algorithm is used to solve the3high of 16

deformation, high speed, and difficult FEM calculation region. The advantages of the two
algorithms, such as a low speed, small deformation area, accurate Lagrange solution, fast
algorithms,
solution speedsuchand
as a low
largespeed, small deformation
deformation area to avoid area,
theaccurate
increaseLagrange solution,load
in computational fast
solution
caused by speed
mesh and a large deformation
distortion, are fully used areatotosolve
avoidthethecoexisting
increase in computational
coupling problemsloadof
caused by mesh distortion,
large deformation, impact,are fully
small used to solve
deformation, the coexisting coupling problems of large
etc.
deformation,
Based onimpact,
the abovesmall deformation,
summary, etc. system is the most important part of castor
the cutting
Based on the above summary, the cutting
harvester picking devices and affects the performance system isandthe power
most important
consumptionpart of castor
harvester picking devices and affects the performance and power consumption
harvesters. Focusing on wave-type disc cutters of the designed cutting system, the ofcutting
castor
harvesters.
process wasFocusing
analyzed onand
wave-type disc cutters
the parameters of the designed
optimized. cuttingofsystem,
The objective the cutting
this paper was to
process
performwas analyzedofand
a simulation the the parameters
castor optimized.
stalk-cutting The objective
process using of this
the coupled paper was
SPH–FEM nu-
to perform
merical a simulation
calculation methodof the castor
based stalk-cutting
on stalk physical process using the
characteristics coupled
[25–28] SPH–FEM
and then to op-
numerical calculationand
timize the structural method basedparameters
operating on stalk physical characteristics
of the disc cutter using[25–28] and thenro-
the orthogonal to
optimize the structural and operating parameters of the disc cutter using
tation combination test. Finally, the numerical computer simulation results were verified the orthogonal
rotation combination
via experimental test. Finally, the numerical computer simulation results were verified
tests.
via experimental tests.
2. Materials and Methods
2. Materials and Methods
2.1. Machine
2.1. Machine Structure
Structure and
and Working
Working Principles
Principles
2.1.1. Main
2.1.1. Main Structure
Structure
The castor
The castorharvester
harvesterpicking
picking device
device waswas designed
designed based
based on a previous
on a previous study,
study, as shownas
shown in Figure 1. The device is attached to a rice or corn combine, which has
in Figure 1. The device is attached to a rice or corn combine, which has low requirementslow re-
quirements
for for linehas
line alignment, alignment, has goodplanting
good agronomic agronomic planting adaptability
adaptability and does notand
missdoes not
plants
miss plants
when when harvesting.
harvesting.

Figure 1. Castor harvester picking device. 1. Capsule recycling mechanism; 2. double-disc cutting
Figure 1. Castor harvester picking device. 1. Capsule recycling mechanism; 2. double-disc cutting
system; 3. dial teeth chain; 4. frame; 5. horizontal auger; 6. transmission system.
system; 3. dial teeth chain; 4. frame; 5. horizontal auger; 6. transmission system.
The castor
The castorharvester
harvesterpicking
pickingdevice
device is mainly
is mainly composed
composed of frame,
of the the frame, the capsule
the capsule recy-
recycling mechanism, the double-disc cutting system, the dial teeth chain, and
cling mechanism, the double-disc cutting system, the dial teeth chain, and the transmission the trans-
mission The
system. system.
main The main structural
structural dimensions
dimensions are shown arein
shown
Table in
1. Table 1. The double-disc
The double-disc cutting
cutting system is primarily composed of the disc cutter, dial teeth
system is primarily composed of the disc cutter, dial teeth chain, etc. The main chain, etc.component
The main
component
of of recycling
the capsule the capsule recycling is
mechanism mechanism is the
the conveyor conveyor
belt. belt. For
For picking twopicking two
rows, the rows,
picking
the picking
device device is
is configured configured
with four disc with four
cutters, discconveyor
three cutters, belts,
three and
conveyor belts, dial
four closed andteeth
four
closed dial teeth chains .
chains.

Table1.1. Main
Table Main technical
technicalparameters
parametersof
ofthe
thecastor
castorharvester
harvesterpicking
pickingdevice.
device.

Item Item Values ValuesItem Values

Item
Values
Boundary dimension/ WorkingWorking
Boundary dimension/(mm × mm × mm)
2360 × 22622360 × 2262 × 567
× 567 15001500
(mm × mm × mm) width/(mm)
width/(mm)
Working speed/(m·s−1 ) 0~1.58 Rows picked/row 2

The structure of the disc cutter in the cutting system of the castor harvester picking
device is an important element that affects harvesting quality and efficiency [29–31]. Ac-
Appl. Sci. 2023, 13, x FOR PEER REVIEW 4 of 17

Working speed/(m·s−1) 0~1.58 Rows picked/row 2

Appl. Sci. 2023, 13, 2116 4 of 16
The structure of the disc cutter in the cutting system of the castor harvester picking
device is an important element that affects harvesting quality and efficiency [29–31]. Ac-
cording to previous test results [32], the structural parameters of the disc cutter are as
cording to previous test results [32], the structural parameters of the disc cutter are as
shown in Figure 2.
shown in Figure 2.

Double-disccutting
Figure2.2.Double-disc
Figure cuttingsystem
systemconsisting
consistingofofwave-type
wave-typedisc
disccutters.
cutters.

2.1.2. Working Principles

2.1.2. Working Principles
During castor harvesting operations, power from the hydraulic motor is transmitted
During castor harvesting operations, power from the hydraulic motor is transmitted
to the dial teeth chain. The disc cutter is coaxial with the driven sprocket of the dial teeth
to the dial teeth chain. The disc cutter is coaxial with the driven sprocket of the dial teeth
chain. The motion of the adjacent dial teeth chain causes the two disc cutters in the cutting
chain. The motion of the adjacent dial teeth chain causes the two disc cutters in the cutting
system to rotate in opposite directions and cut the castor stalk. Then, the cut castor plants
system to rotate in opposite directions and cut the castor stalk. Then, the cut castor plants
are pushed back to the horizontal auger by the dial teeth chain. At the same time, the
are pushedorback
shocking to the
striking ofhorizontal
the deviceauger
causesbythethecastor
dial teeth chain.
capsules At the
to fall samethe
toward time, the
capsule
shocking
recyclingormechanism
striking ofandthe then
device causes
to be the castor
transported capsules
to the to fallauger
horizontal toward theconveyor.
by the capsule
recycling mechanism and then to be transported to the horizontal auger by the
Finally, the plants (including the fallen capsules) are transported to the cleaning device of conveyor.
Finally, the plants
the harvester, (including
completing thethe fallen
castor capsules)operation.
harvesting are transported to the cleaning device of
the harvester, completing the castor harvesting operation.
It can be seen that the double-disc cutting system cuts the whole castor plant during
It can
castor be seen that
harvesting, whichthehas
double-disc
an importantcutting system
effect on thecuts the whole of
performance castor plant
castor during
harvester.
castor harvesting, which has an important effect on the performance of castor harvester.
2.2. Mechanical Analysis
2.2. Mechanical Analysis
By analyzing the force in the cutting process, clarifying the interaction between the
Bydisc
cutter analyzing
and thethe force
castor in the
stalk, andcutting
studyingprocess, clarifying the
the stalk-cutting interaction
mechanism, thebetween the
main factors
cutter discthe
affecting andcutting
the castor
forcestalk,
wereand studying The
determined. the stalk-cutting mechanism,
castor stalk-cutting process the main
was fac-
divided
tors
intoaffecting the cutting force
contact and stageswere determined.
according The castor
to the different stalk-cutting
positions process
and states was
in the di-
study.
vided into contact and cutting stages according to the different positions and states in the
2.2.1. Contact Stage
study.
The maximum stress at the contact stage occurs at the moment when the stalk changes
2.2.1.
fromContact
a static Stage
state, gains kinetic energy and withstands the impact of the disc cutter. The
contact and collision
The maximum stress process at between
the contactcastor stalkoccurs
stage and discat cutter was analyzed.
the moment when the Thestalk
force
and velocity analysis of the stalk are shown in Figure 3. The disc is
changes from a static state, gains kinetic energy and withstands the impact of the disc in contact with the stalk
at a relative velocity V
cutter. The contact andz collision process between castor stalk and disc cutter was ana-of
. When the velocity of the stalk increases to the same level as that
the disc
lyzed. Thecutter,
forcetheir
andrelative
velocityvelocity
analysis is zero.
of theThe relative
stalk displacement
are shown in Figure between
δz 3. The disctheisstalk
in
and the disc cutter does not decrease. In this case, the maximum contact
contact with the stalk at a relative velocity Vz. When the velocity of the stalk increases to force is P max .
the same level as that of the disc cutter, their relative velocity is zero. The relative displace-
ment δz between the stalk and the disc cutter does not decrease. In this case, the maximum
contact force is Pmax.
 Appl. Sci. 2023, 13, x FOR PEER REVIEW 5 of 17
Appl. Sci. 2023, 13, 2116 5 of 16

