OwenM:
<font face="Verdana, Arial" size="2">The soft matrix is deforming while the carbides are not.</font>
Note all steels are like this, the alloy carbides are much harder than the steel they are embedded in. The edge deforms around them.
Pj, carbides are very small, the size depends both on the element in the carbide and the level of segregation in the steel. They do stick out of the surface and thus give the alloy steels their tremendous wear resistance, just like the teeth of a saw take wear when cutting and you can extend its lifetime by impulse hardening the teeth without changing the main body of the saw (which is similar to using harder carbides in the same steel matrix of a blade).
Wayne :
<font face="Verdana, Arial" size="2">This side will in fact, bend over slightly towards the right hand. So bend your left hand slightly towards the right hand. This is NOT a WIRE EDGE</font>
A wire edge is generally what happens when the burr you are describing is aligned perpendicular to the spine. You will see high performance until it deforms which is very quickly. They way to get rid of it is to increase the angle just a little, a degree or so, and alternate sides using light pressure on an abrasive that can grind it off. The other method is to use a stropping motion as since it exerts little pressure on the edge, the burr won't get the necessary force to deform and will be ground away. Joe describes both of these methods in the FAQ.
One of the reasons the Sharpmaker forms burrs so readily is that you are honing with a tremendous pressure on the edge. Even though the force you are applying is probably light, say 100 - 200 g, due to the very small contact areas on the corners, the pressure is probably around 500 lbs per sq in.
On top of that which is what makes the situation even worse, the abrasive is probably not aggressive enough to cut into the steel before it deforms (in regards to high Vanadium steels) . To minimize this make sure you are drawing the blade along the hone, using light pressure and avoid the corners. While they will speed up metal removal, unless the steel is very easy to work (like 1095) they are going to be deforming it readily.
The most important step in getting rid of a burr is not to have it on the edge in the first place. Switch sides often to minimize its formation. Use light force and large contact areas to reduce the pressure on the edge. Clean your hones often as loaded hones have a very low abrasion factor. And make sure you use hones than can aggressivly cut the steel you are sharpening.
Jeff, the next step is to go lower still. For that you would probably want a smaller knife though as the Military was designed for decently heavy work. For most dedicated cutting work you can be around 8 degrees or so per side, with a decent steel, and see no problems. The only reason that most production knives come so thick is that people do a lot of really heavy non-cutting work with them. A lot of the high end performance custom knives have much thinner edges as they are made for people who just want to cut with a knife.
The next step up in performance is to optomize the main bevel. For a high performance cutting knife the blade should not be any thicker than 0.01" behind the edge. Once you start going lower than that the performance truely starts getting fantastic. These are not edges that you would chop, twist, scrap or pry with, but for light materials they will cut very well.
With an optomized edge and primary grind the level of performance will be that high that the blade will outcut even those 1/32" replaceable utility knives (the edges on them are too thick, and the handle ergonomics also make for poor cutting ability). If you really want to impress a tradesman loan him one of your knives that will out perform the knives they carry, as they will cut circles around the "tactical" knives. Boyes knives can do this, as well as Phil Wilson, Ed Schott, I have also used blades from Ray Kirk and Ed Caffery that would do this easily as well.
Here is a blade that has the complete package, it is a MEUK by Allen Blade. Allen did an excellent job on the sheath and grip as well as the shape of the blade. It has a high quality steel (52100) and heat treat (Ed Caffery) , plus an excellent edge geometry combined with a matching primary grind (Ed Caffery) :
http://www.physics.mun.ca/~sstamp/images/meuk_side.jpg
http://www.physics.mun.ca/~sstamp/images/meuk_top.jpg
The primary grind is fully convex with a light distal taper, and narrows to an edge which is barely visible, there is just a *hint* of a secondary grind. The blade is only 0.005" thick behind the edge bevel which is ground at about 11 +/- 1 degrees per side (difficult to measure as it is so small). It melts through most materials like they are not even there :
http://www.physics.mun.ca/~sstamp/images/meuk_wood_cut.jpg
I used the modified Sub-Sniper from Lynn Griffith for comparsion. And while the modified MEUK could slice through the wood more than half way with each cut, the Sub-Sniper which I have heavy thinned (9.5 degree edge bevel) could not even cut halfway on a stroke. The primary grind is significantly thicker and is has a higher drag profile due to the flat vs convex grind.
The above is repeatable, I did it a half a dozen times with each blade. I have done lots more cutting with it for the past while and overall it is performing very well.
-Cliff
[This message has been edited by Cliff Stamp (edited 06-22-2001).]