Band saw blade and method of manufacturing a band saw blade

Abstract

A band saw blade (1) includes: a band-shaped and ring-shaped body portion (11); a tooth portion (12) in which a predetermined number of tooth groups, i.e., a tooth row (TG), including a bias tooth (Rw) are repeatedly formed on one edge side of the body portion (11); and a coating layer (13) formed on the surface of the tooth (12a) of the tooth portion (12). The coating layer (13) on the outer surface in the swing-out direction of the bias tooth (Rw) has a first indentation portion (T82) as a recess (12b), and the thickness of the coating layer (13) of the recess (12b) of the first indentation portion (T82) is thinner than the thickness of the portion other than the recess (12b) of the coating layer (13).

Description

Technical Field

[0001] This disclosure relates to a band saw blade and a method for manufacturing the band saw blade. Background Technology

[0002] Patent document 1 describes a method for coating a band saw blade with a hard material by rolling the band saw blade into a spiral coil and performing the coating process in a coating device.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent No. 5174467 Summary of the Invention

[0006] The method described in Patent Document 1 is a common method for coating band saw blades and is performed at the final stage of the band saw blade manufacturing process. In this method, when the band saw blade is wound into a helical coil, a gap is formed between radially adjacent rows of teeth, thus overlapping and winding a strip-shaped spacer with the band saw blade. By forming this gap, the teeth can be effectively coated.

[0007] Furthermore, conventionally, when the band saw blade has teeth that swing outwards in the thickness direction (i.e., left-right direction), after machining straight teeth into skewed teeth through a swinging process, the teeth are coated. In this case, the thickness of the coating formed by coating may differ between the inner surface (in the swinging direction) and the outer surface (outer side) of the skewed teeth. That is, since the inner surface is shadowed by the swinging angle, the coating thickness formed on the inner surface tends to be thinner than the coating thickness formed on the outer surface (the swinging angle). Therefore, uneven coating thickness occurs in the teeth of the band saw blade, especially the skewed teeth. Therefore, a band saw blade and a method for manufacturing a band saw blade that do not have uneven coating thickness even if the band saw blade has skewed teeth are desired.

[0008] One aspect of this disclosure is a band saw blade comprising: a strip-shaped and annular main body; teeth, wherein a predetermined number of teeth, including offset teeth, are repeatedly formed on an edge side of the main body; and a coating formed on the surface of the teeth of the main body, wherein the coating on the outer surface of the offset teeth in the swing direction has a first indentation portion as a recess, and the thickness of the coating on the recess of the first indentation portion is thinner than the thickness of the portion of the coating outside the recess.

[0009] According to one aspect of this disclosure, a coating is formed before the offset gear is shaped, and the thickness of the coating is uneven in the offset gear.

[0010] One aspect of this disclosure is a method for manufacturing a band saw blade, the band saw blade comprising: a strip-shaped and annular main body portion; teeth portion having a set of teeth, i.e., a tooth row, repeatedly formed on one edge side of the main body portion, including a predetermined number of teeth including off-center teeth; and a coating formed on the surface of the teeth of the teeth portion. The method for manufacturing the band saw blade involves performing a coating forming process on the teeth of an intermediate blade with all teeth being straight teeth to form the coating, followed by a swinging-out process to swing out the predetermined teeth to form the off-center teeth.

[0011] According to one aspect of this disclosure, a coating is formed before the offset gear is swiveled out, thus the thickness of the uncoated offset gear is uneven.

[0012] According to one aspect of this disclosure, it is possible to achieve the effect of uneven coating thickness on the teeth of the band saw blade, especially the off-center teeth. Attached Figure Description

[0013] Figure 1A These are two views showing the side and top surface of the first intermediate blade 1A used in the manufacture of the band saw blade 1 of this embodiment.

[0014] Figure 1B These are two views showing the side and top surface of the spacer 2 used in the manufacture of the band saw blade 1 in this embodiment.

[0015] Figure 2 This is a top view showing the coil body C formed by overlapping and winding the first intermediate blade 1A and the spacer 2.

