Band saw blade and method of manufacturing the band saw blade

Abstract

To provide an inexpensive band saw blade which has a longer length that can be coated in one coating processing, can perform cutting with high productivity, and has less burrs.SOLUTION: A band saw blade (1) comprises: a belt-like endless body part (11); a tooth part (12) in which a tooth row (TG) that is a set of a prescribed number of teeth including a set tooth (Rw) is repeatedly formed on one edge side of the body part (11); and a coat layer (13) which is formed on a surface of teeth (12a) of the tooth part (12). The set tooth (Rw) has a first impression part (T82) as a recess (12b) on the coat layer (13) on an outer face in a swing direction, and a thickness of the coat layer (13) in the recess (12b) of the first impression part (T82) is thinner than a thickness of portions other than the recess (12b) of the coat layer (13).SELECTED DRAWING: Figure 11

Description

[Technical Field]

[0001] The present invention relates to a band saw blade and a method for manufacturing a band saw blade. [Background technology]

[0002] Patent Document 1 describes a method for coating the tooth row of a band saw blade with a hard material by winding the band saw blade into a spiral coil and placing it in a coating device. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5174467 Summary of the Invention [Problem to be solved by the invention]

[0004] The method described in Patent Document 1 is a common coating method for band saw blades, and is performed in the final stage of the band saw blade manufacturing process. In this method, when the band saw blade is wound into a spiral coil, a band-shaped spacer is overlapped and wound together with the band saw blade to form gaps between adjacent tooth rows in the radial direction. Forming these gaps allows for good coating of the tooth rows.

[0005] Conventionally, when the tooth row of a band saw blade has set teeth that are set in the left-right direction, which is the thickness direction, the straight teeth are processed into set teeth by setting processing, and then coating is performed. In this case, the thickness of the coating layer formed on the inner surface (inner surface) and the outer surface (outer surface) of the set tooth in the direction of the set tooth may differ. In other words, because the inner surface is in the shadow of the set tooth inclination, the thickness of the coating layer formed tends to be thinner than that on the outer surface, which is the front surface of the set tooth inclination. Therefore, uneven thickness of the coating layer occurs on the band saw blade, especially on the set tooth. Therefore, there is a demand for a band saw blade that has a coating layer with no uneven thickness even when the band saw blade has set teeth, and a method for manufacturing the band saw blade. [Means for solving the problem]

[0006] In order to solve the above problems, one embodiment of the present invention has the following configurations 1) and 2). 1) A band saw blade comprising: a band-shaped, endless body portion; a tooth portion on one edge side of the body portion, in which tooth rows, which are sets of a predetermined number of teeth including set teeth, are repeatedly formed; and a coating layer formed on the surface of the teeth of the tooth portion, wherein the set teeth have a first impression portion as a recess in the coating layer on the outer surface in the direction of extension, and the thickness of the coating layer in the recess of the first impression portion is thinner than the thickness of the coating layer other than the recess. According to 1) of one aspect of the present invention, it is clear that the coating layer is formed before the setting process of the set tooth, and there is no unevenness in the thickness of the coating layer on the set tooth. 2) A method for manufacturing a band saw blade comprising: a belt-shaped endless body portion; a tooth portion on one edge side of the body portion, in which tooth rows each consisting of a predetermined number of teeth including set teeth are repeatedly formed; and a coating layer formed on the surface of the teeth of the tooth portion, This is a manufacturing method for a band saw blade, in which a coating layer is formed on the teeth of an intermediate blade, all of whose teeth are straight, and then a setting process is performed to set certain of the teeth to form the set teeth. According to 2) of one aspect of the present invention, the coating layer is formed before the set tooth is set, so that the thickness of the coating layer is uniform on the set tooth. [Effects of the Invention]

[0007] According to one aspect of the present invention, an effect is obtained in which there is no unevenness in the thickness of the coating layer, particularly on the set teeth of the band saw blade. [Brief explanation of the drawings]

