Saw blade

Abstract

A saw blade includes a body having a center and a circumferential edge. The saw blade further includes a central portion disposed at a center of the body, the central portion defining a first aperture, a second aperture, and a third aperture circumferentially spaced from each other about the center of the body and configured to receive an alignment protrusion of a tool, the first aperture having a first diameter, the second aperture having a second diameter, and the third aperture having a third diameter. The second aperture has a second diameter different from the first diameter. The saw blade further includes a bore formed in the central portion between the first aperture, the second aperture, and the third aperture, the bore configured to receive an output shaft of a tool. The saw blade also includes a cutting edge extending from the circumferential edge of the body.

Description

Technical Field

[0001] The present disclosure relates to saw blades. Background Art

[0002] Saw blades, such as circular saw blades, table saw blades, chop saw blades, reciprocating saw blades, hand saw blades, and / or the like, are used to remove material from a workpiece to create a cut therein. Utility Model Content

[0003] In some aspects, the technology described herein relates to a saw blade comprising: a body having a center and a peripheral edge; an arbor disposed at the center of the body, the arbor defining a first aperture, a second aperture, and a third aperture, the first aperture, the second aperture, and the third aperture being circumferentially spaced from one another around the center of the body and configured to receive an alignment protrusion of a tool, the first aperture having a first diameter and the second aperture having a second diameter different from the first diameter; a hole formed in the arbor and located between the first aperture, the second aperture, and the third aperture, the hole being configured to receive an output shaft of the tool; and a cutting edge extending from the peripheral edge of the body.

[0004] In some aspects, the technology described herein relates to a saw blade wherein the third aperture has a third diameter that is different than the second diameter.

[0005] In some aspects, the technology described herein relates to a saw blade wherein the third diameter is the same as the first diameter.

[0006] In some aspects, the technology described herein relates to a saw blade wherein the second diameter is greater than the first diameter.

[0007] In some aspects, the technology described herein relates to a saw blade wherein the first diameter is between 3 mm and 8 mm, and wherein the second diameter is between 4 mm and 9 mm.

[0008] In some aspects, the technology described herein relates to a saw blade wherein the hole has a diameter between 25 mm and 31 mm.

[0009] In some aspects, the technology described herein relates to a saw blade wherein a hole has a diameter that is greater than a first diameter and greater than a second diameter.

[0010] In some aspects, the technology described herein relates to a saw blade wherein a ratio of the diameter of the hole to the first diameter is between 3 and 10.5, and wherein a ratio of the diameter of the hole to the second diameter is between 2.5 and 8.

[0011] In some aspects, the technology described herein relates to a saw blade in which the first aperture, the second aperture, and the third aperture are circumferentially equally spaced from one another.

[0012] In some aspects, the technology described herein relates to a saw blade wherein a first aperture is spaced a first radial distance from a center of the body, and wherein a second aperture is spaced a second radial distance from the center of the body, the second radial distance being different than the first radial distance.

[0013] In some aspects, the technology described herein relates to a saw blade wherein the third aperture is spaced a third radial distance from the center of the body, the third radial distance being different than the first radial distance.

[0014] In some aspects, the technology described herein relates to a saw blade wherein the third radial distance is the same as the second radial distance.

[0015] In some aspects, the technology described herein relates to a saw blade wherein a first aperture is spaced a first radial distance from a center of a body, a second aperture is spaced a second radial distance from a center of the body, the second radial distance being different from the first radial distance, a third aperture has a third diameter and is spaced a third radial distance from the center of the body, the third diameter being the same as the first diameter, and the third radial distance being the same as the second radial distance.

[0016] In some aspects, the technology described herein relates to a saw blade comprising: a body constructed of a first material and having a center and a peripheral edge; a central portion disposed at a center of the body; a hole formed in the central portion, the hole being configured to receive an output shaft of a tool; a plurality of cutting teeth extending from the peripheral edge of the body; and a plurality of inserts coupled to the plurality of cutting teeth, each insert constructed of a second material different from the first material and comprising: a first side and a second side opposite the first side, the first side and the second side defining a width of the insert; a cutting edge extending between the first side and the second side; a rake face adjacent to the cutting edge, the rake face defining a recess in the insert; a planar wall extending from the rake face toward the body; and a back face extending from the cutting edge, the back face having a chamfer extending along at least one of the first side and the second side and extending over at least half of the width of the insert.

[0017] In some aspects, the technology described herein relates to a saw blade in which a rake surface of at least some inserts includes a curved wall and a planar wall that define a notch.

[0018] In some aspects, the technology described herein relates to a saw blade wherein a rake surface of at least some inserts includes a first planar wall and a second planar wall defining a recess.

[0019] In some aspects, the technology described herein relates to a saw blade in which the chamfers of at least some inserts are formed by a single chamfered wall extending from a horizontal wall.

[0020] In some aspects, the technology described herein relates to a saw blade in which the chamfer of at least some inserts is formed by first and second chamfered walls extending in opposite directions from a horizontal wall.

[0021] In some aspects, the technology described herein relates to a saw blade in which first and second sides of at least some inserts taper toward each other as the first and second sides extend away from the cutting edge.

[0022] In some aspects, the technology described herein relates to a saw blade comprising: a body constructed of a first material and having a center and a peripheral edge; a central portion disposed at a center of the body; a hole formed in the central portion, the hole being configured to receive an output shaft of a tool; a plurality of cutting teeth extending from the peripheral edge of the body; and a plurality of inserts coupled to the plurality of cutting teeth, each insert constructed of a second material different from the first material and comprising: a first side and a second side opposite the first side; a cutting edge extending between the first side and the second side; a rake face adjacent to the cutting edge, the rake face defining a recess in the insert; a planar wall extending from the rake face toward the body; and a back face extending from the cutting edge; wherein the cutting edges of the plurality of inserts collectively define a cutting diameter of the saw blade between 135 mm and 139 mm.

