As a mechanical engineer/knife collector, I was given the dream task one day, years ago. On a piece of equipment that cut waste from a juice packing machine we needed a better blade that wouldn't get dull quickly. The material was eighth inch thick multi layer plastic with foil/Seran, heat applied, on top of it. All together there was about six layers of plastic and a layer of aluminum. The machine was one that made those little aseptic (sterile) juice cups you see in hospitals and on airplanes. We were cutting the waste after the cups were cut out. The waste was cut into small pieces for easier disposal into a dumpster. Rust was a problem due to the wet environment, the harsh cleaning solutions and the juice (high acid, cranberry, orange, etc.) the regularly came in contact with the waste cutting machine. The blade was a quarter inch thick piece of steel, about 18 inches long and two inches high. I was going to take the easy way out and use 440C. It was easy to get, and had all the properties I was looking for. But I decided to do some experiments, just to be sure. Plus it was a lot of fun to be PAID to play with sharp things.
The blade was tied to a hydraulic piston that moved it down against a smooth bar, so it acted like a big, power scissors to cut the packaging waste. I made up a bunch of little piston powered cutters, and fed them a roll of plastic and aluminum foil. I had a recording pressure gage attached to all this. When the pressure reached a certain level it meant that the blade was dull. The test machine would be set up and let run unattended, it would shut off at a certain pressure and record the number of cuts that were made. Pretty clever, huh? I was very proud of myself, plus had tons of fun making it. I wish I had taken it with me when I retired. I could rent it out to all the knife maker so they could test their steels, edge angles, heat treating, and anything else they were interested in. If anyone out there wants to build one, send me an e-mail.
I had a machinist make e several test blades, 2 inches long sharp edge, quarter inch thick, one inch high, out of every type of steel I could find. They were given an edge angle of 20 degrees. This was a punishing machine that really beat on the blade for long hours, so I couldn't use a steeper angle for fear of breaking it. Picture a machine going "kerCHUNK, kerCHUNK, kerCHUNK, kerCHUNK, kerCHUNK, kerCHUNK, kerCHUNK, kerCHUNK, kerCHUNK, for hours on end and you can see this was not an easy life for the cutting edge. A 15 or 10 degree angle gave us less pressure on the gage, but broke down after a short time. I don't have my notes any more, but I used all the tool steels and all the stainless types I could find through local metal dealers. I also contacted my old college for any odd ball steels they might have had, but they couldn't help me. If my memory is still working, the winner on my test was M2, followed very closely by D2 and finally O1. None of the stainless steels tried survived the rough treatment. We ended up using O1 due to cost. We coated it with Teflon, and the operator was told to dry it after cleaning and spray t with WD-40 during operation. We added an auto oiler after a while, because the operator forgot to spray it. The auto oiler added a lot of time to its life, almost doubling it.
Problems with all this? MANY if you try and apply it to knife blades. I won't bore you, all of you are smart enough to see how this doesn't exactly transpose to the knife world. It was fun and I learned a lot about cutting plastic and foil. Making this testing machine with other materials being fed to the cutting edge would be an interesting task.
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