A lightweight high-toughness rotary tiller design system and method

Abstract

The application discloses a kind of lightweight high tough rotary tiller and its design method, belong to agricultural machinery technical field.The technical problem to be solved by the application is that existing rotary tiller is easily impacted and broken in hilly and mountainous areas, coating thickening leads to increased power consumption, and cannot be considered lightweight, high toughness and wear resistance.The technical scheme is: the failure mechanism is analyzed by the rotary tiller mechanical property parameter acquisition module, and the high toughness 30MnB5 base material is optimized;the structure weak position is identified by the rotary tiller size determination module;by lightweight design and simulation modeling module, the standard rotary tiller is thinned by using the principle of equal strength, and the coating strengthening modeling is carried out on the easy wear part, to obtain the lightweight high tough rotary tiller design scheme.The application solves the problem that impact resistance, wear resistance and low power consumption are difficult to unify, realizes the collaborative improvement of lightweight, high toughness and wear resistance, and reduces the operation resistance and power consumption.

Description

Technical Field

[0001] This invention relates to the field of agricultural machinery design technology, specifically to a lightweight, high-strength, and tough rotary tiller blade design system and method. Background Technology

[0002] Rotary tillers, as a major type of agricultural machinery, break up and level the soil in the field during operation. They can also chop up residual tree roots and other debris in the soil, making it loose and providing a better growing environment for crops. This is especially important in agricultural production in the hilly and mountainous areas that are widely distributed in my country. However, the complex terrain of hilly areas and the presence of hard objects such as tree roots and stones in the soil cause severe impact and wear to the rotary tiller blades.

[0003] Currently, common technical solutions for improving the performance of rotary tillers in the industry mainly fall into two categories: First, surface coating technology is used to strengthen the rotary tiller blades, that is, a wear-resistant coating is applied to the cutting parts of the blade to improve its resistance to soil abrasive wear. Second, the structure and materials of the rotary tiller blades are optimized, for example, by using high-strength steel to enhance the overall strength of the blade body and resist impact loads.

[0004] However, these existing technologies have significant drawbacks. First, while simple surface coating reinforcement can improve wear resistance, it leads to thicker blades, increasing cutting resistance and power consumption during tillage, potentially reducing efficiency. Second, in regions like southern my country with sticky, easily compacted, or rocky soils, rotary tillers not only face wear issues but are also prone to deformation and even breakage due to severe impacts. While conventional high-strength materials offer adequate strength, they often fall short when seeking higher toughness and impact resistance to handle complex working conditions. Simply increasing material thickness to improve strength significantly increases the weight of the rotary tiller, leading to increased power consumption, failing to achieve a balance between lightweight design and high strength and toughness. Furthermore, traditional rotary tiller design methods rely heavily on experience or simple analogical design, lacking a systematic design process based on simulation and material mechanical property analysis, making it difficult to achieve precise structural optimization and weight reduction while ensuring or even improving performance. Summary of the Invention

[0005] The purpose of this invention is to provide a lightweight, high-strength, and tough rotary tiller blade design system and method. This invention fundamentally improves the impact and fracture resistance of the blade body by applying a novel high-strength, high-toughness material as the base material. Based on this, a scientific lightweight design is implemented for the key dimensions of the rotary tiller blade according to the principle of equal strength, achieving a significant reduction in weight while maintaining or even exceeding the load-bearing capacity of the original national standard rotary tiller blade. More importantly, this method applies a coating to the easily worn parts of the lightweight rotary tiller blade for reinforcement, thereby ensuring wear resistance of key components while achieving lightweight and drag reduction. Through a systematic approach of high-strength and tough base material, lightweight structure, and localized wear-resistant reinforcement, combined with modern design methods such as finite element and discrete element coupled simulation and field trials, this invention effectively solves the contradiction in existing rotary tiller blades where wear resistance is not sufficient for lightness, and strength and toughness are not economical. It achieves a unity of lightweight, high strength and toughness, and wear resistance, thereby reducing operating resistance and power consumption and extending the service life of the rotary tiller blade.

[0006] To achieve this objective, the present invention provides a lightweight, high-strength, and tough rotary tiller blade design system, comprising: The rotary tiller mechanical performance parameter acquisition module is used to determine the relationship between failure behavior and mechanical properties of rotary tiller material based on rotary tiller failure data during rotary tilling, obtain the failure mechanism and performance requirements of rotary tiller, and obtain the rotary tiller substrate and mechanical performance parameters of rotary tiller substrate that meet the preset strength and toughness based on the failure mechanism and performance requirements of rotary tiller. The rotary tiller blade size determination module establishes a three-dimensional model of the standard rotary tiller blade according to the set standards, and constructs a finite element simulation model of the standard rotary tiller blade based on the three-dimensional model of the standard rotary tiller blade. Through the three-dimensional model and the finite element simulation model of the standard rotary tiller blade, the stress analysis of the standard rotary tiller blade operation process is carried out to obtain the information of the maximum stress part, the maximum deformation part and the strain distribution during the standard rotary tiller blade tilling process. The lightweight design and simulation modeling module is used to redesign the three-dimensional model of a standard rotary tiller blade based on the rotary tiller blade substrate that meets preset strength and toughness, the mechanical performance parameters of the rotary tiller blade substrate, and the optimized mechanical performance parameters of the rotary tiller blade substrate, combined with the information on the maximum stress area, the maximum deformation area, and the strain distribution, using the principle of equal strength. This results in lightweight rotary tiller blade size data and a lightweight rotary tiller blade three-dimensional model. Wear-resistant coatings are then prepared on designated areas of the lightweight rotary tiller blade three-dimensional model to obtain a coated lightweight rotary tiller blade three-dimensional model.

