Optimization design and analysis of the cutting tool in the tea cake pre-separation mechanism

Abstract

The cutter design in tea cake pre-separation devices plays a critical role in reducing peak cutting forces, enhancing cutting performance, and achieving lightweight implementation of the entire machine. This study focuses on the lightweight design of the tool holder and tool sleeve. Finite element analysis is employed to perform topological optimization, significantly reducing the weight of the tool holder. Additionally, a mathematical model of the cutter pressing on the tea cake is developed to minimize cutting forces. Key parameters such as blade tip width, wedge angle, and thickness are optimized considering cutter wear, sharpness, and blade strength. Particle swarm optimization is applied to determine the optimal peak cutting force. Experimental tests of the prototype cutter demonstrate that the tool holder and sleeve mass decreased from 0.510 to 0.185 kg, achieving a weight reduction of approximately 63.73%. The optimized cutter reduces peak cutting force from 657.58 to 563.50 N, a reduction of about 14.31%. These results validate the feasibility and effectiveness of the proposed optimization approach.