1. Feed machinery and equipment accessories cutter general bearing product introduction
In the process of feed production and processing, it is crucial to cut the material after pelleting, bulking and other molding processes into particles of appropriate length, and the cutter head is the core accessory to undertake this critical task. It directly affects the length consistency, appearance quality and production efficiency of feed particles, and plays an indispensable role in the stable operation of the entire feed production equipment and product quality control.
2. Structure composition
cutter
The cutter is the core part of the cutter bearing, and its shape and size are designed according to different feed production processes and particle requirements. Common cutter shapes are straight knife, curved knife and serrated knife. Straight knife structure is simple, cutting force is more uniform, suitable for the particle shape and cutting accuracy requirements are not particularly high occasions; The scimitar can better adapt to the flow direction of the material in the cutting process, reduce cutting resistance, improve cutting efficiency, and is often used in high-speed and large-output feed production lines. The cutting edge of the serrated knife is serrated, with strong cutting ability, especially suitable for cutting feed materials with higher hardness or more fiber content, which can effectively prevent the material from tearing or crushing during the cutting process and ensure the integrity of the particles. The material of the cutting tool is generally selected with high strength, high hardness and good wear resistance of steel, such as high-speed steel, cemented carbide, etc., to ensure that it maintains a sharp edge in the long-term, high-strength cutting work.
Tool rest
The tool holder is the part that mounts the cutter and provides support and positioning for it. The structural design of the tool holder needs to ensure that the cutter is firmly installed, accurately positioned, and can be easily adjusted and replaced. Generally made of metal casting or forging, it has enough strength and stiffness to withstand the impact force and vibration force generated in the cutting process. The tool holder is usually provided with a mounting slot, positioning hole or clamping device, which is used to accurately fix the position of the cutter, and the extension length and Angle of the cutter can be adjusted according to the need to meet the cutting requirements of different particle lengths. In some advanced cutter total bearing design, the tool holder is also equipped with an automatic adjustment device, which can automatically adjust the position of the cutter according to the flow rate and hardness of the material, so as to achieve intelligent cutting control.
Driving gear
The transmission device is responsible for transferring power to the cutter, making it produce rotation or reciprocating motion, so as to achieve the cutting of the material. Common transmission types include belt drive, chain drive, gear drive and hydraulic drive. The belt drive has the advantages of simple structure, smooth transmission and low noise, which is suitable for small and medium power cutter total bearing, but its transmission efficiency is relatively low, and it may slip when running for a long time with high load. The chain transmission has higher transmission efficiency and carrying capacity, and can adapt to larger torque transmission, but it needs regular lubrication and tension adjustment, otherwise it is easy to produce noise and wear; Gear transmission accuracy is high, transmission ratio is stable, suitable for high cutting speed and accuracy requirements, but the manufacturing cost is high, and at high speed operation may produce large noise; Hydraulic transmission has the characteristics of stepless speed regulation, smooth transmission, strong overload protection, etc. It is often used for large, heavy duty or more complex cutting action control requirements, but it needs to be equipped with a special hydraulic system, which is expensive and relatively complex to maintain.
Regulating mechanism
The adjusting mechanism is used to precisely control the parameters of the cutting position, Angle and depth of the cutter to meet the requirements of different feed products on particle length and shape. The adjustment mechanism usually includes two ways of manual adjustment and automatic adjustment. The manual adjustment mechanism is generally realized by screw, nut, hand wheel and other parts. The operator can manually adjust the position of the cutter according to the production demand. The operation is simple and intuitive, but the adjustment accuracy is relatively low, and the machine needs to be stopped for adjustment during the production process. The automatic adjustment mechanism uses a control system composed of sensors, controllers and actuators, which can automatically adjust the position of the cutter in real time according to the characteristics of the material and production process parameters, achieve automatic and intelligent cutting control, improve production efficiency and product quality stability, but the equipment cost is higher and the maintenance technical requirements are higher.
3. Material characteristics
Cutter material
High-speed steel: High-speed steel is a kind of steel with high hardness, high wear resistance and high thermal stability, its main alloying elements include tungsten, molybdenum, chromium, vanadium and so on. The hardness of the high-speed steel cutter can reach HRC62-65 at normal temperature, which can maintain a sharp cutting edge at a higher cutting speed, and has good toughness and is not easy to break. Suitable for cutting all kinds of ordinary feed materials, such as livestock feed, some aquatic feed, etc., widely used in feed production industry.