[0023] Other features and aspects of the invention will become apparent by consideration of the following detailed description and accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a side view of a saw blade according to an embodiment of the present disclosure.

[0025] Figure 2 is Figure 1 An enlarged side view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at mark 2-2 of FIG.

[0026] Figure 3 is Figure 1 A front view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at mark 3-3 of FIG.

[0027] Figure 4 is Figure 1 A front view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at mark 4-4 of FIG.

[0028] Figure 5 is Figure 1 A top view of the cutting teeth and insert taken at 5-5.

[0029] Figure 6 is Figure 1 A top view of the cutting teeth and insert taken at 6-6 of FIG.

[0030] Figure 7 is a side view of a saw blade according to an embodiment of the present disclosure.

[0031] Figure 8 is Figure 7 An enlarged side view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at 8-8 of FIG.

[0032] Figure 9 is Figure 7 A front view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at 9-9 of FIG.

[0033] Figure 10 is Figure 7 A front view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at 10-10 of FIG.

[0034] Figure 11 is Figure 7 A front view of a cutting tooth among the plurality of cutting teeth and an insert among the plurality of inserts taken at 11-11 of FIG.

[0035] Figure 12 is Figure 7 A top view of the cutting teeth and insert taken at 12-12 of FIG.

[0036] Figure 13 is Figure 7 A top view of the cutting teeth and insert taken at 13-13 of FIG.

[0037] Figure 14 is Figure 7 A top view of the cutting teeth and insert taken at 14-14 of FIG.

[0038] Figure 15 is an exploded perspective view of a saw blade coupled to a tool.

[0039] Before explaining any embodiments of the present disclosure in detail, it should be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or shown in the following drawings. The present disclosure is capable of other embodiments and can be practiced or carried out in various ways. DETAILED DESCRIPTION

[0040] Figure 1 A saw blade 100 according to an embodiment of the present disclosure is shown. In the illustrated embodiment, the saw blade 100 is a circular saw blade that can be selectively used with a circular saw, a table saw, a miter saw, or the like. However, in other embodiments, the saw blade 100 can be a different type of saw blade that can be coupled to a corresponding power tool.

[0041] like Figure 1 As shown in FIG, saw blade 100 includes a core portion or body 104 having a center C and a perimeter or circumferential edge 106; a central portion 108; and a hole 112 formed in central portion 108 and configured to allow saw blade 100 to be mounted on a tool output shaft having a shape complementary to hole 112. In the illustrated embodiment, hole 112 extends completely through body 104 (e.g., a through hole). Hole 112 extends through center C of body 104. In the illustrated embodiment, hole 112 has a circular shape and is configured to be mounted on a circular shaft. Hole 112 defines a diameter D1. In the illustrated embodiment, diameter D1 is between 25 mm and 31 mm. Specifically, diameter D1 is 28 mm. In other embodiments, hole 112 and the shaft may both have another shape, such as a diamond, square, hexagonal, semicircular, and / or the like.

[0042] The illustrated central portion 108 defines a first aperture 116, a second aperture 120, and a third aperture 124. In the illustrated embodiment, the first aperture 116, the second aperture 120, and the third aperture 124 extend completely through the body 104 (e.g., as through holes). In other embodiments, the first aperture 116, the second aperture 120, and the third aperture 124 may extend only partially through the body 104 (e.g., as blind holes). The first aperture 116, the second aperture 120, and the third aperture 124 are configured to receive alignment protrusions of a tool to assist in aligning the saw blade 100 with the output shaft on the tool. The first aperture 116, the second aperture 120, and the third aperture 124 are separated by a non-zero angle A0. In the illustrated embodiment, the non-zero angle A0 is 120 degrees relative to each other and about the center C. Thus, the first aperture 116, the second aperture 120, and the third aperture 124 are each disposed at 120 degrees relative to each other about the center C. In other words, the first aperture 116 , the second aperture 120 , and the third aperture 124 are circumferentially equally spaced from one another.

[0043] First orifice 116 defines a first diameter D2. In the illustrated embodiment, first diameter D2 is between 3 mm and 8 mm. Specifically, first diameter D2 is 5.5 mm. First orifice 116 is smaller than hole 112. The ratio of diameter D1 of hole 112 to first diameter D2 is between 3 and 10.5. In the illustrated embodiment, the ratio of diameter D1 of hole 112 to first diameter D2 is approximately 5. First orifice 116 is located on a circle 118 having a diameter D3, which is concentric with hole 112. In the illustrated embodiment, diameter D3 is 37 mm. In other words, the center of first orifice 116 is radially disposed at a first radial distance of 18.5 mm from center C of body 104. In some embodiments, diameter D3 of circle 118 can be between 34 mm and 40 mm. In this embodiment, the center of first orifice 116 can be radially disposed at a first radial distance of between 17 mm and 20 mm from center C of body 104.

[0044] Second orifice 120 defines a second diameter D4. Second diameter D4 is a different size than first diameter D2. In the illustrated embodiment, second diameter D4 is larger than first diameter D2. In the illustrated embodiment, second diameter D4 is between 4 and 9 millimeters. Specifically, second diameter D4 is 6.5 millimeters. Thus, second diameter D4 is approximately 1 mm larger than first diameter D2. In other words, second diameter D4 is between 10% and 20% larger than first diameter D2. Second orifice 120 is also smaller than hole 112. The ratio of hole 112 diameter D1 to second diameter D4 is between 2.5 and 8. In the illustrated embodiment, the ratio of hole 112 diameter D1 to second diameter D4 is approximately 4.

