Manufacturing process of an ultra-thin circular saw blade

Abstract

The application discloses a manufacturing process of an ultrathin circular saw blade, and aims to solve the problem of poor quality of the ultrathin circular saw blade in use at present and hidden quality defects. The manufacturing process comprises the following steps: S1, grinding, removing burrs, foreign matters and hard matters on the surface of the saw blade body; S2, preheating and heat preservation, preheating the saw blade body in a heating furnace and performing heat preservation; S3, quenching, performing quenching treatment on the saw blade body; S4, flattening, rapidly performing flattening operation after the saw blade body leaves an oil tank; S5, cleaning and removing impurities; and S6, tempering. The manufacturing process of the ultrathin circular saw blade effectively solves the quality problems or hidden quality defects of the high saw blade crack rate, the large body deformation, the poor hardness uniformity of single saw blade and saw blades in the same batch, the insufficient rigidity of the saw blade and the easy cracking of the saw blade after use.

Description

Technical Field

[0001] This invention relates to a heat treatment technology, and more specifically, to a manufacturing process for an ultrathin circular saw blade. Background Technology

[0002] Currently, ultra-thin circular saw blades are in high demand in several fields, such as cutting precious mahogany, louvered panels, radiators, and thermally broken aluminum alloys. The main characteristic of ultra-thin circular saw blades is their thin kerf. To prevent jamming and blade failure during cutting, the blade body needs to be thinner than the cutting edge. The heat treatment process for high-quality ultra-thin saw blades is one of the key processes for product success. Currently used ultra-thin circular saw blades have many shortcomings, such as high crack rate, large body deformation, poor uniformity of hardness in individual blades and batches, insufficient blade rigidity, and susceptibility to cracking after use. These problems lead to poor quality and potential quality risks. Summary of the Invention

[0003] To overcome the above shortcomings, this invention provides a manufacturing process for ultra-thin circular saw blades, which effectively solves quality problems or potential quality hazards such as high crack rate, large deformation of the blade body, poor uniformity of hardness of individual saw blades and saw blades in the same batch, insufficient rigidity of the saw blade, and easy cracking of the blade after use.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a manufacturing process for an ultra-thin circular saw blade, comprising the following steps:

[0005] S1, Grind smooth to remove all burrs, foreign objects, and hard objects from the surface of the saw blade body;

[0006] S2, Preheat and keep warm: Place the saw blade body in the heating furnace for preheating and keep warm;

[0007] S3, Quenching, refers to the quenching treatment of the saw blade body;

[0008] S4, flattening: The saw blade body is quickly flattened after leaving the oil groove;

[0009] S5, cleans and removes impurities;

[0010] S6, tempering.

[0011] In the processing of ultra-thin circular saw blades, S1 grinds the surface of the saw blade body to remove all burrs, metallic foreign objects, and other hard objects, ensuring that the two end faces and laser-cut areas of the ultra-thin saw blade body are free of hard objects. This prevents stress concentration caused by heating or rapid cooling during heat treatment, which could lead to cracks or create potential cracks in the saw blade body. S2 preheats the saw blade body in the heating furnace, serving as a heating transition and reducing the amount of twisting deformation caused by sudden temperature increases. S2 holds the saw blade body at a temperature in the heating furnace, providing sufficient energy and time for the transformation of the ultra-thin saw blade body from pearlite to austenite. S3 quenching achieves the transformation of the saw blade body from austenite to martensite. S4 flattening effectively controls the overall flatness of the saw blade body. S5 cleaning removes impurities to ensure that the ultra-thin saw blade body is free of foreign objects, laying the foundation for subsequent tempering to guarantee flatness. S6 tempering yields a high-hardness, high-flatness ultra-thin saw blade body.

[0012] The manufacturing process of the ultra-thin circular saw blade in this patent effectively solves quality problems or potential quality hazards such as high crack rate, large deformation of the saw blade body, poor uniformity of hardness of individual saw blades and saw blades in the same batch, insufficient rigidity of the saw blade, and easy cracking of the blade after use.

[0013] Preferably, in S2, the preheating temperature of the heating furnace is 780±5℃; the holding temperature of the heating furnace is 820±5℃.

[0014] The preheating temperature and holding temperature of the saw blade body in the heating furnace are set reasonably, which is conducive to improving the quenching effect.

[0015] Preferably, the heating furnace is equipped with a preheating zone and several heat preservation zones. The saw blade body is preheated in the preheating zone for 60-80 seconds and then heat-preserved in the heat preservation zones for 470-510 seconds.

[0016] Sufficient preheating and heat preservation time for the saw blade body provides enough energy and sufficient conversion time for the transformation of the saw blade body from pearlite to austenite.

