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Agricultural residues are the most abundant biomass and animal feed resources. Chopping is a prerequisite for either use, and reducing the shearing force has been considered as one of the most effective approaches to save energy. A smaller force can also permit more compact mechanical parts of the chopping device. In several cases, power consumption may be large even when the shearing force is small, if the corresponding cutting velocity is high. Consequently, it is important to minimise both cutting force and power consumption simultaneously. This paper presents an experimental study to solve such a multi-objective optimisation problem for chopping processes. Maize stalks with wet base moisture content of 81% were chosen as experimental samples. The response surface methodology (RSM) was used to design of experiments and evaluate the effect of cutting parameters, including approach angle, feed angle and cutting velocity, on the cutting force and consumption power. Compared to typical conditions in commercial choppers, where these angles are usually set to be 0°, the optimal setting can reduce cutting force and power consumption by 2.3 times and 4 times, respectively. The results are promising for practical applications in design and operation of chopping machines. • Agricultural residues are the most abundant biomass resource. • Less energy use in chopping residues is important for eco-friendly production. • Cutting force and power consumption are conflicting functions. • Multi-objective optimisation of force and power for stalk chopping process. • Applicable for rotary chopping machines. [ABSTRACT FROM AUTHOR]

Agricultural residues are the most abundant biomass and forage resources. Chopping is a precondition for either use, and reducing the shearing force has been considered as one of the most effective way to save energy. A smaller force can also permit more compact mechanical parts of chopping devices. In several cases, power consumption may be large, even when the shearing force is small, if the corresponding cutting velocity is high. Consequently, it is important to minimize both cutting force and power consumption simultaneously. This paper presents a practical approach to solve the multi-objective optimization problem for chopping processes of corn stalks. Applying the Taguchi design of experiments, a plan of 27 chopping tests was conducted. Based on the grey relational grade analysis and analysis of variance technique, optimum levels as well as the percentage contribution of such parameters were identified. Experimental results showed that the multi-response optimization problem in chopping corn stalks can be effectively addressed through the combination of Taguchi design and grey relational analysis. The results can be expanded for practical applications in design and operation of chopping machines for agricultural residues. [ABSTRACT FROM AUTHOR]