Figure3.3.Schematic
Figure Schematicof
ofstalk
stalkcontact
contactforce
forceand
andvelocity.
velocity.

According
Accordingtotoinelastic
inelasticcollision
collisiontheory,
theory,the therelative
relativedisplacement
displacementδzδzatataagiven
givenmoment
moment
isisas
asfollows:
follows:  1
3PR13 3
 3 PR ∗
aa == 4E * 
(1)
(1)
 4E 
 2 2 1  31
aa22  9 P9P 3
δδzz =
= == ∗2 (2)
(2)
RR  1616RE RE 
* 2

11 (11−−v12v)21 (1 − 1v 22− 2



) v2
== ++ (3)
(3)
EE∗* EE1 1 E2 E2
11 =1 1 + 1 1 (4)
= R+1 (4)
R R1 R2 R2
R
1 1 1
1 =1 +1 (5)
m = m + m (5)
m m1 1 m 2 2
where a is the effective dimension of contact segment m; P is the loading force, N; R is the
where a is the effective dimension of contact segment m; P is the loading force, N; R is the
relative radius of curvature, m; E* is the elasticity modulus, MPa; δz is the displacement of
relative radius of curvature, m; E* is the elasticity modulus, MPa; δz is the displacement
contact point, m; v1 is the contact velocity of the stalk, m/s; E1 is the elasticity modulus of
of contact point, m; v1 is the contact velocity of the stalk, m/s; E1 is the elasticity modulus
the stalk, MPa; v2 is the contact velocity of the disc cutter, m/s; E2 is the elasticity modulus
of the stalk, MPa; v2 is the contact velocity of the disc cutter, m/s; E2 is the elasticity mod-
of the disc cutter, MPa; R1 is the effective radius of the stalk, m; R2 is the effective radius of
ulus of the disc cutter, MPa; R1 is the effective radius of the stalk, m; R2 is the effective
the disc cutter, m; m is the equivalent mass, kg; m1 is the mass of the stalk, kg; and m2 is the
radius
mass of of
thethe disc
disc cutter,
cutter, kg.m; m is the equivalent mass, kg; m1 is the mass of the stalk, kg;
and During
m2 is thethe
mass of the process,
collision disc cutter, kg. of elastic deformation, the centers of the stalk
because
During the collision process, because
and disc cutter approach each other by a displacementof elastic deformation,
δz , and theirthe centers
relative of the is
velocity stalk
as
and disc
follows: cutter approach each other by a displacement δ z, and their relative velocity is as

follows: dδz
v2 − v1 = (6)
dδ dt
v2 − v1 = z (6)
dt
At any instant, the interaction force is as follows:
At any instant, the interaction force is as follows:
dv dv
P(t) = mdv1 1 = −m dv 2 (7)
P(t ) = m1 1 dt = −m2 22 dt (7)
dt dt
This
Thiscan
canbe
beobtained
obtainedusing
usingthe
thefollowing
followingEquations
Equations(6) (6)and
and(7):
(7):
m1 + m 2 d(v 2 − v1 ) d δ z 22

− m + m P = d(v − v=1 ) 2 d δz
− m11 m 2 2 P = dt2 dt= (8)
(8)
m1 m2 dt dt2
According to Equation (2), the following can be obtained:
According to Equation (2), the following can be obtained:
4
P = R 1 2 E * δ z3 2 = Kδ z3 2 (9)
34
P = R1/2 E∗ δz3/2 = Kδz3/2 (9)
Substituting Equations (5), (8) and
3 (9), the following can be obtained:
 Appl. Sci. 2023, 13, x FOR PEER REVIEW 6 of 17
Appl. Sci. 2023, 13, 2116 6 of 16

dδ z
m = − Kδ z3 2 (10)
Substituting Equations (5), (8) anddt(9), the following can be obtained:
The following can be obtained by integrating δz:
dδz
m =2 −Kδ3/2 (10)
1  2  ddtδ z   2zK 5 2
Vz −   = δz (11)
2  by integrating
The following can be obtained dt   5m δz :

V =(dδ v2z−v21 ) t=0 2K

" #
1 2 z (12)
Vz − = δz5/2 (11)
2 dt 5m
where VZ is the velocity of the stalk and the disc cutter approaching each other, m/s.
At the maximum compression displacement, dδ z dt = 0 , using Equation (11) we can
Vz = (v2 − v1 )t=0 (12)
obtain the following:
where VZ is the velocity of the stalk and 2 25
the disc cutter2approaching
25 each other, m/s.
 5mV   15dδ mV = 0, using Equation (11) we can
δz = 
*
At the maximum compression Z
 =
displacement, /dt
Z
12 * 
z (13)
obtain the following:  4K !  2/5  16 R E  !2/5
2 2
According to the Von∗Mises5mV criterion,
Z at the time15mVof Z initial yield, the relationship be-
δz = = 1/2 E∗is as follows:
(13)
tween maximum contact pressure4K Pmax and loading 16Rforce
1
 6 P at
According to the Von Mises criterion, ⋅ E the
*2
 3 time of initial yield, the relationship
Pmax =  3 2  (14)
π ⋅R
between maximum contact pressure Pmax and loading
 force is as follows:
By substituting Equations (9), (13), and
 (14),∗2the
 13maximum force in the contact pro-
cess is obtained as follows: 6P · E
Pmax = (14)
π 3 · R2
4