[0007] Preferably, it also includes a verification module for constructing a discrete element simulation model containing the interaction between soil particles and rotary tillage blades, to obtain a soil-blade interaction environment for simulation. In a simulated soil cutting tool interactive environment, the rotary tillage process was simulated for three-dimensional models of standard rotary tillers, lightweight rotary tillers, and coated lightweight rotary tillers. The force and torque data of the three-dimensional models of the standard rotary tiller, lightweight rotary tillers, and coated lightweight rotary tillers during the operation phase were extracted and compared to obtain simulation data of the drag reduction effect of lightweight rotary tillers and coated lightweight rotary tillers.

[0008] Preferably, based on the simulation data of the drag reduction effect of the lightweight rotary tiller and the simulation data of the drag reduction effect of the coated lightweight rotary tiller, it is determined whether the drag reduction effect reaches the corresponding preset value. If both reach the corresponding preset value, the actual tillage power consumption test is carried out on the standard rotary tiller, the lightweight rotary tiller and the coated lightweight rotary tiller, and the tillage torque data is measured and recorded to obtain the actual drag reduction effect data of the lightweight rotary tiller and the coated lightweight rotary tiller compared with the standard rotary tiller.

[0009] Preferably, the specific method for obtaining the failure mechanism and performance requirements of rotary tillers is as follows: By analyzing field trials or rotary tillage blade failure data, we statistically determine the failure modes and locations; by analyzing the failure locations, we establish a qualitative correlation between the failure phenomena and the material's performance indicators, and deduce the physical mechanism of failure; based on the physical mechanism, failure mode, and location of failure, we propose specific quantitative requirements for material performance.

[0010] Preferably, the specific method for establishing a three-dimensional model of a standard rotary tiller blade according to the set standards, and constructing a finite element simulation model of the standard rotary tiller blade based on the three-dimensional model of the standard rotary tiller blade is as follows: Based on the established technical parameters and structural dimensions of the standard rotary tiller blade, a three-dimensional model of the standard rotary tiller blade is created using modeling software. The simulation software is then imported into the modeling software, the material of the standard rotary tiller blade is selected, and the mechanical performance parameters of the standard rotary tiller blade are input. The three-dimensional model is then meshed, and the continuous geometric geometry of the standard rotary tiller blade is discretized into a mesh composed of multiple geometric elements. Based on the actual working conditions of the standard rotary tiller blade, boundary constraints are applied to the finite element simulation model in combination with the mesh composed of multiple geometric elements, resulting in a finite element simulation model of the standard rotary tiller blade that can be used for mechanical calculations.

[0011] Preferably, the specific method for analyzing the stress on a standard rotary tiller during its operation using a 3D model and a finite element simulation model is as follows: In the finite element simulation model, a distributed load simulating soil cutting resistance is applied to the area where the rotary tiller blade contacts the soil during standard rotary tiller blade operation. Fixed constraints are applied to the mounting holes or central parts where the rotary tiller blade connects to the blade shaft. Based on the specified rotary tiller blade material, the mesh composed of multiple geometric elements, the distributed load, and the boundary constraint conditions, the mechanical response of the rotary tiller blade under static load is calculated through static structural simulation. The simulation software generates stress cloud diagrams, deformation cloud diagrams, and strain cloud diagrams of the rotary tiller blades based on their mechanical response under static loads. Based on these diagrams, the software obtains information on the location of maximum stress, the location of maximum deformation, and the strain distribution during the tilling process.

[0012] Preferably, the specific method for obtaining the dimensional data and 3D model of the lightweight rotary tiller is as follows: Based on the mechanical performance parameters of the standard rotary tiller blade, its three-dimensional model, and the distributed load simulating soil cutting resistance applied in the finite element simulation model, the stress level of the standard rotary tiller blade is obtained. Based on the mechanical performance parameters, maximum stress location, maximum deformation location, and strain distribution information of the optimized rotary tiller blade substrate, and using the principle of equal strength and based on material mechanics formulas, the dimensional data of the lightweight rotary tiller blade are calculated under the stress level of the standard rotary tiller blade or under the same distributed load. A three-dimensional model of the lightweight rotary tiller blade is then constructed based on this dimensional data.

[0013] Preferably, a wear-resistant coating is prepared on designated parts of the lightweight rotary tiller blade 3D model to obtain a coated lightweight rotary tiller blade 3D model: Using modeling features set by modeling software, a new geometric solid 3D model representing a wear-resistant coating with a specific thickness is created from the 3D model of the lightweight rotary tiller blade. The new geometric solid 3D model is then merged with the 3D model of the lightweight rotary tiller blade body to generate a coated lightweight rotary tiller blade 3D model containing a composite structure of substrate and coating.

[0014] The beneficial effects of this invention: This invention proposes a lightweight, high-strength, and tough rotary tiller blade design system. This invention systematically combines the application of high-strength and tough materials, lightweight design, and wear-resistant coating reinforcement of key components in the rotary tiller blade design. Through a structured design method and verification system, it achieves synergistic optimization of the rotary tiller blade's performance. Compared with existing technologies that only apply surface coatings or simply replace materials, this invention starts with failure mechanism analysis and fundamentally improves the impact resistance and fracture resistance of the rotary tiller blade through the application of high-strength and tough 30MnB5 material, solving the problem of traditional rotary tiller blades easily breaking upon impact in rocky and compacted soils in hilly and mountainous areas.

[0015] Leveraging the strength advantages of the materials, this invention employs the principle of equal strength for lightweight rotary tiller blade design, significantly reducing the blade body thickness, the width of the tangential edge, and the thickness of the cutting edge. Without compromising structural strength, this results in a substantial reduction in the overall weight of the rotary tiller blade, directly lowering inertial resistance and power consumption during tillage. More importantly, the lightweight design provides space for subsequent coating reinforcement in critical wear-prone areas. High-hardness, wear-resistant coatings are prepared on these areas using techniques such as plasma welding and laser cladding, effectively enhancing wear resistance and avoiding the problem of increased tillage resistance caused by simply thickening the coating. This achieves a balance between lightweight, strong, and wear-resistant properties.

