1. Feed machinery equipment accessories cutting disc product introduction
In the process of feed production and processing, the cutter head is a key accessory used to cut the material into a specific length of particles after pelletizing, expanding and other molding processes. Its performance directly affects the size accuracy, appearance quality, production efficiency and overall stability of feed particles. A high-quality cutter can ensure that feed pellets meet the standard requirements, meet the feeding habits of different animals, and improve the production efficiency of feed manufacturers.
2. Structural characteristics
discus
The disk body of the cutter is generally round and made of metal material, common high-quality carbon steel, alloy steel and so on. The disc has a certain thickness and diameter, the thickness needs to ensure sufficient strength to withstand various forces in the cutting process, and the diameter is determined according to the output and cutting needs of the feed production equipment, ranging from several hundred millimeters to more than one meter. A shaft hole is arranged in the center of the disc body, which is used to connect with the drive shaft to realize power transmission and drive the whole cutter head to rotate at high speed. At the edge of the disk or at a specific position, there are slots or fixed structures for installing the cutting tool. The accuracy and firmness of these structures have a crucial impact on the installation and cutting effect of the cutting tool.
cutter
The cutter is the core part of the cutter head, and its shape, quantity and arrangement are various. Common cutter shapes include straight knives, curved knives and serrated knives. Straight knife structure is simple, the blade is straight, the cutting force is more uniform, suitable for general feed cutting tasks, the particle shape and cutting accuracy requirements are not particularly high. The blade of the machete is curved, which can better comply with the flow direction of the material when cutting, reduce the cutting resistance, and improve the cutting efficiency, especially when dealing with some soft texture and good fluidity of feed materials. Serrated knife has a sharp serrated blade, its cutting ability is very strong, can easily cope with high hardness, rich fiber content of feed, effectively prevent the material in the cutting process to tear or break, to ensure the integrity of the particles and appearance quality. The number of cutters depends on the size of the disc and the cutting accuracy requirements, generally ranging from a few to dozens, and evenly distributed on the disc to ensure that the material is evenly cut during the rotation process. The connection between the cutter and the disc body is usually welded, bolted or embedded installation, etc. In either way, it is necessary to ensure that the cutter is firmly installed, and will not loosen or displace when rotating at high speed.
Tool holder and fastener
The tool holder is the basic component for installing the cutter, and its structure is designed to provide stable support and accurate positioning for the cutter. The tool holder is generally made of high-strength alloy material, with good wear resistance and impact resistance. The cutter seat is provided with a groove or mounting hole matching the shape of the cutter. After the cutter is installed on the cutter seat, it is secured by bolts, nuts, washers and other fixing parts. These fixtures not only ensure that the cutter does not loosen during normal operation, but also facilitate quick removal and installation when the cutter wears out or needs to be replaced. In some advanced cutter head designs, a mechanism to quickly replace the cutter seat or cutter is also used, such as the use of card slot connection with spring clamping or hydraulic clamping device, which greatly reduces the time to replace the cutter and improves the maintenance efficiency and production continuity of the equipment.
Balancing device
Because the cutter head in the process of high-speed rotation, if there is a mass imbalance, will produce violent vibration, affect the cutting accuracy, shorten the service life of the equipment and even cause safety accidents. Therefore, the cutter head is usually equipped with a balancing device. The balance device generally adopts the way of setting a balance hole on the disk body or installing a balance block to adjust the mass distribution of the cutter head to achieve a dynamic balance state. After the cutter head is manufactured, it will be tested by professional dynamic balance test equipment, and the weight and position of the balance block will be added or adjusted according to the test results
3. Material characteristics
Body material
High quality carbon steel such as No. 45 steel is one of the commonly used materials for cutting cutter disc body, it has good comprehensive mechanical properties, strength and toughness are more balanced, after appropriate heat treatment (such as tempering treatment), hardness up to HB217-255, can meet the strength requirements of the general feed production equipment cutting cutter disc. In some cases with higher requirements for strength and wear resistance, alloy steel materials will be selected, such as 40Cr, 42CrMo, etc. These alloy steels contain chromium, molybdenum and other alloying elements, through tempering and surface quenching and other heat treatment processes, the surface hardness can be significantly improved, such as 42CrMo steel after treatment of surface hardness up to HRC50-55, with better wear resistance and fatigue resistance, can effectively extend the service life of the cutter head, Suitable for large, high yield feed production line cutting disc.