3  4and  the
5 1
By substituting Equations (9), (13), E * (14),
  5 maximum
2
5 force in the contact process
is obtained as follows: P max = ⋅  mV z 
(15)
2π   34 ∗  45 4  5 1
3 3R4E 

5
Pmax = 3 · mVz 2 (15)
2π 3R 4 4
During the contact process, when the maximum contact stress Pmax exceeds the elastic
limitDuring
of the the contact
stalk, process,
the stalk when the
undergoes maximum
plastic contact stress
deformation Pmax exceeds
and enters the elastic
the cutting stage.
limit of the to
According stalk, the stalk
Equation undergoes
(15), the maximumplasticcontact
deformation
force ofand
theenters the cutting
disc cutter stage.
is positively
According
correlated to
withEquation (15), relative
the contact the maximum
velocitycontact force and
of the stalk of the
thedisc cutter ismass
equivalent positively
of the
correlated with the contact relative velocity of the stalk and the equivalent mass
stalk and disc cutter, and negatively correlated with the equivalent radius of curvature. of the stalk
and disc cutter, and negatively correlated with the equivalent radius of curvature.
2.2.2. Cutting Stage
2.2.2. Cutting Stage
When the castor stalks are cut with the disc cutter, the edge and surface of the disc
When the castor stalks are cut with the disc cutter, the edge and surface of the disc
cutter are the key parts that cut the stalk and resist the cutting force. Therefore, this study
cutter are the key parts that cut the stalk and resist the cutting force. Therefore, this study
analyzed the mechanical model of cutting resistance in terms of differentials. As shown
analyzed the mechanical model of cutting resistance in terms of differentials. As shown in
in Figure 4, the cutting resistance of the disc cutter at the moment of cutting mainly in-
Figure 4, the cutting resistance of the disc cutter at the moment of cutting mainly includes
cludes the reaction force F0 exerted by the stalk against the motion of the disc cutter at the
the reaction force F0 exerted by the stalk against the motion of the disc cutter at the cutting
cutting edge, the extrusion force F1x, F1y and friction T2 of the stalk pressed on the external
edge, the extrusion force F1x , F1y and friction T2 of the stalk pressed on the external edge
edge surface, and the extrusion force F and friction T1 of the stalk pressed on the internal
surface, and the extrusion force F and friction T1 of the stalk pressed on the internal edge
edge surface.
surface.

Figure4.4.Cutting
Figure Cuttingforce
forceof
ofthe
thestalk.
stalk.
Appl. Sci. 2023, 13, 2116 7 of 16

The stalk is analyzed as a whole unit with certain physical characteristics. The external
edge surface is divided using a differential method. The extrusion force dF1x on the external
edge differential element plane in the X direction (that is the direction vm of the disc cutter
motion velocity) is obtained as follows:

dF1x = σldy = σldx · tan α (16)

where F1x is the extrusion force on the external edge surface of the disc cutter in the X
direction N; σ is the crushing stress in the X direction, MPa; l is the cutting width, m; and α
is the edge angle, ◦ .
The stress and strain of the stalk during the cutting process was determined using
Hooke’s law, and the stress–strain relationship of the stalk cutting is as follows:

Xe σ
ε= = (17)
x Ex

where ε is the shear strain; Xe is the total stalk thickness, m; x is the stalk thickness when
pressed by the cutter disc, m; and Ex is the elastic modulus of the stalk in the X direction,
MPa.
Next, we substitute Equation (17) into Equation (16) and integrate dF1x . The extrusion
force F1x is as follows:

x2 l
Z x Z x
x
F1x = σl tan αdx = Ex l tan αdx = Ex l tan α (18)
0 0 Xe 2Xe

The extrusion force on the external edge differential element plane in Y direction dF1y
is as follows:
dF1y = ε y Ey ldx = ε x µEy ldx (19)
where F1y is the extrusion force on the external edge surface of disc cutter in the Y direction,
N; εy is the cutting strain of the castor stalk in the Y direction; and Ey is the elastic modulus
of the stalk in the Y direction, MPa.
The extrusion force F1y of the external edge surface in the Y direction is as follows:

x2 l
Z x Z x
x
F1y = ε x µEy ldx = µEy ldx = µEy l (20)
0 0 Xe 2Xe

The friction force T1 on the external edge is as follows:

x2 l  
Ex sin2 α + µω Ey cos2 α


T1 = µ F1x · sin α + F1y · cos α = (21)
2Xe cos ε

where T1 is the friction force on the external edge, N; and µ is the coefficient of dynamic
friction between the blade surface and stalk.

F0 = δlσc (22)

Here, F0 is the acting force of the stalk on the disc cutter, N; δ is the disc cutter thickness, m;
and σc is the yield strength, MPa.
T2 = µi F (23)
Here, T2 is the friction force on the internal edge, N; µi is the coefficient of stalk internal
friction; and F is the pressure of the disc cutter against the stalk, N.
At the cutting moment, the total cutting resistance of the disc cutter is as follows:

FX = F0 + F1x + T1 + T2 · cos α
(24)
FY = F + T2 · sin α
Appl. Sci. 2023, 13, 2116 8 of 16

where FX is the cutting force in the X direction, N; and FY is the cutting force in the Y
direction, N.
Based on the above theoretical analysis, it can be seen that the cutting force of the
disc cutter is closely linked to the physical properties of the stalk and the structural and
technological parameters of the disc cutter. In order to reduce power consumption in the
process of castor harvesting, the cutting resistance mechanical model must be considered
when optimizing the design of the cutting device. Therefore, to reduce the cutting resistance,
Appl. Sci. 2023, 13, x FOR PEER REVIEW 8 of 17
influencing factors, such as the disc cutter thickness and edge angle, were selected for
further study.
2.3.Cutting
2.3. CuttingProcess
ProcessSimulation
SimulationModel
Model
Inthis
In thispaper,
paper,the
theexplicit
explicitdynamics
dynamics software
software LS-DYNA
LS-DYNA waswas used
used to establish
to establish a sim-
a simula-
ulation model of castor stalk cutting, and the cutting process was simulated using
tion model of castor stalk cutting, and the cutting process was simulated using different differ-
ent parameters.
parameters. ThisThis method
method provided
provided a theoretical
a theoretical basisbasis for subsequent
for subsequent field field
tests.tests.

2.3.1.Simulation
2.3.1. SimulationModelModel
For reasonable
For reasonable and andeffective
effectivesimulation
simulation and and calculation,
calculation, the
the disc
disc cutter
cutter model
modelwaswas
simplifiedto
simplified toremove
removethe theparts
partsunrelated
unrelatedto tothe
thecutting
cuttingprocess.
process. SolidWorks
SolidWorkssoftware
softwarewaswas
usedto
used tomodel
modelthe thedisc
disccutter
cutterwhich
whichwas
wasthenthenimported
importedinto
intothe
thesimulation
simulationsoftware.
software.The
The
materialattribute
material attribute ofof the
the disc
disc cutter
cutter was
was 45 45#＃ steel
steel[33]
[33]with
withaaPoisson’s
Poisson’sratio
ratioofof0.31,
0.31,shear
shear
modulusof
modulus 7.9×
of7.9 10 Pa
× 1010 Paand
anddensity
density ofof 7850 kg/m3.3 .
7850 kg/m
AnIsrael
An IsraelKaifeng
Kaifeng5 5castor
castorstalk
stalk with
with a diameter
a diameter of mm
of 22 22 mm waswas modeled.
modeled. To reduce
To reduce the
simulation timetime
the simulation without significantly
without affecting
significantly the simulation
affecting effect,
the simulation a 150, amm
effect 150section was
mm section
modeled
was modeledto represent the stalk.
to represent The physical
the stalk. parameters
The physical of the of
parameters castor stalk with
the castor stalka with
watera
content of 20% of
water content [34–36] are displayed
20% [34–36] in Tablein2.Table 2.
are displayed

Table2.2.Physical
Table Physicalcharacteristics
characteristicsofofaacastor
castorstalk.
stalk.

