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Scientific Research on Industrial Blades and Cutting Tools
Scientific Research on Industrial Blades and Cutting Tools
At Snijer, we closely follow international scientific studies to continuously improve the performance and durability of industrial blades and cutting tools. Below, you will find references to peer-reviewed research articles published in international journals, covering topics such as material selection, wear resistance, coatings, and cutting efficiency.
Material Performance and Wear Resistance
AS Chaus, M Sahul, R Moravčík, R Sobota, Wear, 2021, Elsevier
The present paper describes the wear of high-speed steel (HSS) end mills with special emphasis on the influence of microstructural features, primarily the spatial distribution of eutectic carbides, on wear resistance. Hence, the wear resistance and performance of three HSSs of the same chemical composition but manufactured in three different ways, i.e. gravity casting, vacuum casting and a conventional metallurgical route, were compared. It was shown that the character of eutectic carbide spatial distribution in the HSS plays a major role in its wear performance, and, at the same hardness, it is independent of bending strength and impact toughness. For the studied range of eutectic carbide spatial distributions, tool life could differ up to 65 %. At both cutting speeds, 26 m/min and 40 m/min, the lowest wear resistance was determined for the end mills manufactured from the wrought HSS with uniformly distributed single particles of the dispersed eutectic carbides, and hence significantly higher values of bending strength and impact toughness. In contrast, the end mills manufactured from the as-cast material with coarser eutectic carbide networks along the primary matrix grain boundaries, and therefore worse mechanical properties exhibited the best wear resistance to abrasive and oxidational wear.
AE Aboloje, SO Sada, M Ekpu, J Eyenubo, The International Journal of Advanced Manufacturing Technology, 2024, Springer
With the rising need to promote productivity that is based on quality, energy, and cost, it is imperative that cutting tools are not just selected on the basis of its suitability, but on its efficiency. It is particularly important that workpiece materials are aligned to specific cutting tools, to improve manufacturing costs, lead time, and quality of the overall product and to create flexibility. For this reason, a comparative study of the performance of high-speed steel and tungsten carbide cutting tools has been performed to determine the most suitable for the machining of a 304 Austenite Steel cylindrical bar. The tool wear of the cutting tools was selected as a measured to ascertain their performance in the turning operation. Response surface methodology was employed to analyzing the results and determining their optimal performance. From the study, the tungsten carbide tool recorded optimal parameters as follows: cutting speed 1303 m/min, feed rate 0.354 mm/rev, and depth of cut 0.458 mm with a tool wear of 1.173 mm and for the high-speed steel tool, cutting speed 1321 m/min, feed rate 0.208 mm/rev, and depth of cut 0.682 mm with a tool wear of 2.073 mm. The study judging from the tool wear shows the efficiency of the tungsten carbide tool over the high-speed steel cutting tool, as it can be seen from the results obtained that the lowest tool wear in the turning of the cylindrical steel bar is recorded from the use of the tungsten carbide cutting tool. From the 3D surface plots, it can be confirmed that to obtain a good performance from the different cutting tools, the cutting speed best suited for the cutting tool must be taken into consideration.
Experimental study on the influence of blade shape-composite interaction for dicing CFRP composites
A Riaz, Z Yuan, BS Chohan, K Cheng, The International Journal of Advanced Manufacturing Technology, 2025, Springer
Dicing blades are often used to form microstructures during the machining of difficult-to-cut materials. The impact of dicing process parameters on surface quality is critical during machining, and a better understanding of the influential parameters is desirable. This work employs new dicing blade shapes to evaluate the blade shape-composite interaction influence on the machining of carbon fiber-reinforced plastic (CFRP) composites. The new blade shapes incorporate blunt and flat contact edges to evaluate cutting forces, surface roughness, and morphology of the composite material’s abraded constituents at different cutting depths and fiber cutting angles. The results indicate that the influence of blade shape-composite interaction is crucial for dicing blade machining performance. Flat-end tools can effectively reduce the stress intensity factor than blunt-end tools, resulting in better surface roughness. Flat-end blades give the surface roughness of between 0.20 and 0.72 µm, and is 0.95–4.89 µm, and for blunt-end tools, the range of is between 0.64 and 1.49 µm, and is 2.63–6.38 µm. Surface morphology reveals that for perpendicular fiber cutting, a flat cutting-edge tool can reduce the influence of the interface on crack propagation, prevent fiber-matrix debonding, and obtain a smooth machining surface at higher cutting depths. When the cutting direction is along the fiber, the flat cutting edge tool interacts with the carbon fiber composite material, causing a certain degree of fiber fracture and leaving behind defined contours on the machined surface. Additionally, response optimization verifies the blade shapes with flat ends as optimal blade shapes for the precise dicing of CFRP composites.
