Composite wire, method of manufacturing and use thereof, cutting tool

Abstract

The application provides a composite wire for manufacturing a cutter, a manufacturing method and application thereof, and the cutter. The composite wire comprises a metal wire and a ceramic material in a sheet shape which is compounded in the metal wire. According to the application, when the cutter is manufactured by the composite wire, the metal wire part in the composite wire can form a metal liquid under the influence of a heat source, the ceramic material in a sheet shape can keep solid due to a high melting point, and can be dispersed in the metal liquid and promote the spreading of the metal liquid to form a dense composite structure, so that a cutter with long-lasting sharpness is obtained.

Description

Technical Field

[0001] This application relates to the technical field of kitchen knives, and in particular to a composite filament for manufacturing knives, its manufacturing method and application, and knives. Background Technology

[0002] Users have a strong demand for the long-lasting sharpness of knives, and developers have made various improvements to address this need.

[0003] Some existing technologies disclose the use of a particle-accumulated structure formed by electrical discharge machining as the cutting edge of a cutting tool. While this type of cutting edge possesses a certain initial sharpness, the limited area where the particle-accumulated structure forms makes it easily worn away during subsequent sharpening, resulting in poor long-term sharpness. Other existing technologies disclose the direct fusion of a high-hardness material into the cutting edge area of ​​the tool sheet to form the cutting edge. However, this type of cutting edge is extremely prone to chipping and delamination during use, thus affecting the tool's long-term sharpness.

[0004] Clearly, the cutting edge formed by existing technologies, including the two different methods mentioned above, cannot yet effectively solve the problem of maintaining the sharpness of the cutting tool. Summary of the Invention

[0005] The purpose of this application is to provide a composite filament for manufacturing cutting tools, a manufacturing method thereof, and its application, in order to solve the problem of poor long-term sharpness of existing cutting tools.

[0006] According to a first aspect of this application, this application provides a composite wire for manufacturing cutting tools, wherein the composite wire comprises a metal wire and a sheet-like ceramic material incorporated therein.

[0007] According to the composite filament of this application, a composite filament containing dispersed sheet-like ceramic material is used as a material for manufacturing cutting tools. When using this composite filament to manufacture cutting tools, the metal filament in the composite filament can form molten metal under the influence of a heat source. The sheet-like ceramic material can remain solid due to its high melting point and can be dispersed in the molten metal, promoting the spread of the molten metal to form a dense composite structure. The composite structure itself has multiple layers divided by the sheet-like ceramic material. In this way, the toughness of the cutting tool can be improved without reducing the hardness of the tool, thereby significantly reducing the possibility of edge chipping and obtaining a long-lasting sharp tool.

[0008] In some embodiments, the sheet-like ceramic material is uniformly dispersed in the metal wire; or, the metal wire has a tubular structure, and the sheet-like ceramic material is disposed on the inner or outer wall surface of the tubular structure; or, the metal wire has a tubular structure, and the sheet-like ceramic material is filled in the tubular structure.

[0009] In these embodiments, sheet-like ceramic material can be distributed in multiple locations on the metal wire, thereby enabling the manufacture of various types of composite wires so that users can choose according to their actual needs.

[0010] In some embodiments, the composite filament is in the form of a hollow tube, the inner radius of which is 0.1mm-0.5mm and the outer radius is 0.3mm-1.5mm; or, the composite filament is a solid filament with a radius of 0.3mm-1.5mm.

[0011] In these embodiments, the dimensions of these composite filaments are adapted to existing processes for forming layers through filaments, so as to facilitate the subsequent process of forming corresponding layers through composite filaments, thereby enabling the application of composite filaments to manufacture corresponding products (e.g., cutting tools).

[0012] In some embodiments, in the composite filament, the volume of the ceramic material is 5%-30% of the total volume of the composite filament, and the volume of the metal wire is 70%-95% of the total volume of the composite filament.

[0013] In these embodiments, the volume content of ceramic material is such that it can promote the spread of molten metal composed of metal wires while avoiding excessive ceramic material content that could lead to increased brittleness (increased continuity of ceramic phase can easily lead to crack propagation). With such a volume ratio distribution, composite wires with suitable hardness and toughness can be obtained to improve the strength of the multi-layer composite structure formed on the cutting edge of the tool, thereby further improving the tool's long-lasting sharpness. In some embodiments, the sheet-like ceramic material is a sheet-like material having a main surface area in the millimeter range and a thickness in the micrometer range. As a specific example, the main surface area of ​​the sheet-like ceramic material is 1 mm². 2 -10mm 2 With a thickness of 5μm-50μm, this size of sheet-like ceramic material is conducive to dispersion in the metal wire. Moreover, due to its small size, during the process of the composite wire being heated to form a composite structure, this size of sheet-like ceramic material can drip from the composite wire along with the molten metal and lie flat in the molten metal to promote the spreading of the molten metal through its sheet-like structure, thus promoting the formation of a dense composite structure.

[0014] In some embodiments, the ceramic material includes at least one of oxides, carbides, nitrides, borides, and silicides, which enable the composite filament to have enhanced hardness while also possessing advantages in cost and lightness.

[0015] In some embodiments, the metal wire includes at least one of titanium wire, titanium alloy wire, martensitic stainless steel wire, molybdenum series alloy wire, tool steel alloy wire, nickel-based alloy wire, and cobalt-based alloy wire. These specific metal wires enable the manufactured composite wire to have advantages in cost, corrosion resistance, and hardness suitable for use as an adhesion substrate, while possessing basic toughness.

[0016] In some embodiments, the ceramic material is a covalent ceramic material and / or an ionic ceramic material, both types of ceramic materials having suitable hardness, thereby enabling them to form a composite filament with hardness and toughness together with the metal wire.

[0017] In some embodiments, the ceramic material is a ceramic material modified with polar functional groups, which can relatively reduce the polarity difference between the ceramic material and the molten metal formed by the metal wire, improve the wettability of the molten metal formed by the ceramic material and the metal material in the composite wire, reduce the gaps inside the sheet-like monomers of the multilayer composite structure formed by the composite wire, thereby further improving the structural strength of the multilayer composite structure to further improve the long-term sharpness of the cutting tool.

[0018] In some embodiments, the polar functional groups include at least one of carboxyl, amino, and hydroxyl groups. The introduction of these polar functional groups can not only increase the polarity of the ceramic material and reduce the polarity difference between it and the highly polar liquid metal, but also give it the advantages of being stable at room temperature and being readily available.

[0019] According to a second aspect of this application, a method for manufacturing a composite filament is provided, wherein the method includes: providing a metal strip having a plurality of grooves on its surface; filling the grooves with a sheet-like ceramic material; and then processing the metal strip filled with the sheet-like ceramic material into a composite filament in which the sheet-like ceramic material is incorporated.

[0020] According to the manufacturing method of the composite wire of this application, a composite wire in which a sheet-like ceramic material is incorporated into a metal wire can be manufactured in the above manner. The composite wire can be used to manufacture a cutting edge of a tool with a multi-layer composite structure, thereby ensuring the long-lasting sharpness of the tool due to the increased strength of the cutting edge.

[0021] In some embodiments, prior to the step of filling the groove with sheet-like ceramic material, the ceramic material is further subjected to plasma treatment to obtain a polar functional group modified ceramic material, and the polar functional group modified ceramic material is used as the ceramic material.

[0022] In these embodiments, plasma treatment of ceramic materials enables the grafting of polar functional groups onto the ceramic materials. This reduces the polarity difference between the ceramic materials and the molten metal formed by the metal wire, improves the wettability of the molten metal formed by the ceramic materials and the metal materials in the composite wire, reduces the gaps within the sheet-like monomers of the multilayer composite structure formed by the composite wire, and further enhances the structural strength of the multilayer composite structure to further improve the long-term sharpness of the cutting tool.

[0023] In some embodiments, the polar functional groups include at least one of carboxyl, amino, and hydroxyl groups. The introduction of these polar functional groups can not only increase the polarity of the ceramic material and reduce the polarity difference between it and the highly polar liquid metal, but also give it the advantages of being stable at room temperature and being readily available.

[0024] In some embodiments, the step of processing a metal strip filled with sheet-like ceramic material into a composite wire containing sheet-like ceramic material includes: winding the metal strip filled with sheet-like ceramic material into at least one layer of composite roll; and reducing the diameter and stretching the composite roll to obtain a composite wire containing sheet-like ceramic material. Thus, it is possible to process a metal strip filled with sheet-like ceramic material into a composite wire using existing processes.

[0025] In some embodiments, prior to the diameter reduction stretching, the method further includes the step of applying a coating to the outer side of the composite coil, wherein the coating is a rust-preventive layer and / or a flux layer. The rust-preventive layer can inhibit oxidation and corrosion of the composite coil during storage, and the flux layer can lower the melting point of the welded composite coil and improve the overall wettability of the composite wire obtained after stretching and diameter reduction.

[0026] In some embodiments, the step of providing a metal strip with multiple grooves on its surface includes acid washing and alkaline washing of the metal strip to remove impurities or oxides from the surface of the metal strip, thereby improving the bonding force between the metal wire and the sheet-like ceramic material to be filled subsequently. Then, multiple uniformly arranged grooves are formed on the surface of the metal strip to obtain a metal strip with multiple grooves on its surface, preparing for filling with sheet-like ceramic material and controlling the uniformity of the distribution of sheet-like ceramic material.

[0027] In some embodiments, the ceramic material is a material obtained by stirring and mixing sheet-like ceramic materials at a temperature of 150°C-200°C. In this way, the agglomerates of the sheet-like ceramic materials are easily broken by the shear force of stirring, thereby facilitating the uniform distribution of sheet-like ceramic materials of various sizes in the composite filament.

[0028] According to a third aspect of this application, a composite filament is provided for use in cutting tools, wherein the composite filament is the composite filament described above or a composite filament manufactured according to the manufacturing method of the composite filament described above.

[0029] According to a fourth aspect of this application, a cutting tool is provided, wherein the cutting tool includes a structure formed of the composite filament, wherein the composite filament is the composite filament described above or a composite filament manufactured according to the manufacturing method of the composite filament described above. Attached Figure Description

[0030] The above and other aspects, features, and other advantages of this application will become clearer and more readily understood from the following detailed description of exemplary embodiments in conjunction with the accompanying drawings, in which: Figure 1 This is a schematic cross-sectional view of the composite filament provided according to the first embodiment of the present invention; Figure 2 This is a schematic cross-sectional view of the composite filament provided according to the second embodiment of the present invention; Figure 3 This is a schematic diagram of the front view structure of the tool body according to an embodiment of the present invention; Figure 4 This is a rear view structural schematic diagram of the tool body according to an embodiment of the present invention; Figure 5 This is an enlarged structural schematic diagram of the cross-section of the tool body in the thickness direction according to an embodiment of the present invention; Figure 6 This is a front view schematic diagram of a tool body with a receiving groove according to an embodiment of the present invention; Figure 7 This is a rear view structural schematic diagram of a tool body having a receiving groove according to an embodiment of the present invention; Figure 8 This is an enlarged structural schematic diagram of a cross-section in the thickness direction of a tool body having a receiving groove according to an embodiment of the present invention; Figure 9 This is a schematic diagram of a tool body filled with a multi-layered scale-like structure according to an embodiment of the present invention; Figure 10 This is a schematic diagram of the front view structure of the cutting tool according to the first embodiment of the present invention; Figure 11This is a rear view structural schematic diagram of the cutting tool according to the first embodiment of the present invention; Figure 12 This is an enlarged structural schematic diagram of a cross-section in the thickness direction of a cutting tool according to a first embodiment of the present invention; Figure 13 This is a front view schematic diagram of the cutting tool according to the second embodiment of the present invention; Figure 14 This is an enlarged structural schematic diagram of a cross-section in the thickness direction of a cutting tool according to a second embodiment of the present invention; Figure 15 This is an enlarged structural schematic diagram of a cross-section in the thickness direction of a cutting tool according to a third embodiment of the present invention; Figure 16 This is a physical drawing of the cutting edge of a tool according to an embodiment of the present invention; Figure 17 This is a scanning electron microscope image of the cutting edge of a cutting tool according to another embodiment of the present invention.