Stalk
Density
Density Elasticity Modulus
Elasticity Poisson’s
Poisson’s Shear
Shear Modulus
Modulus Yield
Yield Strength
Strength
Stalk (kg−3·m−3 ) Modulus (MPa) Ratio (MPa) (MPa)
(kg·m ) (MPa) Ratio (MPa) (MPa)
Value
Value 10801080 13.3
13.3 0.252
0.252 4.37
4.37 110
110

Thestalk
The stalkmodel
modelused
usedininthis
thisstudy
studywaswasdivided
dividedinto
intothree
three parts,
parts, asas shown
shown in in Figure
Figure 5.
5. During
During thethe cutting
cutting process,
process, part
part ofof the
the finite
finite elementmesh
element meshwaswasnot
notinincontact
contactwith
withthe
the
disc
disccutter.
cutter.The
TheSPH
SPHparticle
particlewas
wasdefined
definedasas
the slave
the node,
slave node,and thethe
and finite element
finite elementmesh at
mesh
the contact
at the interface
contact with
interface thethe
with SPH
SPH particle was
particle wasthe main
the mainsurface.
surface.The
Thecontact
contactalgorithm
algorithm
was
was**CONTACT-AUTOMATIC-NODES-TO-SURFACE.
CONTACT-AUTOMATIC-NODES-TO-SURFACE.

Figure5.5.Simulation
Figure Simulationmodel
modelusing
usingLS-DYNA
LS-DYNAsoftware.
software.

2.3.2. Contact Erosion Definition and Loading

Setting the coefficient of static friction FS = 0.3 and the coefficient of kinetic friction FD
= 0.2 [36], the node-set on the two disc cutting model applied the moving speed of the X-
axis and the rotation speed in the opposite rotation of the Z-axis. The corresponding K file
was generated by setting the simulation data using LS-PrePost software and then submit-
ting them to the LS-DYNA software for computation.
Appl. Sci. 2023, 13, 2116 9 of 16

2.3.2. Contact Erosion Definition and Loading

Setting the coefficient of static friction FS = 0.3 and the coefficient of kinetic friction
FD = 0.2 [36], the node-set on the two disc cutting model applied the moving speed of the
X-axis and the rotation speed in the opposite rotation of the Z-axis. The corresponding
K file was generated by setting the simulation data using LS-PrePost software and then
submitting them to the LS-DYNA software for computation.

2.4. Simulation Test Design

2.4.1. Test Evaluation Index
To ensure the durability of the disc cutter, cutting resistance has a decisive influence
in optimizing the design of the disc cutter structure. Precompression elastic deformation
causes the cutting force to rise to its peak. Excessive instantaneous cutting force makes
it easy to damage the cutter teeth in the cutting process. Therefore, the maximum cut-
ting force is an index to be investigated in this study. During the test, a torque sensor
(Beijing Xinyuhang Measurement and CT Co., Ltd., model: JN338, measuring time range:
20–2000 ms) was used to measure the torque of the unilateral disc cutter and the maximum
cutting force was calculated according to the peak of the torque curve.
According to Equation (25), the maximum cutting force Fmax calculation formula is as
follows:
T
Fmax = (25)
R
where Fmax is the maximum cutting force, N; R is the radius of disc cutter, m; and T is the
torque, N·m.

2.4.2. Test Factors and Levels

According to the above analysis, the factors affecting the maximum cutting force
include the disc cutter thickness, edge angle, disc cutter rotation speed, and feeding speed.
A quadratic rotation orthogonal combination test was used. The test factors and levels are
shown in Table 3.

Table 3. Test factors and levels.

Disc Cutter Disc Cutter Rotation Feeding Speed Edge Angle

level
Thickness (mm) Speed (r·min−1 ) (m·s−1 ) (◦ )
−2 2 400 0.4 15
−1 3 550 0.6 20
0 4 700 0.8 25
1 5 850 1.0 30
2 6 1000 1.2 35

3. Results Analysis and Optimization

3.1. Simulation Results
Castor stalk cutting is a process in which the disc cutter repeatedly enters the stalk,
cuts it, and releases its elastic and plastic stress. It is primarily divided into three stages,
namely the contact stage, cutting stage, and cracking stage. The castor stalk-cutting process
is shown in Figure 6.
As shown in Figure 6a, at the contact stage, the stalk was clamped with the bilateral
disc cutter, resulting in some compressive shear failure units at the edge. At this time, the
stalk mainly produced elastic strain and remained relatively intact. Because of the fast
rotation speed of the disc cutter, there were two wavy arcs on the disc cutter that cut the
stalk within the stalk diameter. The cutting stage was divided into the first cutting stage
and second cutting stage according to the cutting conditions of the different waved blades.
At the first cutting stage, as shown in Figure 6b, the wave-type disc cutter cut into the castor
stalk and generated an extremely high-stress area on the surface of the stalk. The stalk
underwent elastic–plastic deformation so that it directly formed symmetric deformation
Appl. Sci. 2023, 13, 2116 10 of 16

and failure in the axial direction. At this time, the stress was mainly distributed along
the middle and side direction of the cutting part. In addition, the stalk that had been cut
was also subjected to friction stress on the disc cutter surfaces, and the maximum stress
occurred at this cutting stage. In the second cutting stage (Figure 6c), the cutting length and
invasion depth increased. The anterior part of the stalk axial direction was completely cut
off, forming a wedge-shaped failure zone. This zone was mainly composed of compression
failure elements, and the elastic–plastic strain energy in this zone decreased. The sheared
part of the stalk produced extremely small cuttings. In addition to the large stress caused
by the cutting edge on the stalk, the friction force caused by the disc cutter was small.
Appl. Sci. 2023, 13, x FOR PEER REVIEW 10 Thus,
of 17
the stress value was lower than that produced at the first cutting stage.

(a) t = 0.007 ms (b) t = 0.250 ms

(c) t = 0.830 ms (d) t = 1.360 ms

Figure
Figure 6.
6. Postprocessing
Postprocessingofofthe
thesimulation. (a) (a)
simulation. Effective stress
Effective at 0.007
stress ms; (b)
at 0.007 ms;effective stressstress
(b) effective at 0.250
at
ms; (c) effective stress at 0.830 ms; and (d) effective stress at 1.360 ms.
0.250 ms; (c) effective stress at 0.830 ms; and (d) effective stress at 1.360 ms.