[0008] [Figure 1]Figure 1 shows a first intermediate blade 1A and a spacer 2 used in manufacturing a band saw blade 1, which is an example of a band saw blade according to an embodiment of the present invention, where Figure 1(a) is a two-sided view of a partial side view and a top view of the first intermediate blade 1A, and Figure 1(b) is a two-sided view of a partial side view and a top view of the spacer 2. [Figure 2] FIG. 2 is a plan view showing a coil body C in which the first intermediate blade 1A and the spacer 2 are wound in an overlapping manner. [Figure 3] FIG. 3 is an enlarged view of the F3 region in FIG. [Figure 4] FIG. 4 is a schematic diagram for explaining the coating process of the coil body C by the coating device 7. As shown in FIG. [Figure 5] FIG. 5 is a partial side view showing a second intermediate blade 1B in which a coating layer 13 is formed on the tooth portion 12. As shown in FIG. [Figure 6] FIG. 6 is a cross-sectional view taken along the line S6-S6 in FIG. [Figure 7] 7A and 7B are diagrams for explaining the swing processing of the second intermediate blade 1B, where FIG. 7A is a cross-sectional view showing the state immediately before processing, and FIG. 7B is a cross-sectional view showing the state during processing. [Figure 8] FIG. 8 is a partial top view showing a third intermediate blade 1C obtained by performing bending processing on the second intermediate blade 1B. [Figure 9] FIG. 9 is a diagram illustrating a joining step for joining the third intermediate blade 1C into a loop shape to form the band saw blade 1. As shown in FIG. [Figure 10] 10A and 10B are partial side views showing the surface state of the teeth 12a of the band saw blade 1, with FIG. 10A being a right side view and FIG. 10B being a left side view. [Figure 11] Figure 11 shows a cross section of a tooth 12a in a band saw blade 1, where Figure 11(a) is a partial cross section, Figure 11(b) is an enlarged view of an indentation T81 in Figure 11(a), and Figure 11(c) is an enlarged view of an indentation T82 in Figure 11(a). [Figure 12] 12A and 12B are partial side views showing the surface state of the teeth 112a of the band saw blade 101 of the comparative example, where FIG. 12A is a right side view and FIG. 12B is a left side view. [Figure 13] Figure 13 shows a cross section of a tooth 112a in a band saw blade 101 of a comparative example, where Figure 13(a) is a partial cross section, Figure 13(b) is an enlarged view of the impression T181 in Figure 13(a), and Figure 13(c) is an enlarged view of the impression T182 in Figure 13(a). DETAILED DESCRIPTION OF THE INVENTION

[0009] (Example) Figure 1 shows a first intermediate blade 1A and a spacer 2 used in manufacturing a band saw blade 1, which is an example of a band saw blade according to an embodiment of the present invention, where Figure 1(a) is a two-sided view of a partial side view and a top view of the first intermediate blade 1A, and Figure 1(b) is a two-sided view of a partial side view and a top view of the spacer 2. The band saw blade 1 is formed by starting with a long, strip-shaped first intermediate blade 1A, and then cutting the third intermediate blade 1C to a predetermined length and joining them together in an endless shape, after the second intermediate blade 1B and third intermediate blade 1C are obtained as the manufacturing process progresses.

[0010] First, a method for manufacturing the band saw blade 1 will be described with reference to FIGS. FIG. 2 is a plan view showing a coil body C formed by overlapping and winding a first intermediate blade 1A and a spacer 2. FIG. 3 is an enlarged view of area F3 in FIG. 2. FIG. 4 is a schematic diagram illustrating the coating process of the coil body C using a coating device 7. FIG. 5 is a partial side view showing a second intermediate blade 1B having a coating layer 13 formed on the tooth portion 12. FIG. 6 is a cross-sectional view taken along the line S6-S6 in FIG. 5. FIG. 7 is a diagram illustrating the swing-out process for the second intermediate blade 1B, with FIG. 7(a) being a cross-sectional view showing the state immediately before the process and FIG. 7(b) being a cross-sectional view showing the state during the process. FIG. 8 is a partial top view showing a third intermediate blade 1C obtained by swing-out process for the second intermediate blade 1B. FIG. 9 is a diagram illustrating the joining process for joining the third intermediate blade 1C into an endless band saw blade 1.