Analysis of the sharpness of blades for food cutting
S Schuldt, G Arnold, J Kowalewski, Y Schneider, H Rohm, Journal of Food Engineering, 2016, Elsevier
Although the sharpness of a blade is responsible for cutting performance, there is no single and unambiguous literature definition of sharpness. The blade sharpness index (BSI) proposed by McCarthy et al. (Engineering Fracture Mechanics 74, 2205–2224, 2007) is a dimensionless number, derived from different cutting properties, to classify the sharpness of thin blades such as scalpels. In this study we transfer the BSI concept to blades with geometries typical in food cutting applications. After a series of cutting experiments at two velocities with blades that differed in wedge angle and abrasion state and by using three elastomers as substrate, we identified that the BSI can be regarded as a linear function of blade tip radius and force at cut initiation. The BSI was independent of cutting velocity, cutting substrate and wedge angle. Subsequently, cutting of foods with differently blunted blades revealed a specific impact on cutting performance, which depended on the food properties. Thus the BSI concept itself is helpful to classify the blade state, but it is less sufficient to evaluate the suitability of a knife with respect to a particular cutting application.
Wear processes and performance of blade pair in small‐scale single‐shaft plastic shredder machine
JH Wong, WMJ Karen, SA Bahrin, BL Chua, GJH Melvin, NJ Siambun, Materialwissenschaft und Werkstofftechnik, 2023•Wiley Online Library
Shredder blades and fixed blades were used as a set of blade pair to perform the shredding action. Comparable research was performed on the blade pair to understand its wear mechanism and shredding performance. The loading distribution along the two‐edge shredder blades in helix configuration was identified. Optical microscopy, scanning electron microscopy, energy dispersive x‐ray, x‐ray diffractometer analysis, and hardness tests were used to characterise the surface, elemental composition, microstructure, and hardness of the worn blade pair. The shredder blades’ wear mechanism was categorised as progressive wear which dominant by abrasive, following by adhesive and oxidation wear. The shredding efficiency of the two‐edge shredder blades in helix configuration was 69.24 %, recycling efficiency at 96.83 % and retention of 3.17 % after the shredding process.
Coatings and Surface Treatments
Structural and Mechanical Properties of DLC/TiN Coatings on Carbide for Wood-Cutting Applications
V Chayeuski, V Zhylinski, V Kazachenko, A Tarasevich… - Coatings, 2023, MDPI.
In this work, the diamond-like carbon and titanium nitride (DLC/TiN) multilayer coatings were prepared on a cemented tungsten carbide substrate (WC—3 wt.% Co) using the cathodic vacuum arc physical vapor deposition (Arc-PVD) method and pulsed Arc-PVD method with a graphite cathode for the deposition of TiN and carbon layers, respectively. The structural and mechanical properties of the prepared coatings were studied, and different techniques, such as scanning electron microscope (SEM), energy-dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD), Raman spectroscopy, and microindentation techniques investigated their microstructure, composition, and phases. The prepared coatings had a multilayer structure with distinct phases of DLC, TiN, and carbide substrate. The potentiodynamic polarization method (PDP) was performed for the DLC/TiN multilayer coatings in 3% NaCl solution to evaluate the corrosion resistance of the prepared coatings. It has been shown that the DLC layer provided the coating with a polarization resistance of 564.46 kΩ. Moreover, it has been demonstrated that the DLC/TiN coatings had a high hardness of 38.7–40.4 GPa, which can help to extend the wood-cutting tools’ life.
M Torkghashghaei, W Shaffer, B Ugulino, R Georges, RE Hernández, C Blais, Applied Sciences, 2022, MDPI.