As
As shown
displayedin Figure 6a, at
in Figure 6d,the
thecontact
failurestage,
zone ofthethe
stalk was
disc clamped
cutter with the
was further bilateral
expanded
disc cutter,
and the resulting
cuttings werein some
able compressive
to crack outward. shear
Underfailure units at
the action of the
the edge. At thisdisc
high-speed time, the
cutter,
stalk mainly produced elastic strain and remained relatively intact. Because
the stalk bent significantly and broke. Because most of the elastic and plastic stress of the of the fast
rotation
stalk hadspeed of the discthe
been released, cutter,
overallthere were
stress twoofwavy
value arcs was
the stalk on the disc cutter that cut the
small.
stalk within the stalk diameter. The cutting stage was divided into the first cutting stage
3.2. Results
and second and Analysis
cutting stage according to the cutting conditions of the different waved blades.
At the first cutting
Quadratic stage, as
regression shownand
analysis in multiple
Figure 6b, the wave-type
regression fitting disc
werecutter cut into
performed on the
the
castor stalk using
test results and generated an extremely
Design-Expert software. high-stress
A total of area on the surface
30 treatments wereof conducted,
the stalk. Theas
stalk underwent
shown in Table 4. elastic–plastic deformation so that it directly formed symmetric defor-
mation Theand failure in
regression thefactor
and axial variance
direction.analyses
At this time,
were the stress
carried was
out on mainly
the test distributed
data using
along the middleand
Design-Expert, andthe
side direction
factors withof the cutting
significant part. In addition,
influence the stalk
were screened out,that had been
as shown in
cut was
Table 5. also subjected to friction stress on the disc cutter surfaces, and the maximum stress
occurred
It canatbethis cutting
seen stage.5 In
from Table thatthethesecond cutting
regression stage
model (Figure
was 6c), the
significant (p <cutting length
0.01) and that
and invasion
the lack of fit depth increased.insignificant
was extremely The anterior(ppart of theThe
> 0.05). stalk axial direction
results indicatedwasthatcompletely
the model
cut
termsoff,andforming a wedge-shaped
the factors on the maximum failure zone. force
cutting This zone
were was mainly
extremely composed of com-
significant.
pression failure elements, and the elastic–plastic strain energy in this zone decreased. The
sheared part of the stalk produced extremely small cuttings. In addition to the large stress
caused by the cutting edge on the stalk, the friction force caused by the disc cutter was
small. Thus, the stress value was lower than that produced at the first cutting stage.
As displayed in Figure 6d, the failure zone of the disc cutter was further expanded
and the cuttings were able to crack outward. Under the action of the high-speed disc cut-
ter, the stalk bent significantly and broke. Because most of the elastic and plastic stress of
the stalk had been released, the overall stress value of the stalk was small.
Appl. Sci. 2023, 13, 2116 11 of 16

Table 4. Test schemes and results.

Serial Disc Cutter Disc Cutter Rotation Feeding Speed Edge Angle Maximum Cutting
Number Thickness (mm) Speed (r·min−1 ) (m·s−1 ) (◦ ) Force Y 1 (N)
1 0 0 0 0 134.7
2 −1 1 −1 1 86.3
3 1 −1 −1 1 143.9
4 0 0 0 0 128.7
5 1 1 1 −1 71.2
6 −1 1 1 1 56.4
7 0 0 2 0 74.4
8 0 0 0 −2 144.2
9 0 0 0 0 124.7
10 1 −1 −1 −1 146.3
11 −2 0 0 0 133.8
12 −1 −1 −1 −1 198.1
13 2 0 0 0 107.2
14 0 −2 0 0 181.6
15 0 0 0 0 113.7
16 1 −1 1 −1 100.1
17 0 0 0 0 124.7
18 −1 −1 1 1 120.6
19 −1 −1 −1 1 126.3
20 0 0 0 2 88.6
21 1 1 1 1 73.9
22 1 1 −1 1 97.8
23 1 −1 1 1 111.2
24 1 1 −1 −1 110.8
25 −1 −1 1 −1 168.6
26 −1 1 1 −1 76.2
27 0 2 0 0 97.3
28 −1 1 −1 −1 146.7
29 0 0 0 0 136.7
30 0 0 −2 0 149.3

Table 5. Variance analysis.

Maximum Cutting Force Y 1 (%)

Serials
Sum of Squares Degree of Freedom F Value p Value
Model 31,473.42 14 23 <0.0001
A 1308.33 1 13.38 0.0023
B 13,272.81 1 135.78 <0.0001
C 7625.54 1 78.01 <0.0001
D 4076.83 1 41.71 <0.0001
AB 627.5 1 6.42 0.0229
AC 2.89 1 0.03 0.8658
AD 2460.16 1 25.17 0.0002
BC 155 1 1.59 0.2272
BD 26.52 1 0.27 0.61
CD 547.56 1 5.6 0.0318
A2 232 1 2.37 0.1442
B2 91.77 1 0.94 0.3479
C2 705.28 1 7.22 0.0169
D2 424.35 1 4.34 0.0547
Residual 1466.25 15
Lack of fit 1122.75 10 1.63 0.3062
Pure error 343.5 5
Total 32,939.67 29

3.3. Regression Equations

We eliminated the nonsignificant items and ensured that all factors reached the signifi-
cant or extremely significant level. The regression equation of the maximum cutting force
can be expressed as follows:
 that the lack of fit was extremely insignificant (P > 0.05). The results indicated that the
model terms and the factors on the maximum cutting force were extremely significant.

3.3. Regression Equations

Appl. Sci. 2023, 13, 2116 We eliminated the nonsignificant items and ensured that all factors reached 12
theof sig-
16
nificant or extremely significant level. The regression equation of the maximum cutting
force can be expressed as follows:
Y1 = +127.2 − 7.38x1-23.52x2 − 17.82x3 − 13.03x4 + 6.26x1x2 + 12.40x1x4 + 5.85x3x4 − 5.07x32 (26)
Y1 = +127.2 − 7.38x1 − 23.52x2 − 17.82x3 − 13.03x4 + 6.26x1 x2 + 12.40x1 x4 + 5.85x3 x4 − 5.07x3 2 (26)
According to the variance table, the primary terms x1, x2, x3, and x4, interaction term
According to the variance table, the primary terms x1 , x2 , x3 , and x4 , interaction term
x1xx14x,4,and
andquadratic
quadratic terms
terms xx322 have a significant impact on the maximum cutting force (P <
3 have a significant impact on the maximum cutting force
0.01). The interaction terms x 1x2 and x3x4 have significant effects on the maximum cutting
(p < 0.01). The interaction terms x1 x2 and x3 x4 have significant effects on the maximum
force (0.01
cutting force<(0.01
P < 0.05).
< p <The weights
0.05). of the factors
The weights affecting
of the factors the maximum
affecting cutting cutting
the maximum force are
as follows: disc cutter rotation speed x 2 > feeding speed x3 > edge angle x4 > disc cutter
force are as follows: disc cutter rotation speed x2 > feeding speed x3 > edge angle x4 > disc
thickness
cutter x1. x .
thickness 1

3.4.Analysis
3.4. AnalysisofofthetheResponse
ResponseSurface
Surface
In order to intuitively
In order to intuitively analyzeanalyze the
the relationship
relationship betweentest
between test factors
factors and
and indexes,
indexes, the
the
responsesurface
response surfacediagram
diagramwaswasobtained
obtainedusing
usingDesign-Expert
Design-Expertsoftware
softwaretogether
togetherwith
withthe
the
multifactor
multifactor test
test data.The
data. Theresponse
response surface
surface is is shown
shown inin Figure
Figure 7. 7.