[0017] Preferably, the saw blade body is sent from the heating furnace and quickly enters the oil bath for quenching. The oil bath temperature is 90±5℃ and the quenching time is 15~20S.

[0018] The saw blade body enters the oil tank quickly to avoid the saw blade body temperature dropping due to excessively slow speed, which would affect the quenching effect.

[0019] Preferably, in S4, the saw blade body completes the flattening operation within 2 seconds after leaving the oil groove.

[0020] The pressing process is completed quickly within 2 seconds. At this time, the saw blade body still has a certain temperature, which prevents the saw blade body temperature from dropping due to prolonged time, thus affecting the flattening effect.

[0021] As a preferred embodiment, in S4, the saw blade body is flattened on a flattening machine. The flattening machine is equipped with a heat-insulating pressure plate, the temperature of which is controlled at 70℃~90℃. The pressure plate on the flattening machine flattens the saw blade body, and the flattening time is controlled at 20~25 seconds.

[0022] The pressure plate can achieve temperature control to prevent the saw blade body temperature from getting too low during the flattening process.

[0023] Preferably, in S5, a liquid cleaning agent at a temperature of 60~80℃ is used to clean the saw blade body.

[0024] After cleaning the saw blade body, ensure that there are no foreign objects on the saw blade body to lay the foundation for ensuring flatness in the subsequent tooling tempering.

[0025] Preferably, during S6 tempering, the saw blade body is loaded onto a fixture for tempering. The fixture includes several clamping plates and support rods connected to the clamping plates. Several saw blade bodies are clamped between two adjacent clamping plates, and the edge contours of the saw blade bodies stacked between the two clamping plates are aligned.

[0026] Loading the saw blade body onto the fixture before tempering improves work efficiency. The edges of the saw blade body stacked between the two clamping plates are aligned to prevent deformation during tempering due to misalignment. The clamping plates clamp and position the saw blade body, preventing deformation.

[0027] Preferably, the placement direction of the saw blade body is classified before it is loaded into the tooling, so that the saw blade bodies are stacked and clamped with the front facing up or the front facing down, and all saw blade bodies between two adjacent clamping plates have the same stacking direction.

[0028] The saw blades are stacked in the same direction, so that the edges of the saw blades can be perfectly aligned.

[0029] Preferably, a positioning mechanism is installed near the tooling position. The positioning mechanism includes a positioning seat and two positioning sliders mounted on the positioning seat. The positioning sliders can move radially, and a circumferentially movable support bar is installed on the positioning slider. The support bar is magnetic and can attract the saw blade body. The saw blade body has several heat dissipation holes evenly distributed circumferentially. The positioning seat has a vertical rod, and a buffer head is installed at the upper end of the vertical rod. A buffer spring is installed between the buffer head and the vertical rod, and the upper end of the buffer head is higher than the support bar. When the saw blade body is loaded into the tooling, the saw blade body is first placed on the support rod and supported on the support bar. The support bar attracts the saw blade body and presses the buffer head downward. The circumferential movement of the support bar drives the saw blade body to rotate, so that the heat dissipation holes are aligned with the buffer head. Then, the positioning slider moves radially outward, the support bar separates from the saw blade body, and the saw blade body slides down and stacks under the action of gravity.

[0030] After the saw blades are sorted by their front and back sides, they are stacked. During stacking, the positioning slider is first moved radially inward into position. Then, the saw blade is fitted onto the support rod, which holds the saw blade in place and presses the buffer head downward. The support rod moves circumferentially, causing the saw blade to rotate and align the heat dissipation holes with the buffer head. Afterward, the positioning slider moves radially outward, separating the support rod from the saw blade. Under gravity, the saw blade slides down for stacking. This method allows for the adjustment of the saw blade's orientation, ensuring the edges of stacked saw blades are aligned without subsequent manual adjustment, thus facilitating stacking and improving work efficiency.

[0031] Compared with the prior art, the beneficial effects of the present invention are: (1) The manufacturing process of the ultra-thin circular saw blade of this patent effectively solves the quality problems or quality hazards such as high crack rate of saw blade, large deformation of the body, poor uniformity of hardness of single saw blade and saw blade of the same batch, insufficient rigidity of saw blade, and easy cracking of the plate after use; (2) The saw blade body tooling can automatically adjust its posture when tempering and loading, which facilitates the stacking of saw blade body and is conducive to improving work efficiency. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the saw blade body of the present invention;

[0033] Figure 2 This is a schematic diagram of the tooling structure of Embodiment 1 of the present invention;

[0034] Figure 3 This is a schematic diagram of the tooling structure of Embodiment 2 of the present invention;