[0031] Tag Name 10. Tool body; 20. Receiving groove; 11. First surface; 12. Second surface; 13. First body area; 14. Second body area; 30. Tool; 32. Multi-layered scale-like structure; 321. Scale-like layer; 3211. Scale unit; 31. Cutting edge; 40. Handle connector; 100. Composite wire; 101. Metal wire; 102. Ceramic material. Detailed Implementation

[0032] In the prior art, some composite materials (e.g., a mixture of metal particles and ceramic particles) may have large composite gaps during the coating process due to the difference in polarity between the different materials, resulting in a brittle structure. Furthermore, the structure formed in this way is a mixed structure with high stress, which in turn leads to insufficient durable sharpness of the cutting tools made from this composite material.

[0033] The inventors discovered that by incorporating sheet-like ceramic materials into metal wires, the limitations of traditional single-metal or powder composites can be overcome, creating a new material. During the formation of the composite structure using this new composite wire, the sheet-like ceramic materials in the composite wire can promote the spreading of the molten metal formed by the metal wire. Under the influence of gravity, they can tightly bond with the corresponding metal materials, thereby reducing the composite gap in the formed composite structure. Furthermore, the composite structure itself has multiple layers defined by the sheet-like ceramic materials, resulting in a cutting tool with improved and durable sharpness.

[0034] The following will combine Figures 1 to 17This application introduces a composite wire for manufacturing cutting tools, a method for manufacturing the same, and the same method for manufacturing the cutting tool. It should be noted that the use of directional terms such as "upper," "lower," "left," and "right" in the description of the cutting tool in this application is based on the tool's position in normal use, and is intended to clearly describe the cutting tool according to this application. It should not be construed as limiting the scope of protection of this application.

[0035] According to a first aspect of this application, a composite filament for manufacturing cutting tools is provided, wherein, as... Figure 1 and Figure 2 As shown, the composite filament 100 is a mixed filament in which a sheet-like ceramic material 102 is composited in the metal filament 101, and the melting point of the sheet-like ceramic material is higher than that of the metal filament.

[0036] According to the embodiments of this application, a composite filament containing dispersed sheet-like ceramic material is used as the material for manufacturing cutting tools. When this composite filament is used to manufacture cutting tools, the metal wires in the composite filament can form molten metal under the influence of a heat source. The sheet-like ceramic material can remain solid due to its high melting point and can be dispersed in the molten metal, promoting the spread of the molten metal. By means of weight, a dense composite structure is formed. The dense composite structure has low brittleness due to its low porosity, thereby ensuring the strength of the composite structure. Moreover, the composite structure itself has multiple layers divided by the sheet-like ceramic material. The internal stress of the multi-layer structure is low, which can reduce the risk of chipping. On the other hand, under extreme working conditions, even if one layer of the multi-layer structure cracks, the other layers will not subsequently crack continuously. Instead, they act as reinforcements to reduce the possibility of further cracking. In summary, when the composite filament is used as the material for forming cutting tools, it can satisfy high hardness while providing high toughness, thereby obtaining a long-lasting sharp cutting tool.

[0037] According to this application, metal wire, as an attachment substrate for sheet-like ceramic materials, can provide physical support for sheet-like ceramic materials with high hardness and brittleness, promoting the manufacturing and application of composite wires. For example, metal wire can provide ductility to composite wires, ensuring the feasibility of the winding process during the manufacturing of composite wires, facilitating the production of composite rolls, and allowing composite rolls to be controlled to obtain composite wires of the required size through diameter reduction stretching. It can also ensure the uniform dispersion of sheet-like ceramic materials, thereby avoiding edge chipping caused by localized overload. Furthermore, in the manufacture of cutting tools using composite wire, metal wire is more easily melted by heat sources than sheet-like ceramic materials, and can form a dense composite structure on the tool body in conjunction with the sheet-like ceramic materials to improve the overall strength of the tool, thereby preventing the tool from breaking due to insufficient strength. In addition, metal wire can act as a toughening component in composite wire, improving the bonding force between the composite structure formed by the composite wire and the tool body, thereby preventing the composite structure formed by the composite wire from peeling off.

[0038] In some embodiments, the metal wire is a wire with a hardness in the range of 500HV-800HV, specifically including at least one of titanium wire, titanium alloy wire, martensitic stainless steel wire, molybdenum series alloy wire, tool steel alloy wire, nickel-based alloy wire, and cobalt-based alloy wire. These specific metal wires enable the manufactured composite wire to possess basic toughness while also having advantages in cost, corrosion resistance, and hardness suitable for use as an adhesion substrate.

[0039] According to this application, the sheet-like ceramic material, also known as a ceramic sheet, is a sheet-like ceramic material. When incorporated into a metal wire, it allows the composite wire to form a wire-like structure (composite structure) uniformly mixed with the sheet-like ceramic material. In a preferred embodiment, the sheet-like ceramic material is a flake-like ceramic material, which facilitates the formation of a flake-like composite structure. Furthermore, when the composite structure is multi-layered, it exhibits lower stress, thereby further enhancing the long-lasting sharpness of the cutting tool.

[0040] In some embodiments, the sheet-like ceramic material has a thin sheet structure with two opposing main surfaces. The maximum size of the main surface is 2 square millimeters, the minimum size is 0.5 square millimeters, and the thickness is 10 μm-50 μm. This size of sheet-like ceramic material is conducive to dispersion in the metal wire. Moreover, the small size allows the sheet-like ceramic material to drip from the composite wire along with the molten metal during the process of forming a composite structure by heating the composite wire. It can also lie flat in the molten metal to promote the spreading of the molten metal through its sheet-like structure, thereby promoting the formation of a dense composite structure.

[0041] As a specific example, the main surface can be understood as the upper (lower) surface of a sheet-like ceramic material. Continuing from the example above, the surface area of ​​the main surface, formed by the maximum and minimum dimensions, is 1 mm. 2 -10mm 2 Thus, when the thickness is 10μm-50μm, it possesses the sheet-like structure required by this application.

[0042] According to this application, the ceramic material is an ionic ceramic material and / or a covalent ceramic material, both types of ceramic materials possessing suitable hardness, thereby enabling them to form a composite filament with both hardness and toughness together with the metal wire. As an example, the plate-like ceramic material is a ceramic material with a hardness in the range of 1500 HV to 2500 HV, specifically including at least one of plate-like oxides, plate-like carbides, plate-like nitrides, plate-like borides, and plate-like silicides. As examples, the sheet-like carbides include at least one of sheet-like titanium carbide, sheet-like titanium carbonitride, sheet-like silicon carbide, sheet-like boron carbide, sheet-like tantalum carbide, sheet-like niobium carbide, sheet-like tungsten carbide, and sheet-like tungsten dicarbide; the sheet-like nitrides include at least one of sheet-like titanium nitride, sheet-like titanium aluminum nitride, sheet-like silicon nitride, sheet-like cubic boron nitride, and sheet-like aluminum nitride; the sheet-like oxides include at least one of sheet-like alumina, sheet-like zirconium dioxide, and sheet-like titanium oxide; and the sheet-like borides include at least one of sheet-like titanium diboride and sheet-like zirconium diboride. These specific ceramic materials enable composite filaments to possess enhanced hardness while also offering advantages in cost and lightweight properties.

[0043] According to this application, during the formation of a multilayer composite structure using composite wires, the molten metal has a high density while the ceramic material has a low density. Under the influence of gravity, the molten metal changes from a droplet shape to a sheet-like form due to its flow. At this time, the metal carries the sheet-like ceramic material to flow. During the flow of the molten metal, the sheet-like ceramic material tends to align along the flow direction under shear force, forming a "layered reinforcing phase." The arrangement direction of the sheet-like ceramic material is almost parallel to the surface of the sheet-like monomers (for example, when the multilayer structure is a flake-like structure, the sheet-like monomers refer to the flake-like monomers, which are subsets constituting the multilayer structure) formed by the sheet-like precursors. It also utilizes weight to bond as tightly as possible with the corresponding metal material, forming a multilayer structure with small or even no pores, thereby improving material strength and preventing a decrease in material strength due to porosity. It should be noted that when the molten metal cools and solidifies, the sheet-like ceramic material is encapsulated by the metal matrix, forming a "metal-ceramic-metal" sandwich structure. Furthermore, the interlayer interfaces can achieve strong bonding through micro-mechanical interlocking (such as metal infiltration caused by the surface roughness of the ceramic sheet).

[0044] The inventors discovered that during the process of forming a multi-layer composite structure using composite filaments, the wettability of the sheet-like ceramic material in the composite filaments and the molten metal formed by the metal filaments affects the compactness of the individual sheets in the multi-layer composite structure, thereby affecting the overall structural strength of the constructed multi-layer composite structure and consequently the long-term sharpness of the cutting tool.

[0045] Specifically, when the wettability of the molten metal formed by the sheet-like ceramic material and the metal wire is good, the molten metal can better wet the side surfaces of the sheet-like ceramic material, thereby further reducing the internal gaps in the formed composite structure. This is especially true when covalent ceramic materials are used. Covalent ceramics (such as SiC, Si3N4, and B4C) are bonded by strong covalent bonds, with tightly packed and highly directional atoms, resulting in low surface energy and poor chemical activity. The wettability of these materials with molten metal is usually even worse, making it difficult for the molten metal droplets to spread during the wetting process. This leads to excessively large gaps between the sheet-like monomers in the resulting multilayer composite structure, affecting the structural strength of the multilayer composite structure.

[0046] To further enhance the structural strength of the multilayer composite structure, in some embodiments, the ceramic material is a ceramic material modified with polar functional groups. This can relatively reduce the polarity difference between the ceramic material and the molten metal formed by the metal wire, improve the wettability of the molten metal formed by the ceramic material and the metal material in the composite wire, and reduce the gaps inside the sheet-like monomers of the multilayer composite structure formed by the composite wire. This can further enhance the structural strength of the multilayer composite structure and further improve the long-term sharpness of the cutting tool.

[0047] As an example, polar functional groups include at least one of carboxyl, amino, and hydroxyl groups. The introduction of these polar functional groups can not only increase the polarity of ceramic materials and reduce the polarity difference between them and highly polar liquid metals, but also give them the advantages of being stable at room temperature and being readily available.

[0048] According to this application, there are many composite forms of ceramic materials and metal wires in composite wire materials.

[0049] In some embodiments, the sheet-like ceramic material is uniformly dispersed in the metal wire. That is, it can be understood that multiple sheets of sheet-like ceramic material are distributed in the metal wire. In the composite wire, the metal wire serves as a continuous phase matrix, and at least the sheet-like ceramic material as a dispersed phase is dispersed in the solid portion of the metal wire. Together, they constitute a composite wire having a mixed structure of metal and sheet-like ceramic material.

[0050] In the corresponding manufacturing method, sheet-like ceramic material can be filled and compacted onto one side of a metal strip. Then, the metal strip filled with the sheet-like ceramic material is wound into a multi-layered composite roll. This multi-layered composite roll can be used to manufacture a composite filament in which the sheet-like ceramic material is uniformly dispersed within the metal filament by diameter reduction drawing. Regarding the winding direction of the metal strip, taking the thickness direction of the metal strip relative to the first and second surfaces as an example, when the sheet-like ceramic material is filled on the first surface of the metal strip, the first surface can be positioned closer to the winding shaft than the second surface, or it can be positioned further away from the winding shaft than the second surface. Because the sheet-like ceramic material is already compacted onto the metal strip, it will not detach from the metal strip due to its weight. Therefore, this application does not require excessive limitation on the winding direction of the metal strip.

[0051] As a specific example, such as Figure 1 As shown, sheet-like ceramic material 102 is uniformly dispersed in metal wire 101 to form composite wire 100.

[0052] In other embodiments, the metal wire has a tubular structure, and sheet-like ceramic material is disposed on the inner or outer wall surface of the tubular structure. As a specific example, such as... Figure 2 As shown, sheet-like ceramic material is uniformly dispersed on the inner wall of the tubular structure.

[0053] In some embodiments, the composite filament is in the form of a hollow tube. For example, the inner radius of the hollow tube is 0.1 mm to 0.5 mm, and the outer radius is 0.3 mm to 1.5 mm. Composite filaments of this size are suitable for welding processes, thereby enabling further enhancement of the strength of the multilayer composite structure through welding, which in turn further improves the long-lasting sharpness of the cutting tool.