[0011] First, a first intermediate blade 1A of a predetermined length is prepared as a material, and a spacer 2 of the same length as the first intermediate blade 1A is prepared as a manufacturing jig. As shown in the partial two-sided view of Fig. 1(a), the first intermediate blade 1A has a long, strip-shaped body portion 11 and a tooth portion 12 formed on one edge side (upper edge side) of the body portion 11. The tooth portion 12 has a plurality of teeth 12a formed continuously in the longitudinal direction of the body portion 11. The teeth 12a are straight teeth. The spacer 2 is a long, strip-shaped metal member. The width of the spacer 2 is slightly smaller than the width of the body 11 of the first intermediate blade 1A, and the thickness thereof is indicated as a thickness L2.

[0012] Next, as shown in Fig. 2, the first intermediate blade 1A and the spacer 2 are overlapped with the edges on the opposite sides of the tooth portion 12 aligned, and then wound in a spiral coil to form a coil body C. For simplification in Fig. 2, the first intermediate blade 1A is shown by a solid line, and the spacer 2 is shown by a dashed line. As shown in FIG. 3, the coil body C is formed by overlappingly winding the first intermediate blades 1A adjacent to each other in the radial direction with spacers 2 interposed between them in a spiral coil shape. Since all the teeth 12a of the first intermediate blades 1A are straight teeth, the minimum gap La between the radially adjacent first intermediate blades 1A is the gap between the body portions 11 and the thickness L2 of the spacer 2.

[0013] As shown in FIG. 4, this coil body C is placed in a coating device 7 and subjected to a coating process. Hereinafter, the coil body C before the coating process will be referred to as the untreated coil body Ca, and the coil body C after the coating process will be referred to as the treated coil body Cb.

[0014] The coating process is performed by PVD (Physical Vapor Deposition), but is not limited to this and may be performed by, for example, CVD (Chemical Vapor Deposition). At least the area to be coated on the first intermediate blade 1A is the surface of the tooth portion 12, which is the area of ​​the untreated coil body Ca that is not in contact with the spacer 2. In addition, in the area to be coated, there is a difference in thickness of the vapor deposition layer between the shaded and non-shaded areas, resulting in unevenness.

[0015] After the coating process is performed under predetermined conditions, the processed coil body Cb is taken out and unwound. From the processed coil body Cb, the second intermediate blade 1B is obtained, in which the tooth portion 12 of the first intermediate blade 1A has been coated.

[0016] 5 and 6, on the second intermediate blade 1B, a coating layer 13 (dotted portion) is formed by coating across the tooth portion 12 that was not in contact with the spacer 2 and the edge of the body portion 11 on the tooth portion 12 side. The coating layer 13 (see FIG. 5) may be, for example, a layer of titanium nitride (TiN), titanium aluminum nitride (TiAlN), titanium carbon nitride (TiCN), chromium nitride (CrN), or a combination thereof.

[0017] Next, a setting process is performed in which predetermined teeth among the plurality of straight teeth 12a of the second intermediate blade 1B are set to the left or right using a setting machine to form set teeth. As shown in Figure 7(a), the clam removal machine 8 has a fixing part 81 that supports the second intermediate blade 1B by clamping it in the thickness direction, and a processing part 82 that locally contacts the side of the tooth 12a and presses it in the thickness direction as indicated by the arrow DR1.

[0018] The clam dispenser 8 is fixed by clamping the body 11 between the fixing part 81 so that the tooth part 12 of the second intermediate blade 1B protrudes from the fixing part 81 and is exposed. Next, as shown in FIG. 7(b), the processing portion 82 is pressed from one side of the tooth 12a in the thickness direction, and the tooth 12a is bent and swung out to the other side as shown by the arrow DR2.