Reduced performance of circular saws due to premature chipping of their teeth has been a critical issue in woodcutting industry for many years. This research examined the impact of surface coating and variable engineered micro-geometry of the cutting edges of carbide teeth (tips) on the wear resistance of circular saws used in primary wood processing. CrN/CrCN/DLC, CrN/AlTiN, CrN/CrCN, and CrCN/TiSiCN were deposited on tungsten carbide-cobalt (WC-Co) substrates using the cathodic arc evaporation technique. The CrN/CrCN coating proved to be the one with highest wear resistance and adhesion among those studied. No sign of delamination was observed around the indentation of the CrN/CrCN coating after the adhesion test. Furthermore, no abrasion, delamination or crack was observed on the surface of the CrN/CrCN coating after the three-body abrasion wear test. The results of the dry-sliding wear test revealed that CrN/CrCN coating significantly decreased the wear rate of WC-Co substrates by 74%, 66% and 77% at sliding speeds of 50, 100 and 250 mm/s, respectively. Afterwards, a CrC/CrCN coating was deposited on the teeth of conventional circular saws. Next, the cutting edges of teeth were modified through variable engineered micro-geometry. Tests were conducted at a sawmill with three series of saws: 1-coated and edge-modified, 2-coated and conventional edge geometry, and 3-uncoated and edge-modified. Wood processing was performed during two shifts of 480 min each. The width of the wear land was the criterion used as the wear index. The results of industrial tests showed that saws with edge-modified teeth had significantly less chipping and no breakage at their corners compared to the saw without edge modification (conventional saw). After 480 min of sawing, the wear rate of the coated saw with edge modification decreased by 46% and 16%, compared to the coated saw without edge modification and the uncoated saw with edge-modified teeth, respectively. Those values reached 73 % and 41%, respectively, after 960 min of sawing. The study shows that by optimizing the surface chemistry and the geometry of the cutting edge of WC-Co tips, tool life can be significantly increased therefore reducing downtime due to saw replacement and resharpening, thus significantly increasing productivity in the first transformation of wood.
Cutting Efficiency in Different Materials
Q Zhang, F Liu, D Wu, S Qu, W Liu, Z Chen, Materials, 2023, MDPI
The cutting performance of steel blades is an eternal, attractive topic in the knife industry. It is a complicated process to cut up materials because it usually involves the contact mechanics of the material been cut, the geometry and roughness of the blade edge and the hardness and wear resistance of the blade steel. Therefore, a comprehensive analysis is required to evaluate the cutting performance of knife blades. In this study, such an analysis was conducted based on a quantitative model to describe the cutting depth of paper cards containing SiO2 particles by steel blades, and major contributing factors were summarized. The effect of the micro-geometries of blade edges was thoroughly discussed, and a geometry factor ξ for the micro-geometry of a blade edge was introduced into the model. The experimental results indicated that mechanical processing could produce a rough blade edge and a higher ξ value, accordingly. A similar effect was caused by the carbides in the martensitic steels for blades, and the ξ value was found to increase linearly with the volumetric fraction of the carbides. The extraordinary cutting behavior of the 3V blade implied that fine coherent carbides may result in an efficient improvement (40–50%) in the total cutting depth.
Research on cutting tools edge grinding damage of nano cemented carbide
Y Jiang, M Zhou, L Zhan, Y Tian, M Yang, Y Zhu, X Yuan, W Xu, J Li, Wear, 2025, Elsevier
This paper investigates the damage issues of nano, submicron, and fine cemented carbide tools during the grinding process. Through theoretical analysis of grinding, a grinding force model was established, and the concept of subsurface deformation zone leading to tool edge defects was proposed. Theoretical calculations indicated that nano cemented carbides exhibit minimal grinding damage and superior edge quality. Surface grinding and tool edge grinding experiments were designed and conducted. The results showed that, with the increase in tungsten carbide grain size, the mean free path values increased from 0.034 μm to 0.123 μm and 0.195 μm, the thickness of the subsurface deformation layer increased from 0.7 μm to 1.5 μm and 2.4 μm, the tool edge chipping increased from 1.204 μm to 1.758 μm and 2.560 μm, and the surface roughness of the flank face increased from 0.047 μm to 0.056 μm and 0.070 μm. These findings validated the scientific and effective nature of nanostructured cemented carbides in enhancing tool edge quality. Moreover, the study revealed that among the grinding parameters, grinding depth had the most significant impact on edge chipping, while feed rate and grinding wheel speed had relatively smaller effects. This paper provides theoretical support and experimental data for the application of nano cemented carbides in high-precision tool manufacturing, contributing to the advancement of technology in the field of precision manufacturing.