[0045] Third orifice 124 defines a third diameter D5. Third diameter D5 is a different size than second diameter D4. In the illustrated embodiment, second diameter D4 is larger than third diameter D5. In the illustrated embodiment, third diameter D5 is between 3 mm and 8 mm. Specifically, third diameter D5 is 5.5 mm. Thus, first diameter D2 and third diameter D5 are the same size. In other embodiments, first diameter D2 and third diameter D5 may be different sizes. Third orifice 124 is also smaller than hole 112. The ratio of hole 112 diameter D1 to third diameter D5 is between 3 and 10.5. In the illustrated embodiment, the ratio of hole 112 diameter D1 to third diameter D5 is approximately 5.

[0046] The second aperture 120 and the third aperture 124 are located on a circle 128 having a diameter D6 that is concentric with the aperture 112. In other words, the third aperture is radially disposed at the same distance from the center C of the body 104 as the second aperture. In the illustrated embodiment, the diameter D6 is 40 millimeters. In other words, the center of the second aperture 120 and the center of the third aperture 124 are located at a second radial distance and a third radial distance, respectively, of 20 millimeters from the center C of the body 104. In some embodiments, the diameter D6 is between 37 millimeters and 43 millimeters. In this embodiment, the center of the second aperture 120 and the center of the third aperture 124 can be radially disposed at a second radial distance and a third radial distance, respectively, of between 18.5 millimeters and 21.5 millimeters from the center C of the body 104. As such, the second aperture 120 and the third aperture 124 are located at a different distance from the center C of the body 104 than the first aperture 116. In particular, the second aperture 120 and the third aperture 124 are positioned farther from the center C of the body 104 than the first aperture 116. In other embodiments, the second aperture 120 and the third aperture 124 can also be located at different distances from the center C of the body 104.

[0047] The saw blade 100 further includes a cutting edge 130. In the illustrated embodiment, the cutting edge 130 includes a plurality of cutting teeth 132 that are spaced apart along the outer edge of the body 104 and extend outwardly from the circumferential edge 106. In other embodiments, the cutting edge 130 can have other configurations, such as an abrasive or diamond cutting edge. The cutting teeth 132 and the body 104 can be constructed from a variety of materials, such as high carbon steel. In the illustrated embodiment, the cutting teeth 132 are integrally formed with the body 104 as a single piece. In other embodiments, the body 104 can be made of bimetal and the cutting teeth 132 can be formed of high speed steel that is bonded to the body 104. In other words, the cutting teeth 132 are supported on the body 104. In other embodiments, the saw blade 100 can be made of a variety of materials, such as when the saw blade 100 is a masonry saw blade. In the illustrated embodiment, all of the cutting teeth 132 have generally the same shape and size, but in other embodiments, the relative size of each tooth of the cutting teeth 132 can be different. The saw blade 100 includes a plurality of gullets 136 that allow debris (e.g., chips, chunks, etc.) to pass through during a cutting operation. Each gullet of the plurality of gullets 136 separates adjacent ones of the plurality of cutting teeth 132. The saw blade 100 includes a plurality of inserts 140. In the illustrated embodiment, each of the cutting teeth 132 includes one insert 140 that forms at least a portion of the cutting tooth 132. In other embodiments, only some of the cutting teeth 132 can include an insert 140.

[0048] Referring now to Figure 2Each cutting tooth 132 includes a heel surface 144 and one or more relief surfaces 148 extending between the insert 140 and the heel surface 144. Generally, a gullet in the plurality of gullets 136 is formed between the insert 140 and the heel surface 144 of an adjacent cutting tooth 132. In other words, the plurality of gullets 136 separate adjacent cutting teeth 132. The heel surface 144 defines a radius R1. In the illustrated embodiment, radius R1 is between 0.4 mm and 0.6 mm. Specifically, radius R1 is 0.5 mm. Each heel surface 144 of the plurality of cutting teeth 132 collectively defines a limiting diameter D7. In the illustrated embodiment, limiting diameter D7 is between 135 mm and 137 mm. Specifically, limiting diameter D7 is 136 mm. Each cutting tooth 132 includes a recess 152 defined by adjacent walls 156 of the cutting tooth 132, which meet at a radiused corner. A recess 152 is formed on a side of the cutting tooth 132 opposite the heel surface 144 .

[0049] Continue to see Figure 2 , these inserts 140 can be made of carbide (e.g., tungsten carbide) or a similar material. The inserts 140 can be fastened (e.g., welded, brazed, or otherwise secured) to the cutting teeth 132. In some embodiments, only some of the cutting teeth 132 include the inserts 140. In other embodiments, the cutting teeth 132 do not include the inserts 140. The inserts 140 can be made of a different material than the rest of the body 104 and each cutting tooth 132. In other embodiments, the inserts 140 can be made of a similar material as the rest of the body 104 and the cutting teeth 132, such as high-speed steel.

[0050] Figure 2 1 shows a single insert in the plurality of inserts 140. However, each of the plurality of inserts 140 may include Figure 2 The insert exhibits the following characteristics. Figure 2 The inserts 140 will reflect the features of the plurality of inserts 140 and will also be referred to as "inserts 140." In the illustrated embodiment, the inserts 140 include cutting edges 160. Each cutting edge 160 extends between opposite sides of a corresponding insert 140. The cutting edges 160 of the inserts 140 collectively define a cutting diameter D8 of the saw blade 100. In the illustrated embodiment, the cutting diameter D8 is between 135 mm and 139 mm. Specifically, the diameter D8 is 137 mm (e.g., 5 3 / 8 inches). The saw blade 100 is capable of cutting rebar having a diameter of up to approximately 28.575 mm (e.g., 1 1 / 8 inches or #10 rebar).

