This study focuses on optimizing the chopping processes of corn stalks, which are abundant biomass and forage resources. The reduction of shearing force is crucial for energy efficiency and the compact mechanical design of chopping devices. However, high cutting velocities can still lead to substantial power consumption even with low shearing forces. Therefore, the objective is to minimize both cutting force and power consumption simultaneously. The paper proposes an approach to solve this optimization problem using a modified Taguchi design of experiments and Chauvenet’s criterion for considering the statistically accepted data from repeated tests. By analysing the variance technique, optimal levels of parameters and their percentage contributions were identified. The results demonstrate the analysis of the modified Taguchi design can effectively address the multi-response optimization problem in chopping corn stalks. The findings have practical implications for the design and operation of chopping machines used for agricultural residues.