Question for Cliff Stamp, etc.

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Nov 27, 2002
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I have an industrial application for a circular knife blade and I was curious what steel you would consider. The application is basically a blade spinning at 12,000 rpm, cutting through cardboard, non-woven media (a synthetic), flattened expanded metal (.011" thick) and hot melt adhesive. The blade I am currently using is made from M-2 hardened to 63Rc. I hold up fairly well but needs to be resharpened 15,000" of cut. The blade geometry is primary bevel of 15 degrees included and secondary bevel of 22 degrees included. This may be as good as can be expected, but if you have any suggestions, they would be most appreciated.

Richard Sommer
 
I am not Cliff, and am a wannabee metallurgist, so is my suggestion, just to see how close to the mark I come.

Since you are going through a nonuniform material, toughness cannot be compromised in the name of better wear resistance. M3 and M4 are more wear resistant with more carbies, but less tough than M2. Crucible Particle Metallurgy (CPM) is the answer to this problem.

CPM M4 HC(HS)
has the wear resistance of M4, even better toughness than M2, and likes to be run in the same hardness range.
Datasheet:
http://www.crucibleservice.com/eselector/prodbyapp/highspeed/cpm4hch.html

As for geometry I do not yet know enough to comment.
 
I'm a real metallurgist. LOL Cutting through that mixture of junk can be very abrasive so you would benefit by the higher carbon content and therefore higher wear resistance of the M4.Higher carbon means less toughness unless you go to the CPM version.Give it a try. ....sometimes wannabes are right !
 
i'M Just a numbskull and don't know what the heck anyones sayin.
Just wonderin wheres Cliff?
 
First off check the edge under magnification and determine the cause of blunting. It will be by either; fracture, deformation, or wear. It can also be by corrosion or hot hardness issues but these are not likely in this situation.

If the problem is deformation (not enough hardness) then you should see stress lines in the edge parallel to the edge as well as a lot of straight on rippling. Check the edge straight on as well as to the side. Edges which are too soft will actually be rippled and you can see them take an "s" shape if you look straight down. The edge will look like :

\/\/\/\/\/

instead of :

------------

If the edge has fractured (not enough impact toughness and ductility) the ripples will be much smaller and usually nonexistant, what you will see is very sharp notches in the edge when viewed side on. If you don't see either of these effects then the primary cause of blunting is just wear.

Before you switch to a new steel you can try raising the hardness on M2 (depending on how it is blunting, if you are seeing fracture this obviously isn't a good idea), including a cryo soak after the quench and before the tempering (mainly for wear resitance), as well as modifications to the geometry.

If the edge damage doesn't extend past the secondary bevel then the primary bevel can be lowered further, this will actu to increase the cutting ability and thus lower the various stresses on the edge.

If the edge is getting damaged then you can try adding a very slight microbevel which is more obtuse, it only needs to be of a depth to negate the damage, which can be as small as microns which means just 1-3 passes on the sharpening abrasive.

As for other steels, it is likely at that speed and cutting that media that the blade is getting very hot so you are constrained to the high speed steels. To advance in wear resistance you have a lot of options up to CPM REX 121 which offers significant more wear resistance (about twice) and can be hardened to 70+HRC, and has a much higher red hardness, however the toughness is significantly less than M2.

As a sort of trivial upgrade, CPM M4 REX offers better wear, toughness and red hardness so it would be worth looking into directly. CPM REX M35 does similar but offers better hot hardness improvement.

So in short :

1) inspect the edge under magnification side on and straight down and determine the nature of the blunting

2) consider altering the heat treatment and/or geometry

3) switch to a steel which has improvement in the critical area (hardness, toughness, wear resistance or hot hardness).

Of course as well I would really critically look at the finished edge under magnifiction to inspect the quality of sharpening you may see benefits from altering the sharpening method or abrasive.

-Cliff
 
Thanks, Gentlemen. I will look at the edge this afternoon and let you know tomorrow what I have found.

Richard
 
Gentlemen,

When looking at the edge under 30x magnification, (the strongest I have available) the issue appears to be chipping. I don’t believe hot hardness is an issue, but when the machine is back up and running later this week, I will check to be certain. The damage is very small (.002”-.005”) and does not extend into the primary bevel. I will try adding a small micro bevel to the edge first. If that doesn’t work, I can take the primary bevel down somewhat more. If these still don’t give me better resistance to chipping, I will go with CPM M4. If you have any other thoughts, please let me know. Thanks again for all your assistance.

Richard
 
Can you photograph the damage ? If not if you sent it to me I'd be glad to take a look.
 
What thickness are the blades?

Also, just out of curiosity, at what diameter do the blades start at, and what diameter are they retired?
 
Mete,

I can't photograph the damage since our microscope is just an inexpensive handheld unit. I have no way of attaching our digital camara to it. I can only see the damage when it is magnified to at least 10x. At 10x or 30x I can see no stress cracks, but the chips look just like that, chips. Small nicks that are between .002" and .004" deep and up to .005" wide.

AKA,

The blades are .093 thick and start out at 7" in diameter. We will retire the blade at about 6 1/2" in diameter. We haven't worn one out yet since this is a new process for making our products. We have tried about 2 dozen different blade configurations so far in an attempt to cut the different materials effectively and still have reasonable blade life. So far this is our best combination.

Richard
 
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