[0016] This invention establishes an integrated design methodology and system, forming a complete closed-loop design process from failure analysis and material selection for strength-based lightweight design, discrete element simulation optimization, to coating processes and field verification. This system can utilize failure data and mechanical performance analysis results from standard rotary tillers, through coupled finite element and discrete element simulations, to predict the effectiveness of lightweighting and coating enhancement schemes.

[0017] In summary, this invention achieves a significant performance leap in rotary tiller blades across three dimensions: impact resistance, wear resistance, and low power consumption through a three-pronged design combining a high-strength, tough substrate, lightweight structure, and localized coating reinforcement, coupled with a rigorous simulation and experimental verification system. This helps to significantly extend the service life of rotary tiller blades, reduce energy consumption and tillage resistance in hilly and mountainous areas, and provides innovative technical solutions and design concepts for the green, efficient, and sustainable development of agricultural machinery in my country. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a three-dimensional model of the standard rotary tiller blade of the present invention; Figure 3 Stress distribution of rotary tillage blades; Figure 4 This represents the total deformation degree of the rotary tiller blades. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0020] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: Example 1 A lightweight, high-strength, and tough rotary tiller blade design system, such as Figure 1 As shown, it includes: The rotary tiller mechanical performance parameter acquisition module is used to determine the relationship between failure behavior and mechanical properties of rotary tiller material based on rotary tiller failure data during rotary tilling, obtain the failure mechanism and performance requirements of rotary tiller, and obtain the rotary tiller substrate and mechanical performance parameters of rotary tiller substrate that meet the preset strength and toughness based on the failure mechanism and performance requirements of rotary tiller. The rotary tiller blade size determination module establishes a three-dimensional model of the standard rotary tiller blade according to the set standards, and constructs a finite element simulation model of the standard rotary tiller blade based on the three-dimensional model of the standard rotary tiller blade. Through the three-dimensional model and the finite element simulation model of the standard rotary tiller blade, the stress analysis of the standard rotary tiller blade operation process is carried out to obtain the information of the maximum stress part, the maximum deformation part and the strain distribution during the standard rotary tiller blade tilling process. The lightweight design and simulation modeling module is used to redesign the three-dimensional model of a standard rotary tiller blade based on the rotary tiller blade substrate that meets preset strength and toughness, the mechanical performance parameters of the rotary tiller blade substrate, and the optimized mechanical performance parameters of the rotary tiller blade substrate, combined with the information on the maximum stress area, the maximum deformation area, and the strain distribution, using the principle of equal strength. This results in lightweight rotary tiller blade size data and a lightweight rotary tiller blade three-dimensional model. Wear-resistant coatings are then prepared on designated areas of the lightweight rotary tiller blade three-dimensional model to obtain a coated lightweight rotary tiller blade three-dimensional model.

[0021] In the above technical solution, the impact resistance of the rotary tiller blade is improved by using high-strength and tough materials, reducing the occurrence of fracture failure and thus improving tillage efficiency. Simultaneously, a lightweight design is implemented to thin the rotary tiller blade, leaving space for a reinforced coating on the blade edge, thereby reducing cutting resistance and power consumption. The resulting lightweight rotary tiller blade achieves a weight reduction of up to 24.5%. Furthermore, based on the lightweight and thinned rotary tiller blade, a reinforced coating further improves its wear resistance. Combining discrete element simulation and field tests, the drag reduction effect of the lightweight rotary tiller blade and the coated lightweight blade compared to the standard rotary tiller blade was obtained. In the simulation test, the overall force experienced by the lightweight rotary tiller blade during soil cutting was generally lower than that of the standard rotary tiller blade, reduced by approximately 23.98%; in the field test, the 1.25mm coated lightweight blade reduced power consumption by 22.05% compared to the standard rotary tiller blade.

[0022] In some preferred embodiments, the rotary tiller failure data during rotary tillage includes failure mode and failure location, primarily including two failure modes: Wear failure: During the tillage process, the rotary tiller blades wear down due to friction. When the wear is too high, it will significantly affect the tillage quality and lead to a decrease in key tillage indicators such as soil breaking rate and tillage depth. Impact fracture or deformation failure: When rotary tillers collide with hard objects such as stones and tree roots in the soil, they are prone to deformation or even breakage. This is the main reason for the early damage of rotary tillers in the soil environment. Failure location data includes data on the maximum stress and deformation points during rotary tillage. Failure modes are determined by failure behavior. To resist wear failure, materials need high hardness, and to resist impact fracture failure, materials need high toughness. However, selecting materials based on a single failure data may exacerbate the risk of another type of failure. Prioritizing materials based on the main contradictions and determining the relationship between failure behavior and the mechanical properties of rotary tiller materials can lead to the failure mechanism and performance requirements of rotary tillers.

[0023] In some preferred embodiments, excessive wear can significantly affect the tillage quality of rotary tillers, leading to a decrease in key tillage indicators such as soil breaking rate and tillage depth. Generally, the higher the hardness of the rotary tiller, the stronger its wear resistance, but the lower its toughness, the more prone it is to breakage; conversely, the same applies. Therefore, it is necessary to determine mechanical properties that are both excellent in terms of wear resistance and toughness. Using the performance parameters of the standard rotary tiller base material (65Mn steel) as a benchmark for evaluating the performance of new materials, and based on the failure mechanism analysis of rotary tillers, it was clarified that the new base material must simultaneously meet the performance requirements. In optional embodiments, 30MnB5 was selected from a variety of candidate materials, and its ability to meet the preset requirements was confirmed. By comparing and analyzing the mechanical properties and wear resistance of boron steels with different carbon contents, as well as the application of boron steel in soil-contact components at home and abroad, the material selection range was focused on the boron steel series, which is known for its good hardenability and combination of strength and toughness. From the boron steel series, based on the judgment that its known material properties match the aforementioned performance requirements, 30MnB5 was selected as the base material for a new type of high-strength and high-toughness rotary tillage blade. 30MnB5 was subjected to specific heat treatment to optimize its metallographic structure and obtain the best strength-toughness ratio. The relevant mechanical properties of the heat-treated 30MnB5 were tested, including obtaining key parameters such as yield strength, tensile strength, and impact absorption energy through standard mechanical tests.

