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Based on the mechanical test (shear test, compression test), the bond model of corn kernel and straw was established to explore the rolling and crushing effect of different crushing rollers. The type of crushing roller is different. The material crushing process by the force (extrusion and kneading) is different. The mechanical analysis of the crushing process reveals that the disc crushing roller (DCR) has the characteristics of large unit-length kneading area; the spiral-notched serrated crushing roller (SNSCR) has transverse shearing effect on the material; and they affect the crushing effect of the material. By means of discrete element method and simulation test, multiple regression method and variance analysis method are used to systematically analyze the data. The optimal working parameters of each roll (crushing roll speed, crushing clearance, differential ratio) were obtained. The simulation test and bench test of the crushing process of materials with different roll shapes were carried out under the optimal working parameters. The crushing effect was evaluated with a Binzhou screen and a corn silage grain-crushing score screen. The crushed materials of corn kernel can be divided into three categories according to the size (broken grains passed through 2 mm sieve; broken grains passed through 4.75 mm sieve; and broken grains that cannot pass through 4.75 mm sieve), and the crushed materials of corn stalk can be divided into four categories according to the size and thickness (broken straw through 4 mm sieve; broken straw through 8 mm sieve; broken straw through 19 mm sieve; and broken straw that cannot pass 19 mm sieve). The crushing effect and crushing classification of the simulation test and bench test were basically consistent. The results showed that the disc crushing roller group had the highest comprehensive score with straw rolling rate of 89.1% and grain crushing rate of 87.7%, which was the most suitable for harvesting whole-plant silage maize (WSM). [ABSTRACT FROM AUTHOR]

Based on the mechanical test (shear test, compression test), the bond model of corn kernel and straw was established to explore the rolling and crushing effect of different crushing rollers. The type of crushing roller is different. The material crushing process by the force (extrusion and kneading) is different. The mechanical analysis of the crushing process reveals that the disc crushing roller (DCR) has the characteristics of large unit-length kneading area; the spiral-notched serrated crushing roller (SNSCR) has transverse shearing effect on the material; and they affect the crushing effect of the material. By means of discrete element method and simulation test, multiple regression method and variance analysis method are used to systematically analyze the data. The optimal working parameters of each roll (crushing roll speed, crushing clearance, differential ratio) were obtained. The simulation test and bench test of the crushing process of materials with different roll shapes were carried out under the optimal working parameters. The crushing effect was evaluated with a Binzhou screen and a corn silage grain-crushing score screen. The crushed materials of corn kernel can be divided into three categories according to the size (broken grains passed through 2 mm sieve; broken grains passed through 4.75 mm sieve; and broken grains that cannot pass through 4.75 mm sieve), and the crushed materials of corn stalk can be divided into four categories according to the size and thickness (broken straw through 4 mm sieve; broken straw through 8 mm sieve; broken straw through 19 mm sieve; and broken straw that cannot pass 19 mm sieve). The crushing effect and crushing classification of the simulation test and bench test were basically consistent. The results showed that the disc crushing roller group had the highest comprehensive score with straw rolling rate of 89.1% and grain crushing rate of 87.7%, which was the most suitable for harvesting whole-plant silage maize (WSM).