[0054] According to this application, in the composite wire, the metal wire is the main component, and the sheet-like ceramic material is the auxiliary reinforcing component. As an example, the volume of the ceramic material is 5%-30% of the total volume of the composite wire, and the volume of the metal wire is 70%-95% of the total volume of the composite wire. This allows for the acquisition of a composite wire with suitable hardness and toughness, thereby enhancing the strength of the multi-layered composite structure forming the cutting edge of the tool and further improving the tool's sustained sharpness. Here, the total volume of the composite wire refers to the volume of the solid portion of the composite wire, that is, the total volume of the composite wire excluding internal pores.

[0055] According to a second aspect of this application, a method for manufacturing a composite filament is provided, wherein the method includes providing a metal strip with a plurality of grooves on its surface; filling the grooves of the metal strip with a sheet-like ceramic material; and then processing the metal strip after filling the grooves with the sheet-like ceramic material into a composite filament in which the sheet-like ceramic material is incorporated.

[0056] According to the manufacturing method of the composite wire of this application, a composite wire in which a sheet-like ceramic material is incorporated into a metal wire can be manufactured in the above manner. The composite wire can be used to manufacture a cutting edge of a tool with a multi-layer composite structure, thereby ensuring the long-lasting sharpness of the tool due to the increased strength of the cutting edge.

[0057] The following will describe in detail the manufacturing method of the composite filament according to this application.

[0058] Metal strips are available According to this application, a metal strip refers to a thin strip made of metal. As a specific example, one or more of the following can be selected: titanium strip, titanium alloy strip, martensitic stainless steel strip, molybdenum series alloy strip, tool steel alloy strip, nickel-based alloy strip, and cobalt-based alloy strip. These specific metal strips can meet the requirements of cutting tools for corrosion resistance and have a certain degree of toughness.

[0059] According to this application, the manufacturing method of composite wire may include pickling and alkali washing of metal strip to remove impurities or oxides on the surface of the metal strip, thereby improving the bonding force between the metal wire and the sheet-like ceramic material to be filled subsequently.

[0060] As a specific example, the metal strip can be surface-treated, such as by acid pickling to remove oxide scale, followed by alkaline washing and degreasing, and finally by water washing and drying, to ensure a good bond between the sheet-like ceramic material and the grooves of the metal strip.

[0061] According to this application, after pickling and alkali washing, multiple grooves can be formed on the surface of the metal strip to obtain a metal strip with multiple grooves on its surface. Here, the grooves can be obtained by pressing the metal strip. As a specific example, the metal strip can be unwound and passed through a forming machine, where multiple sets of rollers gradually press grooves into the surface of the metal strip in the thickness direction. These grooves can prepare for filling with sheet-like ceramic material. Here, the size and shape of the grooves can be comparable to the size of the composite sheet-like ceramic material to ensure that the sheet-like ceramic material can be effectively composited with the metal strip, and the spacing between the grooves is uniform, thus ensuring the uniform distribution of the sheet-like ceramic material in the composite roll. It should be noted that the size and shape of the grooves in this application are adapted and adjusted according to the specifications of the welding wire and the flux-cored filling amount; this application does not impose excessive limitations on this.

[0062] As an example, the groove is U-shaped, roughly matching the sheet-like ceramic material, making it easy to fill to construct the composite filament.

[0063] In these embodiments, by pre-setting grooves on the metal strip, the grooves can lock the sheet-like ceramic material in place. The uniform distribution of these grooves ensures even filling of the sheet-like ceramic material, preventing accumulation or localized voids in the composite filament. Furthermore, the grooves allow the ceramic material to embed within the metal strip during filling, forming a mechanically interlocking structure for a tight bond, thus ensuring stability in subsequent processes and guaranteeing the uniform distribution of the sheet-like ceramic material within the composite filament.

[0064] As a specific example, in every 1 square meter of metal strip, there are 500-2000 grooves. The grooves are square, with a length of 1mm-3mm, a width of 0.5mm-1mm, and a depth of 0.05mm-0.5mm. Such uniformly distributed grooves can ensure the uniformity of the distribution of sheet-like ceramic materials in the composite wire.

[0065] According to an embodiment of this application, after subsequent processing, the metal strip can form a portion of the metal wire in the composite filament according to this application, and its specific material is the same as the metal wire material mentioned above.

[0066] As a specific example, the thickness of the metal strip is 0.1mm-1mm, which ensures that it has the toughness to be rolled after the sheet ceramic material is filled, thereby ensuring the formation of the composite roll and laying the foundation for obtaining a composite filament in which the sheet ceramic material can be evenly distributed.

[0067] Provide sheet-like ceramic materials According to this application, the method for manufacturing composite filaments includes the step of providing sheet-like ceramic material, which may adopt the specific type and size of ceramic material described in the above embodiments.

[0068] The inventors discovered that during the formation of a multi-layer composite structure, the wettability of the molten metal formed by the sheet-like ceramic material in the composite filament and the metal filament affects the internal bonding tightness of the sheet-like monomers in the multi-layer composite structure, thereby affecting the overall structural strength of the multi-layer composite structure and thus affecting the long-term sharpness of the cutting tool.

[0069] To further enhance the structural strength of the multilayer composite structure, in some embodiments, prior to filling the grooves of the metal strip with sheet-like ceramic material, the ceramic material is further subjected to plasma treatment to obtain a ceramic material modified with polar functional groups. Plasma treatment allows polar functional groups to be grafted onto the ceramic material, thereby relatively reducing the polarity difference between the ceramic material and the molten metal formed by the metal wire. This improves the wettability of the molten metal formed by the ceramic material and the metal material in the composite wire, reduces the gaps within the sheet-like monomers of the multilayer composite structure formed by the composite wire, and thus further enhances the structural strength of the multilayer composite structure to further improve the long-term sharpness of the cutting tool.

[0070] In some embodiments, the corresponding method for manufacturing ceramic materials includes employing a plasma method, whereby plasma is used to bombard the surface of the ceramic material to introduce polar functional groups (such as -COOH, -NH2, -OH), thereby increasing the surface polarity of the ceramic material. Here, plasma is an ionized gas containing high-energy particles such as electrons, ions, and active free radicals, possessing high energy and high reactivity. When plasma bombards the surface of the ceramic material, its high-energy particles (such as electrons, positive ions, negative ions, excited-state atoms or molecules) interact with the atoms and molecules on the surface of the ceramic material, including processes such as ion bombardment, atomic or molecular reactions, and chemical oxidation. These processes cause the dissociation and repulsion of surface atoms and molecules, thereby achieving etching and processing of the ceramic material surface and introducing polar functional groups. For example, oxygen plasma can be used to introduce oxygen-containing groups (such as -COOH, -OH), while nitrogen plasma or ammonia plasma can be used to introduce amino groups (-NH2).

[0071] As an example, polar functional groups include at least one of carboxyl, amino, and hydroxyl groups. The introduction of these polar functional groups can not only increase the polarity of ceramic materials and reduce the polarity difference between them and highly polar liquid metals, but also give them the advantages of being stable at room temperature and being readily available.

[0072] Premixed dispersed flake ceramic materials According to this application, the method for manufacturing composite filaments further includes a step of stirring and mixing sheet-like ceramic materials, which can improve the dimensional uniformity of the sheet-like ceramic materials through stirring and mixing.

[0073] In some embodiments, the stirring and mixing step is carried out at a preset temperature, wherein the preset temperature is 150℃-200℃. At a certain temperature, the static charge on the surface of the sheet-like ceramic material decreases, the van der Waals force weakens, and the agglomerates of the sheet-like ceramic material are easily broken by shear force, thereby facilitating the uniform distribution of sheet-like ceramic materials of various sizes.

[0074] As a specific example, the weighed, surface-treated sheet-like ceramic material is placed into a mixing device, such as a V-type stirrer or a double cone mixer, and stirred evenly at a certain temperature (such as 150℃-200℃) to avoid agglomeration. The stirring time depends on the equipment and the amount of powder, and is generally 1-2 hours.

[0075] Forming composite rolls According to this application, the grooves of a metal strip are filled with sheet-like ceramic material, and then the metal strip filled with sheet-like ceramic material is rolled into at least one layer of composite roll material. The composite roll material is then stretched by reducing its diameter, thereby obtaining a composite wire material in which sheet-like ceramic material is incorporated into the metal wire material.

[0076] According to this application, the grooves of a metal strip are filled with sheet-like ceramic material. As an example, a suitable filling device, such as a spiral powder feeder, can be used to fill the grooves of the metal strip with the mixed sheet-like ceramic material. During the filling process, a vibration device can be used to perform horizontal vibration with a vibration frequency of 30Hz-100Hz and an amplitude of 0.1mm-1mm, making the sheet-like ceramic material filling more compact and uniform.

[0077] According to this application, a metal strip filled with sheet-like ceramic material is rolled into at least one layer of composite roll material. In the rolling process, the metal strip is pressed and closed by rollers to form the composite roll material.

[0078] It should be noted that the inner radius of the composite roll is 3cm-8cm. With such an inner radius, a composite roll with a sufficiently large inner radius can be obtained, which is quite different from the sheet ceramic material. Therefore, the sheet ceramic material distributed on each roll layer will not be deformed too much due to rolling.

[0079] According to this application, the number of winding layers can be either an even number or an odd number. For example, it can be 2, 4, 6, 8, or 10 layers, or 1, 3, 5, 7, or 9 layers. The inner radius of the composite roll is 3cm-8cm, and the outer radius is 3.2mm-9cm. This thickness facilitates subsequent diameter reduction stretching to prepare for obtaining the composite filament.

[0080] As an example, the winding direction can place the surface of the metal strip filled with sheet-like ceramic material on the inside or outside of the composite roll. This application does not specifically limit the winding direction.

[0081] Set coating According to this application, the method for manufacturing composite wire further includes the step of applying a coating to the outer side of the obtained composite roll before diameter reduction stretching, wherein the coating is a rust-proof layer and / or a flux layer, the rust-proof layer can inhibit the oxidation and corrosion of the composite roll during storage, and the flux layer can reduce the melting point of the welded composite roll and improve the overall wettability of the composite wire obtained after stretching and diameter reduction.

[0082] In some embodiments, the thickness of the anti-rust layer is 1μm-5μm, and the thickness of the flux layer is 0.5μm-2μm. Such thicknesses can ensure their respective functions while avoiding affecting the basic properties of the composite wire.

[0083] In some embodiments, the anti-rust layer can be obtained by brush plating. For example, the dried composite roll can be placed in a plating solution for brush plating to form a metal layer that is not easily oxidized, such as a nickel layer or a copper layer. The brush plating voltage is 12V-15V and the brush plating time is 5s-15s.

[0084] In some embodiments, the flux layer can be obtained by spraying, for example, by pulverizing the flux to 200-300 mesh and mixing it with an adhesive (such as polyvinyl alcohol) to form a slurry. Then, the flux layer is formed by uniformly covering the circumference of the composite roll material by rotating a spray gun (500-1000 rpm).

[0085] Reduced diameter stretched composite rolls, used to manufacture composite filaments According to this application, the manufacturing method of the composite filament may optionally include pre-treatment before stretching, specifically annealing treatment, which involves intermediate annealing of the composite roll (the temperature depends on the metal material) to eliminate work hardening caused by rolling and prevent tensile breakage.

[0086] According to this application, the manufacturing method of the composite wire also includes diameter reduction stretching of the composite roll, which reduces the diameter of the composite roll to obtain a composite wire in which sheet-like ceramic material is incorporated into the metal wire. During the stretching process, the composite roll is subjected to tensile force along its axial direction, causing plastic flow in the metal matrix, which in turn drives the sheet-like ceramic material incorporated within. Due to the differences in the elastic modulus and other mechanical properties of metal and ceramic, although the ceramic material has high hardness, it will also be "stretched" to a certain extent under strong tensile stress, resulting in an increase in its length dimension and a corresponding decrease in its width and thickness dimensions, thus changing its shape.