[0024] In some preferred embodiments, the optimized mechanical property parameters of the rotary tiller substrate are selected as 30MnB5 as the mechanical property parameters of the new high-strength and high-toughness rotary tiller substrate.

[0025] In some preferred embodiments, it also includes a verification module for constructing a discrete element simulation model that includes the interaction between soil particles and rotary tillage blades, to obtain a soil-blade interaction environment for simulation. In a simulated soil cutting tool interactive environment, the rotary tillage process was simulated for three-dimensional models of standard rotary tillers, lightweight rotary tillers, and coated lightweight rotary tillers. The force and torque data of the three-dimensional models of the standard rotary tiller, lightweight rotary tillers, and coated lightweight rotary tillers during the operation phase were extracted and compared to obtain simulation data of the drag reduction effect of lightweight rotary tillers and coated lightweight rotary tillers.

[0026] The aforementioned technical solution precisely couples material substitution and structural thinning through the introduction of lightweight design and simulation modeling modules. It utilizes the higher allowable stress of high-strength and tough new materials and applies the principle of equal strength to selectively thin the structure at identified critical structural locations. This scientifically achieves lightweighting without sacrificing overall structural strength, reserving physical space for subsequent application of wear-resistant coatings to critical wear areas. This fundamentally resolves the contradiction in design where thickening the coating increases resistance while thinning the structure weakens it.

[0027] In some preferred embodiments, the drag reduction effect is determined based on simulation data of the drag reduction effect of the lightweight rotary tiller and the coated lightweight rotary tiller. If both reach the corresponding preset value, the actual tillage power consumption is tested on the standard rotary tiller, the lightweight rotary tiller, and the coated lightweight rotary tiller. The tillage torque data is measured and recorded to obtain the actual drag reduction effect data of the lightweight rotary tiller and the coated lightweight rotary tiller compared to the standard rotary tiller.

[0028] In an optional embodiment, three-dimensional models of lightweight rotary tillers and coated reinforced rotary tillers are created using SOLIDWORKS software. These three-dimensional models are then imported into EDEM simulation software. In EDEM, material properties are defined for both the rotary tiller model and the soil model. The Hertz-Mindlin with Bonding model is selected as the core simulation contact model. This model is a classic model in the discrete element method used to simulate the contact mechanics between particles and between particles and geometric bodies. The bonding component effectively simulates the cohesive force between soil particles, which is crucial for constructing soil aggregates during tillage. The rotary tiller rotation speed is set to 300-600 r / min, the forward speed to 0.5 m / s, and the tillage depth to 120-150 mm. Soil model parameters are defined, including the size, shape, and other geometric properties of the soil particles. The soil's physical properties are also defined, including moisture content, density, elastic modulus, and Poisson's ratio. The contact parameters between materials are defined, including the coefficient of restitution and the static and dynamic coefficients of friction. The coefficient of restitution characterizes the degree of energy recovery after a collision, while the static and dynamic coefficients of friction characterize the frictional properties between the contact surfaces. The bond stiffness, critical bond stress, and particle bond radius of the Hertz-Mindlin with Bonding model are defined. The simulation is run, and after the simulation enters the stable tillage stage, the force and torque data experienced by the rotary tiller blades during operation are exported for comparative analysis with standard rotary tillers to evaluate the drag reduction effect of lightweighting and coating design.

[0029] In the aforementioned technical solution, a virtual test field is constructed by adding a verification module. This allows for the pre-evaluation of the drag reduction effects of different designs before manufacturing the physical prototype using discrete element simulation. It postpones expensive and time-consuming field trials, enabling extensive scheme screening and performance prediction within a computer, thereby significantly reducing R&D costs and timelines. Furthermore, it provides crucial decision-making support for the success of equal-strength lightweight designs and the necessity of coating reinforcement through quantitative comparison of stress and torque data.

[0030] In some preferred embodiments, the specific methods for obtaining the failure mechanism and performance requirements of rotary tillers are as follows: By analyzing field trials or rotary tillage blade failure data, we statistically determine the failure modes and locations; by analyzing the failure locations, we establish a qualitative correlation between the failure phenomena and the material's performance indicators, and deduce the physical mechanism of failure; based on the physical mechanism, failure mode, and location of failure, we propose specific quantitative requirements for material performance.

[0031] The aforementioned technical solution defines a specific method for deriving performance requirements from failure data, transforming the outcome of failure into a design input of material performance indicators. Through statistical phenomena, correlation mechanisms, and a logical chain of quantifiable requirements, the previously vague field experience is transformed into clear and actionable engineering language, providing a direct and explicit selection standard for high-strength and tough materials like 30MnB5.

[0032] In some preferred embodiments, the specific method for establishing a three-dimensional model of a standard rotary tiller blade according to set standards, and constructing a finite element simulation model of the standard rotary tiller blade based on the three-dimensional model of the standard rotary tiller blade is as follows: Based on the established technical parameters and structural dimensions of the standard rotary tiller blade, a three-dimensional model of the standard rotary tiller blade is created using modeling software. The simulation software is then imported into the modeling software, the material of the standard rotary tiller blade is selected, and the mechanical performance parameters of the standard rotary tiller blade are input. The three-dimensional model is then meshed, and the continuous geometric geometry of the standard rotary tiller blade is discretized into a mesh composed of multiple geometric elements. Based on the actual working conditions of the standard rotary tiller blade, boundary constraints are applied to the finite element simulation model in combination with the mesh composed of multiple geometric elements, resulting in a finite element simulation model of the standard rotary tiller blade that can be used for mechanical calculations.