Cemented carbide: Cemented carbide is tungsten carbide, titanium carbide and other hard phase as the main body, with cobalt, nickel and other metals as the binder made of composite materials. Its high hardness, up to HRC80-90, wear resistance and heat resistance is much better than high-speed steel, can withstand higher cutting temperatures and cutting forces. Carbide cutting knife is especially suitable for cutting high hardness, rich fiber content or containing special additives of feed materials, such as some special aquatic feed, pet feed, etc., but the cost of carbide materials is high, and the toughness is relatively low, in the use of the process need to pay attention to avoid excessive impact, otherwise it is prone to collapse phenomenon.
Tool rest material
The tool holder is generally made of high-quality carbon steel or alloy steel, such as 45 steel, 40Cr and so on. These materials have good strength and toughness, and after appropriate heat treatment (such as tempering treatment), they can meet the requirements of strength, stiffness and impact resistance of the tool holder during the cutting process. At the same time, in order to improve the wear resistance and corrosion resistance of the tool holder, the surface can also be treated, such as chrome plating, blackening and other treatments, in order to extend the service life of the tool holder and ensure the stable and reliable operation of the cutter in the harsh feed production environment.
Transmission material
Belt drive: Belts are generally made of rubber or polyurethane materials with good elasticity and wear resistance, which can effectively transmit power and reduce vibration and noise. The pulley is usually made of cast iron or aluminum alloy material, cast iron pulley cost is low, high strength, suitable for general power transmission; The aluminum alloy pulley has the advantages of light weight and good heat dissipation, and is often used in occasions where the weight and heat dissipation of the equipment are high.
Chain drive: The chain is generally made of alloy steel, such as 40Mn, 42CrMo, etc., and its strength and wear resistance are improved by heat treatment. The sprocket is mostly made of high-quality carbon steel or alloy steel forging, and the tooth surface is quenched to improve its hardness and wear resistance, to ensure the good meshing between the chain and the sprocket, and to transfer power stably.
Gear transmission: gear is usually made of high-quality alloy steel, such as 20CrMnTi, 40Cr, etc., after carburizing and quenching treatment, so that the tooth surface has high hardness (HRC58-62) and good wear resistance, and the heart maintains a certain toughness to withstand the bending stress and impact load of the gear in the transmission process. Shaft components are generally made of medium carbon steel or alloy steel, such as 45 steel, 40Cr, etc., after tempering treatment to ensure that it has enough strength and toughness, stable support gear and transfer torque.
Hydraulic transmission: The hydraulic cylinder, hydraulic motor and other main components in the hydraulic transmission device are generally made of high-strength alloy steel, such as 42CrMo, 35CrMo, etc., which has good pressure resistance and wear resistance. The hydraulic pipeline is usually made of seamless steel pipe or high pressure rubber hose to ensure the stable transmission of hydraulic oil in the system and withstand the working pressure of the system.
4. Manufacturing process
Cutter manufacturing process
Forged or rolled blanks: Blanks of high speed steel and carbide cutters are usually prepared by forging or rolling processes. The forging or rolling process can improve the structure of the material, increase its density and mechanical properties, and eliminate internal defects. For high speed steel cutter, after forging, it is also necessary to carry out spheroidizing annealing treatment to reduce hardness and improve cutting performance.
Machining: After forging or rolling treatment of the cutting tool blank, a series of machining processes need to be carried out, including turning, milling, grinding, etc. First, the blank is processed into a rough shape by turning, and the dimensional accuracy and coaxiality requirements are guaranteed; Then the milling process is carried out, and the cutting edge shape and installation part of the cutting tool are processed. Finally, the cutting edge is finely ground by grinding technology to make it reach the required sharpness and surface roughness. In the machining process, it is necessary to use high-precision machine tool equipment and tools, and strictly control the processing parameters to ensure the manufacturing accuracy and quality of the cutting tool.
Heat treatment: Heat treatment is a key process to improve the performance of the cutter. For high-speed steel cutters, the heat treatment process of quenching + three times tempering is generally used. The quenching temperature is usually between 1200-1300 ℃, so that the cutter can obtain a high-hardness martensitic structure, and then the tempering treatment is carried out three times at 550-570 ℃ to eliminate the quenching stress and improve the toughness and thermal stability of the cutter. Due to its own high hardness, carbide cutters generally do not need to undergo overall heat treatment, but after the cutting edge welding or coating treatment, it may be necessary to conduct appropriate low-temperature tempering treatment to eliminate welding stress or coating stress.