[0019] This setting process is performed in either the left or right direction on predetermined teeth of the second intermediate blade 1B by the setting machine 8, to obtain the third intermediate blade 1C shown in FIG. The third intermediate blade 1C has toothed portion 12, for example, five consecutive teeth 12a of the plurality of teeth 12a are formed into one tooth row TG, and this tooth row TG is formed repeatedly in the longitudinal direction. The tooth row TG shown in Fig. 8 is a set of a predetermined number of teeth including set teeth. Specifically, the tooth row TG is a set of five teeth, from the cutting direction (arrow DR3) side, including a right set tooth Rw, a left set tooth Ln, a right set tooth Rn, a left set tooth Lw, and a straight tooth S. The left set tooth Lw and the right set tooth Rw have a larger amount of set extension than the left set tooth Ln and the right set tooth Rn. The configuration of the tooth row TG is not limited to that shown in Fig. 8.

[0020] Next, as shown in FIG. 9, both ends of the body portion 11 of the third intermediate blade 1C are butted together at a joint Pm to form an endless shape, thereby obtaining a band-shaped endless band saw blade 1.

[0021] In the above-described manufacturing method of the band saw blade 1, all of the teeth 12a of the tooth portion 12 are straight at the time of coating, and after coating, a setting process is performed to change some of the straight teeth into set teeth. Therefore, the spacer 2 to be lap-wound with the coil body C to be coated by the coating device 7 may have a thickness L2. In this way, in the manufacturing method of the band saw blade 1, the coating process is performed on all straight teeth. Therefore, there is no difference in the thickness of the coating layer between the inner surface, which is in the shadow in the direction of swing, and the outer surface, which is the front, causing unevenness, as occurs when coating is performed on set teeth. In other words, according to the manufacturing method of the band saw blade 1, the thickness of the coating layer 13 is uniform throughout the coating area.

[0022] As described above, the band saw blade 1 is manufactured by forming the coating layer 13 on the surface of the tooth 12a and then performing the setting process. Therefore, in the setting process, the fixed part 81 and the processing part 82 of the setting machine 8 are pressed against the coating layer 13 from above, so that distinctive indentations different from conventional ones are formed on the edges of the processing part 82 and the fixed part 81. This indentation will be described with reference to Figures 10 and 11 using a right set tooth Rw set to the right as an example.

[0023] Fig. 10 is a partial side view showing the surface condition of the tooth 12a of the band saw blade 1, Fig. 10(a) is a right side view and Fig. 10(b) is a left side view. Fig. 11 is a view showing a cross section of the tooth 12a of the band saw blade 1, Fig. 11(a) is a partial cross section, Fig. 11(b) is an enlarged view of the indentation T81 in Fig. 11(a), and Fig. 11(c) is an enlarged view of the indentation T82 in Fig. 11(a).

[0024] 10(a), 11(a), and 11(b), an indentation T81 (second indentation T81) is formed by the fixing part 81 at the base part of the right side surface, which is the inner surface 12a1 in the projection direction of the tooth 12a of the right set tooth Rw. The indentation T81 is clearly visible in a straight line extending in the longitudinal direction of the body part 11, over the entire longitudinal direction of the tooth 12a. 10(b), 11(a), and 11(c), an indentation T82 (first indentation T82) is formed by the processed portion 82 in the center of the tooth height direction (vertical direction) of the left side surface, which is the outer surface 12a2 in the projection direction of the tooth 12a of the right set tooth Rw. The indentation T82 is linearly inclined so that the cutting direction AR3 side is downward, and can be clearly seen over the entire longitudinal direction of the tooth 12a.

[0025] That is, in the band saw blade 1, the indentation portion T81, the indentation portion T82, and the coating layer 13 have the following characteristics (a), (b), and (c) by forming the coating layer 13 on the tooth 12a as a coating layer forming process and then performing the setting processing as a setting processing process. (A) After the coating layer 13 is formed, the bent portion 12c is formed by the fixing portion 81. As a result, the coating layer 13 has peeled off in the area of ​​the surface of the tooth 12a from the bent portion 12c toward the body portion 11 due to friction with the fixing portion 81, resulting in a low formation density of the coating layer 13 (the dots of the coating layer 13 are not shown in Figures 10 and 11). In other words, the coating layer 13 has different formation densities on the tooth tip side and the body side, with the indentation portion T81 as the boundary. Due to this and the pressing of the processing portion 82 against the coating layer 13, the indentation portion T81 formed on the surface of the tooth 12a is clearly visible. (b) After forming the coating layer 13, the recesses 12b are formed by the processing unit 82. Therefore, the coating layer 13b in the recesses 12b is compressed and has a smaller thickness (thinner thickness) than the other parts of the coating layer 13 (parts other than the recesses). (c) After the coating layer 13 is formed, the recesses 12b are formed by the processed portion 82. Therefore, the indentations T82 are formed on the surface of the coating layer 13 in a manner that is clearly visible.