[0033] In some preferred embodiments, after generating the finite element mesh model of the rotary tiller blade, the translational degrees of freedom of the selected nodes are set to zero in the boundary condition setting module of the simulation software. This fixes the displacements of these nodes in the X, Y, and Z directions in the Cartesian coordinate system, defining this as a fixed constraint. The rotary tiller blade is simulated as being rigidly connected to the cutter head via a central bolt, preventing translational displacement. Applying this constraint eliminates rigid body displacement of the model, enabling stable solution under static loads and allowing accurate calculation of stress and deformation distribution under soil cutting forces.

[0034] The aforementioned technical solution establishes an accurate and repeatable mechanical analysis benchmark for the entire design process by specifying the construction details of the standard rotary tiller blade finite element model. Through precise modeling, mesh generation, and the application of loads and constraints consistent with actual working conditions, the true static stress state of the rotary tiller blade in the soil can be simulated. This reliably outputs core data for guiding lightweight design: the locations of maximum stress and strain, ensuring that all subsequent optimizations are based on a reliable mechanical analysis foundation.

[0035] In some preferred embodiments, the stress analysis of the standard rotary tiller's operation process, using a three-dimensional model and a finite element simulation model, yields information on the locations of maximum stress, maximum deformation, and strain distribution during the tillage process. The specific methods are as follows: In the finite element simulation model, a distributed load simulating soil cutting resistance is applied to the area where the rotary tiller blade contacts the soil during standard rotary tiller blade operation. Fixed constraints are applied to the mounting holes or central parts where the rotary tiller blade connects to the blade shaft. Based on the specified rotary tiller blade material, the mesh composed of multiple geometric elements, the distributed load, and the boundary constraint conditions, the mechanical response of the rotary tiller blade under static load is calculated through static structural simulation. The simulation software generates stress cloud diagrams, deformation cloud diagrams, and strain cloud diagrams of the rotary tiller blades based on their mechanical response under static loads. Based on these diagrams, the software obtains information on the location of maximum stress, the location of maximum deformation, and the strain distribution during the tilling process.

[0036] In some preferred embodiments, after the meshing of the three-dimensional model of the rotary tiller blade is completed, a set of distributed loads simulating soil cutting resistance is applied to the area where the rotary tiller blade contacts the soil to simulate the stress conditions during actual tillage. Simultaneously, a fixing constraint is applied to the mounting hole or central part where the rotary tiller blade connects to the blade shaft to simulate its installation state on the blade shaft. The simulation software solves the static equilibrium equations based on the set material properties (such as the elastic modulus, Poisson's ratio, density, and other mechanical performance parameters of the standard 65Mn rotary tiller substrate), mesh model, loads, and constraints. Its core function is to calculate the stress and deformation generated in each element within the model under a given load. After the calculations are complete, the software generates a series of contour maps to visually display the mechanical response results. Stress contour maps (such as VonMises stress contour maps) show the magnitude and distribution of stress on the rotary tiller blades, thus identifying the areas of maximum stress during tillage. Deformation contour maps (or displacement contour maps) show the deformation of the rotary tiller blades under load, thus identifying the areas of maximum deformation. Strain contour maps show the degree of local deformation of the material, i.e., strain distribution information.

[0037] In some preferred embodiments, the specific methods for obtaining the dimensional data and 3D model of the lightweight rotary tiller blades are as follows: Based on the mechanical performance parameters of the standard rotary tiller blade, its three-dimensional model, and the distributed load simulating soil cutting resistance applied in the finite element simulation model, the stress level of the standard rotary tiller blade is obtained. Based on the mechanical performance parameters, maximum stress location, maximum deformation location, and strain distribution information of the optimized rotary tiller blade substrate, and using the principle of equal strength and based on material mechanics formulas, the dimensional data of the lightweight rotary tiller blade are calculated under the stress level of the standard rotary tiller blade or under the same distributed load. A three-dimensional model of the lightweight rotary tiller blade is then constructed based on this dimensional data.

[0038] The above technical solution creatively applies the basic formulas of materials mechanics to the design of agricultural implements with complex curved surfaces, such as rotary tillers. It provides a calculable and verifiable approach to lightweighting: given the known mechanical properties of the new and old materials and the stress levels at key parts of the standard blade, the minimum thickness achievable by the new blade while maintaining the same strength safety factor can be directly calculated, transforming lightweight design from empirical estimation to precise calculation.

[0039] In some preferred embodiments, a wear-resistant coating is prepared on designated areas of the lightweight rotary tiller blade 3D model to obtain a coated lightweight rotary tiller blade 3D model: Using modeling features set by modeling software, a new geometric solid 3D model representing a wear-resistant coating with a specific thickness is created from the 3D model of the lightweight rotary tiller blade. The new geometric solid 3D model is then merged with the 3D model of the lightweight rotary tiller blade body to generate a coated lightweight rotary tiller blade 3D model containing a composite structure of substrate and coating.

[0040] In the above technical solution, by constructing the geometric entity of the wear-resistant coating in a three-dimensional model, the coating is transformed from a post-processing requirement into a definable geometric feature in the design stage. This achieves digitalization of coating design, enabling precise control over the coating's thickness, shape, and position. This not only provides an accurate model for subsequent discrete element simulation, ensuring the accuracy of drag reduction effect prediction, but also provides clear dimensional and positional guidance for coating preparation in actual production.

