Anti-drag bionic cutting tool and preparation method thereof

Abstract

The invention relates to an anti-drag bionic cutting tool and a preparation method thereof, which are characterized in that unique biological characteristics of sharks and pangolin are combined, and a cutting edge part and a tool body surface of the cutting tool are subjected to innovative combined biological coupling improved design; the special sawtooth shape of shark teeth is simulated, the penetrating power of the cutter during cutting is improved, the shape of squama manis scales and the contact area of the cutter during cutting are used for reference, meanwhile, cutter materials are precisely machined, a nitriding hardening coating is added, and the comprehensive cutting capacity and the resistance reduction performance of the cutter are comprehensively improved; therefore, the composite material shows more excellent performance in practical application.

Description

Technical Field

[0001] This invention relates to the field of cutting tool manufacturing and processing technology, specifically to a drag-reducing bionic cutting tool and its preparation method. Background Technology

[0002] In key sectors such as industrial manufacturing, energy extraction, and aerospace, the efficiency and energy consumption of cutting operations directly and significantly impact overall production efficiency. Traditional cutting tools, when faced with high-speed operation or high-load conditions, experience accelerated tool wear and increased energy consumption due to frictional resistance between the tool and the material being cut. This can also lead to a series of problems, including decreased workpiece surface finish. For example, in oil drilling operations, frictional resistance between the drill bit and the rock formation accounts for 30%-50% of energy consumption; and in metal cutting processes, excessive cutting forces can cause machine tool vibration and negatively affect machining quality. Therefore, effectively reducing frictional resistance during cutting while improving tool durability has become a core direction for technological breakthroughs and innovations in the industry.

[0003] The development of drag-reducing cutting tools is based on this urgent need. By employing various methods such as material optimization, structural design innovation, or surface modification, the friction coefficient between the tool and the material being cut is significantly reduced, thereby achieving multiple goals such as reducing energy consumption, extending tool life, and improving operational efficiency. In recent years, with the continuous advancement of intelligent manufacturing technology and the growing acceptance of green industrial concepts, the application demand for drag-reducing cutting tool technology in high-end equipment manufacturing, new energy development, and other fields has shown a significant growth trend.

[0004] It is worth noting that many animals in nature achieve highly efficient and low-resistance cutting through the synergistic optimization of their cutting organs in terms of structure, materials, and function. For example, shark teeth have a unique serrated structure, which effectively reduces the contact area and thus lowers frictional resistance; while pangolin scales significantly improve wear resistance through the distribution of gradient hardness layers. However, existing research on biomimetic cutting tools is mostly limited to imitating single structures, such as simply replicating serrated shapes or surface textures, failing to achieve multi-coupling design between structure, materials, and function. Therefore, although these biomimetic tools have a certain degree of drag reduction effect, their improvement in wear resistance remains limited, making it difficult to fully meet the complex needs of actual production. In the future, if we can learn more about the multi-dimensional optimization strategies found in nature, it is hoped that more efficient and durable new drag-reducing cutting tools can be developed, thereby bringing more significant benefits to industrial production.

[0005] To address this problem, this invention proposes a novel drag-reducing biomimetic cutting tool and its manufacturing method. The cutting edge mimics the microstructure of a shark's sharp teeth, resulting in enhanced cutting power and sharpness. The blade body borrows the geometric shape of stacked pangolin scales; this biomimetic design significantly improves the drag reduction performance of the blade surface and further optimizes its wear resistance. Furthermore, to further enhance the blade's durability and wear resistance, a nitriding hardening technique is used to harden the scale structure on the blade surface, creating a reasonable hardness gradient between it and the blade substrate. This gradient hardness design effectively improves the blade's wear resistance and extends its service life, resulting in superior performance in practical applications. Summary of the Invention

[0006] In order to provide a solution to the above problems, a drag-reducing bionic cutting tool and its preparation method are proposed.

[0007] The present invention proposes a drag-reducing biomimetic cutting tool, comprising a tool substrate, on which a cutting edge and a blade are provided. The cutting edge is serrated, with a serration height of 50-200μm and a spacing of 30-100μm, arranged periodically. The blade is provided with a scale-like structure, with the scales arranged in an overlapping manner. The surface of the blade is also provided with a nitrided hardening layer, which is tightly bonded to the blade substrate, and the two form a hardness gradient.

[0008] Preferably, the blade shape mimics the serrated structure of shark teeth; the scale-like structure on the blade surface mimics the overlapping scales of a pangolin.

[0009] Preferably, the hardness of the nitrided hardened layer is 1200-1800 HV.

[0010] Preferably, the hardness of the blade base alloy is ≥60HRC.

