Impact-Induced Breakage Behavior During Grain Discharge and Modeling Framework for Discharge Impact Prediction

Grain breakage serves as a primary causative factor for microbial infestation and oxidative deterioration, significantly diminishing product value and resulting in substantial grain waste and economic losses. The grain discharging process represents the most extensively involved and primary breakage-inducing stage throughout harvest handling and processing operations. However, impact and impact-induced breakage behavior during grain discharge are still poorly understood. To elucidate the impact-induced breakage behavior during grain discharge, this study first employed the discrete element method (DEM) to numerically simulate the discharging process, thereby quantifying the variation patterns of grain kinematic characteristics (e.g., velocity and attitude). Building upon the simulated kinematic data, a dedicated impact testing platform was constructed to investigate single-grain breakage. This enabled the determination of critical unit mass impact energy (along 90°: 106.4 J kg−1; along 0°: 57.28 J kg−1) and critical breakage velocity (along 90°: 14.59 m s−1; along 0°: 10.70 m s−1) under two extreme impact attitude conditions. By integrating the DEM-derived kinematics with the experimentally obtained breakage thresholds, a breakage probability zoning diagram for both large-scale and small-scale discharge processes was developed. Finally, leveraging this comprehensive understanding of the flow and breakage mechanics, theoretical models were successfully established to predict key engineering design parameters, including mass flow rate, impact force, and impact pressure. All models were validated and demonstrated excellent predictive capabilities. The research result is of guiding significance for the design of relevant parameters of discharge systems to minimize grain breakage loss to the greatest extent possible.