Shearing Mechanical Behavior of Cotton Stalks Under Residual-Film Wrapping Constraints in a Single-Support Cutting Configuration

To address the high energy consumption and low efficiency in shredding film–stalk mixtures during the resource utilization of cotton-field residues in Xinjiang—issues arising from the large mechanical-property differences among the mixture components—a custom single-support shearing fixture was developed to investigate the effects of residual-film wrapping layers, blade rake angle, sliding-cutting angle, and shearing speed on the <i>F</i>_j^max. Based on a Box–Behnken response surface design combined with analysis of variance and microscopic observations of the shearing process, the results showed that all main-effect factors had extremely significant influences on the <i>F</i>_j^max (<i>p</i> < 0.0001). Their relative contributions followed the following order: number of film wrapping layers > blade rake angle > shearing speed > sliding-cutting angle. Residual-film wrapping markedly increased shear resistance; increasing the sliding-cutting angle effectively reduced the shearing force; and reducing the rake angle facilitated more energy-efficient shredding. Interaction analysis further revealed significant coupling between sliding-cutting angle and shearing speed, rake angle and sliding-cutting angle, and rake angle and shearing speed (<i>p</i> < 0.05). Comparative shearing tests indicated that pure cotton stalks exhibited continuous brittle fracture with relatively stable force–displacement profiles, whereas film–stalk composites showed a sequentially coupled failure mode characterized by “residual-film pre-shearing–primary stalk fracture–secondary film stretching,” leading to multi-peak fluctuations in the force–displacement curves. Based on response surface optimization and mechanistic analysis, a parameter combination of a 35° rake angle, a 4–8° sliding-cutting angle, and medium-to-low shearing speed is recommended for shredding operations. This study elucidates the shearing and fragmentation mechanisms of film–stalk mixtures, provides theoretical guidance for optimizing key structural and operational parameters of post-recovery equipment, and offers important engineering value for promoting farmland residual-film pollution control and agricultural waste resource utilization.