[0035] Figure 4 This is a top view of the tooling in Embodiment 2 of the present invention;

[0036] Figure 5 This is a partially enlarged schematic diagram of the positioning slider position in Embodiment 2 of the present invention;

[0037] In the diagram: 1. Clamping plate, 2. Support rod, 3. Saw blade body, 4. Heat dissipation hole, 5. Center hole, 6. Cutting teeth, 7. Cutting head, 8. Locking nut, 9. Positioning seat, 10. Positioning slider, 11. Positioning groove, 12. Column, 13. Support plate, 14. Piston cylinder, 15. Guide rail, 16. Support bar, 17. Attitude adjustment motor, 18. Gear, 19. Meshing teeth, 20. Upright pole, 21. Buffer head, 22. Buffer spring, 23. Slide groove, 24. Positioning bar. Detailed Implementation

[0038] The technical solution of the present invention will be further described in detail below through specific embodiments and in conjunction with the accompanying drawings:

[0039] Example 1: A manufacturing process for an ultra-thin circular saw blade, comprising the following steps:

[0040] S1, Grinding: Use sanding to remove all burrs, foreign objects, and hard objects from the surface of the saw blade body;

[0041] S2, Preheat and keep warm: Place the saw blade body in the heating furnace for preheating and keep warm;

[0042] S3, Quenching, refers to the quenching treatment of the saw blade body;

[0043] S4, flattening: The saw blade body is quickly flattened after leaving the oil groove;

[0044] S5, cleans and removes impurities;

[0045] S6, tempering.

[0046] In S2, the preheating temperature of the heating furnace is 780±5℃; the holding temperature of the heating furnace is 820±5℃. The heating furnace is equipped with a preheating zone and four holding zones. The saw blade body is preheated in the preheating zone for 60-80 seconds, and then held in the four holding zones for 470-510 seconds. The saw blade body is conveyed on a conveyor belt, passing through the preheating zone and the holding zones sequentially. The heating furnace is in an oxygen-free environment; there must be no overlap between saw blade bodies, and a safe distance of ≥10mm must be maintained between them.

[0047] The saw blade body is rapidly transferred from the heating furnace into an oil bath for quenching. The oil bath temperature is 90±5℃, and the quenching time is 15~20 seconds. The saw blade body enters the oil bath at a 45° angle, and the time from the heating furnace to the oil bath is controlled within 1 second.

[0048] In step S4, the saw blade body completes the flattening operation within 2 seconds after leaving the oil tank. In step S4, the saw blade body is flattened on a flattening machine equipped with heated and insulated pressure plates. The pressure plate temperature is controlled between 70℃ and 90℃. The pressure plates on the flattening machine flatten the saw blade body for 20 to 25 seconds. Pressure plates are installed on both the upper and lower sides of the saw blade body, and the two pressure plates contact the end faces of the saw blade body for flattening. There must be no foreign objects between the pressure plates and the saw blade body.

[0049] In S5, a liquid cleaning agent at a temperature of 60~80℃ is used to clean the saw blade body.

[0050] During S6 tempering, the saw blade body is mounted on a fixture for tempering, resulting in tempered troostite. (See attached image.) Figure 2As shown, the fixture includes several clamping plates 1, support rods 2 connected to the clamping plates, and several saw blade bodies 3 clamped between adjacent clamping plates. The edges of the saw blade bodies stacked between the clamping plates are aligned. Before loading the saw blade bodies into the fixture, the placement orientation of the saw blade bodies is classified so that they are stacked face up or face down, and all saw blade bodies between adjacent clamping plates are stacked in the same direction. No more than 10 saw blade bodies are stacked between adjacent clamping plates. (See attached...) Figure 1 As shown, the saw blade body has several heat dissipation holes 4 evenly distributed around its circumference, a central hole 5 in the middle of the saw blade body, and several cutting teeth 6 evenly distributed along the edge of the saw blade body, with cutting heads 7 on the cutting teeth. When the saw blade body is loaded into the tooling, the central hole and the support rod are fitted together, and the upper end of the support rod is connected to a locking nut 8, which abuts against the uppermost clamping plate.

