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基于EDEM-ANSYS耦合仿真的毛竹除枝刀设计与试验

Design and experiment of Moso bamboo delimbing blade based on EDEM-ANSYS coupled simulation

  • 摘要: 针对毛竹采伐过程中人工除枝效率低且除枝刀片切割性能弱等问题,该研究基于切叶蚁上颚轮廓曲线设计一种仿形除枝刀。以光腿刺切叶蚁兵蚁上颚切齿形态特征为仿生原型,结合其切割机理,通过逆向工程技术提取上颚切齿轮廓曲线,据此设计仿生刃口曲线,并依据该曲线设计一种仿生除枝刀。基于EDEM-ANSYS耦合方法对除枝运动过程进行仿真并采用三因素三水平正交试验分析刀刃角、刀刃厚度和进给速度对粘结键断裂数量和最大等效应力的影响。仿真结果表明,各因素对粘结键断裂数量影响的显著性顺序依次为刀刃角、刀刃厚度、进给速度;对最大等效应力影响的显著性顺序依次为进给速度、刀刃厚度、刀刃角。优化后的参数组合为刀刃厚4 mm、刀刃角26°和进给速度1.6 m/s,此时仿生除枝刀相较于平刃除枝刀最大等效应力下降16.33%,粘结键断裂数量降低6.66%。为验证不同刀型实际切割效果,以含杂率为指标开展台架试验,试验结果表明,平刃除枝刀切割含杂率为4.06%,仿生除枝刀为2.36%,较平刃刀降低1.70%,仿生除枝刀切割性能优于平刃除枝刀。研究结果可为毛竹除枝刀的设计与优化提供理论依据和技术支撑。

     

    Abstract: To address the low efficiency of manual delimbing and the insufficient cutting performance of conventional blades during moso bamboo harvesting, this study proposes a biomimetic profiling delimbing blade inspired by the mandibular contour of the Acanthomyrmex glabfemoralis ant. Soldier ants of this species were selected as the biological prototype because their mandibles, optimized through long-term natural evolution, exhibit outstanding cutting capability and mechanical strength. Using scanning electron microscopy combined with digital image processing, the micro-morphological characteristics and geometric configuration of the serrated mandible teeth were systematically analyzed. Based on these observations, reverse engineering techniques were employed to accurately extract the contour curve of the mandible serrations. A mathematical model of the cutting-edge profile was established, and a biomimetic edge equation was derived. This equation served as the geometric foundation for the structural design of a novel biomimetic delimbing blade. Compared with conventional flat-edge blades, the proposed blade integrates a non-uniform curvature profile intended to enhance stress distribution and cutting stability during operation.To systematically evaluate the cutting performance of the biomimetic blade, a bidirectional coupled dynamic simulation framework was established using EDEM and ANSYS. In EDEM, a discrete element model of bamboo branches was developed, in which the internal reinforced fiber structure of bamboo was represented by the Hertz–Mindlin with Bonding contact model. Bonded particles were used to simulate the mechanical behavior and fracture characteristics of the fibrous vascular bundles. In ANSYS, a finite element model of the blade was constructed with appropriate material properties and boundary conditions. Through a bidirectional coupling interface, real-time data exchange between the blade and the bamboo branch was achieved, enabling synchronous analysis of contact forces, bond breakage evolution, and structural stress response during the delimbing process.On this basis, a three-factor, three-level orthogonal experimental design was implemented to investigate the effects of edge of the blade, blade thickness, and feeding speed on two key performance indicators: the bonding bond breakage number and the maximum equivalent stress. Response surface analysis revealed significant differences in the influence of these factors. For bond breakage quantity, blade edge was the most significant factor, followed by blade thickness, while feeding speed had a comparatively smaller effect. Multi-objective optimization determined the optimal parameter combination as a blade thickness of 4 mm, a blade edge of 26°, and a feeding speed of 1.6 m/s. Under these optimized conditions, the biomimetic blade achieved a 16.33% reduction in maximum equivalent stress and a 6.66% decrease in the number of bond breakages compared to the conventional flat blade.To further validate the reliability of the simulation results, comparative bench experiments were conducted. Both the conventional flat blade and the biomimetic blade were used to cut bamboo branches under identical operating conditions. Cutting quality was evaluated by measuring the impurity rate on the cut surface. The results showed that the average impurity rate for the flat blade was 4.06%, whereas the biomimetic blade achieved a lower value of 2.36%, corresponding to a reduction of 1.7 percentage points. Overall, this study integrates biological inspiration, reverse engineering, and DEM–FEM coupled simulation to develop and optimize a delimbing blade for moso bamboo harvesting. The results provide theoretical insight into the cutting mechanism of fibrous biological materials and offer technical support for the structural design and performance optimization of bamboo delimbing tools.

     

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