How does the multi-blade design of flat knife balance cutting efficiency and tool life?
Publish Time: 2025-03-19
In the field of mechanical processing, flat knife is a commonly used cutting tool, and its design directly affects the processing efficiency and tool life. Multi-blade flat knife (such as 2-blade, 3-blade, 4-blade) can significantly improve the processing efficiency because it can participate in cutting at the same time, but it also puts higher requirements on the life of the tool. So, how to balance cutting efficiency and tool life in multi-blade design has become a key issue in tool design and application.
First of all, the core advantage of multi-blade design is that it can process multiple cutting points at the same time, thereby greatly improving cutting efficiency. For example, compared with 2-blade flat knife, 4-blade flat knife can complete more cutting tasks in the same time, which is especially suitable for mass production and high-efficiency processing scenarios. However, the increase in the number of blades also means that the cutting force shared by each cutting edge is relatively reduced, which reduces the wear rate of a single cutting edge to a certain extent. But at the same time, multi-blade design also brings new challenges, such as the concentration of cutting heat and the increased difficulty of chip removal. If these problems are not handled properly, they will shorten the overall life of the tool.
In order to balance cutting efficiency and tool life in multi-blade design, it is necessary to optimize the geometric parameters of the tool first. The geometric parameters of each cutting edge, such as the rake angle, back angle and main deflection angle, directly affect the distribution of cutting force and the generation of cutting heat. For example, appropriately increasing the rake angle can reduce cutting force and cutting temperature, thereby extending tool life; while a reasonable main deflection angle design helps to improve chip removal and avoid tool wear caused by chip accumulation. Through precise calculation and experimental verification, the most suitable geometric parameter combination for multi-edge flat knives can be found, so that it can reduce wear and thermal damage while cutting efficiently.
Secondly, the selection of materials and the application of coating technology are also important factors in balancing cutting efficiency and tool life. Multi-edge flat knives usually use high-hardness and high-wear-resistant materials, such as cemented carbide or ceramic materials, to cope with the high load and high temperature caused by high-speed cutting. In addition, coating technology (such as TiN, TiAlN coating) can significantly improve the surface hardness and heat resistance of the tool, and reduce friction and wear. For example, TiAlN coating can still maintain excellent performance at high temperatures, which is very suitable for processing difficult-to-process materials such as titanium alloys. By selecting suitable materials and coatings, the service life of the tool can be significantly extended without sacrificing cutting efficiency.
In addition, the optimization of cutting parameters is also the key to balancing efficiency and life. Parameters such as cutting speed, feed rate and cutting depth directly affect the generation of cutting force and cutting heat. Although too high a cutting speed can improve efficiency, it will also cause a sharp rise in cutting temperature and accelerate tool wear; while too low a cutting speed may reduce efficiency and increase processing time. Therefore, it is necessary to find the best combination of cutting parameters through experiments and simulations. For example, when processing aluminum alloys, a higher cutting speed and a medium feed rate can be used to achieve efficient cutting while controlling the cutting temperature within a reasonable range.
In multi-blade design, chip removal cannot be ignored. Multi-blade flat knives will generate a large amount of chips during the cutting process. If the chip removal is not smooth, the chips may be entangled on the tool, resulting in increased cutting force, increased temperature, and even tool breakage. Therefore, the design of a reasonable chip groove and cutting edge shape is an important measure to ensure the efficient operation of a multi-blade flat knife. For example, the spiral chip groove design can effectively guide the chip discharge and reduce the interference of chips on the tool and workpiece.
Finally, the maintenance and care of the tool is also an important part of extending its life. Regularly checking the wear of the tool and replacing or grinding the cutting edge in time can avoid the decline of processing quality and tool damage caused by excessive wear. In addition, the use of appropriate coolants and lubricants can effectively reduce the cutting temperature and reduce tool wear.
In general, the multi-edge design of the flat knife improves cutting efficiency while also bringing challenges to tool life. By optimizing geometric parameters, selecting appropriate materials and coatings, adjusting cutting parameters, improving chip removal design, and strengthening maintenance, a balance between cutting efficiency and tool life can be achieved in the multi-edge design. In the future, with the continuous advancement of materials science and manufacturing technology, the design and application of multi-edge flat knives will be more intelligent, providing stronger support for efficient and high-precision machining.