[0051] Insert 140 includes a rake face 164 adjacent to cutting edge 160. Rake face 164 extends to a front wall 168. In the illustrated embodiment, rake face 164 defines a recess 170 in insert 140. The illustrated recess 170 is defined by a curved wall 172 and a planar wall 176 of rake face 164. Curved wall 172 and planar wall 176 are adjacent to each other. Curved wall 172 defines a radius R2. In the illustrated embodiment, radius R2 is between 0.8 mm and 1.6 mm. Specifically, radius R2 is 1.2 mm. Planar wall 176 is offset from front wall 168 by a non-zero angle A1. In the illustrated embodiment, non-zero angle A1 is between 140 and 160 degrees. Specifically, non-zero angle A1 is 150 degrees.

[0052] The illustrated front wall 168 is a planar wall. Front wall 168 has a length L1. In the illustrated embodiment, length L1 is between 1.8 mm and 2.4 mm. Specifically, length L1 is 2.1 mm. Insert 140 also includes a bottom wall 180 and a rear wall 184 received in recess 152. Front wall 168 and bottom wall 180 are connected at a corner having a radius R3. In the illustrated embodiment, radius R3 is between 0.1 mm and 0.3 mm. Specifically, radius R3 is 0.2 mm. Bottom wall 180 has a length L2. In the illustrated embodiment, length L2 is between 2 mm and 2.8 mm. Specifically, length L2 is 2.4 mm. Bottom wall 180 and rear wall 184 are connected at a corner having a radius R4. In the illustrated embodiment, radius R4 is between 0.5 mm and 0.9 mm. Specifically, radius R4 is 0.7 mm. The insert 140 also includes a relief surface 188 or top wall extending from the cutting edge 160. The relief surface 188 has a distance X1 measured from a rear point of the relief surface 188 to a relief surface 190 of the cutting tooth 132. In the illustrated embodiment, the distance X1 is between 0 mm and 0.2 mm. Specifically, the distance X1 is 0.1 mm.

[0053] Insert 140 includes a second front wall 194 positioned between cutting edge 160 and rake face 164. Specifically, second front wall 194 extends from cutting edge 160 to curved wall 172 of rake face 164. Second front wall 194 is a planar wall and is offset from front wall 168 by an angle A2. In the illustrated embodiment, angle A2 is between -2 degrees and 2 degrees. Specifically, angle A2 is 0 degrees. In other words, second front wall 194 may be parallel to front wall 184, but offset therefrom. Second front wall 194 has a length L3. In the illustrated embodiment, length L3 is between 0.05 mm and 0.35 mm. Specifically, length L3 is 0.2 mm. Insert 140 has a length L4 measured between bottom wall 180 and cutting edge 160. In the illustrated embodiment, length L4 is approximately 4.5 mm.

[0054] Figure 3 Insert 198 is shown among the plurality of inserts 140. A relief surface 188 of insert 198 includes a chamfer that extends along one of the sides of insert 198 and across at least half of the width of insert 198. Specifically, relief surface 188 includes a horizontal wall 202 and a chamfered wall 206. Chamfered wall 206 forms a non-zero angle A3 with horizontal wall 202 and forms a chamfer. In the illustrated embodiment, non-zero angle A3 is between 6 and 10 degrees. Specifically, non-zero angle A3 is 8 degrees.

[0055] The insert 198 defines a width W1 proximate the cutting edge 160. In the illustrated embodiment, the width W1 is between 1.5 mm and 1.7 mm. Specifically, the width W1 is 1.6 mm. In some embodiments, the width of the insert 198 is non-uniform. For example, the width is shown tapering between the bottom wall 180 and the relief surface 188. For example, the insert 198 defines a width W2 proximate the bottom wall 180. In other words, the width of the insert 198 decreases from the cutting edge 160 to the bottom wall 180. In the illustrated embodiment, the difference between the widths W1 and W2 is between 0.1 mm and 0.28 mm. In some embodiments, the width of the insert 198 is greater proximate the second front wall 194 relative to the bottom wall 180. The body 104 of the saw blade 100 defines a width W3. The width W3 of the body 104 is less than the width W1 of the insert 198. In the illustrated embodiment, the width W3 is between 1 mm and 1.4 mm. Specifically, the width W3 is 1.2 mm.

[0056] Figure 4 Insert 210 is shown among the plurality of inserts 140. The relief surface 188 of insert 210 includes a chamfer that extends along another of the sides of insert 210 and across at least half of the width of insert 198. Specifically, relief surface 188 includes a horizontal wall 214 and a chamfered wall 218. Chamfered wall 218 forms a non-zero angle A4 with horizontal wall 214. In the illustrated embodiment, non-zero angle A4 is between 6 and 10 degrees. Specifically, non-zero angle A4 is 8 degrees. Insert 210 defines a width W1.

[0057] The difference between insert 198 and insert 210 is the location of the horizontal walls (e.g., horizontal walls 202, 214) and chamfered walls (e.g., walls 206, 218) relative to the first side S1 of the body 104 (or insert 198, 210) and the second side S2 of the body 104 (or insert 198, 210). For example, for insert 198, horizontal wall 202 is closer to the first side S1, and chamfered wall 206 is closer to the second side S2. In contrast, horizontal wall 214 is closer to the first side S2, and chamfered wall 218 is closer to the second side S1.

[0058] Figure 5 An insert 198 is shown that defines a width W4 proximate the rake face 164 and a width W5 proximate the back wall 184. In the illustrated embodiment, width W4 is between 1.3 mm and 1.9 mm. Specifically, width W is 1.6 mm. The difference between widths W4 and W5 is between 0.06 mm and 0.16 mm. In other words, the width of insert 198 tapers between the rake face 164 and the back wall 184, or the width of insert 198 tapers as it extends away from the cutting edge 160. Figure 6 Insert 210 is shown also tapering from rake face 164 to rear wall 184. In the illustrated embodiment, the difference in widths W4 and W5 of insert 210 is the same as insert 198. In other embodiments, the difference in widths W4 and W5 of insert 210 is different than insert 198.

