Saw blade

Abstract

A reciprocating saw blade including a body, an attachment portion configured to be coupled to a reciprocating saw, and a cutting portion formed on the body. The cutting portion has a plurality of cutting teeth extending along the body. Each cutting tooth includes a tip having a cutting insert with at least one chamfer oriented at an insert angle relative to a portion of a corresponding cutting tooth, a rake face extending from the tip toward the longitudinal axis, a gullet at least partially defined by the rake face, a relief surface extending from the tip opposite the rake face, and a protrusion extending between the gullet and the relief surface. The protrusion is configured to inhibit an object imbedded within a work piece from impacting the rake face. The reciprocating saw blade further includes a ceramic coating overlaying at least the cutting insert of each cutting tooth.

Description

Attorney Docket No. 066042- 1973 -WOO 1SAW BLADECROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to co-pending U.S. Provisional Patent Application No. 63 / 903,248, filed October 22, 2025. and U.S. Provisional Patent Application No. 63 / 723,464, filed November 21 , 2024, the entire contents of all of which are incorporated herein by reference.FIELD OF THE INVENTION

[0002] The present invention relates to saw blades and, more particularly, to saw blades for use with power tools.BACKGROUND OF THE INVENTION

[0003] Saw blades, such as reciprocating saw blades and hole saws, are used for cutting wood, metal, plastics, and other materials. A saw blade typically includes a body, one or more attachment portions, and a cutting portion. The cutting portion comprises a plurality of teeth made up of one or more tooth forms. Tooth forms on saw blades are a major factor in the durability, cost, speed of cutting, and accuracy and quality of cuts made. Each tooth typically includes a tip, a relief face, a rake face, and a gullet. The teeth are generally separated by a pitch length (otherwise identified as the number of teeth per inch (TPI)). Some tooth forms vary along the length of the saw blade or include portions having varied teeth. In some tooth forms, a nail may become lodged in the gullet of a tooth during operation, thereby breaking or otherwise damaging the tooth.SUMMARY OF THE INVENTION

[0004] The present invention provides, in one aspect, a reciprocating saw blade for use with a reciprocating saw. The reciprocating saw blade includes a body defining a longitudinal axis, an attachment portion coupled to the body and configured to be coupled to the reciprocating saw, and a cutting portion formed on the body. The cutting portion includes a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis. Each cutting tooth includes a tip having a cutting insert with at least one chamfer oriented at an insert angle relative to a portion of a corresponding cutting tooth, a rake face extending from the tip toward the longitudinal axis, a gullet at least partially defined by theAttorney Docket No. 066042- 1973 -WOO 1 rake face, a relief surface extending from the tip opposite the rake face, and a protrusion extending between the gullet and the relief surface. The protrusion is configured to inhibit an object imbedded within a work piece from impacting the rake face. The reciprocating saw blade further includes a ceramic coating overlaying at least the cutting insert of each cutting tooth.

[0005] The present invention provides, in another aspect, a reciprocating saw blade for use with a reciprocating saw. The reciprocating saw blade includes a body defining a longitudinal axis, an attachment portion coupled to the body and configured to be coupled to the reciprocating saw, and a cutting portion formed on the body. The cutting portion includes a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis. Each cutting tooth includes a rake face, a relief surface, a pocket positioned between the rake face and the relief surface, and a cutting insert secured to the pocket. The cutting insert has a top portion obliquely oriented at a first insert angle relative to the longitudinal axis, a front portion obliquely oriented at a second insert angle relative to the longitudinal axis, and at least one side surface extending between the top portion and the front portion. The at least one side surface is formed with a chamfer. The reciprocating saw blade further includes a protrusion extending from the relief surface. The protrusion is configured to inhibit an object imbedded within a work piece from impacting the rake face.

[0006] The present invention provides, in another aspect, a reciprocating saw blade for use with a reciprocating saw. The reciprocating saw blade includes a body defining a longitudinal axis, an attachment portion coupled to the body and configured to be coupled to the reciprocating saw, and a cutting portion formed on the body. The cutting portion includes a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis. Each cutting tooth includes a tip having a cutting insert with at least one chamfer and a protrusion spaced from the tip. The protrusion having an apex with a curvilinear shape. The protrusion is configured to inhibit an object imbedded within a work piece from impacting a rake face of each cutting tooth. The reciprocating saw blade further including a ceramic coating overlaying at least the cutting insert of each cutting tooth.

