DEM-FEA Optimization of Cultivator Tyne Geometry for Secondary Tillage

Abstract

Background: The geometry of cultivator tynes is critical to tillage efficiency and structural reliability during secondary tillage. Conventional evaluation methods rely primarily on field experiments, which are time-consuming, costly, and often affected by variable soil conditions. Aims: This study used an integrated Discrete Element Method (DEM) and Finite Element Analysis (FEA) approach to evaluate the effects of cultivator tyne geometry on soil disturbance and structural performance. Study Design: Comparative simulation-based optimisation study. Place and Duration of Study: Department of Farm Machinery and Power Engineering, College of Agricultural Engineering and Technology, Anand Agricultural University, Godhra, from August 2025 to June 2026. Methodology: Three cultivator tyne configurations, comprising the existing design and two modified geometries, were developed using SolidWorks and analysed at forward speeds of 3, 4, and 5 km/h. DEM simulations conducted in Altair EDEM were used to determine draft force and soil disturbance area, and the predicted draft forces were subsequently applied as loading conditions in ANSYS Workbench to evaluate maximum deformation, maximum principal stress, and von Mises stress. Results: A total of 27 numerical simulations (3 tyne configurations × 3 operating speeds × 3 replications) were analysed. Analysis of variance showed that tyne geometry and operating speed significantly affected (p ≤ 0.05) draft force, soil disturbance area, maximum principal stress, maximum deformation, and von Mises stress. The interaction between tyne geometry and operating speed was significant for soil disturbance area and all structural response parameters, but not for draft force. Compared with the existing tyne, Tyne 2 increased the soil disturbance area by 55.77–101.61%, although it required approximately 41% greater draft force. It also reduced maximum deformation by 12.50–60.87% and von Mises stress by approximately 46%, while maximum principal stress remained well below the material yield strength, indicating the structural safety of the optimised design under the simulated conditions. Conclusion: The findings indicate that integrating DEM and FEA provides a useful framework for optimising cultivator tyne geometry. The optimised Tyne 2 increased soil disturbance while maintaining structural safety, indicating its potential to improve secondary tillage performance and reduce reliance on extensive field experimentation.