[0059] Return Reference Figure 1 The plurality of inserts 140 is a collection of inserts 198 and 210. In the illustrated embodiment, the plurality of inserts 140 alternates between inserts 198 and inserts 210. In other words, a cutting tooth 132 having an insert 198 is flanked by an adjacent cutting tooth 132 (each having an insert 210). In some embodiments, the plurality of inserts 140 includes inserts 198 and 210 in different arrangements.

[0060] Figure 7 Another embodiment of a saw blade 300 is shown. The saw blade 300 is similar to the saw blade 100, and features identical to those of the saw blade 100 are indicated by the same reference numerals. Only the differences between the saw blades 100 and 300 will be discussed. For descriptions of features of the saw blade 300 that are not explicitly included below, reference is made to the description of the saw blade 100 above.

[0061] The saw blade 300 includes a plurality of inserts 304 that are received by the plurality of cutting teeth 132. The cutting teeth 132 each include a recess 308 having a geometry that is complementary to the geometry of an insert in the plurality of inserts 304. The recess 308 differs from the recess 152 in that it includes a corresponding geometry for receiving an insert in the plurality of inserts 304, rather than an insert in the plurality of inserts 140.

[0062] In the illustrated embodiment, the insert 304 can be made of a carbide (e.g., tungsten carbide) or a similar material. The insert 304 can be fastened (e.g., welded, brazed, or otherwise secured) to the cutting teeth 132. In some embodiments, only some of the cutting teeth 132 include the insert 304. In other embodiments, the cutting teeth 132 do not include the insert 304. The insert 304 can be made of a different material than the rest of the body 104 and each cutting tooth 132. In other embodiments, the insert 304 is made of a similar material as the rest of the body 104 and the cutting teeth 132, such as high-speed steel.

[0063] Figure 8 304. However, each of the plurality of inserts 304 may include Figure 8 The insert exhibits the following characteristics. Figure 8 The inserts 304 will reflect the features of the plurality of inserts 304 and will also be referred to as "inserts 304." In the illustrated embodiment, the inserts 304 include cutting edges 312. Each cutting edge 312 extends between opposite sides of a corresponding insert 304. The cutting edges 312 of the inserts 304 collectively define a cutting diameter D9 of the saw blade 300. In the illustrated embodiment, the cutting diameter D9 is between 135 mm and 139 mm. Specifically, the diameter D9 is 137 mm (e.g., 5 3 / 8 inches). The saw blade 300 is capable of cutting rebar having a diameter of up to approximately 28.575 mm (e.g., 1 1 / 8 inches or #10 rebar).

[0064] Insert 304 includes a rake face 316 adjacent to cutting edge 312. Rake face 316 extends to front wall 320. In the illustrated embodiment, rake face 316 defines a recess 322 in insert 304. The illustrated recess 322 is defined by a first planar wall 324 and a second planar wall 328 of rake face 316. First planar wall 324 and second planar wall 328 are offset from each other by a non-zero angle A5. In the illustrated embodiment, non-zero angle A5 is between 110 and 140 degrees. Specifically, non-zero angle A5 is 130 degrees. Rake face 316 defines a radius R5 between adjacent walls 324, 328. In the illustrated embodiment, radius R5 is between 0.1 mm and 0.5 mm. Specifically, radius R5 is 0.3 mm.

[0065] The illustrated front wall 320 is a planar wall. The front wall 320 connects to the bottom wall 332 at a corner having a radius R6. In the illustrated embodiment, the radius R6 is between 0.1 millimeter and 0.3 millimeter. In particular, the radius R6 is 0.2 millimeter. The bottom wall 332 connects to the corner wall 336 at a corner having a radius R7. In the illustrated embodiment, the radius R7 is between 0.1 millimeter and 0.2 millimeter. In particular, the radius R7 is 0.15 millimeter. The corner wall 336 is coupled to the back wall 340.

[0066] The insert 304 also includes a relief surface 344 or top wall connected to the back wall 340 at a corner. The relief surface 344 defines a non-zero angle A6 (e.g., a top corner clearance). In the illustrated embodiment, the non-zero angle A6 is between 8 degrees and 12 degrees. In particular, the non-zero angle A6 is 10 degrees. The relief surface 344 has a distance X2 measured from a back point of the relief surface 344 to the relief surface 190 of the cutting tooth 132. In the illustrated embodiment, the distance X2 is between 0 millimeter and 0.2 millimeter. In particular, the distance X2 is 0.1 millimeter.

[0067] The insert 304 includes a second front wall 348 between the cutting edge 312 and the rake surface 316. In particular, the second front wall 348 extends from the cutting edge 312 to the first planar wall 324 of the rake surface 316. In the illustrated embodiment, the second front wall 348 is parallel to the back wall 340. The second front wall 348 defines a length L5. In the illustrated embodiment, the length L5 is between 0.1 millimeter and 0.5 millimeter. In particular, the length L5 is 0.3 millimeter.