[0087] As a concrete entity, the drawing process is carried out through straight-line drawing and roller drawing. The diameter of the welding wire is gradually reduced through multiple drawing passes to achieve the required specifications. During the drawing process, the drawing speed and reduction amount must be carefully controlled to avoid problems such as wire cracking. For example, when drawing the outer radius from 6cm to 1cm, the reduction amount can be set to 0.5mm-1cm per pass, obtaining the required composite wire size through successive reductions. Another example is a drawing speed of 20m / min-200m / min. In a preferred embodiment, a gradient drawing speed can be set, for example, dividing the drawing stage into a first stage and a second stage. The first stage drawing speed is maintained in the range of 20m / min-50m / min, and the second stage drawing speed is controlled in the range of 100-200m / min to balance production efficiency and composite wire quality.

[0088] In some embodiments, the method for manufacturing composite filaments further includes a step of cleaning the surface of the drawn composite filaments, specifically using ultrasonic cleaning (acetone or anhydrous ethanol, frequency 40kHz, time 10-15min) to remove oil and impurities, and to prevent cracks caused by surface defects during stretching.

[0089] Straightening and Cutting In some embodiments, the manufacturing method of the composite wire further includes straightening and cutting. Specifically, the composite wire is straightened using a straightening device to ensure its straightness meets requirements, facilitating subsequent use and welding operations. Then, according to packaging requirements, the welding wire is cut to a certain length for later use, or directly coiled into a disc.

[0090] According to a third aspect of this application, a method for manufacturing a cutting tool is provided, wherein the method for manufacturing a cutting tool includes the following steps.

[0091] Step S101: Provide the tool body.

[0092] Step S102: Coating the tool body with composite wire to form a composite structure including a metal material in which flake-like ceramic material is dispersed, thereby manufacturing a tool with a cutting edge including the composite structure, and the composite structure can form the cutting edge of the tool.

[0093] According to the tool manufacturing method provided in this application embodiment, when manufacturing a tool using this composite wire, the metal material in the composite wire can form a molten metal under the influence of a heat source, while the sheet-like ceramic material can remain solid due to its high melting point and can be dispersed in the molten metal, promoting the spread of the molten metal to form a dense composite structure, thereby ensuring the tool's long-lasting sharpness. Furthermore, the metal wire enables the composite wire to possess a certain degree of toughness, and the sheet-like ceramic material can act as a reinforcing phase, enabling the composite wire to possess a certain degree of hardness. This combination of toughness and hardness allows the composite wire to form a tool with both hardness and toughness, further improving the tool's long-lasting sharpness.

[0094] In some embodiments, the sidewalls of the tool body in the thickness direction (corresponding to the region forming the cutting edge of the tool) have receiving grooves, and the step of forming the composite structure includes: filling the receiving grooves with composite filaments; the manufacturing method further includes: sharpening the blade so that the composite structure and the tool body together form the cutting edge of the tool and serve as the cutting edge of the tool.

[0095] In this application, the sharpening process is a bevel grinding process, or other methods that can achieve sharpening, such as flat grinding.

[0096] In this application, a double-sided sharpening operation is performed after filling the composite structure. Specifically, after filling the composite structure, a double-sided bevel grinding process is used to form the final cutting edge of the tool. On the one hand, this ensures the thickness and flatness of the substrate (the part of the tool body opposite the receiving groove) used to fill the composite structure, allowing the composite structure to bond tightly with the tool body and enhancing the overall structural stability of the tool. On the other hand, the angle of the two bevels can be controlled through the sharpening process, allowing the final cutting edge of the tool to develop in a direction that is symmetrically or nearly symmetrically distributed between the composite structure and the tool body, thereby obtaining a cutting edge of a tool with a composite structure that has a larger filling volume.

[0097] In these embodiments, by combining the oblique grinding process, the cutting edge of the tool is formed together with the tool body through a composite structure. In this way, a cutting edge with suitable hardness, impact toughness and interlayer bonding strength can be manufactured, avoiding chipping or rolling, thereby ensuring the long-lasting sharpness of the tool.

[0098] In this application, impact toughness refers to the ratio of the energy absorbed before fracture under impact load to the original cross-sectional surface area of ​​the specimen, expressed in joules per square centimeter (J / cm²). 2 () or feet-pounds (ft-lb). Here, the impact toughness has a non-linear relationship with the tool hardness.

[0099] In some embodiments, the hardness of the composite structure of the cutting edge is 600HV-1000HV, and the hardness of the tool body of the cutting edge is 500HV-800HV. The combination of these two parts can form a cutting edge with suitable hardness and toughness, thereby avoiding chipping of the cutting edge.

[0100] The hardness and brittleness of materials have always been a paradox in the materials science world; the higher the hardness, the more brittle the material. This contradiction is particularly pronounced in welding materials due to the stress accumulation during the melting process. Specifically, after coating and molding, the coating layer (e.g., spray layer, cladding layer, weld layer) of a single type of material has high internal stress, leading to problems such as spalling or cracking even under relatively small external forces. While composite materials are also subjected to stress after coating and molding, the differences in cooling coefficients and hardness between different materials can offset or even eliminate some of the internal stress. For example, during the cooling process of composite filaments, different materials deform under the influence of internal stress. When the two materials deform in opposite directions, the internal stresses of the two materials in the coating layer cancel each other out, significantly reducing the overall internal stress of the coating layer. Furthermore, when composite filaments are subjected to external impact, if one of the harder material layers fractures, it will be blocked by the adjacent softer material layer. Therefore, it will not experience the continuous fracture seen in a single cladding material; the fracture will only occur within a specific layer and will not extend to the entire material, thus improving the overall toughness of the material.

[0101] In general, during the melting process of existing materials, due to factors such as melting deformation, the coating layer formed by the material for cutting tools has greater stress. Greater stress leads to greater brittleness of the cladding layer, making the cutting tools with this cladding layer prone to chipping.

[0102] According to the tool manufacturing method provided in the embodiments of this application, a composite wire can be formed by combining a sheet-like ceramic material into a metal wire. During the process of forming a composite structure through the composite wire, the sheet-like ceramic material in the composite wire can promote the spreading of the molten metal formed by the metal wire, and under the influence of gravity, it can tightly bond with the corresponding metal material to reduce the composite gap of the formed composite structure. Furthermore, the composite structure itself has multiple layers divided by the sheet-like ceramic material, thereby obtaining a cutting edge with a composite structure and improving the long-lasting sharpness of the tool.

[0103] As a specific example, the composite structure includes a metallic material and a sheet-like ceramic material dispersed in the metallic material, which serves as the cutting edge of the knife. A knife with such a cutting edge and cutting edge can have a certain degree of toughness and hardness due to the presence of both metallic and ceramic materials, thereby further improving the knife's long-lasting sharpness.

[0104] Figure 17 This is a scanning electron microscope (SEM) image of the cutting edge of a tool according to an embodiment of the present invention. See also: Figure 17 As can be seen, the cutting edge of the knife has a composite structure. The gray-black color represents sheet-like ceramic material, while the gray-white color represents metallic material.

[0105] In a preferred embodiment, the multilayer structure can be further optimized by using composite wires to form molten droplets at intervals. This multilayer structure disperses the impact load and avoids localized stress concentration, thus significantly reducing the risk of chipping due to stress concentration during use and further enhancing the tool's long-term sharpness. Arc welding can be used to form the molten droplets from the composite wires at intervals, with the interval time not less than 0.05 s. For example, the time can be selected from 0.05 s to 0.5 s, such as, but not limited to, 0.1 s to 0.4 s or 0.2 s to 0.3 s.

[0106] In the embodiments of this application, the further optimized structure can be formed as a multi-layered scale structure. Compared with a multi-layered structure of the same volume that is stacked in the same direction through a single layer, the multi-layered scale structure has more levels and more layers in more directions. Therefore, the multi-layered scale structure can better disperse impact loads and avoid local stress concentration, thereby largely avoiding chipping due to stress concentration during use, and further improving the long-term sharpness of the tool.

[0107] In some embodiments, the multi-layered scaly structure and the tool body together form the cutting edge of the tool, serving as the cutting edge. It can be understood that a portion of the thickness direction of the cutting edge is a multi-layered scaly structure, while another portion is the tool body. This composite cutting edge possesses suitable impact toughness and can maintain its sharpness over time. Furthermore, the scaly structure of the cutting edge can form a micro-serrated structure at the cutting edge during sharpening through the individual scales and the gaps between them, thereby enabling the tool to exhibit better cutting performance.

[0108] Furthermore, the composite wire material contains both metal wire and flake-like ceramic material. When using this composite wire material to manufacture knives, the metal wire in the composite wire material can form molten metal under the influence of a heat source. Due to the influence of gravity and buoyancy, it will lie flat in the molten metal. The flat flake structure promotes the spread of the molten metal into flake-like monomers. Thus, knives with flake-like cutting edges can be manufactured by stacking the flake-like monomers, thereby reducing the stress at the cutting edge and improving the long-lasting sharpness of the knife by leveraging the strength of the multi-layer flake-like structure.

[0109] The manufacturing method of the cutting tool provided in the embodiments of this application will be described in detail below.

[0110] Provide tool body In this application, the tool body 10 is generally formed as a cuboid. Figures 3 to 5 The diagram illustrates the general structure of the tool body 10, which has a uniform thickness in all regions along the thickness direction and two opposing surfaces in that direction. However, this application is not limited to this. For example, according to the tool body of this application, the two surfaces in the thickness direction may also be slightly inclined surfaces, thus the tool body may also be generally formed into an inverted conical structure.

[0111] According to this application, the shape of the knife body 10 can be specifically set according to the type of knife it forms. In an exemplary embodiment, the knife is a kitchen knife, and the knife body 10 has a knife prototype formed from a substrate through blanking. Exemplarily, the knife body 10 is generally formed into an inverted conical structure or a cuboid structure.

[0112] According to this application, the substrate (material) forming the initial blank can be stainless steel or carbon steel with a carbon weight percentage of 0.6%-1.4% and a hardness of 400HV-1000HV. Specifically, the stainless steel can be at least one martensitic stainless steel material selected from 3Cr13, 4Cr13, 5Cr15MoV, 6Cr13MoV, 7Cr17MoV, and 102Cr17MoV. The carbon steel can be high-carbon steel or low-carbon steel. The knife body formed by these materials has a certain degree of hardness and toughness, and can serve as a base material to further improve the impact toughness of the knife. Together with the composite structure composed of metal materials and sheet-like ceramic materials, it forms the cutting edge of the knife, thereby making the knife persistently sharp and resistant to chipping during daily use.

[0113] Forming a receiving groove According to this application, the length direction of the tool body corresponds to the length direction of the formed tool, the width direction of the tool body corresponds to the width direction of the formed tool, and the thickness direction of the tool body corresponds to the thickness direction of the formed tool.

[0114] In this application, a receiving groove is formed on the sidewall of the tool body in the thickness direction (at the position where the cutting edge of the tool will be formed later), thereby obtaining a tool body with a receiving groove on the sidewall in the thickness direction. When manufacturing the receiving groove, a groove can be cut in the sidewall of the tool body in the thickness direction along a certain direction. For example, it can start from the sidewall in the width direction of the tool body and extend in the width direction to form a receiving groove with a large area.

[0115] As an example, the width of the receiving groove is 3%-10% of the width of the tool body. Here, the width of the receiving groove is the extension length of the receiving groove in the width direction of the tool body. In this way, the relatively long extension length in the width direction of the tool body can be fully utilized, thereby ensuring that the subsequent filling of the scaly structure has a sufficient amount. In addition, the larger width of the receiving groove can form a groove bottom with a larger surface area, which can increase the bonding surface area between the multi-layer scaly structure and the tool body, thereby improving the bonding force between the two and effectively preventing the multi-layer scaly structure from delaminating during use.

[0116] As an example, the depth of the receiving groove is 40%-60% of the thickness of the tool body. Here, the depth of the receiving groove is the length of its extension in the thickness direction of the tool body. In this way, by cooperating with subsequent beveling, the final tool retains more multi-layered scaly structures in the thickness direction. These multi-layered scaly structures in the thickness direction suppress brittle fracture at the cutting edge, improving the tool's sustained sharpness. For example, the tool retains reliable sustained sharpness even after subsequent continuous sharpening.

