This study focuses on developing a finite element model for Caragana korshinskii Kom. branches and calibrating the necessary parameters. Using Caragana korshinskii Kom. branches in full bloom as the subject, we established a finite element model with ABAQUS and analyzed the relationship between the shear force and displacement. The Johnson–Cook model was employed to create a finite element shear model for Caragana korshinskii Kom. branches and to calibrate its parameters. Plackett–Burman and climbing tests were conducted to identify key parameters influencing the shear mechanical model of Caragana korshinskii Kom. branches, specifically the yield stress and strain. This included the strengthening index and fracture strain. Through central composite design experiments, the optimal parameters for the shear model of Caragana korshinskii Kom. branches were identified: a yield stress of 18.65 MPa, a strain strengthening index of 0.59, and a fracture strain of 0.54. The results indicated that the maximum error in the simulated shear force values for Caragana korshinskii Kom. branches of varying diameters was 9.68%. Additionally, the difference between the simulated and actual tensile force values was 1.7%. These findings indicate that the calibrated finite element model is accurate and effective in simulating the failure behavior of Caragana korshinskii Kom. branches, providing a valuable tool for optimizing cutting and harvesting processes.

Caragana korshinskii Kom. (CKB), widely cultivated in Inner Mongolia, China, has potential for silage feed development due to its favorable nutritional characteristics, including a crude protein content of 14.2% and a neutral detergent fiber content below 55%. However, its vascular bundle fiber structure limits the efficiency of lactic acid conversion and negatively impacts silage quality, which can be improved through mechanical crushing. Currently, conventional crushing equipment generally suffers from uneven particle size distribution, high energy consumption, and low processing efficiency. In this study, a layered aggregate model was constructed using the discrete element method (DEM), and the Hertz–Mindlin with Bonding contact model was employed to characterize the heterogeneous mechanical properties between the epidermis and the core. Model accuracy was enhanced through reverse engineering and a multi-particle-size filling strategy. Key parameters were optimized via a Box–Behnken experimental design, with a core normal stiffness of 7.37 × 10¹¹ N·m⁻¹, a core shear stiffness of 9.46 × 10¹⁰ N·m⁻¹, a core shear stress of 2.52 × 10⁸ Pa, and a skin normal stiffness of 4.01 × 10⁹ N·m⁻¹. The simulated values for bending, tensile, and compressive failure forces had relative errors of less than 10% compared to experimental results. The results showed that rectangular hammers, due to their larger contact area and more uniform stress distribution, reduced the number of residual bonded contacts by 28.9% and 26.5% compared to stepped and blade-type hammers, respectively. Optimized rotational speed improved dynamic crushing efficiency by 41.3%. The material exhibited spatial heterogeneity, with the mass proportion in the tooth plate impact area reaching 43.91%, which was 23.01% higher than that in the primary hammer crushing area. The relative error between the simulation and bench test results for the crushing rate was 6.18%, and the spatial distribution consistency reached 93.6%, verifying the reliability of the DEM parameter calibration method. This study provides a theoretical basis for the structural optimization of crushing equipment, suppression of circulation layer effects, and the realization of low-energy, high-efficiency processing.