[0068] The insert 304 defines an axis 350 that is perpendicular to the wall 340 and intersects a bottom edge 352 of the insert 304. The axis 350 locates different features of the insert 304. An intersection 356 defined between the front wall 320 and the second planar wall 328 of the rake surface 316 is located at a distance X3 perpendicular to the axis 350. In the illustrated embodiment, the distance X3 is between 2.03 millimeters and 2.23 millimeters. In particular, the distance X3 is 2.13 millimeters. A center point of the radius R5 is located at a distance X4 perpendicular to the axis 350. In the illustrated embodiment, the distance X4 is between 2.88 millimeters and 3.08 millimeters. In particular, the distance X4 is 2.98 millimeters. The insert 304 defines a length L6 measured from the axis 350 to the cutting edge 312. In the illustrated embodiment, the length L6 is approximately 4.5 millimeters. The insert 304 defines a length L7 measured along the axis 350 from the front wall 320 to the back wall 340. In the illustrated embodiment, the length L7 is between 2.6 millimeters and 3 millimeters. In particular, the length L7 is 2.8 millimeters.

[0069] Figure 9An insert 360 of the plurality of inserts 304 is illustrated. The relief surface 344 of the insert 360 has a chamfer that extends along both sides S3, S4 of the insert 304 and extends over at least half of the width of the insert 304. In particular, the relief surface 344 includes a horizontal wall 364, a first chamfer wall 368, and a second chamfer wall 372. The horizontal wall 364 defines a length L8. In the illustrated embodiment, the length L8 is between 0.05 mm and 0.35 mm. In particular, the length L8 is 0.2 mm. The horizontal wall 364 is disposed at a distance X5 from the first side S3 of the insert 360. In the illustrated embodiment, the distance X5 is approximately 0.7 mm. The horizontal wall 364 is disposed at a distance X6 from the second side S4 of the insert 360. In the illustrated embodiment, the distance X6 is approximately 0.7 mm. In the illustrated embodiment, the distances X5, X6 are the same value. In other embodiments, the distances X5, X6 are different values. The first chamfer wall 368 extends between the first side S3 of the insert 360 and the horizontal wall 364.

[0070] The first chamfer wall 368 is at a non-zero angle A7 from the horizontal wall 364. In the illustrated embodiment, the non-zero angle A7 is between 25 degrees and 35 degrees. In particular, the non-zero angle A7 is 30 degrees. The second chamfer wall 372 extends between the second side S4 of the insert 360 and the horizontal wall 364. The second chamfer wall 372 is at a non-zero angle A8 from the horizontal wall 364. In the illustrated embodiment, the non-zero angle A8 is between 25 degrees and 35 degrees. In particular, the non-zero angle A8 is 30 degrees. The first chamfer wall 368 and the second chamfer wall 372 together form a chamfer.

[0071] The insert 360 defines a width W6 proximate the cutting edge 312. In the illustrated embodiment, the width W6 is between 1.4 mm and 2.1 mm. In particular, the width W6 is 1.6 mm. In some embodiments, the width of the insert 360 is non-uniform. For example, the width tapers between the bottom wall 332 and the relief surface 344. For example, the insert 360 defines a width W7 proximate the bottom wall 332. In other words, the width of the insert 360 decreases from the cutting edge 312 to the bottom wall 332. In the illustrated embodiment, the difference between the widths W6 and W7 is between 0.06 mm and 0.20 mm. In some embodiments, the width of the insert 360 is greater proximate the bottom wall 332 relative to the relief surface 344. In other embodiments, the width of the insert 360 is greater proximate the relief surface 344 relative to the bottom wall 332. Figure 9 In the illustrated configuration of the insert 360, the length of the first chamfer wall 368 is equal to the length of the second chamfer wall 372.

[0072] Figure 10Insert 376 is shown among the plurality of inserts 304. The relief surface 344 of insert 376 includes a horizontal wall 380, a first chamfered wall 384, and a second chamfered wall 388. Horizontal wall 380 defines a length L9. In the illustrated embodiment, length L9 is between 0.15 mm and 0.45 mm. Specifically, length L9 is 0.3 mm. Horizontal wall 380 is positioned at a distance X7 relative to first side S5 of insert 376. In the illustrated embodiment, distance X7 is approximately 0.8 mm. Horizontal wall 380 is positioned at a distance X8 relative to second side S6 of insert 376. In the illustrated embodiment, distance X8 is approximately 0.5 mm. In some embodiments, distances X7 and X8 are the same value. In the illustrated embodiment, distances X7 and X8 are different values.

[0073] A first chamfered wall 384 extends between a first side S5 of the insert 376 and the horizontal wall 380. The first chamfered wall 384 forms a non-zero angle A9 with the horizontal wall 380. In the embodiment shown, the non-zero angle A9 is between 6 degrees and 14 degrees. Specifically, the non-zero angle A9 is 10 degrees. A second chamfered wall 388 extends between a second side S6 of the insert 376 and the horizontal wall. The second chamfered wall 388 forms a non-zero angle A10 with the horizontal wall 380. In the embodiment shown, the non-zero angle A10 is between 15 degrees and 25 degrees. Specifically, the non-zero angle A10 is 20 degrees. The first chamfered wall 382 and the second chamfered wall 388 together form a chamfer. Figure 10 In the illustrated configuration of the insert 376 , the length of the first chamfered wall 384 is greater than the length of the second chamfered wall 388 .

[0074] Figure 11 Insert 390 is shown among the plurality of inserts 304. The relief surface 344 of insert 390 includes a horizontal wall 394, a first chamfered wall 398, and a second chamfered wall 402. Horizontal wall 394 defines a length L10. In the illustrated embodiment, length L10 is between 0.15 mm and 0.45 mm. Specifically, length L10 is 0.3 mm. Horizontal wall 394 is positioned at a distance X9 relative to first side S7 of insert 390. In the illustrated embodiment, distance X9 is approximately 0.5 mm. Horizontal wall 394 is positioned at a distance X10 relative to second side S8 of insert 390. In the illustrated embodiment, distance X10 is approximately 0.8 mm. In the illustrated embodiment, distances X9 and X10 are different values. In some embodiments, distances X9 and X10 are the same value.