[0007] The present invention provides, in another aspect, a reciprocating saw blade for use with a reciprocating saw. The reciprocating saw blade includes a body defining a longitudinal axis, an attachment portion coupled to the body and configured to be coupled to the reciprocating saw, and a cutting portion formed on the body. The cutting portion includesAttorney Docket No. 066042- 1973 -WOO 1 a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis. Each cutting tooth includes a tip having a cutting insert with at least one round edge, a rake face extending from the tip toward the longitudinal axis, a gullet at least partially defined by the rake face, and a relief surface extending from the tip opposite the rake face.

[0008] The present indention provides, in another aspect, a reciprocating saw blade for use with a reciprocating saw. The reciprocating saw blade includes a body defining a longitudinal axis, an attachment portion coupled to the body and configured to be coupled to the reciprocating saw, and a cutting portion formed on the body. The cutting portion includes a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis. Each cutting tooth includes a rake face, a relief surface, a pocket positioned between the rake face and the relief surface, and a cutting insert secured to the pocket. The cutting insert has a top portion obliquely oriented relative to the longitudinal axis, a front portion obliquely oriented relative to the longitudinal axis, a first side surface extending between the top portion and the front portion, and a second side surface extending between the top portion and the front portion opposite the first side surface. The first side surface and the second side surface are each formed with a round edge.BRIEF DESCRIPTION OF DRAWINGS

[0009] FIG. 1 is a perspective view of a saw blade according to an embodiment of the present invention.

[0010] FIG. 2 is a side view of the saw blade of FIG. 1.

[0011] FIG. 3 is an enlarged side view of a second end portion of the saw blade of FIG. 1.

[0012] FIG. 4 is an enlarged perspective view of the second end portion of the saw blade of FIG. 3.

[0013] FIG. 5 is an enlarged perspective view of a plunge point of the saw blade of FIG. 1.

[0014] FIG. 6 is an enlarged side view of a cutting tooth of the saw blade of FIG. 1.

[0015] FIG. 7 is an enlarged top view of the cutting tooth of FIG. 6.

[0016] FIG. 8 is an enlarged perspective view of the cutting tooth of FIG. 6.Attorney Docket No. 066042- 1973 -WOO 1

[0017] FIG. 9A is a cross-sectional view of the cutting tooth of FIG. 6.

[0018] FIG. 9B is a cross-sectional view of the cutting tooth of FIG. 6, the cutting tooth including a coating applied onto a cutting insert.

[0019] FIG. 10 is a cross-sectional view of a protrusion of the saw blade of FIG. 1.

[0020] FIG. 11 is a flow chart of a manufacturing process of the saw blade of FIG. 1.

[0021] FIG. 12 is a perspective view of a reciprocating saw.

[0022] FIG. 13 is a perspective view of a saw blade according to another embodiment of the present invention.

[0023] FIG. 14 is an enlarged perspective view of a second end portion of the saw blade of FIG. 13.

[0024] FIG. 15 is an enlarged side view of a cutting tooth of the saw blade of FIG. 13.

[0025] FIG. 16 is an enlarged perspective view of the cutting tooth of FIG. 15.

[0026] FIG. 17 is a cross-sectional view of the cutting tooth of FIG. 15.

[0027] FIG. 18 is a side view of a saw blade according to another embodiment of the present invention.

[0028] FIG. 19 is an enlarged perspective view of a portion of the saw blade of FIG. 18.

[0029] FIG. 20 is an enlarged side view of cutting teeth of the saw blade of FIG. 18.

[0030] FIG. 21 is an enlarged top view of the saw blade of FIG. 18.

[0031] FIG. 22 is a side view of a saw blade according to another embodiment of the present invention.

[0032] FIG. 23 is an enlarged perspective view of a portion of the saw blade of FIG. 22.

[0033] FIG. 24 is an enlarged side view of cutting teeth of the saw blade of FIG. 22.

[0034] FIG. 25 is an enlarged top view of the saw blade of FIG. 22.Attorney Docket No. 066042- 1973 -WOO 1

[0035] FIG. 26 is a perspective view of a saw blade according to another embodiment of the present invention.

[0036] FIG. 27 is an enlarged perspective view of cutting teeth of the saw blade of FIG.26.

[0037] FIG. 28 is an enlarged side view of the cutting teeth of FIG. 27.

[0038] FIG. 29 is an enlarged rear view of the cutting teeth of FIG. 27

[0039] FIG. 30 is an enlarged top view of the cutting teeth of FIG. 27.

[0040] FIG. 31 is a perspective view of a saw blade according to another embodiment of the present invention.

[0041] FIG. 32 is an enlarged perspective view of cutting teeth of the saw blade of FIG.31.

[0042] FIG. 33 is a perspective view of a saw blade according to another embodiment of the present invention.

[0043] FIG. 34 is an enlarged perspective view of cutting teeth of the saw blade of FIG.33.