[0016] Figure 3 yes Figure 2 A magnified view of region F3 in the image.

[0017] Figure 4 This is a schematic diagram illustrating the coating process of the coating device 7 on the coil body C.

[0018] Figure 5 This is a side view showing the second intermediate blade 1B with a coating 13 formed on the tooth portion 12.

[0019] Figure 6 yes Figure 5 A sectional view at position S6-S6.

[0020] Figure 7A This is a diagram used to illustrate the swivel machining of the second intermediate blade 1B, and it is a cross-sectional view showing the state to be machined.

[0021] Figure 7B This is a diagram illustrating the swivel machining of the second intermediate blade 1B, and it is a cross-sectional view showing the state during machining.

[0022] Figure 8This is a top view showing the third intermediate blade 1C, to which the second intermediate blade 1B has undergone swing-out machining.

[0023] Figure 9 This diagram illustrates the joining process of joining the third intermediate blade 1C in a ring shape to form the band saw blade 1.

[0024] Figure 10A This is a right-side view showing the surface condition of the main part of the tooth 12a of the band saw blade 1.

[0025] Figure 10B This is a left-side view showing the surface condition of the teeth 12a of the band saw blade 1.

[0026] Figure 11A This is a sectional view showing the cross-section of tooth 12a of band saw blade 1.

[0027] Figure 11B yes Figure 11A Enlarged view of the indentation T81 in the image.

[0028] Figure 11C yes Figure 11A Enlarged view of the indentation T82 in the image.

[0029] Figure 12A This is a right-side view showing the surface condition of the teeth 112a of the band saw blade 101 in the comparative example.

[0030] Figure 12B This is a left-side view showing the surface condition of the teeth 112a of the band saw blade 101 in the comparative example.

[0031] Figure 13A This is a cross-sectional view showing the cross-section of the tooth 112a of the band saw blade 101 in the comparative example.

[0032] Figure 13B yes Figure 13A Enlarged view of the indentation T181 in the image.

[0033] Figure 13C yes Figure 13A Enlarged view of the indentation T182 in the image. Detailed Implementation

[0034] Figure 1A These are two views showing the side and top surface of the first intermediate blade 1A used in the manufacture of the band saw blade 1 of this embodiment. Figure 1BThese are two views showing the side and top surface of the spacer 2 used in the manufacture of the band saw blade 1 according to this embodiment. The band saw blade 1 is formed by using a long strip-shaped first intermediate blade 1A as raw material, passing through a second intermediate blade 1B and a third intermediate blade 1C, which are intermediate bodies obtained during the manufacturing process, and then connecting the parts obtained by cutting the third intermediate blade 1C to a predetermined length in a ring shape.

[0035] First, refer to Figure 1 and... Figures 2-9 The manufacturing method of band saw blade 1 is explained. Figure 2 This is a top view showing the coil body C formed by overlapping and winding the first intermediate blade 1A and the spacer 2. Figure 3 yes Figure 2 A magnified view of region F3 in the image. Figure 4 This is a schematic diagram illustrating the coating process of the coating device 7 on the coil body C. Figure 5 This is a side view showing the second intermediate blade 1B with a coating 13 formed on the tooth portion 12. Figure 6 yes Figure 5 A sectional view at position S6-S6. Figure 7A This is a diagram used to illustrate the swivel machining of the second intermediate blade 1B, and it is a cross-sectional view showing the state to be machined. Figure 7B This is a diagram illustrating the swivel machining of the second intermediate blade 1B, and it is a cross-sectional view showing the state during machining. Figure 8 This is a top view showing the third intermediate blade 1C, to which the second intermediate blade 1B has undergone swing-out machining. Figure 9 This diagram illustrates the joining process of joining the third intermediate blade 1C in a ring shape to form the band saw blade 1.