[0051] In the processing of ultra-thin circular saw blades, S1 grinds the surface of the saw blade body to remove all burrs, metallic foreign objects, and other hard objects, ensuring that the two end faces and laser-cut areas of the ultra-thin saw blade body are free of hard objects. This prevents stress concentration caused by heating or rapid cooling during heat treatment, which could lead to cracks or create potential cracks in the saw blade body. S2 preheats the saw blade body in the heating furnace, serving as a heating transition and reducing the amount of twisting deformation caused by sudden temperature increases. S2 holds the saw blade body at a temperature in the heating furnace, providing sufficient energy and time for the transformation of the ultra-thin saw blade body from pearlite to austenite. S3 quenching achieves the transformation of the saw blade body from austenite to martensite. S4 flattening effectively controls the overall flatness of the saw blade body. S5 cleaning removes impurities to ensure that the ultra-thin saw blade body is free of foreign objects, laying the foundation for subsequent tempering to guarantee flatness. S6 tempering yields a high-hardness, high-flatness ultra-thin saw blade body.

[0052] This invention solves the problems of high crack rate in the ultra-thin saw blade body during production and easy cracking after use. The process to achieve this function mainly relies on sanding to smooth out local defects in the ultra-thin saw blade and remove hard foreign objects on the saw blade surface, which are most feared during the flattening and tooling processes in production. This eliminates the hidden dangers of cracking during heat treatment and use, and also eliminates the local unevenness caused by hard foreign objects during flattening and tooling. At the same time, after the ultra-thin saw blade comes out of the oil tank, it needs to be placed in a flattening machine within 2 seconds for end face flattening. The temperature of the pressure plate in contact with the saw blade needs to be controlled between 70℃ and 90℃.

[0053] This invention solves the problem of large deformation of the saw blade body. The process to achieve the second beneficial effect mainly relies on: preheating in a mesh belt heating furnace at 780±5℃, which acts as a heating transition for the ultra-thin saw blade, reducing the amount of torsional deformation caused by sudden temperature increases; maintaining the mesh belt heating furnace at 820℃±5℃, providing sufficient energy and time for the ultra-thin saw blade to transform from pearlite to austenite; staged oil quenching at 90±5℃ to achieve the transformation of the thin saw blade from austenite to martensite; rapid entry into a constant temperature pressing at 70℃~90℃ within 2 seconds after leaving the oil bath, effectively controlling the overall flatness of the ultra-thin saw blade, which is one of the core control points; E, constant temperature cleaning with cleaning agents on the production line to remove impurities, ensuring no foreign matter on the ultra-thin saw blade body, laying the foundation for subsequent tooling tempering to guarantee flatness; F, tooling tempering, obtaining a high-hardness, high-flatness ultra-thin saw blade body, which is another core point.

[0054] This invention solves the problem of poor hardness uniformity in individual saw blades and saw blades from the same batch in ultra-thin saw blade bodies. It primarily addresses this by ensuring sufficient preheating and heat preservation in a mesh belt heating furnace, and by using oil cooling for uniform cooling and sufficient time to control the hardness uniformity during the quenching stage. Simultaneously, through the rational design and use of tooling during the tempering process, it ensures temperature uniformity during tempering and guarantees sufficient time to ensure uniform hardness during tempering.

[0055] This invention solves the problem of insufficient rigidity in the saw blade body, which leads to premature lifespan termination due to deformation after use. This beneficial effect is mainly achieved by improving the rigidity of the saw blade body through the tempering process.

[0056] Example 2: A manufacturing process for an ultra-thin circular saw blade, the process steps of which are similar to those of Example 1, the main difference being that in this example, a positioning mechanism is installed near the tooling position, as shown in the attached figure. Figure 3 Appendix Figure 4 Appendix Figure 5As shown, the positioning mechanism includes a positioning seat 9 and two positioning sliders 10 mounted on the positioning seat. The two positioning sliders are arranged opposite each other. The upper surface of the positioning seat has a positioning groove 11 that matches the lowermost clamping plate. The lower end of the lowermost clamping plate of the tooling is placed in the positioning groove. A column 12 is provided on the positioning seat corresponding to the positioning sliders. The upper end of the column is connected to a support plate 13. The positioning slider is slidably mounted on the support plate. The positioning slider can move radially. The positioning slider is driven by a piston cylinder 14. The piston cylinder is mounted on the support plate, and the piston cylinder extension rod is connected to the positioning slider. A guide rail 15 is provided on the support plate, and a guide groove is provided on the lower surface of the positioning slider. The guide groove matches the guide rail. A circumferentially movable support bar 16 is installed on the positioning slider. The support bar is magnetic and can attract the saw blade body. A magnetic block is installed on the support bar. An attitude adjustment motor 17 is installed on the positioning slider and corresponding to the support bar. The output shaft of the attitude adjustment motor is connected to a gear 18. The support bar has an arc-shaped structure, and the outer edge of the support bar has meshing teeth 19. The meshing teeth mesh with the gear for transmission. The saw blade body has four circumferentially distributed heat dissipation holes. A vertical rod 20 is provided on the positioning base, with one vertical rod corresponding to each positioning slider. Through holes are provided on the clamping plate and corresponding to the vertical rods, through which the vertical rods pass. A buffer head 21 is installed at the upper end of the vertical rod, and a buffer spring 22 is installed between the buffer head and the vertical rod. The upper end of the buffer head extends above the support bar and has a hemispherical structure. The circumferential movement length of the support bar is greater than the circumferential distance between two adjacent heat dissipation holes, ensuring that the heat dissipation holes align with the buffer head during the rotation of the saw blade body. An arc-shaped groove 23 is provided on the positioning slider, and the support bar is fitted into the groove. An arc-shaped positioning strip 24 is connected to the positioning slider, with the lower end of the positioning strip abutting against the outer edge of the upper surface of the support bar, thereby positioning the support bar.