[0041] In an optional implementation, the design steps for lightweight, high-strength, and tough rotary tillers are as follows: Based on the failure of rotary tillers during tillage, the relationship between their failure behavior and the mechanical properties of the materials was determined. A three-dimensional model of the IT245 rotary tiller blade was established, and a finite element simulation model of rotary tiller operation was constructed. The stress conditions of the IT245 rotary tiller during operation were analyzed to determine the areas of maximum stress and deformation during tillage. Analyzing the structural dimensions of the national standard IT245 rotary tiller, the optimized dimensions of the rotary tiller were determined to be the blade thickness, the side width of the tangential edge, and the thickness of the tangential edge. Based on material strength and rotary tiller failure behavior, 30MnB5 was selected as the high-strength and tough rotary tiller base material. 30MnB5 was subjected to appropriate heat treatment, and its relevant mechanical properties were tested. Lightweight rotary tillers were designed to achieve lightweight rotary tillage blades, and the dimensions of the rotary tillers were determined. A three-dimensional model of lightweight rotary tillers and coating reinforcement was established, and a discrete element simulation model of soil and high-strength and tough rotary tillers was constructed. The rotary tillage process of standard 65Mn rotary tillers, lightweight 30MnB5 rotary tillers, and coated lightweight tillers was simulated, and the rotary tillage resistance was analyzed. Wear-resistant coatings are applied to easily worn areas of rotary tillers using surface technologies such as plasma welding, laser cladding, and brazing. The processed rotary tillers undergo a final heat treatment to ensure their strength, impact resistance, and wear resistance. Field power consumption tests were conducted on standard rotary tillers, lightweight rotary tillers, and coated tillers to verify their drag reduction effect.

[0042] In the above technical solution, the IT245 rotary tiller blade, 'I' represents the 'I-type' blade holder installation, which is different from other installation methods such as the 'S-type'. 'T' represents the 'T-type' blade shape, i.e., a wide blade, typically 50mm wide, suitable for general dryland tillage. '245' represents the turning radius of 245mm, which is the most important dimensional parameter of the rotary tiller blade, determining the tillage depth range.

[0043] In some preferred embodiments, the material used has significantly higher strength and energy absorption performance than ordinary national standard rotary tillage blades, which can be called high strength and toughness. In optional embodiments, according to mechanical property tests, the strength of 30MnB5 is about 1.8-2 times that of 65Mn, and the energy absorption performance of 30MnB5 is about 2-3 times that of 65Mn.

[0044] Example 2 A lightweight, high-strength, and tough rotary tiller blade design method, comprising: Based on the failure data of rotary tillers during tillage, the relationship between failure behavior and mechanical properties of rotary tiller materials is determined, and the failure mechanism and performance requirements of rotary tillers are obtained. Based on the failure mechanism and performance requirements of rotary tillers, the mechanical property parameters of rotary tiller substrates that meet the preset strength and toughness are obtained. A three-dimensional model of a standard rotary tiller blade is established based on the set standards, and a finite element simulation model of the standard rotary tiller blade is constructed based on the three-dimensional model of the standard rotary tiller blade. Through the three-dimensional model and the finite element simulation model of the standard rotary tiller blade, the stress analysis of the standard rotary tiller blade operation process is carried out to obtain the information on the maximum stress part, the maximum deformation part and the strain distribution during the standard rotary tiller blade tillage process. Based on the rotary tiller substrate that meets the preset strength and toughness, the mechanical property parameters of the rotary tiller substrate, and the optimized mechanical property parameters of the rotary tiller substrate, the three-dimensional model of the standard rotary tiller is redesigned using the principle of equal strength, combined with the information on the maximum stress area, the maximum deformation area, and the strain distribution. This results in the dimensional data of the lightweight rotary tiller and the three-dimensional model of the lightweight rotary tiller. A wear-resistant coating is then prepared on the designated areas of the three-dimensional model of the lightweight rotary tiller to obtain a three-dimensional model of the lightweight rotary tiller with the coating.

[0045] In some preferred embodiments, it also constructs a discrete element simulation model that includes the interaction between soil particles and rotary tillage blades, thereby obtaining a soil-blade interaction environment for simulation. In a simulated soil cutting tool interactive environment, the rotary tillage process was simulated for the three-dimensional models of the standard rotary tiller, the lightweight rotary tiller, and the coated lightweight rotary tiller. The force and torque data of the three-dimensional models of the standard rotary tiller, the lightweight rotary tiller, and the coated lightweight rotary tiller during the operation stage were extracted and compared to obtain the simulation data of the drag reduction effect of the lightweight rotary tiller and the coated lightweight rotary tiller. Based on simulation data of drag reduction effect of lightweight rotary tillers and coated lightweight rotary tillers, it is determined whether the drag reduction effect reaches the corresponding preset value. If both reach the corresponding preset value, actual tillage power consumption tests are conducted on standard rotary tillers, lightweight rotary tillers and coated lightweight rotary tillers, and tillage torque data is measured and recorded to obtain the actual drag reduction effect data of lightweight rotary tillers and coated lightweight rotary tillers compared to standard rotary tillers.

