Multilayer Kitchen Knife Forging for Hardness and Edge Durability
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Solution Overview
Problem
Conventional kitchen knives made of stainless steel have low hardness, leading to rapid wear and frequent replacement due to their material properties, which are not suitable for long-lasting cutting performance.
Innovation Solution
A method of manufacturing a knife using a multilayer material obtained by repeatedly refining and forge-welding iron sand ingots, involving processes such as heating, forging, grinding, applying mud, quenching, and etching to create a knife with enhanced hardness and durability, and a beautiful wave pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stainless steel is used for manufacturing kitchen knives, then the manufacturing process is simple and the material is readily available, but the hardness is low leading to rapid wear and frequent replacement
Solution Approach 1:
The patent applies composite materials by combining multiple layers of iron sand ingots with different compositions and properties. The multilayer structure includes layers with varying carbon content, alloying elements, and microstructures that are forge-welded together. This composite approach creates a knife blade with superior hardness, wear resistance, and durability while maintaining traditional manufacturing processes.
Solution Approach 2:
The patent segments the knife blade into multiple distinct layers, each with specific functions. The multilayer material consists of alternating layers of high-carbon iron sand ingots (for hardness and edge retention) and low-carbon iron sand ingots (for toughness and ductility). This segmentation allows each layer to contribute its unique properties to the overall performance of the knife.
2Device complexity
If conventional single-layer materials are used, then the manufacturing process is simple, but the cutting performance deteriorates rapidly due to low hardness
Solution Approach 1:
The patent applies preliminary action by pre-forming multiple iron sand ingots with specific compositions and microstructures before assembly. The iron sand ingots are prepared in advance with controlled carbon content, alloying elements, and grain structures through separate refining and forging processes. This preliminary preparation ensures that each layer has the optimal properties required for the final multilayer blade, enabling superior cutting performance that lasts throughout the knife's service life.
3Reliability
If multilayer material with repeated refining and forge-welding is used, then hardness and durability are significantly improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies parameter changes by systematically varying the composition, microstructure, and processing parameters of each iron sand ingot layer. The carbon content, alloying element concentrations, heating temperatures, and forging pressures are precisely controlled for each layer to achieve the desired hardness, toughness, and wear resistance. These parameter variations create a multilayer structure with optimized performance characteristics that justify the increased manufacturing complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting knife exhibits significantly improved hardness, long-lasting cutting properties, and excellent durability, along with a visually appealing wave pattern, surpassing the limitations of conventional stainless steel knives.
Implementation Method 1
heating and then forging the multilayer material to form a knife-shaped form
Implementation Method 2
forge-welding the stacked iron sand ingots to form forge-welded iron sand ingots
Implementation Method 3
heating the knife-shaped form applied with the mud, followed by quenching through oil-cooling
Implementation Method 4
etching the surface of the quenched knife-shaped form to form a pattern on the surface
Data Source
AI summary
This application relates to a method of manufacturing a knife using a multilayer material. In one aspect, the method includes preparing a multilayer material for manufacturing a knife, and heating and then forging the multilayer material to form a knife-shaped structure including a blade part and a handle part. The method also includes grinding the blade part to form a sharpened knife-edge and applying mud, including kaolin and white clay, to an entire surface of the knife-shaped structure and removing the mud applied to the blade part. The method further includes heating the knife-shaped structure applied with the mud, and quenching the heated knife-shaped structure through oil-cooling. The method further includes etching a surface of the quenched knife-shaped structure to form a pattern on the surface and grinding the surface-etched knife-shaped structure to form a knife having a final shape.