(a) (b)
Figure
Figure 7. 7. Response
Response surface
surface of the
of the maximum
maximum cutting
cutting force.
force. (a) Interaction
(a) Interaction factors
factors of cutter
of disc disc cutter rota-
rotation
tion speed and thickness ; and (b) interaction factors of edge angle and feeding speed.
speed and thickness; And (b) interaction factors of edge angle and feeding speed.

Figure
Figure 7a7a shows
shows thethe interaction
interaction between
between disc
disc cutter
cutter thickness
thickness and
and disccutter
disc cutterrotation
rotation
speedononthe
speed themaximum
maximumcuttingcuttingforce
forcewhen
whenthethefeeding
feedingspeed
speedand
andedgeedgeangle
angleareareatatanan
intermediatelevel.
intermediate level.ItItcan
canbebeconcluded
concludedfrom fromFigure
Figure7a7athat
thatwhen
whenthe thedisc
disccutter
cutterrotation
rotation
speedisislower,
speed lower,the
the maximum
maximum cutting
cutting force
force increases
increasesnotably
notablywith
withthetheincrease
increase in in
thethedisc
cutter thickness. However, when the disc cutter rotation speed is higher,
disc cutter thickness. However, when the disc cutter rotation speed is higher, this trend this trend is rel-
atively gentle. As the thickness of the disc cutter increases, the fiber
is relatively gentle. As the thickness of the disc cutter increases, the fiber undergoesundergoes elastic–
elastic–plastic recovery and squeezes the disc cutter, which leads to greater cutting surface
resistance and an increase in the maximum cutting force of the disc cutter. When the disc
cutter rotation speed is low, the castor stalk only partially produces sufficient elastic–plastic
deformation. Therefore, the friction force of the disc cutter caused by the elastic–plastic
deformation is larger, and the maximum cutting force significantly increased. When the disc
cutter rotation speed is high, the stalk is cut at one time and there is less local elastic–plastic
deformation. The failure process tends to be a one-time fracture, and the maximum cutting
force increases slowly.
According to the correlation regression equation and the density of contour distribu-
tion in the response surface, the maximum cutting force is influenced by the interaction
between the edge angle and the feeding speed, as shown in Figure 7b. When the edge
angle is small, the maximum cutting force decreases significantly with increased feeding
speed. When the edge angle is large, the maximum cutting force increases slowly and then
flattens out as the feeding speed increases. The main reason for this is that the smaller
cutting angle usually results in higher local stress, which makes it easier to break the stalk
fiber, and the maximum cutting force is, therefore, smaller. The sliding-cutting angle is
negatively correlated with the cutting resistance. With a small edge angle, a faster feeding
speed causes a notable increase in the sliding-cutting angle and the maximum cutting force
decreases. When the edge angle is larger, the physical structure resistance of the cutting
Appl. Sci. 2023, 13, 2116 13 of 16

edge is larger, and the increase in the sliding-cutting angle is insignificant, resulting in a
nonsignificant increase in the maximum cutting force.

3.5. Parameter Optimization

In order to obtain the best cutting parameters for a wave-type disc cutter, the optimiza-
tion module of the Design-Expert software was used to optimize and solve the regression
model. Its constraint conditions were as follows:

2≤A≤6


 

400 ≤ B ≤ 1000

 
s.t.


 0.4 ≤ C ≤ 1.2 (27)
15 ≤ D ≤ 35

 


minY1 ( A, B, C, D )


The multiobjective optimization solution was calculated as follows: a disc cutter

thickness of 2.71–3.15 mm, a disc cutter rotation speed of 844.2–942.1 r/min, a feeding
speed of 0.89–1.01 m/s, and an edge angle of 29.2–33.9◦ , where the maximum cutting force
is less than 50 N.

4. Verification Test Results

4.1. Test Materials and Devices
The verification test bench was built in September 2022. The main instruments used
were as follows: a sensor (Beijing Xinyuhang Measurement and CT Co., Ltd., model
JN338-A); a torque speed measuring instrument (Beijing Xinyuhang Measurement and CT
Co., Ltd., model JN338); a transport motor (Beijing Times Superior Electrical Technology
Co., Ltd., model SD110AEA12020-SH3, rated power 1.2 kW, rated speed 2000 rad/min,
rated moment 6 N/m); a cutting motor (Beijing Times Superior Electrical Technology Co.,
Ltd., model SD110AEA12020-SH3, rated power 1.5 kW, rated speed 1500 rad/min, rated
moment 10 N/m); and a driver (Beijing Times Superior Electrical Technology Co., Ltd.,
model SD300-30AL-GBN).
As shown in Figure 8, the verification test was carried out on the test bench. A 10A
single-sided double-hole bending plate chain was selected as the stalk sample conveyor
chain. The disc cutter on one side was coaxial with the cutting motor and torque sensor
through the detachable flange. The disc cutter on the other side was coaxial with the dial
teeth chain and the cutting motor. The torque measuring instrument was connected to the
sensor and communicated with the computer in real-time through the RS232 serial port.
During the test, the drivers were firstly used to drive the cutting motors to the designed
rotation speed, and then the other driver was used to drive the feed motor to clamp and
advance the samples at the set speed until the cutting process was completed. With this test
device, the disc cutter could be changed and the feeding and cutting rotation speeds could
be adjusted and measured. The maximum cutting torque of the disc cutter was obtained by
using the torque measuring instrument to study the maximum force in the cutting process.
The castor cultivar was Israel Kaifeng No.5. After the cutting test, the cut part of the
stalk was used as for the determination of the physical properties. The average diameter of
the castor stalk at 150 mm from the ground was 21.6 mm.
 During the test, the drivers were firstly used to drive the cutting motors to the designed
rotation speed, and then the other driver was used to drive the feed motor to clamp and
advance the samples at the set speed until the cutting process was completed. With this
test device, the disc cutter could be changed and the feeding and cutting rotation speeds
Appl. Sci. 2023, 13, 2116
could be adjusted and measured. The maximum cutting torque of the disc cutter was14ob- of 16
tained by using the torque measuring instrument to study the maximum force in the cut-
ting process.

(a) (b)
Figure 8. 8.
Figure Verification test
Verification testdevice.
device.(a)(a)
Schematic diagram.
Schematic (b)(b)
diagram. Cutting test
Cutting bench—1.
test measurement
bench—1. measurement
and control system; 2. cutting system; 3. feeding device; and 4. dynamical system.
and control system; 2. cutting system; 3. feeding device; and 4. dynamical system.