[0046] In an optional implementation, the method steps are as follows: 1. Determine the relationship between the failure behavior of rotary tillers and material strength based on the failure characteristics of the rotary tillers during tillage; 2. A three-dimensional model of the IT245 standard rotary tiller blade was created using SOLIDWORKS software, as shown below. Figure 2 A static structural analysis module coupling finite element method (FEM) and discrete element method (DIM) was established. A 3D model of the rotary tiller blade and its stress data were imported, and the rotary tiller blade model was meshed for static simulation analysis to obtain the locations of maximum deformation and strain during rotary tiller blade operation. Figure 3 , Figure 4 ; 3. Analyze the stress on the IT245 rotary tiller during operation to determine the areas of maximum stress and deformation during tillage; 4. Analyze the structural dimensions of the national standard IT245 rotary tiller blade and determine the optimized dimensions of the rotary tiller blade as blade thickness, tangential edge width, and tangential edge thickness; 5. By comparing and analyzing the mechanical properties and wear resistance of boron steels with different carbon contents, as well as the application of boron steels in soil contact parts at home and abroad, 30MnB5 was selected as the base material for rotary tillage blades. 6. Perform appropriate heat treatment on 30MnB5. The heat treatment process is heating at 880 ℃, holding for 2 h, quenching in water, tempering at 200 ℃, holding for 1 h, and testing its relevant mechanical properties. 7. Based on the strength difference between 30MnB5 and 65Mn, a lightweight rotary tiller was designed using the principle of equal strength, and the thickness of the rotary tiller blade body, the width of the tangential edge, and the thickness of the tangential edge were determined. 8. A three-dimensional model of the lightweight rotary tiller blade and the coated and reinforced blade was established using SOLIDWORKS software and imported into EDEM simulation software. The Hertz-Mindlin with Bonding model was selected as the simulation contact model. In the simulation, the rotary tiller blade rotation speed was set to 300 r / min, the tillage depth to 150 mm, and the forward speed to 0.5 m / s. The parameters of the soil model were set, including soil particle size and intrinsic parameters, which included soil moisture content, density, elastic modulus, and Poisson's ratio. The material contact parameters were set, including the coefficient of restitution, static friction coefficient, and dynamic friction coefficient between soil particles and between soil and the rotary tiller blade. The model contact parameters included the bonding stiffness (normal and tangential stiffness), the critical bonding stress (normal and tangential critical stress), and the particle bonding radius. 9. Simulate the rotary tillage process of lightweight 30MnB5 rotary tillers and standard 65Mn rotary tillers. Taking the stable phase of the rotary tillage simulation, export the force and torque data of the standard rotary tiller, lightweight rotary tiller, and coated lightweight tiller for comparative analysis. 10. A wear-resistant coating was prepared and reinforced on the easily worn parts of the rotary tiller blade using plasma welding. The plasma welding was performed using a plasma arc welding machine with a welding voltage of 40 V, a welding current of 70 A, and an arc current of 7 A. The flow rates of the welding powder and shielding gas were 2.5 L·min⁻¹. The single-pass weld width was 5 mm, the overlap rate was 25%, the nozzle-to-substrate distance was 10 mm, and the thickness of the coating on the rotary tiller blade surface was approximately 1.25 mm. The powder composition of the rotary tiller blade surface coating included, by mass percentage: C: 0.18%, Si: 1.05%, Mn: 0.21%, Cr: 16.55%, Ni: 2.12%, Al: 0.042%, Fe: 79.85%. During power consumption testing, a Sardin SD804 tractor was used as the power source, and a DYN-200 dynamic torque sensor (range 0~20000) was used. The torque data during rotary tillage is measured using a torque meter (N·m, accuracy 0.1%). The Z200 torque measurement software records torque and other data during rotary tillage. The tractor's forward speed is 0.5 m / s, and the tillage depth is 150 mm.

[0047] Example 3 A lightweight, high-strength, and tough rotary tiller designed based on the design method described in Example 2 is characterized by the following steps: A lightweight rotary tiller substrate is manufactured using an optimized rotary tiller base material, based on a three-dimensional model of the coated lightweight rotary tiller and its dimensional data, and then subjected to heat treatment; a wear-resistant coating is prepared on designated areas of the lightweight rotary tiller substrate using surface engineering technology to obtain a coated lightweight rotary tiller; and the entire coated lightweight rotary tiller is then subjected to heat treatment to obtain a lightweight, high-strength, and tough rotary tiller.

[0048] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

Claims

1. A lightweight, high-strength, and tough rotary tiller blade design system, characterized in that, It includes: The rotary tiller mechanical performance parameter acquisition module is used to determine the relationship between failure behavior and mechanical properties of rotary tiller material based on rotary tiller failure data during rotary tilling, obtain the failure mechanism and performance requirements of rotary tiller, and obtain the rotary tiller substrate and mechanical performance parameters of rotary tiller substrate that meet the preset strength and toughness based on the failure mechanism and performance requirements of rotary tiller. The rotary tiller blade size determination module establishes a three-dimensional model of the standard rotary tiller blade according to the set standards, and constructs a finite element simulation model of the standard rotary tiller blade based on the three-dimensional model of the standard rotary tiller blade. Through the three-dimensional model and the finite element simulation model of the standard rotary tiller blade, the stress analysis of the standard rotary tiller blade operation process is carried out to obtain the information of the maximum stress part, the maximum deformation part and the strain distribution during the standard rotary tiller blade tilling process. The lightweight design and simulation modeling module is used to redesign the three-dimensional model of a standard rotary tiller blade based on the rotary tiller blade substrate that meets preset strength and toughness, the mechanical performance parameters of the rotary tiller blade substrate, and the optimized mechanical performance parameters of the rotary tiller blade substrate, combined with the information on the maximum stress area, the maximum deformation area, and the strain distribution, using the principle of equal strength. This results in lightweight rotary tiller blade size data and a lightweight rotary tiller blade three-dimensional model. Wear-resistant coatings are then prepared on designated areas of the lightweight rotary tiller blade three-dimensional model to obtain a coated lightweight rotary tiller blade three-dimensional model.

2. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 1, characterized in that: It also includes a verification module for building a discrete element simulation model that includes the interaction between soil particles and rotary tillage blades, to obtain the soil-blade interaction environment for simulation. In a simulated soil cutting tool interactive environment, the rotary tillage process was simulated for three-dimensional models of standard rotary tillers, lightweight rotary tillers, and coated lightweight rotary tillers. The force and torque data of the three-dimensional models of the standard rotary tiller, lightweight rotary tillers, and coated lightweight rotary tillers during the operation phase were extracted and compared to obtain simulation data of the drag reduction effect of lightweight rotary tillers and coated lightweight rotary tillers.

3. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 2, characterized in that: Based on simulation data of drag reduction effect of lightweight rotary tillers and coated lightweight rotary tillers, it is determined whether the drag reduction effect reaches the corresponding preset value. If both reach the corresponding preset value, actual tillage power consumption tests are conducted on standard rotary tillers, lightweight rotary tillers and coated lightweight rotary tillers, and tillage torque data is measured and recorded to obtain the actual drag reduction effect data of lightweight rotary tillers and coated lightweight rotary tillers compared to standard rotary tillers.

4. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 1, characterized in that: The specific method for obtaining the failure mechanism and performance requirements of rotary tillage blades is as follows: By analyzing field trials or rotary tillage blade failure data, we statistically determine the failure modes and locations; by analyzing the failure locations, we establish a qualitative correlation between the failure phenomena and the material's performance indicators, and deduce the physical mechanism of failure; based on the physical mechanism, failure mode, and location of failure, we propose specific quantitative requirements for material performance.

5. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 1, characterized in that: The specific method for establishing a 3D model of a standard rotary tiller blade based on the set standards, and then constructing a finite element simulation model of the standard rotary tiller blade based on the 3D model of the standard rotary tiller blade is as follows: Based on the established technical parameters and structural dimensions of the standard rotary tiller blade, a three-dimensional model of the standard rotary tiller blade is created using modeling software. The simulation software is then imported into the modeling software, the material of the standard rotary tiller blade is selected, and the mechanical performance parameters of the standard rotary tiller blade are input. The three-dimensional model is then meshed, and the continuous geometric geometry of the standard rotary tiller blade is discretized into a mesh composed of multiple geometric elements. Based on the actual working conditions of the standard rotary tiller blade, boundary constraints are applied to the finite element simulation model in combination with the mesh composed of multiple geometric elements, resulting in a finite element simulation model of the standard rotary tiller blade that can be used for mechanical calculations.

6. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 5, characterized in that: The specific method for analyzing the stress on a standard rotary tiller during operation using a 3D model and a finite element simulation model is as follows: In the finite element simulation model, a distributed load simulating soil cutting resistance is applied to the area where the rotary tiller blade contacts the soil during standard rotary tiller blade operation. Fixed constraints are applied to the mounting holes or central parts where the rotary tiller blade connects to the blade shaft. Based on the specified rotary tiller blade material, the mesh composed of multiple geometric elements, the distributed load, and the boundary constraint conditions, the mechanical response of the rotary tiller blade under static load is calculated through static structural simulation. The simulation software generates stress cloud diagrams, deformation cloud diagrams, and strain cloud diagrams of the rotary tiller blades based on their mechanical response under static loads. Based on these diagrams, the software obtains information on the location of maximum stress, the location of maximum deformation, and the strain distribution during the tilling process.

7. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 1, characterized in that: The specific method for obtaining the dimensional data and 3D model of the lightweight rotary tiller blades is as follows: Based on the mechanical performance parameters of the standard rotary tiller blade, its three-dimensional model, and the distributed load simulating soil cutting resistance applied in the finite element simulation model, the stress level of the standard rotary tiller blade is obtained. Based on the mechanical performance parameters, maximum stress location, maximum deformation location, and strain distribution information of the optimized rotary tiller blade substrate, and using the principle of equal strength and based on material mechanics formulas, the dimensional data of the lightweight rotary tiller blade are calculated under the stress level of the standard rotary tiller blade or under the same distributed load. A three-dimensional model of the lightweight rotary tiller blade is then constructed based on this dimensional data.

8. The lightweight, high-strength, and tough rotary tiller blade design system according to claim 1, characterized in that: A wear-resistant coating was applied to specific areas of the lightweight rotary tiller blade 3D model, resulting in a coated lightweight rotary tiller blade 3D model: Using modeling features set by modeling software, a new geometric solid 3D model representing a wear-resistant coating with a specific thickness is created from the 3D model of the lightweight rotary tiller blade. The new geometric solid 3D model is then merged with the 3D model of the lightweight rotary tiller blade body to generate a coated lightweight rotary tiller blade 3D model containing a composite structure of substrate and coating.

9. A design method for lightweight, high-strength, and tough rotary tillers, characterized in that, It includes: Based on the failure data of rotary tillers during tillage, the relationship between failure behavior and mechanical properties of rotary tiller materials is determined, and the failure mechanism and performance requirements of rotary tillers are obtained. Based on the failure mechanism and performance requirements of rotary tillers, the mechanical property parameters of rotary tiller substrates that meet the preset strength and toughness are obtained. A three-dimensional model of a standard rotary tiller blade is established based on the set standards, and a finite element simulation model of the standard rotary tiller blade is constructed based on the three-dimensional model of the standard rotary tiller blade. Through the three-dimensional model and the finite element simulation model of the standard rotary tiller blade, the stress analysis of the standard rotary tiller blade operation process is carried out to obtain the information on the maximum stress part, the maximum deformation part and the strain distribution during the standard rotary tiller blade tillage process. Based on the rotary tiller substrate that meets the preset strength and toughness, the mechanical property parameters of the rotary tiller substrate, and the optimized mechanical property parameters of the rotary tiller substrate, the three-dimensional model of the standard rotary tiller is redesigned using the principle of equal strength, combined with the information on the maximum stress area, the maximum deformation area, and the strain distribution. This results in the dimensional data of the lightweight rotary tiller and the three-dimensional model of the lightweight rotary tiller. A wear-resistant coating is then prepared on the designated areas of the three-dimensional model of the lightweight rotary tiller to obtain a three-dimensional model of the lightweight rotary tiller with the coating.

10. A lightweight, high-strength, and tough rotary tiller blade designed based on the design method described in claim 9, characterized in that, Using a three-dimensional model of a coated lightweight rotary tiller and its dimensional data, a lightweight rotary tiller substrate was manufactured using an optimized substrate and then heat-treated. A wear-resistant coating was then applied to specific areas of the lightweight rotary tiller substrate using surface engineering techniques, resulting in a coated lightweight rotary tiller. Finally, the coated lightweight rotary tiller was subjected to overall heat treatment to obtain a lightweight, high-strength, and tough rotary tiller.

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