[0036] First, a first intermediate blade 1A of predetermined length is prepared as raw material, and a spacer 2 of the same length as the first intermediate blade 1A is prepared as a manufacturing fixture. Figure 1A As shown, the first intermediate blade 1A has a long strip-shaped main body 11 and a toothed portion 12 formed on one edge (upper edge) of the main body 11. The toothed portion 12 has a plurality of teeth 12a continuously formed along the long side of the main body 11. These teeth 12a are straight teeth. Figure 2 As shown in Figure B, the spacer 2 is a long strip-shaped component made of metal. The width of the spacer 2 is slightly smaller than the width of the main body 11 of the first intermediate blade 1A, and its thickness is expressed as thickness L2.

[0037] Next, as Figure 2 As shown, the first intermediate blade 1A and the spacer 2 are overlapped with their edges aligned on opposite sides of the teeth 12, and then wound into a spiral coil shape to form a coil body C. Figure 2 In the diagram, for simplicity, the first intermediate blade 1A is represented by a solid line, and the spacer 2 is represented by a dashed line. For example... Figure 3As shown, the coil body C is wound into a spiral coil shape with the spacer 2 between the radially adjacent first intermediate blades 1A. All the teeth 12a of the first intermediate blades 1A are straight teeth, so the minimum gap La between the radially adjacent first intermediate blades 1A is the gap between the main body parts 11 and the thickness L2 of the spacer 2.

[0038] like Figure 4 As shown, the coil body C is placed into the coating device 7 for coating treatment. Hereinafter, the coil body C before coating treatment will be referred to as the coil body before treatment Ca, and the coil body C after coating treatment will be referred to as the coil body after treatment Cb.

[0039] The coating process is performed using PVD (Physical Vapor Deposition), but is not limited to it; for example, CVD (Chemical Vapor Deposition) could also be used. In the first intermediate blade 1A, the area where the coating process is performed is at least the surface of the tooth 12 and the portion of the coil body Ca that was not in contact with the spacer 2 before processing. Furthermore, within the area where the coating process is performed, the thickness of the vapor-deposited layer varies between shaded and unshaded areas, resulting in unevenness.

[0040] After the coating process is performed under predetermined conditions, the treated coil body Cb is removed and the winding is unwound. From the treated coil body Cb, a second intermediate blade 1B is obtained, on which the teeth 12 of the first intermediate blade 1A have been coated.

[0041] like Figure 5 as well as Figure 6 As shown, on the second intermediate blade 1B, a coating 13 (with dotted portion) is formed on the edge of the tooth 12 side of the main body portion 11, which is not in contact with the spacer 2, through a coating process. Coating 13 (see reference) Figure 5 For example, it can be a layer of titanium nitride (TiN) or titanium aluminum nitride (TiAlN), or it can be titanium carbon nitride (TiCN), chromium nitride (CrN), or a combination thereof.

[0042] Next, a swing-out process is performed to swing out predetermined teeth among the multiple straight teeth (teeth 12a) of the second intermediate blade 1B to the left or right using the full saw 8, thus creating offset teeth. For example... Figure 7A As shown, the sawing machine 8 has: a fixing part 81 that clamps and supports the second intermediate blade 1B in the thickness direction; and a processing part 82 that partially abuts against the side of the tooth 12a and presses it in the thickness direction indicated by arrow DR1.

[0043] The fixing part 81 of the sawing machine 8 clamps and fixes the main body part 11 in such a way that the teeth 12 of the second intermediate blade 1B protrude from the fixing part 81. Next, as... Figure 7B As shown, the processing unit 82 presses one side of the tooth 12a in the thickness direction, causing the tooth 12a to bend and swing out to the other side as indicated by arrow DR2.