[0026] In contrast, the indentations T181 and T182 formed on the comparative band saw blade 101 manufactured using a conventional manufacturing method in which a coating process is performed after forming set teeth are shown in Figures 12 and 13. Fig. 12 is a partial side view showing the surface condition of the tooth 112a of the band saw blade 101 of the comparative example, Fig. 12(a) is a right side view and Fig. 12(b) is a left side view. Fig. 13 is a view showing a cross section of the tooth 112a of the band saw blade 101 of the comparative example, Fig. 13(a) is a partial cross section, Fig. 13(b) is an enlarged view of the indentation T181 in Fig. 13(a), and Fig. 13(c) is an enlarged view of the indentation T182 in Fig. 13(a).

[0027] 12(a), 13(a), and 13(b), an impression T181 is formed at the base of the right side surface of the tooth 112a of the right set tooth Rw by the fixing part 81. The impression T181 is visible thinly and slightly in a straight line extending in the longitudinal direction of the body part 11, and in some cases in part of the tooth 112a. 12(b), 13(a), and 13(c), an indentation T182 is formed by the processed portion 82 in the center of the tooth height direction (vertical direction) on the left side surface of the tooth 112a of the right set tooth Rw. The indentation T182 is thin and slightly visible in a straight line inclined downwards on the cutting direction AR3 side, and in some cases in part of the tooth 112a.

[0028] In the band saw blade 101 of the comparative example, the following characteristics (ii), (iii) and (iv) are generated in the impression portion T181, impression portion T182 and coating layer 113 by performing a setting process after forming the coating layer 113 on the tooth 112a. (iv) The coating layer 113 is formed after the bent portion 112c is formed on the surface of the tooth 112a by the fixing portion 81. Therefore, the formation density of the coating layer 113 is approximately the same on the cutting edge side and the body side, with the bent portion 112c as the boundary. (e) The coating layer 113 is formed after the recesses 112b are formed by the processing portion 82. Therefore, the thickness of the coating layer 113b in the recesses 112b is approximately the same as that of the other portions of the coating layer 113. (f) After the bent portions 112c and the recessed portions 112b are formed, the coating layer 113 is formed to cover the bent portions 112c and the recessed portions 112b. Therefore, the bent portions 112c and the recessed portions 112b are hidden by the coating layer 113, and the indentations T181 and T182 may be partially difficult to see or may not be visible at all.

[0029] As described above, the band saw blade 1 of the embodiment is subjected to a retraction process after the coating layer 13 is formed, resulting in a characteristic configuration of the manufactured product itself that differs from conventional products. In other words, the characteristics of band saw blade 1, (a), (b), and (c), are differences corresponding to (d), (e), and (f), respectively, in the comparative band saw blade 101, and are characteristic configurations unique to band saw blade 1 that make band saw blade 1 distinguishable from other band saw blades.

[0030] As described above, the band saw blade 1 of one embodiment of the present invention comprises a band-shaped, endless body portion 11, a tooth portion 12 on one edge side of the body portion 11, in which a tooth row TG is repeatedly formed, which is a set of a predetermined number of teeth 12a including set teeth Rw, and a coating layer 13 formed on the surface of the teeth 12a of the tooth portion 12, and the set teeth Rw have a first impression portion T82 as a recess 12b in the coating layer 13 on the outer surface 12a2 in the casting direction, and the thickness of the coating layer 13 at the recess 12b of the first impression portion T82 is thinner than the thickness of the portion of the coating layer 13 other than the recess 12b.

[0031] Furthermore, this band saw blade 1 may further have a second indentation portion T81 as a bent portion 12c on the outer surface of the coating layer 13 of the inner surface 12a1 in the swing direction of the set tooth Rw, and the coating layer 13 may have a lower formation density on the body portion 11 side than on the tooth tip side, with the second indentation portion T81 as the boundary.

