How to Maximize Circular Slitter Blades Performance and Durability

Maximizing Circular Slitter Blade Performance for Longer Service Life

In the rapidly evolving environment of conversion, a single component could be the difference between achieving a very high yield production day and an expensive downtime shift - namely, circular slitting blades. The maintenance of the cutting edge of a slitting blade is very important for both product quality and bottom-line business efficiency when slitting thin plastic film or heavy-duty foil or abrasive textile materials. 

There is no longer room for a lack of major repair or improved maintenance technique; therefore, we have composed this guide to discuss the important engineering techniques to consider in order to achieve optimal productivity and longevity from your precision circular slitter knives.

1. Material Selection: The Foundation of Performance

A blade's maximum lifespan begins long before it touches a workpiece. In addition, the type of metal used to manufacture industrial circular slitter blades must correspond exactly with how it will be used. For example:

• Tungsten Carbide Circular Slitter Blades

Tungsten carbide has become the benchmark for maximum abrasion resistance and will maintain its cutting edge potentially 10 times longer than steel when used to cut non-ferrous materials or very abrasive composite materials.

• High-Speed Steel (HSS) Slitter Knives

High-speed steels are a balanced combination between toughness and hardness in terms of general-purpose blades used in slitting applications, which frequently experience shock-loading.

• Powder Metallurgy Slitter Blades

Likely to become increasingly popular by 2026, steels exhibit a more uniform distribution of the carbide phase than conventional D2 steels, resulting in superior edge retention and chipping resistance.

2. Advanced Coatings for Precision Circular Slitter Knives

Circular slitting knives of modern technology have been extensively studied with respect to their surface science. The correct slitter blade coating can reduce friction by up to 50% and increase the life of the Knife by between 35% and 50%.

• Titanium Nitride (TiN) Coating

Identified by the gold color it has, tiN will increase the surface hardness of the knife and is very effective for reducing dust during the plastic film converting process.

• Diamond-Like Carbon (DLC) Coating

This coating is referred to as a "Zero Friction" coating and is required when cutting or converting sticky materials, Adhesives. DLC does not allow for the accumulation of residue, which produces heat and dulling at an early stage.

• Ceramic Coatings for Abrasive Materials

Ceramic coating has been developed to protect against abrasive material (Materials containing mineral additives such as calcium carbonate) that are being cut or converted.

3. Optimizing Operating Parameters

There is a huge amount of information available about the proper set-up of the circular slitter knives. The main idea is to have the proper clearance between the top blade and bottom blade in order to provide the necessary pressure to cut effectively. 

Recommended Slitter Blade Clearance

The "One Piece of Paper" Rule of Thumb applies here. 

• If there is too much clearance between the top and bottom blades, you will experience what is known as "wire drawing" where the material gets pulled into the blade and bunched up, resulting in burrs, etc. 

• If there is too little clearance between the top and bottom blades, there will be a direct contact of metal-to-metal, which causes severe heat spikes, microscopic chipping, and ultimately fails the blade.