Simulation and Experimental Investigation of the Effects of Process Parameters on the Thermal Characteristics of Alfalfa Open-Die Densification at Ambient Temperature

Alfalfa densification is a critical step in feed utilization and biomass energy conversion because it directly affects the transport efficiency, storage stability, and energy consumption of biomass processing systems. However, the thermodynamic behavior of the densification process remains poorly understood, especially under open-die conditions without external heating. This study investigated the thermo-mechanical characteristics of alfalfa pellet open-die densification without external heating by combining experimental measurements with ANSYS macro-continuum simulation. Stress transmission and temperature field distributions were analyzed. The results showed that the pellet quality index under different process conditions remained above 800, meeting the requirements for pelleted feed. Moisture content had a more significant effect on forming pressure than other factors; as moisture content increased, the forming pressure decreased. At an aspect ratio of 5.0, the forming pressure was below 45 kN. Simulation results further indicated that aspect ratio had a stronger influence on frictional behavior during densification. Under an aspect ratio of 5.0, the energy consumption was 888.53 J, and the heat flux reached 0.0062 W/mm2. These results indicate that frictional dissipation driven by radial force is the dominant mechanism governing thermo-mechanical coupling. Moisture content and aspect ratio significantly affected both peak compression force and coupling intensity. Although reducing moisture content or increasing aspect ratio improved pellet quality, it also increased die load due to enhanced radial force. The coupling intensity followed the order: peak pressure stage > moving stage > compression stage. These findings reveal the evolution of stress and temperature fields during alfalfa densification, offering critical theoretical guidance for optimizing densification process parameters.