J Svoreň, Ľ Naščák, Š Barcík, P Koleda, Š Stehlík, Applied Sciences, 2022, MDPI
Optimal cutting conditions, which lead to a high quality of the machined surface and low energy consumption, are crucial for wood processing. This paper describes the effect of feed speed, cutting speed and mean chip thickness on energy consumption and saw blade surface temperature during the spruce (Picea excelsa) cutting process. In the experiment, the energy consumption and the surface temperature of the saw blades were measured to find the optimal cutting conditions for the energy-efficient cutting process. The surface temperature of the circular saw blade was monitored online using a non-contact infrared sensor connected directly to a PC via a USB connector. The results show that the cutting power and the surface temperature of the circular saw blade increased with increasing feed speed. The lowest values of cutting power were shown by the saw blade CSB3. Compared to the classic CSB1 circular saw blade, the values were lower by 8%. The surface temperature of the circular saw blade is highest at the outer edge (area of the heel of the teeth), and decreases towards the center of the circular saw blade. For an identical mean chip thickness, energy-efficient cutting was achieved at a feed speed of 21 m/min. There must be a trade-off between machine productivity and energy consumption. Monitoring the cutting process of circular saws using intelligent sensors is the way to adaptive control systems that ensure higher quality of the machined surface and cost-effective machining.
V Nasir, A Mohammadpanah, J Cool, Wood material science & engineering, 2020, Taylor & Francis
This paper investigates the effect of rotation speed and vibration response of a circular saw on the sawing process of Douglas-fir wood. An idling test was conducted on a guided circular saw to determine its stable operation speeds and vibration behavior. Short-time Fourier transform analysis was performed on saw idling test data, and variation of excited frequencies of the blade as a function of rotation speed was obtained. The saw blade critical speeds and the rotation speeds that correspond to saw flutter instability were identified. Then experimental cutting tests were conducted at different cutting conditions and the effect of rotation speed and saw vibration response on cutting power consumption and sawing accuracy was investigated. The results showed that conducting a saw idling test and vibration response analysis can identify the saw critical and flutter speeds, which is essential for identifying the optimum rotation speed of circular saw. There was a significant increase in power consumption when cutting at super-critical and super-flutter speed. The effect of rotation speed on sawing accuracy is complex and nonlinear. This effect interacts with feed speed, which makes it difficult to generalize sawing accuracy versus rotation speed in the circular sawing process.
Analysis of the sharpness of blades for food cutting
S Schuldt, G Arnold, J Kowalewski, Y Schneider, H Rohm, Journal of Food Engineering, 2016, Elsevier
Although the sharpness of a blade is responsible for cutting performance, there is no single and unambiguous literature definition of sharpness. The blade sharpness index (BSI) proposed by McCarthy et al. (Engineering Fracture Mechanics 74, 2205–2224, 2007) is a dimensionless number, derived from different cutting properties, to classify the sharpness of thin blades such as scalpels. In this study we transfer the BSI concept to blades with geometries typical in food cutting applications. After a series of cutting experiments at two velocities with blades that differed in wedge angle and abrasion state and by using three elastomers as substrate, we identified that the BSI can be regarded as a linear function of blade tip radius and force at cut initiation. The BSI was independent of cutting velocity, cutting substrate and wedge angle. Subsequently, cutting of foods with differently blunted blades revealed a specific impact on cutting performance, which depended on the food properties. Thus the BSI concept itself is helpful to classify the blade state, but it is less sufficient to evaluate the suitability of a knife with respect to a particular cutting application.
On the sharpness of straight edge blades in cutting soft solids: Part II–Analysis of blade geometry
CT McCarthy, AN Annaidh, MD Gilchrist - Engineering Fracture Mechanics, 2010, Elsevier
In Part I of this paper a new metric, titled the “blade sharpness index” or “BSI”, for quantifying the sharpness of a straight edge blade when cutting soft solids was derived from first principles and verified experimentally by carrying out indentation type cutting tests with different blade types cutting different target or substrate materials. In this Part II companion paper, a finite element model is constructed to examine the effect of different blade variables including tip radius, wedge angle and blade profile on the BSI developed in Part I. The finite element model is constructed using ABAQUS implicit and experiments are performed to characterise the non-linear material behaviour observed in the elastomeric substrate. The model is validated against the experiments performed in Part I and a suitable failure criterion is determined by carrying out experiments on blades with different tip radii. The paper finds that a simple maximum stress criterion is a good indicator for predicting the onset of cutting. The validated model is then used to examine blade geometry. It is shown that finite element analysis is an important tool in helping to understand the mechanics of indentation. Furthermore, the study finds that all the blade geometric variables have an influence on the sharpness of a blade, with the BSI being most sensitive to tip radius. Increasing the tip radius and wedge angle decreases the sharpness of the blade.
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