Modal analysis and discrete element simulation of a counter-rotating cutter roller for tobacco stalk extraction

To explore the mechanical performance of the reverse-rotating knife roller, a core component of the tobacco stalk pulling machine, during the tobacco stalk pulling operation, and to ensure its safe and stable operation. This paper verifies the dynamic stability of the counter-rotating knife roller in the tobacco stalk extraction operation through Ansys modal analysis and combined with EDEM discrete element simulation. The results show that the first six natural frequencies (230–310 Hz) differed by 97.5%–98.1% from the actual operational frequency (5.67 Hz), significantly exceeding the 15% safety threshold, thereby effectively mitigating resonance risks. Establish the Hertz-Mindlin bond contact model to quantify the interaction between the cutter drum and the soil, mean soil-cutting resistance reached 1 187 N (peak: 2 124 N), mean torque 247 N·m (peak: 514 N·m), and mean power consumption 4.3 kW (peak: 10.3 kW). Field test data demonstrated less than 10% discrepancy with simulation results, validating the effectiveness of the computational model.This study can provide reference for promoting the safety and stability of tobacco stubble removal machinery.