Development and Validation of a Film–Soil Composite Model Based on the Discrete Element Method

Residual film recovery is a crucial approach to mitigating agricultural “white pollution” and ensuring sustainable land use. Currently, the development of residual film recovery machines relies primarily on theoretical analysis and field performance tests. The lack of support from computational simulation models often leads to suboptimal mechanical performance, severely restricting the design and optimization of recovery equipment. To address this, this study proposes a method for constructing and experimentally validating a discrete element model of plow-layer residual film using EDEM software. First, field tests were conducted to measure soil compaction and residual film distribution at various depths. The ultimate tensile force of the residual film was also evaluated to provide fundamental data for model development. Using the Hertz–Mindlin with bonding contact model in EDEM, the intrinsic parameters of the residual film were selected and optimized. Combined with a Box–Behnken experimental design, a quadratic regression model relating normal stiffness per unit area, critical normal stress, and bond radius to the ultimate tensile force of the film was constructed. The optimal parameter combination was determined as follows: normal stiffness = 1.11 × 106 N·m−3, critical normal stress = 2.45 × 106 Pa, and bond radius = 0.03 mm. Under these parameters, the theoretically predicted ultimate tensile force was 1.18 N, and the simulated value yielded a relative error of only 1.69%, validating the effectiveness of the single-film model. Furthermore, using the field-measured data, a coupled film–soil model was established via the “rainfall” method to conduct simulated penetration tests. Parameter calibration was executed using the multivariate Newton–Raphson iteration method. The optimal bonding parameters for soil particles were identified as follows: normal stiffness per unit area = 9.6 × 105 N/m2, shear stiffness per unit area = 9.6 × 105 N/m2, critical normal stress = 5.38 × 105 Pa, critical shear stress = 5.38 × 105 Pa, and bond radius = 4.3 mm. The average simulated penetration resistance was 59.61 N, showing a relative error of 5.91% compared to the field-measured value of 56.28 N. These results demonstrate that the developed coupled film–soil DEM can be effectively applied to simulate the lifting and throwing processes of plow-layer residual film recovery machines, thereby providing vital modeling support for the design and optimization of residual film recovery mechanisms.