5. Performance characteristics
High cutting performance
The cutter master has an efficient cutting capacity, which can quickly and accurately cut feed materials into particles of the desired length. The material, shape and cutting edge design of the cutting tool and the performance of the transmission device directly affect the cutting efficiency. For example, the high hardness and wear resistance of the carbide cutter enable it to maintain a sharp edge when cutting at high speed, reducing cutting resistance and improving cutting speed; Advanced transmission devices, such as hydraulic transmission or high-precision gear transmission, can provide stable power output to ensure that the rotary or reciprocating motion of the cutter is smooth and fast, so as to achieve efficient cutting operations. In large feed production lines, efficient cutter total bearing can significantly improve production efficiency and meet the needs of large-scale feed production.
Precise cutting control
Through the precise control of the adjusting mechanism, the cutter general bearing can realize the precise cutting of feed particle length. Whether it is manual adjustment or automatic adjustment, the particle length error can be controlled within a very small range according to different feed product formulations and production process requirements. For example, in the production of pet feed, the precision of the particle length is required to be high, and the precise cutting control of the total bearing of the cutter can ensure that the length of each particle of pet feed meets the standard, improve the appearance quality and palatability of the product, and meet the needs of pets. Precise cutting control can also reduce packaging, transportation and storage problems caused by inconsistent particle lengths, improving the overall efficiency of feed production.
Good stability and reliability
The cutter head needs to run continuously for a long time in the feed production process, so its stability and reliability are crucial. High-quality material selection, reasonable structural design and superb manufacturing process make the cutter master can work stably and reliably under harsh working conditions. The high strength and stiffness of the tool holder can effectively support the cutter and prevent it from shaking or deformation during the cutting process; The reliable transmission of the transmission device can ensure the continuous power supply of the cutter to avoid power interruption or transmission failure; The high wear resistance and heat resistance of the cutter are enough to maintain good performance in the long cutting work and reduce the number of replacement and maintenance. The stable and reliable cutter total bearing can reduce the failure rate of feed production equipment, improve the utilization rate of production equipment, and reduce the economic loss caused by equipment downtime.
Wide adaptability
There are many kinds of feed materials, and their physical properties (such as hardness, fiber content, humidity, etc.) differ greatly, and the total bearing of the cutter needs to have a wide range of adaptability and can cope with various types of feed materials. Different materials and shapes of the cutter can be selected according to the characteristics of the material, such as carbide cutter suitable for cutting high hardness materials, serrated knife suitable for processing fiber rich materials; The adjusting mechanism can flexibly adjust the cutting parameters according to the change of the material to ensure a good cutting effect. In addition, the cutter can also be matched with different models and specifications of feed production equipment, whether it is a small feed processing plant or a large feed production enterprise, you can choose the right cutter general bearing according to their own equipment and production needs, to achieve efficient and high-quality feed production.
6. FAQ
Q: What is the main material of the total bearing of the cutter?
A: The cutter head is usually made of high-strength steel or alloy steel to ensure that it has sufficient strength and wear resistance. These materials can withstand high loads and long periods of use.
Q: How to choose the right cutter total bearing size?
A: The selection of the appropriate cutter total bearing size needs to consider the power, speed and load of the equipment. Ensure that the selected size can meet the design requirements and conditions of use of the equipment.
Q: What are the surface treatment processes of the total bearing of the cutter?
A: The common surface treatment process of the cutter includes quenching, carburizing and nitriding. These processes can improve the hardness and wear resistance of the surface and extend the service life.
Q: How to ensure the transmission efficiency of the total bearing of the cutter?
A: In order to ensure the transmission efficiency of the total bearing of the cutter, the coordination accuracy between the shaft and the total bearing should be ensured, the lubrication system should be regularly checked and maintained, and the lubricating oil should be kept clean and appropriate.
Q: What problems may occur during the use of the cutter master?
Answer: The cutter general bearing in the use of the process may appear wear, fracture, deformation or poor fit and other problems. These problems are usually caused by overload, inadequate lubrication, or material defects.
Q: How long is the replacement cycle of the cutter general bearing?
A: The replacement cycle of the cutter master depends on the frequency of use, the working environment and the operating condition of the equipment. In general, when significant wear, deformation or inability to effectively drive is found, a new cutter bearing should be considered.
Q: What are the special requirements of the cutter general bearing in different application scenarios?
Answer: In different application scenarios, the cutter general bearing may have different special requirements. For example, cutters used in high temperature environments always need to have high temperature resistance; For use in corrosive environments, corrosion-resistant materials are required.
