Dull or imperfect blades ruin production runs, waste material, and lead to downtime and rework. In manufacturing environments — such as textile, rubber, and packaging production — blades often encounter abrasive materials that can cause wear over time. Choosing the wrong industrial blade can minimize its lifespan, so your operation ends up dealing with frequent disruptions.
The key to avoiding these issues, extending blade life, and optimizing cutting performance is abrasion resistance. This post covers the topic in detail, from blade materials and coatings to real-world applications.
So, what is abrasion resistance, and why should you care? Abrasion resistance refers to a blade’s ability to withstand wear or damage from rubbing, scraping, and friction against other materials. You should care because abrasion wear affects the longevity and cutting performance of your blade; it also represents a significant safety risk.
Blades with high abrasion resistance ratings typically maintain their sharpness and edge even in the most demanding cutting environments, such as textile and rubber manufacturing plants. The material composition of these blades, including high alloy steels (tungsten carbide) and high-speed steels (HSS), makes them more suitable for these environments.
Specially designed blades use a combination of material composition, surface coatings, and hardness ratings to guard against abrasive materials. In industrial settings, those materials might include hard particles in the workpiece (glue residue, recycled materials, and other debris) and environmental contaminants (dust, sand, or other naturally occurring particles).
Abrasive wear can dull even the best industrial knives. Some materials essential to industrial cutting operations are inherently abrasive, including fiberglass, composites, rubber, and hydraulic fluids. The materials can act like sandpaper on a blade’s edge.
The constant, high-friction interaction between the blade and the material actively wears down and dulls the blade. Depending on the cutting speed and angle, the abrasion rate might be much higher than expected, leading to higher replacement and maintenance costs.
You can improve the lifespan of your blades by cutting at the proper speed and angle for the material. You should also look for blades with superior hardness and resistance to abrasion.
Understand that hardness is a good indicator of how a blade stands up to abuse, but it isn’t the definitive solution to abrasive wear. Hardness tells you how resistant to deformation, scratching, and wear a blade is, but it doesn’t always correlate with toughness.
Several factors contribute to blade toughness and durability, such as its material and surface coatings. For industrial knives designed to hold up against friction and abuse, you need blades with high-abrasion resistance. This refers to a material's or coating’s ability to withstand the wear and tear that stems from friction. Blades with a high abrasion resistance rating are designed for longevity, functionality, and a reduced need for maintenance and replacement.
A hardened steel blade, or one with steel and other alloys, often has a smoother surface and greater tensile strength than other cutting tools. With a higher tensile strength, the blade can withstand forces applied while cutting. Minimal surface roughness typically results in less friction. Still, increasing a blade’s abrasion resistance may come down to applying the appropriate coatings for your specific applications.
The use of modern blade coatings is an essential aspect of improving a blade’s durability. The materials address issues relating to wear and blade failure. Coatings like titanium nitride (TiN) or diamond-like carbon (DLC) increase the surface hardness of the blade. Standard tests, such as the Vickers hardness test, show coatings like DLC can reach hardness levels of up to 5,000, which surpasses many traditional steels.
Some coatings, such as PTFE, aid in corrosion prevention and help reduce friction for smoother cutting. The substances provide a protective barrier from corrosive elements, including rust, chemicals, and other environmental factors.
Some coatings can improve the thermal management properties of a material. For example, ceramic-based coatings help blades disperse heat during cutting, preventing thermal fatigue.
Despite the benefits of many of these coatings, they can present limitations in high-friction applications. TiN, for instance, oxidizes at higher temperatures, which can compromise its wear resistance. DLC presents the potential for stress and cracking; this is primarily a problem for thick coatings of the material or those applied via chemical vapor.
The right coating for your business depends on the application and operation. You can review the effectiveness of each coating by looking at the spec sheet or by seeking the results of oscillatory abrasion tests or real-world application studies.
Beyond material and coating, blade geometry, which encompasses factors like blade shape, edge design, and thickness, influences a blade’s abrasion resistance and cutting efficiency. The blade shape dictates how force is distributed. It determines how the blade engages with the material, influencing the blade’s cut.
Edge design (e.g., square, single-beveled, or double-beveled) affects sharpness, friction, and precision. Bevel angles further refine this: acute angles offer cleaner cuts, moderate angles balance sharpness and durability, and obtuse angles provide maximum strength for heavy-duty use.
Blade thickness influences rigidity and efficiency. Thicker blades resist flexing under pressure, while thinner blades allow faster, more precise cuts.
Choosing the right blade material is paramount for enhancing performance and reducing downtime in abrasive environments. In the rubber industry, blades are used to cut and shape rubber materials. These materials, especially in their raw or unvulcanized state, can be quite abrasive, requiring materials like D2 tool steel or carbide to ensure a longer blade life and precise cuts.
In the hydraulics industry, blades are typically used for hose cutting. Hydraulic hoses are usually made with robust materials like steel braiding to withstand high pressures. Choosing high-speed steel with specific edge geometries like scallops and a higher abrasion safety rating can counter the abrasive attributes of the material, leading to better cuts and a longer lifespan.
The right blade for your operation may not exist yet. Instead of dealing with delays and increased costs working with subpar blades, consider working with us to create custom blades that work.
For over 150 years, we’ve been manufacturing world-class industrial blades, knives, and tools right here in the USA. Family-owned since the beginning, our legacy is built on our commitment to quality. Our blades offer superior reliability compared to foreign alternatives, helping you reduce downtime and improve productivity where it matters most.
Contact us to get an abrasion-resistant blade that meets your operational demands.