OK, another quick one:
Luong, why not keep
every edge at 15dps/20micro when even the 65Rc W2 (with what, 2% carbide amidst the matrix?) ripples/chips in the tests that may simulate actual use by future customers? What i am seeing in your results is that it doesn't matter how much or how little carbide you have in the apex steel, it's going to suffer below that geometry either by fold or fracture. So why mess with the geometry of
the very apex when you already have a good idea of the threshold of sustainability, and beyond that threshold it can be very difficult to control the user-applied forces and responses in the cutting medium - the scale is just so small and the forces so high. Not to mention that increasing the apex angle from 10-dps to 15-dps reduces your mechanical advantage minimally (from 23% of optimum to 14% in just the
very very tip of the cutting) while increasing your edge-strength
3.5X ? (I think i did the math right)
Feed the apex what it needs to survive, to sustain itself. If you don't see damage at 67Rc at 10-dps after a few hits, does that mean you won't see damage after 100 hits? Each hit is unique, each has the potential to induce failure if you are riding so close to the threshold of structural integrity. If you build your knives with too thin of edge geometry, it may survive the test this time but not next time, or may fail in this way this time but a different way next time, it is becoming too hard to reasonably control the variables. When we build a structure, we calculate the expected loads and then
overbuild to sustain the structure above and beyond what is expected.
Setting your apex geometry to 15/20micro should get rid of damage in the edge-bevel (micro-chips and rolls/ripples), if your observations hitherto may be relied upon. If you have a problem within the edge-bevel at that geometry, you know that something is wrong.
Then simply modify the BET for each blade as you have been doing - 0.005, 0.010, 0.015, 0.020 - to provide the required strength in the primary of the blade to prevent massive "moon-chips". An edge that dulls can be resharpened. But a primary that fractures = unusable blade. Your knives, regardless of HT,
will dull with use, so just give them an apex that can reduce major failure (including crack-nucleation) and work instead on the HT that allows the thinnest
primary for maximum efficiency.
I know you know all this. But I want you to simplify to get your R&D into production more quickly