Comprehensive DEM Calibration Using Face Central Composite Design and Response Surface Methodology for Rice–PLA Interactions in Enhanced Bucket Elevator Performance

This research presents a comprehensive methodology for calibrating Discrete Element Method (DEM) parameters governing rice grain interactions with biodegradable Polylactic Acid (PLA) components in agricultural bucket elevator systems. Rice grains, a critical global food staple requiring efficient post-harvest handling, were modeled as three-sphere clusters to accurately represent their physical dimensions (6.5 mm length), while the Hertz–Mindlin contact model provided the theoretical framework for particle interactions. The calibration process employed a multi-phase experimental design integrating Plackett–Burmann screening, steepest ascent method, and Face Central Composite Design to systematically identify and optimize critical micro-mechanical parameters for agricultural material handling. Statistical analysis revealed the coefficient of static friction between rice and PLA as the dominant factor, contributing 96.49% to system performance—significantly higher than previously recognized in conventional agricultural processing designs. Response Surface Methodology generated predictive models achieving over 90% correlation with experimental results from 3D-printed PLA shear box tests. Validation through comparative velocity profile analysis during bucket elevator discharge operations confirmed excellent agreement between simulated and experimental behavior despite a 20% discharge velocity variance that warrants further investigation into agricultural material-specific phenomena. The established parameter set enables accurate virtual prototyping of sustainable agricultural handling equipment, offering post-harvest processing engineers a powerful tool for optimizing bulk material handling systems with reduced environmental impact. This integrated approach bridges fundamental agricultural material properties with sustainable engineering design principles, providing a scalable framework applicable across multiple agricultural processing operations using biodegradable components.