[0044] The predetermined teeth of the second intermediate blade 1B are swung out by the saw machine 8 in either the left or right direction to obtain... Figure 8 The third intermediate blade 1C is shown. For example, the tooth portion 12 of the third intermediate blade 1C is constructed by forming a group of five consecutively formed teeth as a tooth row TG, and repeatedly forming the tooth row TG in the length direction. Figure 8 The tooth row TG shown is a group of teeth including a predetermined number of offset teeth. Specifically, tooth row TG is a group of five teeth starting from the cutting direction (arrow DR3): right offset tooth Rw, left offset tooth Ln, right offset tooth Rn, left offset tooth Lw, and spur tooth S. The swing amount of left offset tooth Lw and right offset tooth Rw is greater than that of left offset tooth Ln and right offset tooth Rn. The structure of tooth row TG is not limited to this. Figure 8 The structure shown.

[0045] Next, as Figure 9 As shown, the two ends of the main body 11 of the third intermediate blade 1C are welded together at the joint Pm where the two ends of the main body 11 abut against each other. Thus, a strip-shaped and annular band saw blade 1 is obtained.

[0046] In the above-described method for manufacturing the band saw blade 1, all teeth 12a of the tooth section 12 are straight teeth during the coating process. After the coating process, a swing-out process is performed to make the predetermined straight teeth become off-center teeth. Therefore, the spacer 2 that overlaps and winds the coil body C can be of thickness L2. In this way, the method for manufacturing the band saw blade 1 coats all straight teeth. Therefore, unlike the case where the off-center teeth are coated, there will be no difference in coating thickness between the inner surface that is the shadow in the swing-out direction and the outer surface that is the surface in the swing-out direction, resulting in spots. That is, according to the method for manufacturing the band saw blade 1, the thickness of the coating 13 becomes uniform within the coating area.

[0047] As described above, the band saw blade 1 is manufactured by performing a swing-out process after forming a coating 13 on the surface of the tooth 12a. Therefore, during the swing-out process, the fixing part 81 and the processing part 82 of the band saw 8 are pressed against the coating 13, resulting in characteristic indentations at the edges of the processing part 82 and the fixing part 81, which are different from conventional indentations. (See reference...) Figure 10A , Figure 10B , Figure 11A , Figure 11B as well as Figure 11C The indentation section will be explained using the right-hand eccentric tooth Rw, which swings to the right, as an example.

[0048] Figure 10AThis is a right-side view showing the surface condition of the teeth 12a of the band saw blade 1. Figure 10B This is a left-side view showing the surface condition of the teeth 12a of the band saw blade 1. Figure 11A This is a sectional view showing the cross-section of tooth 12a of band saw blade 1. Figure 11B yes Figure 11A An enlarged view of the indentation section T81 in the image. Figure 11C yes Figure 11A Enlarged view of the indentation T82 in the image.

[0049] like Figure 10A , Figure 11A as well as Figure 11B As shown, an indentation portion T81 (second indentation portion T81) formed by the fixing portion 81 is formed at the root portion of the right side surface of the inner surface 12a1 in the swing direction of the right-hand side tooth 12a, which becomes the right-hand side tooth Rw. The indentation portion T81 is clearly visually confirmed as a straight line extending along the long side direction of the main body portion 11, covering the entire long side direction of the tooth 12a. Figure 10B , Figure 11A as well as Figure 11C As shown, an indentation portion T82 (first indentation portion T82) formed by the machining portion 82 is formed at the center of the tooth height direction (vertical direction) on the left side of the outer surface 12a2 of the tooth 12a that becomes the right-hand offset tooth Rw in the swing direction. The indentation portion T82 is clearly visually confirmed to be a straight line inclined downward with the cutting direction AR3 side as the entire long side direction of the tooth 12a.

