Since non-standard dovetail knives need to meet the cutting requirements of specific workpieces, the reliability of their design directly affects the processing quality and efficiency. The design verification process uses scientific methods and rigorous testing to comprehensively evaluate the structure, materials, performance, etc. of dovetail knives, thereby ensuring that customized products are stable and reliable in practical applications.
In the initial stage of design verification, tools such as finite element analysis (FEA) are used to perform theoretical analysis and simulation calculations on non-standard dovetail knives. The geometric parameters, material properties, and expected cutting conditions of the dovetail knife are input into the model to simulate the stress distribution, deformation, and temperature field changes of the tool during the cutting process. For example, by simulating the stress concentration phenomenon under different edge angles, the design is optimized to avoid early chipping; the influence of cutting heat on the material properties of the tool is analyzed to ensure that the tool can still maintain good cutting performance under high temperature conditions. These simulation calculation results provide data support for the structural design optimization of the dovetail knife and ensure the reliability of the tool from a theoretical level.
The material properties of the dovetail knife are crucial to its reliability. In the design verification process, the selected materials are strictly tested for performance. Through hardness testing, impact toughness testing, metallographic analysis and other means, the hardness, toughness, organizational structure and other indicators of the material are tested to see if they meet the design requirements. For example, the hardness and grain size of cemented carbide materials directly affect the wear resistance and chipping resistance of the tool. Only when the material performance meets the standard can the dovetail knife be guaranteed to have good durability during the cutting process and reduce the risk of tool failure due to material problems.
According to the design plan, the sample of non-standard dovetail knife is trial-produced, and high-precision processing equipment and processes are used to ensure the dimensional accuracy and surface quality of the tool. Preliminary performance tests are carried out on the trial samples, including dynamic balance detection of the tool and edge sharpness detection. A dovetail knife with poor dynamic balance will vibrate when rotating at high speed, affecting the cutting accuracy and tool life; and insufficient edge sharpness will increase cutting resistance and reduce processing efficiency. Through these preliminary tests, problems existing in the sample manufacturing process are discovered in time and improved, laying the foundation for subsequent actual cutting tests.
Actual cutting experiments are the key link in verifying the reliability of non-standard dovetail knife. The sample is installed on the machine tool, and a cutting experiment is carried out under the working conditions simulating actual processing to process the workpiece material that meets the customized requirements. During the experiment, data such as cutting force, cutting temperature, tool wear, and surface roughness of the processed surface are collected. By analyzing these data, the cutting performance of the dovetail knife is evaluated. For example, excessive cutting force may indicate that the cutting angle design of the tool is unreasonable; excessive tool wear may be related to material properties or coating process. According to the experimental results, the tool design is adjusted and optimized until the customized requirements are met.
In order to ensure the reliability of non-standard dovetail knives in long-term use, long-term stability and durability tests are also required. Let the tool continue to perform cutting operations for a certain period of time or a certain amount of processing, and observe the changes in tool performance over time. For example, detect whether the tool has problems such as edge fatigue cracks and coating peeling after long-term cutting, and evaluate whether the tool life meets the design expectations. Through long-term testing, potential reliability risks are discovered, and the design and manufacturing process are further improved to ensure the long-term stability of the dovetail knife in actual applications.
The design and verification process of non-standard dovetail knife is to evaluate and optimize customized products from design to manufacturing to practical application through multiple links such as theoretical analysis, material testing, sample trial production, actual cutting experiments and long-term stability testing. Each link is closely connected and complements each other to ensure that the non-standard dovetail knife meets the use requirements in terms of structure, material, performance, etc., thereby ensuring the reliability of customized products and providing customers with efficient and stable cutting tools.
