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

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.