[0075] A first chamfered wall 398 extends between a first side S7 of the insert 390 and the horizontal wall 394. The first chamfered wall 398 forms a non-zero angle A11 with the horizontal wall 394. In the embodiment shown, the non-zero angle A11 is between 15 degrees and 25 degrees. Specifically, the non-zero angle A11 is 20 degrees. A second chamfered wall 402 extends between a second side S8 of the insert 390 and the horizontal wall 394. The second chamfered wall 402 forms a non-zero angle A12 with the horizontal wall 394. In the embodiment shown, the non-zero angle A12 is between 6 degrees and 14 degrees. Specifically, the non-zero angle A12 is 10 degrees. The first chamfered wall 298 and the second chamfered wall 394 together form a chamfer. Figure 11 In the illustrated configuration of the insert 390 , the length of the first chamfered wall 398 is shorter than the length of the second chamfered wall 402 .

[0076] The difference between insert 376 and insert 390 is the location of the horizontal walls (e.g., horizontal walls 380, 394) and chamfered walls (e.g., walls 384, 388, 398, and 402) relative to the first side S1 of body 104 (or inserts 376, 390) and the second side S2 of body 104 (or inserts 376, 390). For example, for insert 376, horizontal wall 380 is closer to first side S1 than to second side S2. In contrast, for insert 390, horizontal wall 394 is closer to second side S2 than to first side S1.

[0077] Figure 12 An insert 360 is shown, defining a width W8 proximate the rake face 316 and a width W9 proximate the back wall 340. In the illustrated embodiment, width W8 is between 1.2 mm and 1.8 mm. Specifically, width W8 is 1.5 mm. The difference between widths W8 and W9 is between 0.06 mm and 0.16 mm. In other words, the width of the insert 360 tapers between the rake face 316 and the back wall 340, or the width of the insert 360 tapers as the insert extends away from the cutting edge 312. Figure 13 The insert 376 is shown also tapering from the rake face 316 to the rear wall 340 . Figure 14 Insert 390 is shown also tapering from rake face 316 to rear wall 340. In the illustrated embodiment, the difference between widths W8 and W9 of inserts 360, 376, 390 is the same value. In some embodiments, the difference between widths W8 and W9 of inserts 360, 376, 390 is different values.

[0078] Return Reference Figure 7, the plurality of inserts 304 is a collection of inserts 360, 376, 390. In the illustrated embodiment, the plurality of inserts 304 is a repeating pattern of inserts 360, 376, 390. In other embodiments, the inserts 304 can be arranged in any repeating or non-repeating pattern around the periphery of the saw blade 300.

[0079] In some embodiments, the saw blade 100, 300 includes a coating 500. In some embodiments, the coating 500 is a thin film ceramic coating that covers at least the plurality of inserts 140, 304. In some embodiments, the coating 500 can be disposed on a portion of the teeth of the saw blade 100, 300. In some embodiments, the coating 500 can be disposed on the entirety of each of the cutting teeth 132. In some embodiments, the coating 500 can be disposed on the entire blade of the saw blade 100, 300. In some embodiments, the coating 500 is applied to the inserts 140, 304 of the saw blade 100, 300, respectively.

[0080] In some embodiments, the coating 500 is composed of aluminum titanium nitride (AlTiN). Due to the formation of a protective aluminum oxide layer at the surface, the AlTiN coating increases oxidation resistance at elevated temperatures. In addition, due to microstructural changes and solid solution hardening, the AlTiN coating increases the hardness of the deposited film. Furthermore, the AlTiN coating ages and hardens at temperatures typical during operation of the saw blades 100, 300. In other embodiments, the coating 500 is composed of aluminum chromium nitride (AlCrN). The AlCrN coating has high thermal hardness and high wear resistance under extreme mechanical stress. The AlCrN coating is particularly beneficial in high-speed applications (such as those experienced by the saw blades 100, 300). In another embodiment, the coating 500 is composed of aluminum titanium chromium nitride (AlTiCrN). The AlTiCrN coating has high hardness, toughness, and oxidation temperature. The AlTiCrN coating is particularly beneficial for machining hardened steel, stainless steel, super alloys, and other difficult-to-machine materials. However, in other embodiments, the coating 500 is composed of a titanium-based material. For example, the coating 500 is made of titanium molybdenum nitride (TiMoN). TiMoN coating is a ceramic material.

[0081] In some embodiments, the coating 500 can be applied via physical vapor deposition (PVD), which is a variety of vacuum deposition methods. PVD is a process in which a material (such as the coating 500) is transformed from a condensed phase into a vapor phase and then back into a thin film condensed phase to produce a thin film or coating. In some embodiments, the PVD process can include evaporation, in which vapor particles of the coating 500 travel directly to the substrate where they condense back into a solid state. In other embodiments, the PVD process can include sputtering, in which a thin film is deposited from a source onto a substrate. In further embodiments, the coating 500 can be applied via other methods such as hot-dip galvanizing, thermal spraying, electroplating, sherardizing, etc.

[0082] Figure 15 A saw blade, such as one of saw blades 100, 300, is shown coupled to a tool 600. The tool 600 may be a powered tool having a motor, a drive mechanism, and a power source (e.g., a battery pack). In other embodiments, the tool 600 may be a non-powered tool. The illustrated tool 600 is a powered rebar cutter and has an output shaft 604 configured to receive the saw blade 100, 300. The output shaft 604 operably couples the saw blade 100, 300 to the motor of the tool 600 to drive (e.g., rotate) the saw blade 100, 300. In the illustrated embodiment, the output shaft 604 includes a saw blade flange 608 and a fastener 612 (e.g., a bolt, screw, etc.) for securing the saw blade 100, 300 to the tool 600. The saw blade flange 608 is received in the aperture 112 of the saw blade 100, 300. In other embodiments, the output shaft 604 may have other configurations.