Cutter material
The material selection of the cutter mainly depends on the characteristics of the feed material and the cutting requirements. For ordinary feed materials, high-speed steel cutters are a more common choice. High speed steel has high hardness (HRC62-65), high wear resistance and good toughness, which can maintain a sharp blade at a certain cutting speed and is not easy to break when impacted. For example, when cutting some common livestock and poultry feed, the high-speed steel cutter can stably complete the cutting task to ensure the dimensional accuracy and appearance quality of the particles. However, when facing feed materials with higher hardness, such as feed containing a lot of bone meal or mineral additives, or feed with a very high fiber content, such as some grass feeds or special aquatic feeds, carbide cutters are more suitable. Tungsten 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 hardness can be as high as HRC80-90, wear resistance and heat resistance is far higher than high-speed steel, can easily cope with the high hardness and high fiber material cutting challenges, but the toughness of carbide cutting tool is relatively low. In the process of use, special attention should be paid to avoid excessive impact or collision, so as to avoid the phenomenon of falling edge.
4. Manufacturing process
Disk system manufacturing technology
The manufacture of the disc body usually begins with forging or casting blank. The forging process can refine the grain of the metal material and make the structure more dense, so as to improve the strength and toughness of the disk. The casting process is suitable for the disk system with complex shape and mass production, which can reduce the production cost, but the process parameters in the casting process need to be strictly controlled to reduce the defects such as pores, shrinkage holes and sand holes. After the blank manufacturing is completed, it is necessary to annealing or normalizing treatment to eliminate forging or casting stress and improve the cutting performance of the material. Then mechanical processing, including turning, milling, drilling and other processes. Turning is used to process the outer circle, shaft hole and end face of the disk body to ensure its dimensional accuracy and surface roughness; Milling is used for machining cutter mounting slots or fixed structures; Drilling is used to process balance holes or other connecting holes. In the machining process, it is necessary to use high-precision machine tool equipment and tools, and strictly control the processing parameters to ensure that the accuracy indicators of the disk body meet the requirements. Finally, heat treatment is carried out according to the material and performance requirements of the disk body, such as tempering treatment, quenching + tempering treatment, etc., to improve the hardness, strength and wear resistance of the disk body. For alloy steel plates, surface hardening can further improve the surface hardness, enhance the wear resistance and fatigue resistance.
Cutter manufacturing process
The manufacturing process of high speed steel cutter is more complicated. First, the blank is prepared by forging or rolling process. Forging or rolling process can improve the structure of the material, improve its density and mechanical properties, and eliminate internal defects. After forging, it is necessary to carry out spheroidizing annealing treatment to reduce hardness and facilitate subsequent machining. The machining process includes turning, milling, grinding, etc., turning processes the rough shape of the cutting tool, milling processes the shape of the cutting edge, grinding is used to fine grind the cutting edge to achieve the required sharpness and surface roughness requirements. After the machining is completed, the heat treatment process of quenching + three times tempering is carried out. The quenching temperature is generally between 1200-1300 ℃, so that the cutter can obtain a high hardness martensitic structure, and then three tempering treatment at 550-570 ℃ to eliminate the quenching stress and improve the toughness and thermal stability of the cutter. Due to its very 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. For the cutting edge welding process, advanced welding technology and equipment should be used to ensure welding quality and avoid welding defects. The coating treatment can be nitriding treatment, hard chromium plating treatment, PVD (physical vapor deposition) coating treatment, etc., to further improve the wear resistance, corrosion resistance and cutting performance of the cutter. For example, the PVD coating process can deposit a coating material with extremely high hardness, wear resistance and excellent lubrication on the surface of the cutter, such as TiN, TiAlN, etc., significantly extending the service life of the cutter.