4.2.The
Testcastor cultivar was Israel Kaifeng No.5. After the cutting test, the cut part of the
Results
stalk was usedthe
To test asoptimal
for the determination
combination ofof the physical
parameters for properties. Thethe
the disc cutter, average diameter
operating param-
ofeters
the castor stalk at 150 mm from the ground was 21.6 mm.
were set as follows: the disc cutter thickness at 3 mm, the disc cutter rotation speed at
942 r/min, the feeding speed at 1.0 m/s, and the edge angle at 30◦ . In these conditions, the
4.2. Test Results
predicted value of the maximum cutting force was 42.64 N according to Equation (26). The
To test the
verification testoptimal combination
was repeated of parameters
five times, for the
and the results aredisc cutter,in
recorded the operating
Table 6. pa-
rameters were set as follows: the disc cutter thickness at 3 mm, the disc cutter rotation
speed
Tableat6.942 r/min,
Bench the feeding speed at 1.0 m/s, and the edge angle at 30°. In these condi-
test results.
tions, the predicted value of the maximum cutting force was 42.64 N according to Equa-
tion (26). The verification test was five times, and theVerification
repeated Value
Optimization results areTest
recorded in
Item
Table 6. 1 2 3 4 5
Maximum cutting force (N) 42.64 43.5 45.8 46.1 41.5 46.2
Table 6. Bench test results.

Through experimental verification, the experimental dataVerification Testwith the nu-

were compared
Item Optimization Value
merical simulation data. The analysis showed that the test
1 results2 were 3generally
4 consistent
5
with the simulation results
Maximum cutting force (N) and that the error
42.64 was less than
43.5 10%. The experimental
45.8 46.1 41.5 46.2 data
were slightly higher than the simulation data. The results indicated that the simulation
model was effective
Through and reasonable
experimental andthe
verification, could provide technical
experimental support
data were for thewith
compared design
theof
castor harvesters.
numerical simulation data. The analysis showed that the test results were generally con-
sistent with the simulation results and that the error was less than 10%. The experimental
5. Conclusions
data were slightly higher than the simulation data. The results indicated that the simula-
In order
tion model was to reduceand
effective thereasonable
cutting resistance of provide
and could wave-type disc cutters
technical supportinfor
thethe
picking
de-
devices of castor harvesters,
sign of castor harvesters. this study used the SPH–FEM coupling algorithm and LS-
DYNA software to simulate the dynamic process of cutting castor. Based on the orthogonal
5. rotation combination test, the effects of disc cutter thickness, disc cutter rotation speed,
Conclusions
feeding speed, and disc cutter edge angle on the maximum cutting force were simulated.
In order to reduce the cutting resistance of wave-type disc cutters in the picking de-
The simulation results were optimized using the response surface method, and the optimal
vices of castor of
combination harvesters,
parameters this
wasstudy usedusing
verified the SPH–FEM coupling
experimental algorithm
tests. The and LS-
conclusions were
DYNA software
as follows: to simulate the dynamic process of cutting castor. Based on the orthogo-
nal rotation combination test, the effects of disc cutter thickness, disc cutter rotation speed,
(1) Simulation tests showed that the disc cutter rotation speed, feeding speed, disc cutter
thickness, and edge angle had a highly significant influence on the maximum cutting
force. The influence of each factor on the maximum cutting force was in the order of
disc cutter rotation speed > feeding speed > edge angle > disc cutter thickness. The
following optimal parameters were obtained: disc cutter thickness of 2.71–3.15 mm,
disc cutter rotation speed of 844.2–942.1 r·min−1 , feeding speed of 0.89–1.01 m·s−1 ,
and edge angle of 29.2–33.9◦ , where the maximum cutting force was less than 50 N;
(2) The operating parameters were set as follows: disc cutter thickness at 3 mm, disc
cutter rotation speed at 942 r/min, feeding speed at 1.0 m/s, and edge angle at 30◦ ,
Appl. Sci. 2023, 13, 2116 15 of 16

with a predicted maximum cutting force of 42.64 N. The verification test indicated that
the maximum cutting force obtained by the SPH–FEM coupling simulation method
was generally consistent with the castor-cutting bench test using the optimized combi-
nation of parameters and that there was no significant difference in the data obtained
using the two methods. The simulation method can, therefore, be used to study
castor harvester disc cutters and provides an effective method for further parameter
optimization of castor disc cutters.

Author Contributions: Conceptualization, F.K., D.W. and L.S.; methodology, Q.X., Y.S. and C.C.;
software, Q.X., H.H. and T.W.; validation, D.W., L.S. and Y.S.; writing—original draft preparation,
F.K., D.W. and T.W.; writing—review and editing, F.K., D.W. and H.H. All authors have read and
agreed to the published version of the manuscript.
Funding: This research was funded by the Agricultural Science and Technology Innovation Program
of Chinese Academy of Agricultural Sciences (CAAS-ASTIP-31-NIAM-05) and supported by National
Natural Science Foundation of China (52205261).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Not applicable.
Acknowledgments: We greatly appreciate the careful and precise reviews provided by the anony-
mous reviewers and editors.
Conflicts of Interest: The authors declare no conflict of interest.

References
1. Alexopoulou, E.; Papatheohari, Y.; Zanetti, F.; Tsiotas, K.; Papamichael, I.; Christou, M.; Namatov, I.; Monti, A. Comparative
studies on several castor (Ricinus communis L.) hybrids: Growth, yields, seed oil and biomass characterization. Ind. Crops Prod.
2015, 75, 8–13. [CrossRef]
2. Pari, L.; Suardi, A.; Stefanoni, W.; Latterini, F.; Palmieri, N. Environmental and Economic Assessment of Castor Oil Supply
Chain:A Case Study. Sustainability 2020, 12, 6339. [CrossRef]
3. Suurbaar, J.; Mosobil, R.; Donkor, A.M. Antibacterial and antifungal activities and phytochemical profle of leaf extract from
diferent extractants of Ricinus communis against selected pathogens. BMC Res. Notes 2017, 10, 660. [CrossRef]
4. Severino, L.S.; Auld, D.L. A framework for the study of the growth and development of castor plant. Ind. Crops Prod. 2013, 46,
25–38. [CrossRef]
5. Baldanzi, M.; Fambrini, M.; Pugliesi, C. Redesign of the castorbean plant body plan for optimal combine harvesting. Ann. Appl.
Biol. 2003, 142, 299–306. [CrossRef]
6. Wu, C.F.; Chen, W.C.; Sheng, C.T. Study on the harvester development of ricinus communis. J. Agric. Fore. 2013, 62, 33–44.
7. Liu, L.; Wu, T.; Kong, F.T.; Sun, Y.F.; Chen, C.L.; Xie, Q.; Shi, L. Optimized design and experiment of the picking mechanism for
brush-roller castor harvesters. Trans. Chin. Soc. Agric. Eng. 2021, 37, 19–29.
8. Stefanoni, W.; Latterini, F.; Malkogiannidis, V.; Salpiggidis, V.; Alexopoulou, E.; Pari, L. Mechanical Harvesting of Castor Bean
(Ricinus communis L.)with a Combine Harvester Equipped with Two Different Headers: A Comparison of Working Performance.
Energies 2022, 15, 2999. [CrossRef]
9. Rostek, T.; Homberg, W. Locally graded steel materials for self-sharpening cutting blades. Procedia Eng. 2017, 207, 2185–2190.
[CrossRef]
10. Song, Y.P.; Wu, K.; Wang, W. Fabrication of self-sharpening blades via vacuum-rolling composite technology and its interfacial
material microstruature and properties. Trans. Chin. Soc. Agric. Eng. 2020, 51 (Suppl. 2), 586–592.
11. Momin, M.A.; Wempe, P.A.; Grift, T.E. Effects of four base cutter blade designs on sugarcane stem cut quality. Trans. ASABE 2017,
60, 1551–1560. [CrossRef]
12. Hang, H.D.; Wang, Y.X.; Tang, Y.Q.; Zhao, F.; Kong, X.F. Finite element simulation of sugarcane cutting. Trans. Chin. Soc. Agric.
Eng. 2011, 27, 161–166. [CrossRef]
13. Meng, Y.M.; Wei, J.D.; Wet, J.; Chen, H.; Cui, Y.S. An ANSYS/LS-DYNA simulation and experimental study of circular saw blade
cutting system of mulberry cutting machine. Comput. Electron. Agric. 2019, 157, 38–48. [CrossRef]
14. Xie, L.X.; Wang, J.; Cheng, S.M.; Zeng, B.S.; Yang, Z.Z. Optimisation and finite element simulation of the chopping process for
chopper sugarcane harvesting. Biosyst. Eng. 2018, 175, 16–26. [CrossRef]
15. Cao, W.B.; Sun, W.L.; Niu, C.; Jiao, H.B.; Chen, B.B. Combed Safflower Picking Device Based on ANSYS/LS DYNA. Trans. Chin.
Soc. Agric. Mach. 2018, 49, 123–131.
Appl. Sci. 2023, 13, 2116 16 of 16