[0117] In this application, a receiving groove is provided on the sidewall of the tool body in the thickness direction. When the tool body has a cuboid structure, the receiving groove can also be formed into a regular structure, such as a rectangle, triangle, or ellipse. In an exemplary embodiment, the receiving groove of the tool body is formed as a rectangular groove. As an example, the width of the receiving groove is 3mm to 15mm, the depth is 40% to 60% of the thickness of the tool body, the length is at least equal to 1 / 3 of the length of the tool body, and it corresponds at least to the cutting edge area of ​​the formed tool. It is understood that in some embodiments, the tool body contains multiple layers along its length, in which case the length of the receiving groove is equal to the length of the tool body. In other embodiments, the tool body partially contains multiple layers along its length, the length of which is equal to 1 / 3 to 2 / 3 of the length of the tool body, and it corresponds at least to the cutting edge area of ​​the formed tool.

[0118] According to this application, a receiving groove is formed on the surface of the tool body in the thickness direction. For example... Figures 3 to 8 As shown, the surface of the tool body 10 in the thickness direction includes a first surface 11 and a second surface 12. The tool body 10 also includes a handle connector 40 disposed on the side wall in the length direction of the tool. In this case, the first surface 11 is located on the right side of the handle connector 40, and the second surface 12 is located on the left side of the handle connector 40, wherein a receiving groove is formed on the second surface 12. It should be noted that the receiving groove can also be formed on the first surface 11.

[0119] In this application, the tool body 10 is a plate-like structure of uniform thickness, which can be 2.0mm-3mm thick. For example... Figures 3 to 8 As shown, the tool body 10 has a cuboid structure, and the centerline of the tool body 10 in the thickness direction is S1. Here, the centerline in the thickness direction is a straight line that divides the tool body 10 into two equal halves along the thickness direction. The bottom wall of the receiving groove 20 coincides with S1, is parallel to S1, and has a distance of no more than 0.5 mm from S1, or is slightly inclined relative to S1 (e.g., the inclination angle is no more than 10°). Thus, the receiving groove has a large coverage area in the thickness direction (approximately 1 mm or more). With the multi-layered flake structure completely filling the receiving groove, the beveled edge ensures that the final manufactured tool has a large amount and many layers of multi-layered flake structure on the cutting edge, thereby helping to suppress brittle fracture at the cutting edge and improving the tool's long-term sharpness. Especially when the multi-layered flake structure has different hardness in the thickness direction, a hardness gradient can be formed in the thickness direction of the cutting edge, which is more conducive to suppressing brittle fracture at the cutting edge and reducing stress, thereby significantly improving the tool's long-term sharpness.

[0120] In some embodiments, the method of manufacturing the tool further includes a step of roughening the receiving groove (sandblasting, wire drawing) to improve the surface roughness of the inner wall (bottom wall and side wall) of the receiving groove, laying the foundation for the subsequent formation of a multi-layered scaly structure.

[0121] Filled multi-layer structure According to this application, the sub-layers in the multi-layer structure can be stacked in any direction. In exemplary embodiments, the sub-layers can be stacked along the thickness, width, or length direction of the blade. In a preferred embodiment, the sub-layers in the multi-layer structure are stacked along the width direction, thus corresponding to the force direction of cutting food, thereby reducing the possibility of blade chipping through multi-layer composite. In a more preferred embodiment, the multi-layer structure is formed as a multi-layer scale-like structure, which has a three-dimensional or two-dimensional multi-layer structure. The multi-dimensional structure can withstand mechanical impacts from different directions, especially in multi-scenario applications such as chopping meat (blade direction) and smashing garlic (blade perpendicular direction). The multi-layer structure can disperse impact loads and avoid local stress concentration.

[0122] According to this application, a multi-layered structure is formed / filled in the receiving groove. Thus, through subsequent double-edging, the cutting edge formed by the multi-layered structure and a portion of the tool body serves as the cutting edge of the tool. Here, the cutting edge can also be referred to as the cutting tip or the cutting edge of the tool. Such a cutting edge possesses suitable hardness, impact resistance, and bonding strength, making it less prone to chipping or rolling, thereby ensuring the tool's long-lasting sharpness.

[0123] According to this application, the multilayer structure possesses a hardness gradient, meaning that the hardness along the thickness direction of the multilayer structure exhibits a gradient transition or alternating distribution. This hardness distribution design allows the multilayer structure to withstand different loads at different locations, thereby more effectively dispersing impact forces, avoiding local stress concentration, and improving the overall performance of the structure. In a preferred embodiment, the hardness of the multilayer structure exhibits an alternating distribution along the thickness direction, which can better suppress brittle fracture of the tool. For example, in the multilayer structure, the odd-numbered layers from the outside to the inside in the thickness direction are high-hardness material layers (layers 1, 3, 5, 7, 9). Even-numbered layers (2nd, 4th, 6th, 8th) The first layer has the second highest hardness, and in the event of brittle fracture, only the first layer will fracture. The second layer, due to its higher toughness, will inhibit the fracture from propagating further inward, thus suppressing brittle fracture at the cutting edge. Specifically, this method forms a multi-layered, scaly structure with either soft-hard-soft or hard-soft-hard material layers. When the hard material layer undergoes plastic deformation, it acts on the soft material layer. The soft material layer cannot stop the deformation, so the hard material layer will deform to some extent, releasing the stress in the hard material layer. Furthermore, when the hard material layer fractures, the soft material layer acts as a "barrier" to prevent further fracture, thus avoiding multi-layered structure failure. In addition, the multi-layered structure can undergo interlaminar sliding, absorbing energy and reducing chipping. Furthermore, it should be noted that in the case of a multi-layered, scaly structure, even if there is no hardness gradient, the stress between adjacent layers will interact and partially cancel each other out because the orientation of the individual lamellae in each layer is not completely consistent.

[0124] In this application, the aforementioned hardness gradient can be achieved by adjusting the material composition and heat treatment process of each layer in the multilayer structure. For example, to adjust the material composition of each layer in the multilayer structure, different composite wires can be used in adjacent layers to construct a hardness gradient with alternating hardness distributions. As another example, regarding the heat treatment process, after forming the multilayer structure, the surface layer can be subjected to high-frequency quenching (to increase surface hardness) to form a hardness gradient of "soft core - hard surface".

[0125] In other embodiments, the multilayer structure can also have uniform hardness, meaning that the hardness of each part remains essentially consistent throughout the entire multilayer structure. A multilayer structure with uniform hardness offers better process control during manufacturing, ensuring consistent performance across all parts. When it forms the cutting edge with the tool body, it helps maintain a relatively uniform stress state on the cutting edge during use, thereby guaranteeing the tool's cutting performance.

[0126] The multi-layered scale-like structure according to this application will be described in detail below.

[0127] According to this application, the multilayer flake-like structure has a composite structure formed by aligning or staggering adjacent flake-like layers. Here, the flake-like layers can be stacked as thin sheet-like units in the thickness direction of the tool, and the multiple flake-like layers stacked in the thickness direction can have generally similar structures. For example, the flake-like layer can be formed by aligning or staggering multiple individual flakes in the length direction of the tool, or by aligning or staggering multiple individual flakes sequentially in the length and width directions of the tool.

[0128] like Figure 10 As shown, the multi-layered scale-like structure 32 is composed of multiple overlapping scale units 3211, exhibiting a complex three-dimensional structure formed by the stacking or arrangement of multiple scale units 3211. Compared with multi-layered structures, this scale-like multi-layered structure possesses significantly greater impact toughness, interlayer bonding strength, and multi-layered morphology.

[0129] Reference Figures 10 to 12 The multi-layered scale structure 32 includes multiple scale-like layers 321 stacked along the thickness direction of the tool, wherein each scale-like layer 321 includes multiple scale sub-layers arranged along the width direction of the tool, and the scale sub-layers include multiple scale units 3211 overlapping along the length direction of the tool.

[0130] In these embodiments, the defined multi-layered flake structure possesses a three-dimensional multi-layered structure. That is, it has layered gradients in the length, width, and thickness directions. This multi-layered flake structure, with its stacked structure in multiple directions, exhibits superior impact resistance, significantly suppresses brittle fracture at the cutting edge, and, due to its multi-layered morphology, prevents chipping, thereby further enhancing the tool's sustained sharpness. In particular, the multi-layered structure with varying hardness in the thickness direction allows the material's toughness to inhibit further inward fracture propagation, thus suppressing brittle fracture at the cutting edge. Furthermore, the multi-layered flake structure allows for interlaminar sliding, absorbing energy and reducing chipping.

[0131] Correspondingly, the manufacturing method of the cutting tool can also optimize the construction of a multi-layered scaly structure by controlling the spraying process of the composite filament.

[0132] The following describes specific embodiments of constructing a multi-layered flake structure by controlling the spraying process of composite filaments.

[0133] In this application, a composite filament containing sheet-like ceramic material is used, which can easily form a multi-layered flake-like structure in the receiving groove of the tool body by forming molten droplets at preset time intervals. Combined with the oblique grinding sharpening process, the cutting edge of the tool is formed by the multi-layered flake-like structure and the tool body together. In this way, a tool cutting edge with suitable hardness, impact toughness, and interlayer bonding strength can be manufactured, avoiding chipping or rolling, thereby ensuring the tool's long-lasting sharpness. Specifically, under the influence of a heat source, the metal material in the metal wire at the front end of the composite filament can be completely melted into molten metal, and the sheet-like ceramic material drips down with it. Since the temperature provided by the heat source has not yet reached its melting point, this part of the ceramic material does not melt but is dispersed in the molten metal. Therefore, when forming a flake-like structure using this composite filament, the metal wires in the composite filament act as a binder, forming a molten metal that fully wets the surface of the tool body. The sheet-like ceramic material in the composite filament is flattened by buoyancy and gravity in the molten metal, promoting the lateral spread of the molten metal. This results in a more uniform, multi-layered flake-like structure, reducing stress on the tool structure and increasing overall strength, thereby further enhancing the tool's long-lasting sharpness. Furthermore, the sheet-like ceramic material is flush with the tool body surface due to buoyancy in the molten metal, allowing for further layering within the flake-like structure, increasing the number of layers and enhancing the tool's strength. Additionally, the sheet-like ceramic material can form a metallurgical bond with the tool body through the molten metal, thus improving the tool's long-lasting sharpness from the perspective of bonding strength.

[0134] To further optimize the formed flake-like structure, composite filaments can be used to sequentially form molten droplets (a molten metal containing dispersed flake-like ceramic material) under specific conditions (such as thermal melting). When the droplets come into contact with the tool body or with a portion of the already formed flake-like structure, they spread out, forming a preliminary flake shape and size. By controlling the formation of droplets at preset intervals—that is, after the previous droplet has completed spreading and formed a preliminary shape, the next droplet is formed, and the currently formed droplet is fused with the preliminary flake shape constructed at the previous moment—adjacent flake units overlap, further optimizing the formed flake-like structure and improving the tool's sharpness.

[0135] According to this application, the multi-layered scale-like structure can have two-dimensional or three-dimensional multi-layers, that is, it has a multi-layered structure in two-dimensional or three-dimensional directions. The specific formation method will be described below.

[0136] In some embodiments, the step of forming a multi-layered scale-like structure in the receiving groove includes moving the composite filament along the length direction of the tool and forming droplets at a preset time interval, such that adjacent droplets overlap, thereby causing the scale units of adjacent droplets to overlap to form scale sub-layers; forming multiple scale sub-layers along the width direction of the tool and connecting adjacent scale sub-layers to form a scale-like layer; and sequentially stacking multiple scale-like layers in the thickness direction of the tool body to form a three-dimensional multi-layered scale-like structure; wherein, the previous droplet in an adjacent droplet can spread out and be in a semi-solidified state within a preset time and overlap with the next droplet.

[0137] In other embodiments, the step of forming a multi-layered flake structure includes: moving a composite filament along the length of the tool and forming droplets at a preset time interval, such that adjacent droplets overlap, thereby causing the flake monomers of adjacent droplets to overlap to form a flake layer; and sequentially stacking multiple flake layers in the thickness direction of the tool body to form a two-dimensional multi-layered flake structure; wherein, the previous droplet in an adjacent droplet can spread out and be in a semi-solidified state within a preset time and overlap with the next droplet.

