Justification of the Design and Operating Parameters of the Improved Disc Grain Crusher

Illia Bilous, Algirdas Jasinskas, Volodymyr Dudin, Savelii Kukharets (), Elchyn Aliiev, Rolandas Domeika, Simona Paulikienė and Tomas Ūksas
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Illia Bilous: Department of Engineering of Technical Systems, Dnipro State Agrarian and Economic University, Serhiya Yefremova Str. 25, 49000 Dnipro, Ukraine
Algirdas Jasinskas: Department of Agricultural Engineering and Safety, Faculty of Engineering, Agriculture Academy, Vytautas Magnus University, Studentų Str. 15A, LT-53362 Akademija, Kaunas District, Lithuania
Volodymyr Dudin: Department of Engineering of Technical Systems, Dnipro State Agrarian and Economic University, Serhiya Yefremova Str. 25, 49000 Dnipro, Ukraine
Savelii Kukharets: Department of Mechanical, Energy and Biotechnology Engineering, Faculty of Engineering, Agriculture Academy, Vytautas Magnus University, Studentų Str. 15A, LT-53362 Akademija, Kaunas District, Lithuania
Elchyn Aliiev: Department of Engineering of Technical Systems, Dnipro State Agrarian and Economic University, Serhiya Yefremova Str. 25, 49000 Dnipro, Ukraine
Rolandas Domeika: Department of Agricultural Engineering and Safety, Faculty of Engineering, Agriculture Academy, Vytautas Magnus University, Studentų Str. 15A, LT-53362 Akademija, Kaunas District, Lithuania
Simona Paulikienė: Department of Mechanical, Energy and Biotechnology Engineering, Faculty of Engineering, Agriculture Academy, Vytautas Magnus University, Studentų Str. 15A, LT-53362 Akademija, Kaunas District, Lithuania
Tomas Ūksas: Department of Mechanical, Energy and Biotechnology Engineering, Faculty of Engineering, Agriculture Academy, Vytautas Magnus University, Studentų Str. 15A, LT-53362 Akademija, Kaunas District, Lithuania

Agriculture, 2025, vol. 15, issue 22, 1-23

Abstract: The study examines the influence of key structural and technological parameters of a disc crusher with impact plates—the distance between liners, installation angle, and linear movement speed—on the crushing process of maize, wheat, and barley grains. Numerical modeling using the Discrete Element Method (DEM) in Simcenter STAR-CCM+ revealed patterns of variation in breaking force during impact cutting. An integral efficiency criterion was proposed to minimize the breaking force while maximizing productivity and reducing energy consumption. Rational process parameters were determined for each crop, considering their physico-mechanical properties: liner distance l = 1.68–1.79 mm, installation angle β = 21.8–25.3°, particle velocity V = 4.72–5.86 m/s, disc speed n = 1503–1865 rpm, and clearance δ = 0.68–0.79 mm. Experimental studies yielded models describing specific energy consumption, dust-like fraction, and crushing degree depending on the liner angle, number, and rotation speed. Optimization showed that energy consumption was lowest for wheat (3.63 kWh/t) and highest for barley (6.76 kWh/t). The dust fraction was greatest for maize (5.13%) and lowest for barley (1.34%). Optimal grinding regimes were found at n = 1500–1764 rpm, β = 15.9–17.7°, and z = 9 plates. The results confirm the efficiency of adapting crusher parameters to grain properties.

Keywords: disc crusher; impact plates; numerical modeling; grain; energy consumption; grinding optimization (search for similar items in EconPapers)
JEL-codes: Q1 Q10 Q11 Q12 Q13 Q14 Q15 Q16 Q17 Q18 (search for similar items in EconPapers)
Date: 2025
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