16. Souza, V.H.S.; Dias, G.L.; Santos, A.A.R.; Costa, A.L.G.; Santos, F.L.; Magalhães, R.R. Evaluation of the interaction between a
harvester rod and a coffee branch based on finite element analysis. Comput. Electron. Agric. 2018, 150, 476–483. [CrossRef]
17. Ibrahmi, A.; Bentaher, H.; Hbaieb, M.; Maalej, A.; Mouazen, A.M. Study the effect of tool geometry and operational conditions on
mouldboard plough forces and energy requirement: Part 1. Finite element simulation. Comput. Electron. Agric. 2015, 117, 258–267.
[CrossRef]
18. Ahmadi, E.; Barikloo, H.; Kashfi, M. Viscoelastic finite element analysis of the dynamic behavior of apple under impact loading
with regard to its different layers. Comput. Electron. Agric. 2016, 121, 1–11. [CrossRef]
19. Zheng, Z.J.; Kulasegaram, S.; Chen, P.; Chen, Y.Q. An efficient SPH methodology for modelling mechanical characteristics of
particulate composites. Def. Technol. 2021, 17, 135–146. [CrossRef]
20. Afrasiabi, M.; Klippel, H.; Röthlin, M.; Wegener, K. An improved thermal model for SPH metal cutting simulations on GPU. Appl.
Math. Model. 2021, 100, 728–750. [CrossRef]
21. Song, H.; Pan, P.; Ren, G.; Yang, Z.; Xu, J. SPH/FEM modeling for laser-assisted machining of fused silica. Int. J. Adv. Manuf.
Technol. 2020, 106, 5–6. [CrossRef]
22. Hasanpour, A.; Istrati, D.; Buckle, I. Coupled SPH-FEM Modeling of Tsunami-Borne Large Debris Flow and Impact on Coastal
Structures. J. Mar. Sci. Eng. 2021, 9, 1068. [CrossRef]
23. Du, M.; Wang, H.; Dong, H.; Guo, Y.; Ke, Y. Numerical research on kerf characteristics of abrasive waterjet machining based on
the SPH-DEM-FEM approach. Int. J. Adv. Manuf. Technol. 2020, 111, 3519–3533. [CrossRef]
24. Liu, Q.T.; Qiu, Y.G.; Qing, S.L.; Wang, W.Z. Cutting Force Calculation of Sugarcane Stalk. Trans. Chin. Soc. Agric. Mach. 2006, 37,
89–92. [CrossRef]
25. Li, C.; Zhang, H.S.; Wang, Q.C.; Chen, Z.J. Influencing Factors of Cutting Force for Apple Tree Branch Pruning. Agriculture 2022,
12, 312. [CrossRef]
26. Wang, T.; Liu, Z.; Yan, X.; Mi, G.; Liu, S.; Chen, K.; Zhang, S.; Wang, X.; Zhang, S.; Wu, X. Finite Element Model Construction and
Cutting Parameter Calibration of Wild Chrysanthemum Stem. Agriculture 2022, 12, 894. [CrossRef]
27. Liu, Y.; Huang, X.; Ma, L.; Zong, W.; Zhan, G.; Lin, Z. Design and Test of Static Sliding Cut Angle Constant Cutting Machine for
Chain Oil Sunflower Harvester Header. Trans. Chin. Soc. Agric. Mach. 2021, 52, 99–108. [CrossRef]
28. Xun, X.L.; You, Y.; Wang, D.C.; Li, S.B.; Zhu, L.; Liao, L.L. Design and Experiment of Rotary Cutter Disc Type Flat Stubble Cutting
Device for King Grass Harvester. Trans. Chin. Soc. Agric. Mach. 2022, 53, 112–124. [CrossRef]
29. Fu, Z.; Wang, D.; Li, W.; Huang, Y.; Zhu, R. Design and experiment of two-disc rotary mower of alfalfa. Trans. Chin. Soc. Agric.
Mach. 2018, 49, 214–220. [CrossRef]
30. Liu, F.J.; Yang, X.J.; Fang, X.F. Design and experiment of chopper divice in sugarcane harvester. Trans. Chin. Soc. Agric. Mach.
2018, 49, 90–94. [CrossRef]
31. Kong, F.T.; Wang, D.F.; Shi, L.; Wu, T.; Chen, C.L.; Sun, Y.F.; Xie, Q. Design and experiment of disc-cutting picking device of castor.
Trans. Chin. Soc. Agric. Eng. 2021, 37, 1–9. [CrossRef]
32. Wang, M.W.; Xue, Z.; Song, D.Q.; Zhang, L.F.; Zhang, J. Model analysis of cassavastalk cutter based on ANSYS. J. Chin. Agric.
Mech. 2016, 37, 102–105+117. [CrossRef]
33. Hou, J.M.; Bai, J.B.; He, T.; Yang, Y.; Li, J.P.; Yao, E.C. Design and Experiment of Castor Dehulling and Cleaning Device with
Double Curved Table. Trans. Chin. Soc. Agric. Mach. 2018, 49, 132–140. [CrossRef]
34. Ugwu, K.C.; Egwuagu, O.M.; Omoruyi, A. Determination of some mechanical and aerodynamic properties of castor fruits and
seeds. Int. J. Sci. Eng. Res. 2015, 6, 659–666.
35. Lorestani, A.N.; Jaliliantabar, F.; Gholami, R. Physical and mechanical properties of castor seed. Qual. Assur. Saf. Crops Foods 2013,
4, e29–e32. [CrossRef]
36. Hou, J.M.; Bai, J.G.; Yao, E.C.; Zhu, H.J. Design and Parameter Optimization of Disc Type Cutting Device for Castor Stem.
ACCESS 2020, 8, 191152–191162. [CrossRef]

Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual
author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to
people or property resulting from any ideas, methods, instructions or products referred to in the content.