[0050] That is, in the band saw blade 1, after the coating forming process in which coating 13 is formed on the teeth 12a, a swing-out processing process is performed, thereby producing the following characteristics (A), (B), and (C) in the indentation portion T81, indentation portion T82, and coating 13. (A) After the coating 13 is formed, the curved portion 12c is formed by the fixing portion 81. Therefore, in the coating 13, the area on the surface of the teeth 12a from the curved portion 12c to the main body portion 11 side is peeled off due to friction with the fixing portion 81, etc., resulting in a low coating density (in Figure 10A , Figure 10B , Figure 11A , Figure 11B as well as Figure 11C(The dots of coating 13 are not shown). That is, coating 13 has a different density on the tooth tip side and the main body side, with the indentation T81 as the boundary. Due to this and the pressing of the processing part 82 on coating 13, the indentation T81 formed on the surface of tooth 12a is clearly visually confirmed. (B) After coating 13 is formed, recess 12b is formed by processing part 82. Therefore, the coating 13b in recess 12b is compressed and its thickness becomes smaller (thinner) compared to other parts of coating 13 (parts other than recesses). (C) After coating 13 is formed, recess 12b is formed by processing part 82. Therefore, the indentation T82, which is clearly visually confirmed, is formed on the surface of coating 13.

[0051] In contrast, the indented portions T181 and T182 formed on the band saw blade 101 in the comparative example are as follows: Figure 12A , Figure 12B , Figure 13A , Figure 13B as well as Figure 13C As shown. The band saw blade 101 of this comparative example is manufactured using a conventional manufacturing method that involves coating after the teeth are formed. Figure 12A This is a right-side view showing the surface condition of the teeth 112a of the band saw blade 101 in the comparative example. Figure 12B This is a left-side view showing the surface condition of the teeth 112a of the band saw blade 101 in the comparative example. Figure 13A This is a cross-sectional view showing the cross-section of tooth 112a of band saw blade 101 in the comparative example. Figure 13B yes Figure 13A An enlarged view of the indentation section T181. Figure 13C yes Figure 13A Enlarged view of the indentation part T182.

[0052] like Figure 12A , Figure 13A as well as Figure 13B As shown, an indentation T181 formed by the fixing part 81 is formed at the root portion of the right side face of tooth 112a of the right-hand offset tooth Rw. Depending on the situation, the indentation T181 is visually confirmed as a straight line extending along the long side of the main body 11 and slightly thinner in a portion of tooth 112a. Figure 12B , Figure 13A as well as Figure 13C As shown, an indentation T182 formed by the machining part 82 is formed at the center of the tooth height direction (vertical direction) on the left side of tooth 112a of right-hand offset tooth Rw. Depending on the situation, the indentation T182 is visually confirmed as a straight line inclined downward in the cutting direction AR3 and slightly thinner in a part of tooth 112a.

[0053] In the comparative example band saw blade 101, after the coating 113 is formed on the tooth 112a, a swing-out process is performed, resulting in the following characteristics (D), (E), and (F) of the indentation portion T181, the indentation portion T182, and the coating 113. (D) The coating 113 is formed after the curved portion 112c is formed on the surface of the tooth 112a by the fixing portion 81. Therefore, the formation density of the coating 113 is approximately the same on the tip side and the body side, with the curved portion 112c as the boundary. (E) The coating 113 is formed after the recess 112b is formed by the processing portion 82. Therefore, the coating 13b of the recess 112b has approximately the same thickness compared to other parts of the coating 113. (F) After the curved portion 112c and the recess 112b are formed, the coating 113 is formed in a manner that covers the curved portion 112c and the recess 112b. Therefore, the curved portion 112c and the recessed portion 112b are hidden by the coating 113, and there are localized areas of the indented portions T181 and T182 that are difficult or impossible to visually confirm.

[0054] As described above, the band saw blade 1 of the embodiment, by performing a swing-out process after forming the coating 13, produces a product with a characteristic structure that differs from existing products. That is, (A), (B), and (C), which are characteristics of the band saw blade 1, are differences from (D), (E), and (F) of the comparative example band saw blade 101, respectively. As a characteristic structure of the band saw blade 1, it is possible to distinguish the band saw blade 1 from other band saw blades.

[0055] As described above, the band saw blade 1 of this embodiment includes: a strip-shaped and annular main body portion 11; a tooth portion 12, which has a set of teeth 12a, including a predetermined number of off-center teeth Rw, repeatedly formed on one edge side of the main body portion 11, namely a tooth row TG; and a coating 13, which is formed on the surface of the teeth 12a of the tooth portion 12, wherein the coating 13 on the outer surface 12a2 of the off-center teeth Rw in the swing direction has a first indentation portion T82 as a recess 12b, and the thickness of the coating 13 on the recess 12b of the first indentation portion T82 is thinner than the thickness of the portion of the coating 13 other than the recess 12b.

