3.1.2. Discrete Element Simulation Model
The establishment of the simulation model can simulate the movement process of the auger under different parameters. By analyzing the effects of the cutting angle of the end cutting blade and the helix angle parameters on ditching performance, the interaction law between the parameters is explored, providing a basis for setting actual operating parameters.
Through moisture content measurements of desert soil, it was found that the moisture content increases with depth. To ensure that the established simulation model can realistically reflect the actual conditions of desert sandy soil, the rational selection of a soil discrete element contact model is crucial. In this study, the Hertz–Mindlin with JKR Cohesion contact model was adopted as the contact model between sandy soil particles [
34,
35]. Based on elasticity theory, the JKR model describes inter-particle forces using surface energy, which can fully account for various complex conditions during particle motion. This makes the movement of sand particles during auger rotation more consistent with the real state and accurately reflects the ditching performance of the transverse ditching device.
After measuring the moisture content of desert sandy soil at different depths, this study selected particles with three specific moisture contents to establish the soil bin model. The moisture contents of the model from the upper layer to the lower layer are 1%, 3%, and 5%, respectively. Each moisture content corresponds to three different shapes of sandy soil particles: spherical, elongated, and prismatic, with mass fractions of 0.5, 0.2, and 0.3, respectively. The relevant parameters of the soil discrete element model [
33,
36,
37,
38,
39,
40] are listed in
Table 4. According to the difference in moisture content at different depths of desert sand, differentiated parameters were designed for the upper, middle and lower sand layers. With the increase in sand depth, the moisture content increases accordingly. The density of sand particles increases from 1650 kg/m
3 to 1779 kg/m
3, the shear modulus increases from 1.15 × 10
7 Pa to 2.7 × 10
8 Pa, and the JKR surface energy increases from 0.004 to 0.124. This variation is highly consistent with the actual characteristics of desert sand, i.e., higher moisture content, greater compaction and stronger cohesion in deeper layers.
According to the burial depth requirement of 20–30 cm for Salix psammophila sand barriers, a virtual soil bin with dimensions of 250 mm × 250 mm × 250 mm was established in the model. The soil bin was divided into three layers: an upper sandy soil layer with a thickness of 80 mm, a middle layer of 80 mm, and a lower layer of 90 mm. After parameter configuration, three virtual planes were generated. The lower-layer sandy soil particles were first created via the EDEM dynamic particle factory, followed by the middle and upper layers. For each layer, three types of sandy soil particles were simultaneously generated according to the preset mass fraction ratio, with a particle generation duration of 1 s for each single layer. Upon completion of all sandy soil particle simulation, the particles were compacted and then bonding bonds were generated for the compacted sandy soil. A simplified 3D model of the transverse ditching device, constructed using SolidWorks 2024, was imported into EDEM, as shown in
Figure 9 below.
To shorten the simulation time, a single auger was used to simulate the ditching process. The initial position of the auger was 10 mm above the sand surface, with a preset downward drilling depth of 230 mm (including a 30 mm auger tip length). The downward feed speed and return speed were set to 0.1 m/s and 0.2 m/s, respectively, and the auger rotational speed was 230 r/min, as shown in
Figure 10. It can be observed from the figure that during operation, the auger performs both rotational and downward feeding motions simultaneously. At time
t1, the auger begins to contact the sand surface. From
t2 to
t3, the auger continues to feed downward until it reaches the preset ditching depth at
t3. During this period, sand from different depths is driven upward by the auger flight and finally transported to the surface. The stage from
t4 to
t5 represents the return stroke of the auger. At
t4, sand flowing back from the side of the ditch wall can be seen being lifted to the ground again via the auger flight. By
t5, the auger is fully reset, completing one working cycle.
To investigate the dynamic characteristics and mechanical response of sand layers at different depths during ditching, this paper analyzed the temporal variations in velocity and force for the upper, middle, and lower sand layers throughout the operation. The results are shown in
Figure 11. During the 3–4 s interval, the auger performed ditching in the upper sand layer. Under the cutting and disturbance of the auger, both the velocity and force of the upper sand exhibited a significant upward trend. In the 4–5 s interval, the auger advanced into the middle sand layer. At this stage, the velocity and force of both the upper and middle sand entered a dynamically stable range. Meanwhile, as the upper sand was no longer under direct auger action, its velocity and force showed a slow decrease compared with the previous stage. After 5 s, the auger operated on the lower sand layer, with its disturbance zone covering the entire sand profile. During auger lifting, the disturbance intensity of sand at different depths exhibited a gradient distribution: upper layer > middle layer > lower layer. Correspondingly, the soil lifting volume also showed that the upper sand was significantly higher than that of the middle and lower layers.