[0138] In these embodiments, molten droplets are formed at regular time intervals using composite filaments. These droplets spread out and flatten under gravity, and external temperatures cause them to solidify into a semi-solid state, thus creating a scale-like rudimentary structure (a soft material with a basic scale-like structure, initially solidified but still retaining some plasticity). This scale-like rudimentary structure possesses a certain degree of morphological stability, unaffected by subsequent droplets, and facilitates metallurgical bonding with the scale-like rudimentary structure formed by the next droplet, further enhancing the overall strength of the scale-like structure. Furthermore, the overlapping structure between adjacent scale units absorbs and disperses the impact energy generated during cutting, reducing tool damage and breakage due to impact and improving the tool's impact resistance.

[0139] According to this application, the surface of the groove has an arc-shaped unevenness, which facilitates the formation of flat, scale-like monomers by the molten droplets under the influence of surface tension, thereby forming a scale-like structure.

[0140] According to this application, any heat source in the prior art can be used for the heat source that can cause the composite wire to form molten droplets sequentially. For example, specific methods may include electron beam fused wire deposition (EBFF), electric arc additive manufacturing (WAAM), pulsed MIG welding, CMT (cold metal transfer) technology, STT (short-terminal tack welding) technology, arc welding or plasma welding, laser welding, gas welding, etc. For example, the temperature range under the influence of the heat source is 1500℃-3000℃.

[0141] In some embodiments, the composite wire can be induced to form molten droplets by arc welding. The parameters of arc welding include a welding current of 100-500A, a welding voltage of 20-40V, and a welding speed of 0.1cm / s-1cm / s.

[0142] In some embodiments, the composite wire is formed into molten droplets by welding at a power of 2kW-20kW. The outer radius of the composite wire is 0.3mm-1.5mm, and the inner radius is 0.1mm-0.5mm, thereby controlling the surface area of ​​the individual flakes to be 10mm². 2 -100mm 2 And the thickness is 100μm-500μm.

[0143] In these embodiments, by controlling the welding power and the size of the composite wire, the size of the formed droplets can be controlled appropriately, thereby enabling the manufacture of scale monomers that meet the requirements for the long-term sharpness of the cutting tool, thus laying the groundwork for constructing a suitable scale-like structure.

[0144] In some embodiments, by controlling the moving speed of the composite filament to be 0.1 cm / s-1 cm / s, the overlapping area of ​​adjacent scale units in the length direction is 10%-80% of the area of ​​the scale unit, so as to obtain scale sub-layers. In this way, the cutting edge of the formed tool also has a layered gradient in the length direction. Thus, the multi-layer scale structure has suitable hardness, impact resistance and bonding force, which can not only suppress brittle fracture and chipping of the cutting edge, but also prevent the blade from rolling due to its high hardness, thereby further improving the tool's lasting sharpness.

[0145] Angled grinding According to this application, a tool body filled with a multi-layered scaly structure is obliquely ground to achieve double-sided cutting. The oblique grinding allows the multi-layered scaly structure and the tool body to jointly form the cutting edge of the tool, which serves as the cutting edge. The multi-layered scaly structure at the cutting edge is the portion remaining after grinding the multi-layered scaly structure formed in the receiving groove.

[0146] Figure 9 This is a schematic diagram of a tool body with a multi-layered scale-like structure according to an embodiment of the present invention. (Refer to...) Figure 9 , can be followed in sequence Figure 9 AA ， And BB ， The dotted lines shown are polished to create a shape with... Figure 12 The cutting edge of the tool is shown.

[0147] In a preferred embodiment, the bottom wall of the receiving groove coincides with the centerline S1 in the thickness direction of the tool body 10, AA ， And BB， The dashed line shown is the centerline S1 intersecting in the thickness direction, and AA ， And BB ， The dashed line shown is symmetrically arranged about the center line S1 in the thickness direction of the tool body 10.

[0148] According to this application, refer to Figures 10 to 12 The multi-layered scale-like structure 32 includes multiple scale-like layers stacked along the thickness direction. It can also be understood that the multiple scale-like layers are arranged sequentially from the bottom of the groove 20 to the opening of the groove. Each scale-like layer 321 includes multiple scale sub-layers arranged along the width direction of the tool, and the scale sub-layers include multiple scale units 3211 that are stacked along the length direction of the tool.

[0149] In this application, the multi-layered scaly structure of the cutting edge is the remaining portion after grinding the multi-layered scaly structure formed in the receiving groove. The multi-layered scaly structure is formed at high temperature, and the material has large internal stress. The internal stress will exacerbate the occurrence of brittle fracture. Setting the scaly structure as a multi-layered structure can disperse the impact load, relieve the internal stress, avoid local stress concentration, and form the cutting edge of the tool together with the tool body in a soft and hard composite process, thereby improving the tool's long-term sharpness.

[0150] In some embodiments, the multiple flake-like layers arranged in the thickness direction support each other, effectively resisting external forces generated during cutting and improving the overall strength and durability of the tool. In a preferred embodiment, the multiple flake-like layers arranged in the thickness direction have different hardnesses, thereby creating a hardness gradient in the thickness direction within the multi-layer flake-like structure. This further enhances the impact toughness of the tool with the multi-layer flake-like structure and improves the tool's sustained sharpness.

[0151] In the embodiments of this application, the composite filaments forming adjacent scaly layers can have different hardnesses, thereby forming scaly layers with different hardnesses. This results in a hardness gradient in the multi-layered scaly structure. In the subsequent oblique grinding process, the scaly layers forming the cutting edge can further refine the micro-serration structure of the tool due to the hardness gradient, thereby further improving the long-lasting sharpness.

[0152] According to this application, the composite filaments of adjacent flake layers in a multi-layered flake structure have different hardnesses. As an example, the hardness difference between adjacent flake layers in the thickness direction is in the range of 30 HV to 100 HV, which can reduce the internal stress at the cutting edge and reduce the brittleness of the material at the cutting edge.

[0153] According to this application, the multi-layered flake structure 32 includes multiple flake layers 321 stacked along the thickness direction of the tool. Each flake layer 321 includes multiple sub-layers of flakes arranged along the width direction of the tool. Each sub-layer of flakes includes multiple individual flakes 3211 overlapping along the length direction of the tool. The overlapping arrangement of the multiple individual flakes 3211 better disperses stress, improves the impact resistance of the multi-layered flake structure, and thus further enhances the tool's sustained sharpness. Furthermore, the overlapping and supporting relationship between adjacent flakes ensures that when one layer of flakes wears, the other layers can continue to function, effectively preventing the rapid spread of wear towards the tool body, thereby significantly improving the tool's wear resistance and extending its service life.

[0154] Remelting According to this application, in order to further reduce the brittleness of the material, the cutting tool with a multi-layered scaly structure can be remelted, that is, the multi-layered scaly structure of the cutting tool can be repeatedly heated by heat sources such as plasma welding, laser welding, and gas welding to make the multi-layered scaly structure more uniform and further reduce brittleness.

[0155] As an example, the remelting power is 2kW-20kW, and the tool movement speed is 0.1cm / s-3cm / s. If the movement speed is fast, the densification effect through remelting is not obvious, and if the movement speed is slow, cracking is likely to occur, which is counterproductive. According to a fourth aspect of this application, a cutting tool is provided, wherein the cutting edge of the tool includes a composite structure formed of composite filament, the composite filament being easily constructed to obtain a dense and multi-layered composite structure, thereby obtaining a durable and sharp cutting tool.

[0156] As a specific example, the composite structure includes a metallic material and a sheet-like ceramic material dispersed in the metallic material, forming the cutting edge of the knife. A knife with such a cutting edge and cutting edge can have a certain toughness and hardness due to the presence of both metallic and ceramic materials, thereby further improving the knife's long-lasting sharpness.

[0157] In some embodiments, a metal silicate or borate compound is formed at the junction of the metal layer and the ceramic sheet. This metal silicate or borate compound is obtained by reacting the ceramic material and the metal wire after melting, thereby further enhancing the density and bonding strength of the formed composite structure. For example, some of the metal wire surface has a metal oxide (e.g., NiO). The surface oxide reacts with oxide-type ceramic materials (e.g., SiO2, B2O3, Na2O) to form a metal silicate or borate compound (such as Ni2SiO4), thereby improving the bonding strength between the ceramic and metal in the composite structure.

[0158] In some embodiments, the cutting tool 30 further includes a cutting tool body 10 connected to a composite structure. The composite structure is a multi-layer structure, that is, the multi-layer structure is connected to the cutting tool body 10. The cutting tool body 10 has a receiving groove 20 formed in the region near the cutting edge of the cutting tool. The multi-layer structure fills the receiving groove 20 and can be combined with the cutting tool body 10 to form the cutting edge of the cutting tool and form the cutting edge 31 of the cutting tool.

[0159] As a specific example, refer to Figure 12 and Figure 14 In the cutting tool, the tool body 10 can be divided into a first body region 13 located above and a second body region 14 connected below the first body region. The first body region 12 is disposed above the composite structure and constitutes the blade of the cutting tool. The second body region 14 protrudes relative to the lower end face of the first body region 13 and is disposed adjacent to the composite structure along the thickness direction of the cutting tool, and together with the composite structure, forms the cutting edge of the cutting tool.

[0160] In this application, through the Figure 9 The tool shown is double-edged, thus forming a tool that simultaneously has a second body region 14 and a cutting edge portion with a composite structure.

[0161] In these embodiments, the cutting edge of the tool, with its multi-layered structure and a combination of hard and soft materials, possesses suitable impact toughness and interlayer bonding strength, preventing chipping and ensuring the tool's long-lasting sharpness. Furthermore, the structure of the cutting edge allows for the formation of micro-serrations during sharpening through the interlayer gaps, resulting in improved cutting performance.

[0162] According to this application, the multi-layer structure is formed as a multi-layer scale-like structure. The multi-layer scale-like structure has a three-dimensional or two-dimensional multi-layer structure. The multi-dimensional structure can withstand mechanical impacts in different directions, especially in multi-scenario applications such as knives, such as chopping meat (blade direction) and smashing garlic (blade perpendicular direction). With a multi-dimensional stacked structure, it can disperse impact loads and avoid local stress concentration.

[0163] Figure 16 This is a photograph of the cutting edge of a tool according to an embodiment of the present invention. See also... Figure 16 As can be seen, the cutting edge has a multi-layered scale-like structure.

[0164] In the first embodiment, as Figures 10 to 12 As shown, the multi-layered scale structure 32 includes multiple scale-like layers 321 stacked along the thickness direction of the tool 30. Each scale-like layer 321 includes multiple scale sub-layers arranged along the width direction of the tool 30. Each scale sub-layer includes multiple scale units 3211 overlapping along the length direction of the tool 30.

[0165] In these embodiments, the defined multi-layered scaly structure has a three-dimensional multi-layered structure. That is, it has layered gradients in the length, width, and thickness directions. Thus, the multi-layered scaly structure has suitable impact resistance and can effectively suppress brittle fracture at the cutting edge, preventing chipping and thereby further improving the long-term sharpness of the tool.

[0166] In the second embodiment, as Figure 13 and Figure 14 As shown, the multi-layered scale structure 32 includes multiple scale-like layers 321 stacked along the thickness direction of the tool 30, and the scale-like layers 321 include multiple scale units 3211 stacked along the length direction of the tool 30.

[0167] In these embodiments, the defined multi-layered scaly structure has a two-dimensional multi-layered structure. That is, it has layered gradients in both the length and thickness directions. Thus, the multi-layered scaly structure has suitable impact resistance and can effectively suppress brittle fracture at the cutting edge, preventing chipping and thereby further improving the long-term sharpness of the tool.

[0168] In some embodiments, the multiple scale-like layers 321 stacked in the thickness direction of the tool are arranged alternately with varying hardness. In this way, adjacent scale-like layers 321 can overlap and support each other. When a certain scale layer wears out, the other layers can still continue to function, effectively preventing wear from spreading rapidly to the tool body, thereby significantly improving the wear resistance of the tool and extending its service life.

[0169] In some embodiments, the scales arranged along the length of the tool have the same hardness, the hardness is alternately distributed, or the hardness is gradient-transitional. This allows for further optimization of the impact resistance of the multi-layer scale structure through hardness arrangement.