[0011] A method for preparing a drag-reducing biomimetic cutting tool includes the following steps:

[0012] (1) Multi-coupling biomimetic modeling: Through SEM, XRD and biomechanical testing, the structural parameters, material composition and occlusal pattern of animal cutting organs are analyzed to establish a coupled biomimetic model;

[0013] (2) Tool substrate preparation: Tungsten-molybdenum alloy is selected and the substrate is made by forging, heat treatment and precision machining;

[0014] (3) Biomimetic structure forming: femtosecond laser processing is used to prepare serrated cutting edges and blade scale structures on the substrate and surface;

[0015] (4) Gradient hardness modification: A nitrided layer is deposited on the surface of the blade through a low-temperature plasma nitriding process, which combines with the base alloy of the blade to form a gradient hardness layer.

[0016] Preferably, the heat treatment process conditions in step (2) are: solution treatment at 1050℃ for 3-5 hours and aging treatment at 550℃ for 4-6 hours.

[0017] Preferably, the femtosecond laser processing parameters in step (3) are: wavelength 1064nm, power 5-8kW, and scanning speed 100-300mm / s.

[0018] Preferably, the low-temperature plasma nitriding process conditions in step (4) are nitriding at 450°C for 3-5 hours.

[0019] Preferably, the thickness of the nitrided layer is 0.2-0.6 mm.

[0020] The advantages of this invention compared to existing technologies are:

[0021] I. Combining the unique biological characteristics of sharks and pangolins, an innovative combined bio-coupling design was implemented for the blade's cutting edge and surface. By mimicking the serrated shape of shark teeth, the blade's penetration and cutting efficiency are significantly improved. Simultaneously, drawing inspiration from the ridged scales of pangolins, the contact area between the blade and the object being cut is cleverly reduced, effectively lowering resistance during cutting and thus reducing energy consumption and improving cutting smoothness. This improvement overcomes the limitations of existing biomimetic blades that can only simply replicate a single biological texture. By organically combining the advantages of multiple biological forms, it comprehensively and systematically enhances the blade's overall cutting ability and drag reduction performance, resulting in superior performance in practical applications.

[0022] Second, a nitrided hardening coating is added to the biomimetic structure surface of the blade. This coating design creates a significant hardness gradient between the surface hardening layer and the blade substrate. This unique "soft and hard" structure not only significantly improves the overall impact resistance of the blade but also effectively disperses and absorbs impact force when subjected to external forces, thereby extending the tool's lifespan. Furthermore, the nitrided coating has a higher degree of smoothness compared to the blade substrate surface. This smooth surface characteristic further reduces the resistance encountered by the tool during cutting, making the cutting process smoother, reducing energy consumption, and improving cutting efficiency.

[0023] Third, to comprehensively improve the overall performance of the cutting tool, we implemented a multi-step solution heat treatment process on the tool's substrate during production. This series of heat treatment steps not only effectively improves the internal microstructure of the substrate but also significantly enhances its mechanical properties and wear resistance. Simultaneously, for the tool's surface morphology, laser processing technology is employed. A high-precision laser beam is used to finely process the tool surface, achieving a dual improvement in surface finish and precision. Through these comprehensive processing methods, the performance of the cutting tool is enhanced. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the cutting tool.

[0025] Figure 2 This is an enlarged structural diagram of point A;

[0026] Figure 3 This is a schematic diagram of the cross-sectional structure of the cutting tool;

[0027] In the diagram: 1 - Tool body; 2 - Cutting edge; 3 - Tool body; 4 - Serrated structure; 5 - Scale-like structure; 6 - Nitrided hardened layer. Detailed Implementation

[0028] Example

[0029] The blade body 1 is equipped with a cutting edge 2 and a blade 3. The cutting edge features a unique serrated structure 4, inspired by the biological morphology of shark teeth. By mimicking the sharpness and bite force of shark teeth, numerous tiny and sharp micro-serrations are densely distributed at the tip of the cutting edge 2. These micro-serrations greatly enhance the cutting efficiency and penetration power of the cutting edge 2. The serrations at the tip of the cutting edge 2 are not randomly distributed, but rather exhibit a regular, periodic arrangement. This arrangement ensures that the serrations maintain uniform force during cutting, effectively extending to the entire cutting edge 2 of the blade, giving the entire cutting edge 2 excellent cutting performance.

[0030] The blade 3 is equipped with a scale-like structure 5. The design of this scale-like structure 5 is inspired by the biological form of pangolin scales. It presents a shield-shaped form with a protrusion in the middle and sharp edges. This design enhances the overall strength and wear resistance of the blade.