Manufacturing technology of tool holder and fixer
The tool holder is generally manufactured by forging or casting process, and then machined. Machining processes include turning, milling, drilling, boring, etc., turning the shape of the cutter seat, milling the grooves or mounting holes matched with the cutter, drilling and boring are used to process connecting holes and positioning holes. After the tool holder is manufactured, it is necessary to conduct heat treatment, such as tempering treatment, to improve its hardness and strength, and to enhance wear resistance and impact resistance. Fixed parts such as bolts, nuts, etc. are made of standard parts or customized production according to the special requirements of the cutter head, and the manufacturing process needs to ensure the reliability and stability of the connection, and the screw thread accuracy and strength level of the bolts should meet the relevant standards and design requirements.
5. Performance characteristics
High precision cutting
Cutter heads are designed and manufactured to achieve high precision cutting results. The length error of feed particles can be controlled within a very small range by precise disc processing, cutter installation and adjustment, and balancing device application. For example, in the production of pet feed or aquatic feed, the accuracy of the particle length is higher, and the high-quality cutting disc can make the particle length error not more than ±0.5mm, ensuring that each grain of feed meets the standard, improving the quality stability and market competitiveness of the product. High-precision cutting can also reduce packaging, transportation and storage problems caused by inconsistent particle lengths, such as uneven packaging and particle breakage during transportation.
High cutting efficiency
The high speed rotation of the cutter head and the reasonable cutter design make it have high cutting efficiency. The material and structure of the disc ensure the stability during high-speed rotation, and can withstand large centrifugal and cutting forces. The shape, number and arrangement of the cutters are optimized for different material characteristics. For example, the design of machetes and serrated knives can effectively reduce cutting resistance and increase cutting speed. In large feed production lines, the high cutting efficiency of the cutter head can significantly increase the production capacity to meet the needs of large-scale feed production. At the same time, the high cutting efficiency also means that the energy consumption per unit time is reduced, which helps to improve the economic efficiency of feed production enterprises.
Good wear resistance and durability
Because the cutter head is always in contact with the feed material and produces friction during the working process, good wear resistance is an important performance characteristic. The selection of disk material and heat treatment process make its surface have a certain hardness and wear resistance, and can resist the wear of materials. The cutter material is optimized for wear resistance, whether it is high-speed steel or carbide cutter, it can maintain a sharp blade during a long cutting work and reduce the frequency of changing the cutter. In addition, the wear resistance of the tool holder and fixed parts is also guaranteed, and through material selection and surface treatment, it is ensured that the cutting tool will not be loosened or displaced due to wear during long-term use. The good wear resistance and durability make the service life of the cutter head long, reduce the maintenance cost and downtime of the equipment, and improve the utilization of the production equipment.
Stability and reliability
The cutter head needs continuous and stable operation in the feed production equipment, and its stability and reliability are very important. The balance device of the disc body ensures that there will be no violent vibration during high-speed rotation, reducing the impact on other parts of the equipment, such as bearings, drives, etc., wear and damage. The solid installation of the cutter and the reliable connection between the cutter holder and the fixture ensure that there will be no safety hazards such as loosening or falling off the cutter during the cutting process. At the same time, the material and manufacturing process of the cutter head ensure that it can work stably and reliably under different working environments and material conditions, whether it is high temperature, high humidity environment or in the face of different hardness and properties of feed materials, it can maintain good performance, providing continuous protection for feed production.
6. FAQ
Q: What is the main material 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 size?
A: Choosing the right cutter head 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 cutter head?
A: The common surface treatment process of the cutter head includes quenching, carburizing and nitriding. These processes can improve the hardness and wear resistance of the surface and extend the service life.
Q: What problems may occur during the use of the cutter head?
A: The cutter head may suffer from wear, fracture, deformation or poor fit during use. These problems are usually caused by overload, inadequate lubrication, or material defects.
Q: What are the heat treatment processes of the cutter head?
A: The heat treatment process of the cutter head includes quenching, tempering and normalizing. These processes can improve the mechanical properties of the material, increase its hardness and wear resistance, and thus extend the service life of the cutter head.
Q: How does the design of the cutter head affect production efficiency?
A: The design of the cutter head directly affects the production efficiency. Reasonable design can improve cutting efficiency, reduce energy consumption, and extend the service life of the equipment. Therefore, it is very important to choose the cutter head design suitable for the specific application requirements.
