Greenjacket :
I've only once seen a crack/dink develope, run, into a fracture.
Generally yes, since the blades thicken as you run back it takes more energy to deform/fracture them. However I have seen it done, if you don't repair the edges. Soft steels can rip, the harder ones usually just get a fracture the size of the dent.
Twisting and flexing actions get then to run whild, to catastrophy.
Yes, which is why while I don't believe you have to grind out all damage done to large blades, you should make every effort to restore them as much as possible. I lightly tap dents back into place and grind the sides flat to reduce the lateral stresses they take. If there is a large fracture I will round out the inside to prevent growth. And I keep a close watch on heavily damaged areas and if they start to grow, grind them out.
most of the worlds cutting has been done with inexpensive industrial tools
Yes, because that is all they have usually, not because they are the best tools for the job. Most manual labor jobs, especially in very rural areas can pay next to nothing. You ask someone who is making 0.50 $ an hour if he wants to buy a $500 blade and he is going to look at you like you are insane. However does that mean that a custom $200 fillet knife (machete / whatever) doesn't offer any advantage over a $10 one - no.
That being said, I don't think traditional tools are of low quality. While I don't think they of of the same quality as the higest end blades you can buy, they are far from junk. And for good reason as they are bought by serious users who can't afford to replace them, nor struggle with poor performance. I have discussed QC with traditional bladesmiths (Malyasia) and the user feedback can be very dramatic on poor quality blades.
Last time he stopped by he had brought over a dozen traditonal large blades of various design, they were all siezed in I think China, which was a tremendous loss. It would have been interesting to work with them and compare them to "modern" takes on the same blades.
Thanks for the details, one thing that bothers me about accidental impact results is that the nature is inherently random. It is thus difficult to guage the relative performance, especially when the results can be so far apart time wise, not to mention the difference in target composition and swing.
For example, I generally avoid knotty wood due to the difficulty of the cut, as well as the forces it can generate on the blade. However I do like to know how a blade will perform on wuch material as sometimes is has to be cut. So often I will pick out ten sections of so of the worst cases and chop them up going through the knots with the test blade and a bunch of reference blades. This is artificial in the sense as it serves no functional use, but does allow me to guage the durability much more accurately.
In regards to the really high accidnetal impacts like you mention, do you have some kind of standard to compare to or just judge by experience based on past performance when they do happen naturally?
-Cliff