[0031] To further enhance the durability and wear resistance of the blade, a nitrided hardening layer 6 is applied to the blade surface. This nitrided hardening layer 6 is tightly bonded to the blade body 3, forming a hardness gradient between them. This gradient design not only ensures the overall strength of the blade body 3, but the nitrided hardening layer 6 also effectively resists external environmental corrosion and wear, extending the service life of the knife.

[0032] Example 1

[0033] The base material of the cutting tool is selected from high-performance tungsten-molybdenum alloys with a hardness of not less than 60 HRC to ensure excellent wear resistance and strength. The following four key steps are strictly followed during the precision manufacturing process of the tool:

[0034] (1) Multi-coupling biomimetic modeling: First, using advanced technologies such as scanning electron microscopy (SEM), X-ray diffraction (XRD), and biomechanical testing, the structural parameters, material composition, and unique occlusal patterns of animal cutting organs are analyzed in depth. Based on this detailed analysis data, a precise multi-coupling biomimetic model is constructed to provide a scientific basis for subsequent tool design.

[0035] (2) Tool substrate preparation: Selecting tungsten-molybdenum alloy material that meets the requirements, after precision forging, it is placed in a high-temperature furnace for solution treatment at 1050℃ for 3 hours. Subsequently, it is subjected to aging treatment at 550℃ for 4 hours. After this series of heat treatments, the performance of the alloy material is significantly improved. After fine machining, the tool substrate that meets the design requirements is finally produced.

[0036] (3) Bionic Structure Forming: Advanced femtosecond laser processing technology is employed, with a laser wavelength set at 1064nm, a power range of 5kW, and a scanning speed controlled at 100mm / s. This high-precision laser processing method is used to fabricate serrated cutting edges and scale-like structures on the cutting edge and surface of the tool substrate. Specific design parameters are: the serration height of the cutting edge is 50 micrometers, and the spacing is 30 micrometers, to ensure excellent drag reduction performance and cutting efficiency during the cutting process.

[0037] (4) Gradient Hardness Modification: The tool is nitrided at 450°C for 3 hours using a low-temperature plasma nitriding process. During this process, a uniform nitrided layer gradually deposits on the surface of the tool body, with a thickness controlled at 0.2 mm. This nitrided layer is tightly bonded to the tool body's base alloy, forming a gradient hardness layer, which significantly improves the tool's wear resistance and service life. After this series of meticulous processes, a biomimetic cutting tool with excellent drag reduction properties is finally obtained.

[0038] Example 2

[0039] The base material of the cutting tool is selected from high-performance tungsten-molybdenum alloys with a hardness of not less than 60 HRC to ensure excellent wear resistance and strength. The following four key steps are strictly followed during the precision manufacturing process of the tool:

[0040] (1) Multi-coupling biomimetic modeling: First, using advanced technologies such as scanning electron microscopy (SEM), X-ray diffraction (XRD), and biomechanical testing, the structural parameters, material composition, and unique occlusal patterns of animal cutting organs are analyzed in depth. Based on this detailed analysis data, a precise multi-coupling biomimetic model is constructed to provide a scientific basis for subsequent tool design.

[0041] (2) Tool substrate preparation: Selecting tungsten-molybdenum alloy material that meets the requirements, after precision forging, it is placed in a high-temperature furnace for solution treatment at 1050℃ for 4 hours. Subsequently, it is subjected to aging treatment at 550℃ for 5 hours. After this series of heat treatments, the performance of the alloy material is significantly improved. After fine machining, the tool substrate that meets the design requirements is finally produced.

[0042] (3) Bionic Structure Forming: Advanced femtosecond laser processing technology is employed, with a laser wavelength set at 1064nm, a power range of 7kW, and a scanning speed controlled at 200mm / s. This high-precision laser processing method is used to fabricate serrated cutting edges and scale-like structures on the cutting edge and surface of the tool substrate. Specific design parameters are: the serration height of the cutting edge is 125 micrometers, and the spacing is 60 micrometers, to ensure excellent drag reduction performance and cutting efficiency during the cutting process.

[0043] (4) Gradient Hardness Modification: The tool is nitrided at 450°C for 4 hours using a low-temperature plasma nitriding process. During this process, a uniform nitrided layer gradually deposits on the surface of the tool body, with a thickness controlled at 0.4 mm. This nitrided layer is tightly bonded to the tool body's base alloy, forming a gradient hardness layer, which significantly improves the tool's wear resistance and service life. After this series of meticulous processes, a biomimetic cutting tool with excellent drag reduction performance is finally obtained.

