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Aiming at the problems of low qualified rate of cotton stalk crushing length after operation of cotton stalk crushing and returning device, easy accumulation and uneven distribution of broken stalks after throwing and returning to the field, a side throwing cotton stalk crushing and returning device which can be installed on the residual film recycling machine was designed. The structure and working principle of the device were expounded. The structure design and operation performance analysis of key components such as cotton stalk crushing device, lateral conveying device and broken stalk throwing device were carried out, and the structure and operation parameters of key components were preliminarily determined. The discrete element simulation analysis and experimental design of the straw scattering device were carried out. According to the design scheme, a type of side throwing cotton stalk crushing and returning device was developed and installed on the residual film recycling machine for three-factor and three-level quadratic regression orthogonal field experiment. The results showed that when the forward speed of the machine was 8 km/h, the rotation speed of the crushing knife shaft was 2 000 r/min, and the rotation speed of the screw conveyor was 1 200 r/min, the qualified rate of cotton stalk crushing length was 93.96%, the throwing uniformity was 86.98%, the average cotton stalk crushing length was 116.9 mm, and the average stubble height was 71.4 mm. The machine had the best field operation effect under this parameter combination. The test indexes of the device can meet the design and agronomic requirements, which provided a theoretical basis and support for the structural optimization design of the cotton stalk crushing and returning device.