[0032] The band saw blade 1 having these characteristics has a coating layer 13 of uniform thickness formed on the portion required for cutting by a coating process during the manufacturing process.

[0033] Furthermore, as described above, one embodiment of the method for manufacturing a band saw blade of the present invention is a method for manufacturing a band saw blade that includes a band-shaped, looped body portion 11, a tooth portion 12 on one edge side of the body portion 11, in which a tooth row TG, which is a set of a predetermined number of teeth 12a including set teeth Rw, is repeatedly formed, and a coating layer 13 formed on the surface of the teeth 12a of the tooth portion 12.After performing a coating layer formation process to form the coating layer 13 on the teeth 12a of the intermediate blade 1A, all of which have straight teeth S, a setting process is performed to set certain of the teeth 12a to form set teeth Rw.

[0034] In this method of manufacturing a band saw blade, the coating process, which is the coating layer forming step, is performed only on the straight teeth, thereby making it possible to form a coating layer of uniform thickness.

[0035] Furthermore, in this embodiment of the method for manufacturing a band saw blade, the coating layer forming process may further include winding the intermediate blade 1A and the band-shaped spacer 2 in a lapped state so that the tooth portion 12 is exposed to form a spiral coil-shaped coil body C, and then feeding the formed coil body C into a coating device 7 to form the coating layer 13.

[0036] The embodiments of the present invention are not limited to the above-described configurations, and modifications may be made without departing from the spirit of the present invention.

[0037] There is no limitation on the configuration of the set teeth and straight teeth of the tooth row TG of the band saw blade 1. There is no limitation on the material and method of forming the coating layer 13. The thickness of the spacer 2 may be set as thin as possible within a range in which a good coating layer 13 can be obtained depending on the type of band saw blade 1 and the conditions of the coating process. This allows the length of the saw blade on which the coating layer can be formed in one coating process to be longer. [Explanation of symbols]

[0038] 1 bandsaw blade 1A First intermediate blade 1B Second intermediate blade 1C 3rd intermediate blade 11 Torso 12 Tooth 12a tooth 12a1 Inner surface 12a2 Exterior 12b Recess 12c Bend part 13,13b Coating layer 2 spacers 7 Coating equipment 8. Clam-serving machine 81 Fixed part 82 Processing Department C Coil body Coil body before Ca treatment Cb processed coil body La Gap L2 thickness Ln,Lw Left set tooth Pm junction Rn,Rw Right set tooth T81,T82 Indentation part TG dentition S straight teeth

Claims

1. A belt-shaped endless body portion; a tooth portion on one edge side of the body portion, in which a tooth row, which is a set of a predetermined number of teeth including set teeth, is repeatedly formed; a coating layer formed on the surface of the teeth of the tooth portion; Equipped with The set tooth has a first impression portion as a recess in the coating layer on the outer surface in the projection direction, A band saw blade, wherein the thickness of the coating layer in the recess of the first impression portion is thinner than the thickness of the coating layer in the portion other than the recess.

2. The set tooth has a second indentation portion as a bent portion in the coating layer on the inner surface in the swing direction, The band saw blade according to claim 1 , wherein the coating layer has a lower formation density on the body side than on the tooth tip side, with the second indentation portion as a boundary.

3. A method for manufacturing a band saw blade comprising: a band-shaped, endless body portion; a tooth portion on one edge side of the body portion, in which tooth rows each including a predetermined number of tooth sets including set teeth are repeatedly formed; and a coating layer formed on the surfaces of the teeth of the tooth portion, A method for manufacturing a band saw blade in which a coating layer is formed on the teeth of an intermediate blade, all of whose teeth are straight, and then a setting process is performed to set certain of the teeth to form the set teeth.

4. 4. A method for manufacturing a band saw blade as described in claim 3, wherein the coating layer forming process includes overlapping the intermediate blade and a band-shaped spacer so that the tooth portion is exposed to form a spiral coil-shaped coil body, and then feeding the formed coil body into a coating device to form a coating layer.

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