[0056] Alternatively, the band saw blade 1 may have a second indentation portion T81 on the outer surface of the coating 13 on the inner surface 12a1 of the offset tooth Rw in the swing direction, which serves as a bending portion 12c. The coating 13 has a lower formation density on the body portion 11 side compared to the tooth tip side, with the second indentation portion T81 as the boundary.

[0057] The band saw blade 1 with these features has a coating 13 of uniform thickness formed in the part to be cut by a coating process during manufacturing.

[0058] Furthermore, as described above, in the band saw blade manufacturing method of this embodiment, the band saw blade includes: a main body 11, which is a ring-shaped strip; a toothed portion 12, which repeatedly forms a predetermined number of toothed groups 12a, i.e., tooth rows TG, including off-center teeth Rw, on one edge side of the main body 11; and a coating 13, which is formed on the surface of the teeth 12a of the toothed portion 12. After performing a coating forming process to form the coating 13 on the teeth 12a of the intermediate blade 1A, where all teeth 12a are straight teeth S, the band saw blade manufacturing method performs a swinging process to swing out the predetermined teeth 12a to become off-center teeth Rw.

[0059] The band saw blade manufacturing method of this scheme only applies a coating process to the straight teeth. As a result, a coating of uniform thickness can be formed.

[0060] Alternatively, the band saw blade of this scheme can be manufactured by the following method: in the coating forming process, the intermediate blade 1A and the strip-shaped spacer 2 are overlapped and wound in such a way that the teeth 12 are exposed to form a spiral coil body C, and the formed coil body C is put into the coating device 7 to form a coating 13.

[0061] This embodiment is not limited to the structure described above, and modifications can be made without departing from the spirit of this disclosure.

[0062] The structure of the offset and straight teeth of the tooth row TG of the band saw blade 1 is not limited. The material and formation method of the coating 13 are not limited. The thickness of the spacer 2 can be set as thin as possible within the range that allows for a good coating 13, depending on the type of band saw blade 1 and the conditions of the coating process. As a result, the length of the saw teeth that can be coated in a single coating process can be longer.

[0063] The disclosure of this application relates to the subject matter described in Japanese Patent Application No. 2021-168801 filed on October 14, 2021, the entire contents of which are incorporated herein by reference.

Claims

1. A band saw blade, characterized in that, have: The main body is strip-shaped and ring-shaped; A toothed portion, wherein a predetermined number of teeth, including offset teeth, are repeatedly formed on one edge side of the main body portion; and A coating formed on the surface of the teeth of the tooth portion. The coating on the outer surface of the eccentric tooth in the swing direction has a first indentation portion as a recess. The thickness of the coating in the recess of the first indentation is thinner than the thickness of the coating outside the recess.

2. The band saw blade according to claim 1, characterized in that, The coating on the inner surface of the eccentric tooth in the swing direction has a second indentation portion as a bending portion. The coating has a lower formation density on the body side compared to the tooth tip side, with the second indentation portion as the boundary.

3. A method for manufacturing a band saw blade, the band saw blade comprising: a strip-shaped and annular main body portion; teeth portions having a predetermined number of teeth, including offset teeth, repeatedly formed on one edge side of the main body portion; and a coating formed on the surface of the teeth portions. The method for manufacturing this band saw blade is characterized by, After performing a coating forming process on the teeth of the intermediate cutting tool, which has all straight teeth, a swinging process is performed to swing out the predetermined teeth to become the offset teeth.

4. The method for manufacturing a band saw blade according to claim 3, characterized in that, The coating forming process involves overlapping and winding the intermediate blade and the strip-shaped spacer in such a way that the teeth are exposed to form a spiral coil body, and then feeding the formed coil body into a coating device to form a coating.

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