In the production of lithium batteries and other applications, electrode sheet cutting is a critical process. However, issues such as dusting and burrs during cutting not only compromise the quality and performance of electrode sheets but also pose significant risks to subsequent cell assembly, battery safety, and service life. Leveraging our extensive industry experience and technical expertise in carbide products, we have developed five comprehensive solutions to effectively address these challenges, enhancing both production efficiency and product quality.
I. Optimize Tool Material and Structural Design
(1) Select High-Hardness, Wear-Resistant Carbide Materials
Electrode sheet cutting demands exceptional hardness and wear resistance from cutting tools. Conventional tools tend to dull quickly during cutting, leading to dusting and burrs. In contrast, high-performance carbide materials such as WC-Co series with higher cobalt content significantly enhance wear resistance. The cobalt binder phase strengthens the cohesion between tungsten carbide particles, ensuring prolonged edge sharpness and minimizing dusting and burrs caused by tool wear.
(2) Adopt Specialized Tool Geometries
Beyond material selection, tool design plays a pivotal role. For example:
- Sharp Cutting Edge Angles: Reduce cutting resistance and tearing forces, minimizing burr formation.
- Chip Breaker Grooves: Facilitate smooth chip evacuation, preventing chip accumulation and reducing dusting.
- Precision Roundness and Concentricity: Ensure cutting stability, further mitigating defects.
II. Precise Control of Cutting Process Parameters
(1) Optimize Cutting Speed
Excessive cutting speeds generate heat, softening the electrode material and exacerbating dusting and burrs. Conversely, speeds that are too low reduce productivity. Through rigorous testing and data analysis, we recommend:
- Thin/Soft Materials: 10-15 meters per minute
- Thick/Hard Materials: 8-12 meters per minute
These ranges balance quality and efficiency for different electrode specifications.
(2) Adjust Feed Rate
Proper feed rates ensure smooth cutting without overloading the tool. Recommended ranges:
- General Guidelines: 0.05-0.2 mm/revolution
- Material-Specific Adjustments: Thicker/harder materials require lower feed rates
Synchronized adjustment with cutting speed optimizes results.
(3) Control Cutting Temperature
Heat generated during cutting can degrade material properties and tool performance. Implement cooling systems (e.g., spray cooling, cold air) to maintain temperatures below 40°C. This reduces thermal deformation, extends tool life, and eliminates defects caused by overheating.
III. Regular Tool Maintenance and Replacement
Tool edges inevitably wear during prolonged use. Establish a maintenance schedule including:
- Visual and Microscopic Inspections: Monitor edge wear using precision instruments.
- Replacement Interval: 7-10 days for 8-hour daily operations (adjust based on material and usage intensity).
- Precision Installation: Ensure correct alignment to prevent secondary issues.
IV. Select Appropriate Cutting Equipment and Auxiliary Systems
(1) High-Performance Cutting Machines
Invest in equipment featuring:
- High-Precision Spindles: Minimize vibration and ensure consistent cutting.
- Advanced Control Systems: Enable precise speed and position control (e.g., servo-driven systems).
- Stable Transmission Mechanisms: Reduce errors and enhance process stability.
(2) Dust Collection and Adsorption Systems
Install efficient dust extraction and electrostatic adsorption devices to:
- Maintain Clean Work Environments: Prevent dust contamination of electrode surfaces.
- Improve Product Quality: Eliminate defects caused by airborne particles.
V. Enhance Operator Training and Standardize Processes
Operator skill and adherence to protocols directly impact cutting quality. Implement:
- Comprehensive Training Programs: Cover process parameters, tool handling, equipment maintenance, and quality control.
- Standard Operating Procedures (SOPs): Document best practices for parameter adjustment, tool installation, and routine checks.
- Quality Management Systems: Establish regular inspections to identify and resolve issues promptly.
Resolving dusting and burrs in electrode sheet cutting requires a holistic approach encompassing tool selection, process optimization, equipment maintenance, and operator training. By implementing these five solutions, manufacturers can significantly improve cutting quality, ensuring the stability and reliability of lithium battery production. As a leading provider of carbide cutting tools, we offer not only premium products but also comprehensive technical support to help businesses thrive in competitive markets.