[0170] In some embodiments, the receiving groove is a square groove. In the receiving groove, the thickness of the flake layer 321 is 100μm-500μm, and the thickness of the multilayer flake structure 32 is 400μm-1500μm. At the cutting edge of the tool, the thickness of the flake layer 321 is 100μm-500μm, and the thickness of the thickest part of the multilayer flake structure 32 is 400μm-1500μm. Here, the thickness of the thickest part of the multilayer flake structure 32 is the thickness of the upper end of the multilayer flake structure 32 that contacts the tool body.

[0171] In some embodiments, the inner wall of the receiving groove may be a continuous concave arc surface (without abrupt corners) or a surface with abrupt corners (corners), for example, a T-shape. It should be noted that this application does not intentionally limit the shape of the inner wall of the receiving groove.

[0172] In the third embodiment, as Figure 15 As shown, the cross-section of the inner wall of the accommodating groove is concave arc-shaped. In the corresponding manufacturing method, the molten droplet can start from the central region at the bottom of the groove and expand outward layer by layer along the arc-shaped surface to form uninterrupted scale-like monomers, ultimately constructing a multi-layered scale-like structure. This avoids the molten droplet from being affected by gravity or inertial displacement, thus preventing the formation of the multi-layered scale-like structure.

[0173] In a specific embodiment, the inner wall of the receiving groove is a continuous concave arc surface. The inner wall of the receiving groove with a continuous concave arc surface does not have abrupt angles. Therefore, when forming a multi-layered scale structure, it can provide better adhesion conditions for the molten droplet than an inner wall with abrupt angles (e.g., the square groove mentioned above). It can guide the molten droplet to transition smoothly along the continuous concave arc surface, thereby ensuring the continuity of the scale-like monomers and the bonding of each region inside the multi-layered scale structure.

[0174] According to this application, the multi-layered scale structure is stacked using a conventional alignment mechanism or a staggered method. The multi-layered scale structure stacked using a conventional alignment mechanism has good impact resistance and interlayer bonding strength, while the multi-layered scale structure stacked using a staggered method can absorb external forces layer by layer and form a good mechanical interlocking effect, thus possessing significant impact resistance and interlayer bonding strength.

[0175] In some embodiments, the surface area of ​​the flake monomer is 10 mm. 2 -100mm 2 And the thickness is 100μm-500μm; and / or, the overlap area of ​​adjacent scale monomers in the length direction is 10%-80% of the area of ​​a single scale monomer.

[0176] In these embodiments, the scale sublayers composed of the aforementioned scale monomers have a tightly stacked structure, thereby ensuring the tightness of the scale-like layers formed by the stacking of multiple scale sublayers. This, in turn, enables the tight bonding of the multi-layer scale-like structure formed by the stacking of multiple scale-like layers, resulting in a tight three-dimensional multi-layer structure. The multi-layer scale-like structure has suitable impact resistance and can effectively suppress brittle fracture at the cutting edge, preventing chipping and thus further improving the long-lasting sharpness of the tool.

[0177] In some embodiments, adjacent scale sub-layers are staggered or aligned along the width direction of the tool. Multiple scale sub-layers arranged in the width direction create a layered structure in the tool's width direction to resist external forces from that direction. Furthermore, when an external force acts on the tool's width direction, the staggered or aligned scale sub-layers absorb energy layer by layer through localized deformation, sliding, or micro-fractures, rather than concentrating it at a single cross-section, thereby further reducing the risk of edge chipping. Additionally, adjacent scale-like layers in the thickness direction are also staggered or aligned. Thus, multiple scale-like layers arranged in the thickness direction create a layered structure in the tool's thickness direction to resist external forces from that direction. Furthermore, when an external force acts on the tool's thickness direction, the staggered or aligned scale sub-layers absorb energy layer by layer through localized deformation, sliding, or micro-fractures, rather than concentrating it at a single cross-section, thereby further reducing the risk of edge chipping.

[0178] According to this application, in the cutting tool, the centerline in the thickness direction of the cutting tool is S2. The bottom wall of the receiving groove 20 coincides with S2, is parallel to S2, and has a distance of no more than 5 mm between it and S2, or is slightly inclined relative to S1 (for example, the inclination angle is no more than 10°). The multi-layered scale-like structure is arranged sequentially along the groove bottom to the groove opening. In this way, the multi-layered scale-like structure can have a large filling amount in the thickness direction of the cutting tool, thereby improving the long-term sharpness of the cutting tool.

[0179] Reference Figure 12 The centerline in the thickness direction of the tool is S2, and the bottom of the groove accommodating the groove coincides with S2. In the manufactured cutting edge of the tool, the outer surface of the multi-layered scale-like structure serves as the first cutting face, and a portion of the outer surface of the tool body serves as the second cutting face opposite to the first cutting face. The angle between the first cutting face and S2 is θ1, and the angle between the second cutting face and S2 is θ2. The cutting edge with a cut-off angle of θ1 and θ2 is θ, where θ1 is 5°-20°, θ2 is 5°-20°, and the sum of θ1 and θ2 is θ. A cutting edge with a suitable cut-off angle facilitates cutting and improves the cutting experience.

[0180] In knife manufacturing, the selection of material hardness is often a challenging issue. Firstly, while choosing a high-hardness material effectively inhibits edge curling, it simultaneously induces embrittlement, increasing the risk of chipping. Conversely, choosing a low-hardness material, while improving toughness and preventing chipping, weakens the knife's resistance to plastic deformation, making it more prone to edge curling. Therefore, overcoming the trade-off between hardness and toughness has become a key bottleneck in knife manufacturing.

[0181] The inventors discovered that the critical hardness value for edge rolling and chipping is 600 HV. Knives made of materials with a hardness not exceeding 600 HV are prone to edge rolling but will not chip. Knives made of materials with a hardness exceeding 600 HV will not have edge rolling but will be prone to chipping. Based on this, by using materials with higher hardness and making structural changes, knives can be manufactured that are neither prone to chipping nor rolling, breaking the trade-off between hardness and toughness, thus ensuring the long-lasting sharpness of the knives.

[0182] According to this application, the hardness of the tool body is between 400 HV and 1000 HV. A tool body with such hardness can be formed from different materials. For example, the materials used to form the tool body include at least one of carbon steel, 3Cr13 stainless steel, 4Cr13 stainless steel, 5Cr15MoV stainless steel, 7Cr13MoV stainless steel, 8Cr13MoV stainless steel, and 9Cr18MoV stainless steel. The multi-layered flake structure is composed of composite wire. This further enhances the impact toughness of the cutting edge of the tool obtained by combining the flake structure and the tool body.

[0183] In some embodiments, when the hardness of the tool body is greater than 600 HV, the hardness of at least a portion of the composite structure is greater than or equal to the hardness of the tool body; when the hardness of the tool body is 400 HV-600 HV, the hardness of at least a portion of the composite structure is greater than the hardness of the tool body and greater than or equal to 600 HV. In these embodiments, when the hardness of the tool body is greater than 600 HV, the tool body is at or above the critical hardness value where it will not scuff but is prone to chipping. In this case, the hardness of at least a portion of the composite structure is equal to or greater than the hardness of the tool body. This compensates for the increased brittleness of the tool due to high hardness by utilizing the appropriate impact toughness and interlayer bonding strength of the composite structure. Therefore, it reduces the possibility of chipping due to high hardness and improves the tool's sustained sharpness. When the hardness of the tool body is between 400 HV and 600 HV, the tool body is in the range where it is prone to scuffing but will not chip. In this case, the hardness of at least a portion of the composite structure can be greater than the hardness of the tool body, and greater than or equal to 600 HV. Thus, at least a portion of the composite structure (the first region) ensures that the cutting edge obtained by combining the composite structure and the tool body has improved overall hardness, preventing chipping. Since at least a portion of the composite structure is part of the composite structure, it also has a layered structure. The layered structure has suitable impact toughness and interlayer bonding strength. Through the synergistic effect of the layered structure and the high hardness of the partial region, the possibility of chipping due to the high hardness of the composite structure can be reduced. In this way, the tool is not easy to chip or chip, breaking the inverse relationship between hardness and toughness, thereby ensuring the tool's long-lasting sharpness.

[0184] In an exemplary embodiment, when the hardness of at least a portion of the composite structure is greater than the hardness of the tool body, the hardness difference between the at least a portion of the composite structure and the tool body is 50HV-200HV. In this way, the impact toughness of the composite structure can be used to further reduce the possibility of chipping due to the hardness of the composite structure being at or above the hardness threshold that makes it easy to chip. This ensures that the cutting edge of the tool is not prone to chipping or rolling, thereby further improving the tool's long-lasting sharpness.

[0185] In an exemplary embodiment, where the hardness of at least a portion of the composite structure is greater than the hardness of the tool body, the volume of the portion of the composite structure is 70%-100% of the total volume of the composite structure, taking the total volume of the composite structure as 100%. This ensures that the composite structure has a suitable proportion of high-hardness regions, which, together with the tool body, guarantee an improved overall hardness at the cutting edge, further enhancing the tool's wear resistance and preventing edge chipping.

[0186] In a specific embodiment, the composite structure further includes a second region in addition to the first region (at least a part of the first region). The hardness of the second region is less than that of the first region. The first and second regions are alternately arranged. The hardness of the second region is greater than, equal to, or less than that of the base portion. The second region serves as a buffer and connects the first region and the base portion to ensure the overall bonding performance of the cutting edge. The second region is a part of the composite structure other than the first region. The volume ratio of the second region can be 0%-30%. In other words, the volume of the second region does not exceed 30% of the total volume of the composite structure.

[0187] It should be noted that in this application, the composite structure simultaneously possessing the first region and the second region is composed of multiple composite filaments of different hardnesses, and this application does not impose further limitations on this. A portion of the metallic and ceramic materials in the composite filaments forms the first region, while the other portion of the metallic material forms the second region.

[0188] In some embodiments, the composite structure is formed by welding, thermal spraying, or cladding, and the formation methods are diverse, which can simplify the manufacturing process of the cutting tool.

[0189] According to this application, a multi-layered flake-like structure extends along the width direction of the cutting tool. In some embodiments, the multi-layered flake-like structure extends from the cutting edge along the width direction to a region corresponding to a width of 0.1mm-10mm from the cutting edge. This ensures that the tool retains a usable multi-layered flake-like structure even after continuous sharpening, thereby improving the tool's long-lasting sharpness. When the distance is less than 0.1mm, the process is difficult to implement, and it cannot be confirmed that the cutting edge will have cladding material after sharpening. Furthermore, the small distance makes it difficult to achieve the multi-layered flake-like structure. When the distance is greater than 10mm, the cost is high and the improvement in lifespan is not significant.

[0190] In some embodiments, the cutting edge of the tool includes a cutting action area and non-cutting action areas located at both ends of the cutting action area along its length. The composite structure is formed at least on the cutting action area, thereby ensuring the long-term sharpness of the cutting action area and reducing costs while maintaining the long-term sharpness of the tool.

[0191] The beneficial effects of the present invention will be described in more detail below with reference to specific embodiments.

[0192] Example 1 The cutting tool according to Example 1 is prepared by the following method.

[0193] Step S10: Provide a tool body with a thickness of 2mm and uniform thickness. The tool body is made of 4Cr13 stainless steel.

[0194] In step S20, a rectangular receiving groove with a length of 180 mm (blade length is 180 mm), a width of 10 mm, and a depth of 1 mm is formed by extending the end of the tool body in the width direction. The bottom wall of the receiving groove coincides with the centerline of the tool body in the thickness direction, thereby forming the tool body.

[0195] Step S30: A composite wire with an outer radius of 1.0 mm and an inner radius of 0.3 mm, and in the shape of a strip, is welded together. (The composite wire is a mixture of titanium-tungsten alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm².) 2 -10mm 2 The molten droplet, with a thickness of 10μm-50μm, and comprising 20% ​​of the total volume of the composite wire and 85% of the total volume of the titanium-tungsten alloy wire, is formed at a welding power of 10kW. As the droplet spreads and forms a scale-like structure, another droplet is formed, fusing with the scale-like structure. This results in the overlapping of adjacent scale-like individual units to form a scale-like structure. The surface area of ​​the scale unit within the receiving groove is 10mm². 2 -30mm 2 The thickness is 300μm-500μm, and the receiving groove of the tool body is filled with a 6-layer scale-like structure.

