Optimising hammer blade design for agricultural waste processing using finite element simulation

Abstract This study presents a strength analysis of the hammer blade component in a multifunctional chopper machine using the Finite Element Method (FEM). In response to the growing demand for affordable and high-quality animal feed, efficient processing of agricultural waste—such as hard-to-digest corn cobs—is essential. Multifunctional chopper machines equipped with shredding and crushing blades offer a practical solution, with the hammer blade playing a critical role in determining processing effectiveness. This research evaluates the mechanical performance of the blade under varying material types (Cast Iron, AISI 304, and AISI 1066) and dynamic loads (254.44 N, 305.36 N, and 380.45 N) using Autodesk Fusion 360 simulation software. The analysis focuses on Von Mises stress, displacement, and factor of safety values to determine the most suitable material. Results show that AISI 1066 exhibits the highest stress and displacement values but also the highest safety factor, indicating its superior strength and reliability under dynamic conditions. Critical stress points are primarily located at the blade’s edges and impact zones. These findings provide valuable insights for optimising blade design and material selection, contributing to the development of more efficient and durable agricultural machinery.