[0044] Example 3

[0045] The base material of the cutting tool is selected from high-performance tungsten-molybdenum alloys with a hardness of not less than 60 HRC to ensure excellent wear resistance and strength. The following four key steps are strictly followed during the precision manufacturing process of the tool:

[0046] (1) Multi-coupling biomimetic modeling: First, using advanced technologies such as scanning electron microscopy (SEM), X-ray diffraction (XRD), and biomechanical testing, the structural parameters, material composition, and unique occlusal patterns of animal cutting organs are analyzed in depth. Based on this detailed analysis data, a precise multi-coupling biomimetic model is constructed to provide a scientific basis for subsequent tool design.

[0047] (2) Tool substrate preparation: Selecting tungsten-molybdenum alloy material that meets the requirements, after precision forging, it is placed in a high-temperature furnace for solution treatment at 1050℃ for 5 hours. Subsequently, it is subjected to aging treatment at 550℃ for 6 hours. After this series of heat treatments, the performance of the alloy material is significantly improved. After fine machining, the tool substrate that meets the design requirements is finally manufactured.

[0048] (3) Bionic Structure Forming: Advanced femtosecond laser processing technology is employed, with a laser wavelength set at 1064nm, a power range of 8kW, and a scanning speed controlled at 300mm / s. This high-precision laser processing method is used to fabricate serrated cutting edges and scale-like structures on the cutting edge and surface of the tool substrate. Specific design parameters are: the serration height of the cutting edge is between 200 micrometers, and the spacing is 100 micrometers, to ensure excellent drag reduction performance and cutting efficiency during the cutting process.

[0049] (4) Gradient Hardness Modification: The tool is nitrided at 450°C for 5 hours using a low-temperature plasma nitriding process. During this process, a uniform nitrided layer gradually deposits on the surface of the tool body, with a thickness controlled at 0.6 mm. This nitrided layer is tightly bonded to the tool body's base alloy, forming a gradient hardness layer, which significantly improves the tool's wear resistance and service life. After this series of meticulous processes, a biomimetic cutting tool with excellent drag reduction performance is finally obtained.

[0050] In summary, although the present invention has been disclosed above with reference to preferred embodiments, the above preferred embodiments are not intended to limit the present invention. Those skilled in the art can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be determined by the scope defined in the claims.

Claims

1. A drag-reducing biomimetic cutting tool, characterized in that, The tool includes a tool body, on which a cutting edge and a blade are provided. The cutting edge is serrated with a height of 50-200μm and a spacing of 30-100μm, arranged periodically. The blade is provided with a scale-like structure, with the scales arranged in an overlapping manner. The surface of the blade is also provided with a nitrided hardening layer, which is tightly bonded to the blade body, and the two form a hardness gradient.

2. The drag-reducing bionic cutting tool according to claim 1, characterized in that: The blade's edge shape mimics the serrated structure of shark teeth; the scale-like structure on the blade's surface mimics the overlapping scales of a pangolin.

3. The drag-reducing bionic cutting tool according to claim 2, characterized in that: The hardness of the nitrided hardened layer is 1200-1800 HV.

4. The drag-reducing bionic cutting tool according to claim 2, characterized in that: The hardness of the blade base alloy is ≥60HRC.

5. The method for preparing a drag-reducing bionic cutting tool according to claim 1, characterized in that: Includes the following steps: (1) Multi-coupling biomimetic modeling: Through SEM, XRD and biomechanical testing, the structural parameters, material composition and occlusal pattern of animal cutting organs are analyzed to establish a coupled biomimetic model; (2) Tool substrate preparation: Tungsten-molybdenum alloy is selected and the substrate is made by forging, heat treatment and precision machining; (3) Biomimetic structure forming: femtosecond laser processing is used to prepare serrated cutting edges and blade scale structures on the substrate and surface; (4) Gradient hardness modification: A nitrided layer is deposited on the surface of the blade through a low-temperature plasma nitriding process, which combines with the base alloy of the blade to form a gradient hardness layer.

6. The method for preparing a drag-reducing bionic cutting tool according to claim 5, characterized in that: The heat treatment process conditions in step (2) are: solution treatment at 1050℃ for 3-5 hours and aging treatment at 550℃ for 4-6 hours.

7. The method for preparing a drag-reducing bionic cutting tool according to claim 5, characterized in that: The femtosecond laser processing parameters in step (3) are: wavelength 1064nm, power 5-8kW, and scanning speed 100-300mm / s.

8. The method for preparing a drag-reducing bionic cutting tool according to claim 5, characterized in that: The low-temperature plasma nitriding process conditions in step (4) are nitriding at 450°C for 3-5 hours.

9. The method for preparing a drag-reducing bionic cutting tool according to claim 8, characterized in that: The thickness of the nitrided layer is 0.2-0.6 mm.

Images