In the discrete element model of this study, the upper, middle, and lower sand layers were assumed to be homogeneous, which is a simplification adopted to improve modeling and computational efficiency. To evaluate the influence of intra-layer parameter inhomogeneity on the simulation results, a parametric sensitivity analysis was conducted in this study using the JKR surface energy of the three sand layers as the key parameter. A fluctuation range of ±20% based on the baseline values was set to investigate its effects on trenching depth and working torque, as shown in
Table 5. The results showed that when the JKR surface energy varied within ±20%, the trenching depth ranged from 4.9 to 5.6 cm with a maximum variation of 5.7%, and the working torque ranged from 2.3 to 2.71 N·m with a maximum variation of 8.4%. All the above deviations were less than 10%, which is within the acceptable engineering error range for discrete element simulations of agricultural machinery. Among them, the variation in JKR surface energy in the middle sand layer had the most significant effect on working torque, with a maximum deviation of 8.4%. This can be attributed to the fact that the middle layer is the main cutting zone of the auger, and its cohesion characteristics directly determine the cutting resistance. Nevertheless, the deviation was still within the allowable range. Therefore, for the purpose of this study, the three-layer homogeneous model can be used as an effective and reliable simplified modeling method.
3.1.3. Simulation Single-Factor Experiments
To determine the factor levels and value ranges for the parameter optimization test of the helical cutter, this study took ditching depth and maximum torque during auger operation as test indicators. The helix angle and the cutting angle of the end-face cutting blade were selected as test variables to carry out single-factor experiments, aiming to explore the influence law of each factor on the test indicators. According to the technical specifications in the Agricultural Machinery Design Manual, five levels were set for each factor: helix angles of 10°, 15°, 20°, 25°, and 30°, and cutting angles of 10°, 15°, 20°, 25°, and 30°. A multi-level single-factor experiment was designed accordingly. Meanwhile, the helix angle and cutting angle were fixed at 20°, the auger rotational speed was set to 230 r/min, and the auger descending speed was set to 10 cm/s. Each test level was repeated three times. For the measurement of ditching depth, during the EDEM post-processing stage, the model was first processed using the clipping command. Clipping was performed at 15 mm forward and backward from the central vertical plane, respectively. The ditching depth was then measured from the clipped view, which was taken as the actual ditching depth of the auger. Regarding the acquisition of the maximum auger torque, this paper used the torque measurement tool in the EDEM post-processing module to record the maximum torque value during the entire working cycle. The test results are shown in
Figure 12.
It can be seen from
Figure 12 that the ditching depth generally shows a trend of first increasing and then decreasing with the increase in the cutting angle and helix angle. The torque exhibits a trend of stable fluctuation in the early stage and gradual decrease in the later stage with the increase in the cutting angle and increases slowly at first and then tends to be stable with the increase in the helix angle. The maximum ditching depth occurs when both the cutting angle and helix angle are 20°, while the minimum corresponds to the parameter combination of a cutting angle of 10° and a helix angle of 30°. The maximum torque appears under the conditions of a cutting angle of 15° and a helix angle of 20°, and the minimum torque occurs when the cutting angle and helix angle are 30° and 10°, respectively. Therefore, the ranges of the cutting angle and helix angle for the optimized orthogonal test of the auger are determined to be 20–30° and 15–25°, respectively.
3.1.4. Orthogonal Test for Auger Parameter Optimization
Based on the single-factor experiments, a two-factor, three-level orthogonal experiment was designed with the cutting angle and helix angle as the experimental factors, and the ditching depth and torque as the experimental indicators, to explore the optimal structural combination of the auger. Design-Expert 13 was used to process and analyze the test results. Each group of experiments was repeated three times, and the test results are shown in
Table 6.
The regression models for all test indicators were highly significant (
p < 0.01), and the
p-values of the lack-of-fit terms were not significant, indicating that the regression models had a high goodness of fit. The regression equations between each test indicator and the factors are as follows:
With the objectives of maximizing
Y1 and minimizing
Y2, the optimization was performed using the optimization function in Design-Expert 13 software. The objective function is defined as:
where
x1 is the soil-cutting angle and
x2 is the helix angle. The optimal parameter combination was obtained as follows: a soil-cutting angle of 30° and a helix angle of 20.37°, corresponding to a ditching depth of 5.52 cm and a torque of 2.6 N·m.
The optimized auger structural parameters were selected for simulation verification tests, with an auger rotational speed of 230 r/min, a descending speed of 0.1 m/s, and a return speed of 0.2 m/s. Torque analysis is shown in
Figure 13. Simulation tests showed that the ditching depth was 5.7 cm and the maximum torque was 2.78 N·m. Compared with the predicted values of the regression model, the relative errors were 3.1% and 6.5%, respectively, which verified the accuracy of the regression model.