[0196] Step S40: Perform oblique grinding with the centerline in the thickness direction as a reference (e.g., refer to...). Figure 9 (The auxiliary lines shown are used for oblique grinding), thereby forming the cutting tool according to Embodiment 1 of this application.

[0197] Example 2 Except that the tool body is made of 5Cr15MoV stainless steel instead of 4Cr13 stainless steel, the tool of Example 2 is manufactured using the same method as in Example 1.

[0198] Example 3 Except for using carbon steel with a carbon content of 0.9% instead of 4Cr13 stainless steel to make the knife body, the knife of Example 3 was manufactured using the same method as in Example 1.

[0199] Example 4 Except that the tool body is made of 7Cr17MoV stainless steel instead of 4Cr13 stainless steel, the tool of Example 4 is manufactured using the same method as in Example 1.

[0200] Example 5 In addition to using another type of composite wire (the composite wire is a mixture of martensitic stainless steel wire and uniformly dispersed plate-like ceramic material, wherein the dispersed plate-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 5 was manufactured using the same method as in Example 1.

[0201] Example 6 In addition to using another type of composite wire (the composite wire is a mixture of molybdenum-nickel alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 6 was manufactured using the same method as in Example 1.

[0202] Example 7 In addition to using another type of composite wire (the composite wire is a mixture of tool steel alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 7 was manufactured using the same method as in Example 1.

[0203] Example 8 In addition to using another type of composite wire (the composite wire is a mixture of nickel-chromium alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 8 was manufactured using the same method as in Example 1.

[0204] Example 9 In addition to using another type of composite wire (the composite wire is a mixture of cobalt-chromium alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 9 was manufactured using the same method as in Example 1.

[0205] Example 10 In addition to using another type of composite filament (the composite filament is a mixture of titanium filaments with uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite filament is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 10 was manufactured using the same method as in Example 1.

[0206] Example 11 In addition to using another type of composite wire (the composite wire is a mixture of titanium-tungsten alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is zirconium oxide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 11 was manufactured using the same method as in Example 1.

[0207] Example 12 In addition to using another type of composite wire (the composite wire is a mixture of titanium-tungsten alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is silicon nitride with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 12 was manufactured using the same method as in Example 1.

[0208] Example 13 In addition to using another type of composite wire (the composite wire is a mixture of titanium-tungsten alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is titanium boride with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 13 was manufactured using the same method as in Example 1.

[0209] Example 14 In addition to using another type of composite wire (the composite wire is a mixture of titanium-tungsten alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten silicide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 14 was manufactured using the same method as in Example 1.

[0210] Example 15 In addition to using another type of composite wire (the composite wire is a mixture of titanium alloy wire and uniformly dispersed sheet-like ceramic material, wherein the dispersed sheet-like ceramic material is tungsten carbide with a surface area of ​​1 mm²), another type of composite wire is used. 2 -10mm 2 In addition to forming a multi-layered scale-like structure with a thickness of 10μm-50μm, the tool of Example 15 was manufactured using the same method as in Example 1.

[0211] Example 16 In addition to the fact that the surface area of ​​the individual scales is 30mm 2 -70mm 2 The tool of Example 16 was manufactured using the same method as in Example 1, with a thickness of 200μm-300μm (controlled by power control at 12kW).

[0212] Example 17 In addition to the fact that the surface area of ​​the individual scales is 70mm 2 -100mm 2 The tool of Example 17 was manufactured using the same method as in Example 1, with a thickness of 100μm-200μm (by controlling 16kW).

[0213] Comparative Example 1 Except that a titanium-tungsten alloy wire with dispersed tungsten carbide particles was used instead of the composite wire in Example 10, the cutting tool of Comparative Example 1 was manufactured using the same method as in Example 10.

[0214] Comparative Example 2 Except for using 4Cr13 stainless steel particles and filling the receiving groove in step S20 by plasma spraying, the cutting tool of Comparative Example 2 was manufactured using the same method as in Example 1.

[0215] Comparative Example 3 Except for using tungsten carbide particles and plasma spraying to fill the receiving groove in step S20, the cutting tool of Comparative Example 3 was manufactured using the same method as in Example 1.

[0216] Comparative Example 4 Except that a titanium-tungsten alloy wire with dispersed zirconium oxide particles was used to replace the composite wire of Example 11, the cutting tool of Comparative Example 4 was manufactured using the same method as in Example 11.

[0217] Comparative Example 5 Except that a titanium-tungsten alloy wire with dispersed silicon nitride particles was used instead of the composite wire in Example 12, the cutting tool of Comparative Example 5 was manufactured using the same method as in Example 12.

[0218] Comparative Example 6 Except that a titanium-tungsten alloy wire with dispersed titanium boride particles was used instead of the composite wire in Example 13, the cutting tool of Comparative Example 6 was manufactured using the same method as in Example 13.

[0219] Comparative Example 7 Except that a titanium-tungsten alloy wire with dispersed tungsten silicide particles was used instead of the composite wire in Example 14, the cutting tool of Comparative Example 7 was manufactured using the same method as in Example 14.

[0220] Performance metrics testing The cutting edge thickness of the tools in Examples 1-17 and Comparative Examples 1-7 was the same, and performance index tests were performed on them respectively. The test results are recorded in Table 1 below. The performance test method is as follows: (1) Durable sharpness test method: The durability of sharpness is tested using a simulated tool life test method, the details of which are described below.

[0221] The simulated tool life test method is as follows: The tool to be tested is fixed horizontally with the cutting edge facing down on a tool holder. After adding weights, it is pressed onto a simulated object with a pressure of 16N. The simulated object (using 3mm kraft paper) is kept stationary while being cut. The tool holder is driven by a motor and pneumatic pressure, causing the tool to cut in the X-axis direction at a reciprocating speed of 50mm / s. Simultaneously, it rises in the Z-axis direction and displaces 1mm in the Y-axis direction, shaping the simulated object. The cutting stroke is 100mm. The test ends after every 5 cuts. An evaluation object (ham sausage) is used to determine the tool's durable sharpness. The test ends when the evaluation object cannot be cut. The total number of cuts from the start to the end of the test is recorded as the tool's durable sharpness. The more cuts, the higher the durable sharpness, and vice versa. This project requires the tool's durable sharpness to exceed 1000 cuts.

[0222] (2) Impact resistance test (the impact resistance test can comprehensively evaluate the bonding strength and brittleness of the coating): A 500g steel ball is dropped from different heights (in cm, tested once at 10cm intervals) to impact the surface of the coating, and the coating is observed to see if there are any phenomena such as peeling, cracking or denting. The impact resistance performance can reflect whether the coating is prone to chipping after being subjected to external force. The higher the impact resistance test data (the higher the height), the better the impact resistance performance, and vice versa. This project requires the impact resistance test of the tool to be above 100cm.

[0223] (3) Supplementary bonding strength test method: Borrowing the bonding strength test method from GB / T8642 "Determination of Bond Strength of Thermal Spray Coatings", the "tensile method" is adopted. The two ends of the "substrate-coating" sample are fixed using a special fixture, and an axial tensile load is applied until the sample breaks at the interface between the coating and the substrate, inside the coating, or inside the substrate. The "bonding strength" is calculated based on the maximum load at break and the effective bonding area of ​​the coating. Bonding strength reflects how easily the coating separates from the tool body after being subjected to external force. A higher bonding strength value indicates a stronger bonding force, and vice versa. This project requires the tool's bonding strength to be 100 N / mm². 2 above.

[0224] Table 1 Performance test data of embodiments and comparative examples of this application.

[0225]

[0226] In summary, the above tests show that the impact resistance and bonding strength of the cutting tool according to this application meet the requirements. The fact that these two indicators meet the requirements suggests that the tool is unlikely to have good long-term sharpness. Specifically, the impact resistance test reflects whether the scaly structure chipped after being subjected to external force, while the bonding strength reflects whether the scaly structure easily separates from the substrate after being subjected to external force.

Claims

1. A composite filament for manufacturing cutting tools, characterized in that, The composite filament (100) includes a metal filament (101) and a sheet-like ceramic material (102) incorporated in the metal filament (101).

2. The composite filament according to claim 1, characterized in that, The ceramic material (102) is uniformly dispersed in the metal wire (101); or, the metal wire (101) has a tubular structure, and the ceramic material (102) is disposed on the inner or outer wall of the tubular structure; or, the metal wire (101) has a tubular structure, and the ceramic material (102) is filled in the tubular structure.

3. The composite filament according to claim 1, characterized in that, The composite filament (100) is in the shape of a hollow tube, with an inner radius of 0.1mm-0.5mm and an outer radius of 0.3mm-1.5mm; or, the composite filament (100) is a solid filament with a radius of 0.3mm-1.5mm.

4. The composite filament according to any one of claims 1 to 3, characterized in that, In the composite wire (100), the volume of the ceramic material (102) is 5%-30% of the total volume of the composite wire (100), and the volume of the metal wire (101) is 70%-95% of the total volume of the composite wire (100).

5. The composite filament according to any one of claims 1 to 3, characterized in that, The main surface area of ​​the ceramic material (102) is 1 mm². 2 -10mm 2 The ceramic material (102) has a thickness of 5μm-50μm; and / or the ceramic material (102) includes at least one of oxides, carbides, nitrides, borides and silicides; and / or the metal wire (101) includes at least one of titanium wire, titanium alloy wire, martensitic stainless steel wire, molybdenum series alloy wire, tool steel alloy wire, nickel-based alloy wire and cobalt-based alloy wire; and / or the ceramic material (102) is a covalent ceramic material and / or an ionic ceramic material.

6. The composite filament according to any one of claims 1 to 3, characterized in that, The ceramic material (102) is a ceramic material modified with polar functional groups.

7. The composite filament according to claim 6, characterized in that, The polar functional group includes at least one of carboxyl, amino, and hydroxyl groups.

8. A method for manufacturing a composite filament, characterized in that, The method includes: Provide a metal strip with multiple grooves on its surface; The groove is filled with sheet-like ceramic material, and then the metal strip filled with sheet-like ceramic material is processed into a composite wire in which sheet-like ceramic material is incorporated into the metal wire.

9. The method according to claim 8, characterized in that, Before the step of filling the groove with sheet-like ceramic material, the following steps are also included: Plasma treatment is performed on ceramic materials to obtain ceramic materials modified with polar functional groups, and the ceramic materials modified with polar functional groups are used as the ceramic materials.

10. The method according to claim 9, characterized in that, The polar functional group includes at least one of carboxyl, amino, and hydroxyl groups.

11. The method according to claim 8, characterized in that, The steps of processing a metal strip filled with sheet-like ceramic material into a composite wire containing sheet-like ceramic material include: A metal strip filled with sheet-like ceramic material is rolled into at least one layer of composite roll material; The composite roll is stretched by reducing its diameter to obtain a composite wire material in which sheet-like ceramic material is incorporated into the metal wire.

12. The method according to claim 11, characterized in that, Prior to the diameter reduction stretching, the method further includes: The step of applying a coating to the outer side of the composite roll material, wherein the coating is a rust-proof layer and / or a soldering flux layer.

13. The method according to claim 8, characterized in that, The step of providing a metal strip with multiple grooves on its surface includes: The metal strip is subjected to acid pickling and alkali washing, and then multiple uniformly arranged grooves are formed on the surface of the metal strip to obtain a metal strip with multiple grooves on the surface.

14. The method according to claim 8, characterized in that, The ceramic material is obtained by stirring and mixing sheet-like ceramic materials at a temperature of 150℃-200℃.

15. An application of a composite wire in cutting tools, characterized in that, The composite filament (100) is a composite filament according to any one of claims 1-7 or a composite filament manufactured by the method of manufacturing a composite filament according to any one of claims 8 to 14.

16. A cutting tool, characterized in that, The cutting tool includes a composite structure formed from the composite filament (100), wherein the composite filament (100) is a composite filament according to any one of claims 1-7 or a composite filament manufactured by the method of manufacturing a composite filament according to any one of claims 8 to 14.

Images