[0057] When the saw blade body is loaded into the tooling, it is first placed on the support rod and supported on the support bar. The support bar attracts the saw blade body and presses the buffer head downward. The attitude adjustment motor drives the support bar to move circumferentially, thereby rotating the saw blade body so that the heat dissipation hole is aligned with the buffer head. Under the action of the buffer spring, the buffer head is inserted into the heat dissipation hole. Then, the piston cylinder drives the positioning slider to move radially outward, separating the support bar from the saw blade body. Under the action of gravity, the center hole slides downward along the support rod, and the heat dissipation hole slides downward along the upright, causing the saw blade body to slide down for stacking. Other process steps are the same as in Example 1.

[0058] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any way. Other variations and modifications may be made without departing from the technical solutions described in the claims.

Claims

1. A manufacturing process for an ultra-thin circular saw blade, characterized in that, Includes the following steps: S1, Grind smooth to remove all burrs, foreign objects, and hard objects from the surface of the saw blade body; S2, Preheat and keep warm: Place the saw blade body in the heating furnace for preheating and keep warm; S3, Quenching, refers to the quenching treatment of the saw blade body; S4, flattening: The saw blade body is quickly flattened after leaving the oil groove; S5, cleans and removes impurities; S6, Tempering; During tempering, the saw blade body is loaded onto a fixture for tempering. The fixture includes several clamping plates and support rods connected to the clamping plates. Several saw blade bodies are clamped between adjacent clamping plates, and the edges of the stacked saw blade bodies between the clamping plates are aligned. A positioning mechanism is installed near the fixture. The positioning mechanism includes a positioning seat and two positioning sliders mounted on the positioning seat. The positioning sliders can move radially, and circumferentially movable support bars are installed on the positioning sliders. The support bars are magnetic and can attract the saw blade bodies. Several circumferentially evenly distributed... A heat dissipation hole is installed. A vertical rod is provided on the positioning seat, and a buffer head is installed at the upper end of the vertical rod. A buffer spring is installed between the buffer head and the vertical rod, and the upper end of the buffer head is higher than the support bar. When the saw blade body is loaded into the tooling, the saw blade body is first put on the support rod and supported on the support bar. The support bar attracts the saw blade body and presses the buffer head downward. The support bar moves circumferentially, thereby driving the saw blade body to rotate, so that the heat dissipation hole is aligned with the buffer head. Then the positioning slider moves radially outward, the support bar separates from the saw blade body, and under the action of gravity, the saw blade body slides down and is stacked.

2. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, in S2, the preheating temperature of the heating furnace is 780±5℃; and the heat preservation temperature of the heating furnace is 820±5℃.

3. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, The heating furnace is equipped with a preheating zone and several heat preservation zones. The saw blade body is preheated in the preheating zone for 60-80 seconds, and the saw blade body is kept in the heat preservation zones for 470-510 seconds.

4. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, The saw blade body is sent out of the heating furnace and quickly enters the oil bath for quenching. The oil bath temperature is 90±5℃ and the quenching time is 15~20S.

5. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, In S4, the saw blade body completes the flattening operation within 2 seconds after leaving the oil groove.

6. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, In S4, the saw blade body is flattened on a flattening machine. The flattening machine is equipped with a heat-insulating plate, and the temperature of the plate is controlled at 70℃~90℃. The plate on the flattening machine flattens the saw blade body, and the flattening time is controlled at 20~25 seconds.

7. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, In S5, a liquid cleaning agent with a temperature of 60~80℃ is used to clean the saw blade body.

8. The manufacturing process of an ultra-thin circular saw blade according to claim 1, characterized in that, Before the saw blade body is loaded into the tooling, the placement direction of the saw blade body is classified so that the saw blade body is stacked and clamped with the front facing up or the front facing down, and all saw blade bodies between two adjacent clamping plates have the same stacking direction.

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