Design and Testing of a Shearing and Breaking Device for Mulch Film and Cotton Stalk Mixtures

Highlights This article presents a shearing and breaking device for mulch film and stalk mixtures after mechanized recovery. The focus is on a curved V-shaped mechanism with three-dimensional precompression and shearing functions. The device can efficiently and continuously perform film crushing, stalk crushing, and entanglement breaking. The crushed film and stalk mixture is conducive to material separation, further treatment, and recycling. Abstract . Because the mixture of mulch film and stalks collected in harvested cotton fields in Xinjiang, China, cannot be separated mechanically, a technical solution for shearing and breaking is proposed. This study designed a shearing and breaking device for film and stalk mixtures that can continuously perform film crushing, stalk crushing, and entanglement breaking. The design focuses on a curved V-shaped shearing mechanism, which provides three-dimensional shearing and improves the crushing of film and stalks. The linear speed of the conveying rollers (x1), the working angle of the shearer (x2), and the speed of the shearer spindle (x3) were selected as influencing factors, and the crushed film rate (Ph), crushed stalk rate (Gh), and broken entanglement rate (Kh) were used as evaluation indexes in quadratic orthogonal rotation combination tests. The test results were analyzed with Design-Expert software, and a regression model between each factor and the evaluation indexes was established to analyze the significance of each factor’s influence. The results showed that the influences of the three factors on Ph in descending order were x3, x2, and x1. The order of influence on Gh and Kh was x3, x1, and x2. The optimization module in the software was used for parameter optimization, and the optimal combination of working parameters of the device was x1 = 0.98 m s-1, x2 = 153°, and x3 = 753 r min-1. The optimized parameter combination was tested and verified, and the results were Ph = 77.28%, Gh = 87.78%, and Kh = 85.30%. The test results are basically consistent with the predicted values, and the optimized working parameters are reliable and can meet the requirements for the shear fracture of film and stalk mixtures. This research provides a technical reference for the cutting and crushing of complex mixed solid materials. Keywords: Agricultural machinery, Curved V-shaped moving knife, Design, Film and stalk mixture, Parameter optimization.