[0083] The illustrated tool 600 also includes a plurality of alignment protrusions 616, 620, 624. In the illustrated embodiment, the tool 600 includes three alignment protrusions 616, 620, 624 corresponding to the three apertures 116, 120, 124 of the saw blades 100, 300. Specifically, the first alignment protrusion 616 is shaped and sized to fit within the first aperture 116, the second alignment protrusion 620 is shaped and sized to fit within the second aperture 120, and the third alignment protrusion 624 is shaped and sized to fit within the third aperture 124. The alignment protrusions 616, 620, 624 assist in aligning the saw blade 100, 300 with the output shaft 604 on the tool 600. The alignment protrusions 616, 620, 624 may also assist in driving (e.g., rotating) the saw blade 100, 300. In the illustrated embodiment, the alignment protrusions 616, 620, 624 are coupled to and extend from the output shaft 604. In other embodiments, the alignment protrusions 616, 620, 624 can be located elsewhere on the tool 600.

[0084] Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure described.

[0085] Various features of the present disclosure are set forth in the following claims.

Claims

1. A saw blade, characterized in that: include: a body having a center and a peripheral edge; a central portion disposed at a center of the body, the central portion defining a first aperture, a second aperture, and a third aperture, the first aperture, the second aperture, and the third aperture being circumferentially spaced from one another about the center of the body and configured to receive an alignment protrusion of a tool, the first aperture having a first diameter and the second aperture having a second diameter different from the first diameter; a bore formed in the central portion between the first, second, and third apertures, the bore configured to receive an output shaft of the tool; as well as A cutting edge extends from a circumferential edge of the body.

2. The saw blade according to claim 1, wherein: The third aperture has a third diameter different from the second diameter.

3. The saw blade according to claim 2, wherein: The third diameter is the same as the first diameter.

4. The saw blade according to claim 3, wherein: The second diameter is larger than the first diameter.

5. The saw blade according to claim 1, wherein: The first diameter is between 3 mm and 8 mm, and wherein the second diameter is between 4 mm and 9 mm.

6. The saw blade according to claim 5, wherein: The hole has a diameter between 25 mm and 31 mm.

7. The saw blade according to claim 1, wherein: The hole has a diameter that is larger than the first diameter and larger than the second diameter.

8. The saw blade according to claim 7, wherein: A ratio of the diameter of the hole to the first diameter is between 3 and 10.5, and wherein a ratio of the diameter of the hole to the second diameter is between 2.5 and 8.

9. The saw blade according to claim 1, wherein: The first aperture, the second aperture, and the third aperture are circumferentially equally spaced from one another.

10. The saw blade according to claim 1, wherein: The first aperture is spaced a first radial distance from the center of the body, and wherein the second aperture is spaced a second radial distance from the center of the body, the second radial distance being different from the first radial distance.

11. The saw blade according to claim 10, wherein: The third aperture is spaced a third radial distance from the center of the body, the third radial distance being different from the first radial distance.

12. The saw blade according to claim 11, wherein: The third radial distance is the same as the second radial distance.

13. The saw blade according to claim 1, wherein the first aperture being spaced a first radial distance from the center of the body, the second aperture being spaced a second radial distance from the center of the body, the second radial distance being different from the first radial distance, the third aperture having a third diameter and being spaced a third radial distance from the center of the body, The third diameter is the same as the first diameter, and The third radial distance is the same as the second radial distance.

14. A saw blade, characterized in that: include: a body comprised of a first material and having a center and a peripheral edge; a central portion disposed at the center of the body; a bore formed in the central portion, the bore configured to receive an output shaft of a tool; a plurality of cutting teeth extending from a circumferential edge of the body; as well as a plurality of inserts coupled to the plurality of cutting teeth, each insert being constructed of a second material different from the first material and comprising a first side and a second side opposite the first side, the first side and the second side defining a width of the insert, a cutting edge extending between the first side and the second side, a rake surface adjacent the cutting edge, the rake surface defining a recess in the insert, a planar wall extending from the rake face toward the body, and A relief surface extends from the cutting edge, the relief surface having a chamfer extending along at least one of the first side and the second side and extending over at least half of the width of the insert.

15. The saw blade according to claim 14, wherein: The rake surface of at least some of the inserts includes a curved wall and a planar wall, the curved wall and the planar wall defining the recess.

16. The saw blade according to claim 14, wherein: The rake surface of at least some of the inserts includes a first planar wall and a second planar wall, the first planar wall and the second planar wall defining the recess.

17. The saw blade according to claim 14, wherein: The chamfer of at least some of the inserts is formed by a single chamfered wall extending from the horizontal wall.

18. The saw blade according to claim 14, wherein: The chamfer of at least some of the inserts is formed by a first chamfered wall and a second chamfered wall extending in opposite directions from the horizontal wall.

19. The saw blade according to claim 14, wherein: The first side and the second side of at least some of the inserts taper toward each other as the first side and the second side extend away from the cutting edge.

20. A saw blade, characterized in that: include: a body comprised of a first material and having a center and a peripheral edge; a central portion disposed at the center of the body; a bore formed in the central portion, the bore configured to receive an output shaft of a tool; a plurality of cutting teeth extending from a circumferential edge of the body; as well as a plurality of inserts coupled to the plurality of cutting teeth, each insert being constructed of a second material different from the first material and comprising a first side and a second side opposite the first side, a cutting edge extending between the first side and the second side, a rake surface adjacent the cutting edge, the rake surface defining a recess in the insert, a planar wall extending from the rake face toward the body, and a flank surface extending from the cutting edge; Wherein, the cutting edges of the plurality of inserts collectively define a cutting diameter of the saw blade between 135 mm and 139 mm.

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