[0044] FIG. 35 is a perspective view of a saw blade according to another embodiment of the present invention.

[0045] FIG. 36 is an enlarged perspective view of cutting teeth of the saw blade of FIG.35.

[0046] FIG. 37 is a perspective view of a saw blade according to another embodiment of the present invention.

[0047] FIG. 38 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 37.

[0048] FIG. 39 is an enlarged side view of the cutting teeth of FIG. 38.

[0049] FIG. 40 is a rear view of the cutting teeth of FIG. 38.Attorney Docket No. 066042- 1973 -WOO 1

[0050] FIG. 41 is a perspective view of a saw blade according to another embodiment of the present invention.

[0051] FIG. 42 is a rear view of cutting teeth of the saw blade of FIG. 38.

[0052] FIG. 43 is a perspective view of a saw blade according to another embodiment of the present invention.

[0053] FIG. 44 is an enlarged perspective view of cutting teeth of the saw blade of FIG.40.

[0054] FIG. 45 is a perspective view of a saw blade according to another embodiment of the present invention.

[0055] FIG. 46 is a rear view of cutting teeth of the saw blade of FIG. 45.

[0056] FIG. 47 is a perspective view of a saw blade according to another embodiment of the present invention.

[0057] FIG. 48 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 47.

[0058] FIG. 49 is an enlarged side view of the cutting teeth of FIG. 47.

[0059] FIG. 50 is an enlarged rear view of the saw blade of FIG. 47.

[0060] FIG. 51 is a perspective view of a saw blade according to another embodiment of the present invention.

[0061] FIG. 52 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 51.

[0062] FIG. 53 is a perspective view of a saw blade according to another embodiment of the present invention.

[0063] FIG. 54 is an enlarged perspective view of cutting teeth of the saw blade of FIG.Attorney Docket No. 066042- 1973 -WOO 1

[0064] FIG. 55 is a perspective view of a saw blade according to another embodiment of the present invention.

[0065] FIG. 56 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 55.

[0066] FIG. 57 is a perspective view of a saw blade according to another embodiment of the present invention.

[0067] FIG. 58 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 57.

[0068] FIG. 59 is an enlarged side view of the cutting teeth of the saw blade of FIG. 57.

[0069] FIG. 60 is an enlarged rear view of the cutting teeth of the saw blade of FIG. 57.

[0070] FIG. 61 is a perspective view of a saw blade according to another embodiment of the present invention.

[0071] FIG. 62 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 61.

[0072] FIG. 63 is a perspective view of a saw blade according to another embodiment of the present invention.

[0073] FIG. 64 is an enlarged front perspective view of cutting teeth of the saw blade of FIG. 63.

[0074] FIG. 65 is an enlarged rear perspective view of the cutting teeth of FIG. 63.

[0075] FIG. 66 is an enlarged side view of the cutting teeth of FIG. 63.

[0076] FIG. 67 is an enlarged rear view of the cutting teeth of FIG. 63.

[0077] FIG. 68 is a perspective view of a saw blade according to another embodiment of the present invention.

[0078] FIG. 69 is an enlarged perspective view of cutting teeth of the saw blade of FIG.Attorney Docket No. 066042- 1973 -WOO 1

[0079] FIG. 70 is a perspective view of a saw blade according to another embodiment of the present invention.

[0080] FIG. 71 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 70.

[0081] FIG. 72 is a perspective view of a saw blade according to another embodiment of the present invention.

[0082] FIG. 73 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 72.

[0083] FIG. 74 is a perspective view of a saw blade according to another embodiment of the present invention.

[0084] FIG. 75 is an enlarged front perspective view of cutting teeth of the saw blade of FIG. 74.

[0085] FIG. 76 is an enlarged rear perspective view of the cutting teeth of FIG. 74.

[0086] FIG. 77 is an enlarged side view of the cutting teeth of FIG. 74.

[0087] FIG. 78 is a rear view of the saw blade of FIG. 74.

[0088] FIG. 79 is a perspective view of a saw blade according to another embodiment of the present invention.

[0089] FIG. 80 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 79.

[0090] FIG. 81 is a perspective view of a saw blade according to another embodiment of the present invention.

[0091] FIG. 82 is an enlarged front perspective view of cutting teeth of the saw blade of FIG. 81.

[0092] FIG. 83 is an enlarged rear perspective view of the cutting teeth of FIG. 81.

[0093] FIG. 84 is an enlarged side view of the cutting teeth of FIG. 81.Attorney Docket No. 066042- 1973 -WOO 1

[0094] FIG. 85 is an enlarged rear view of the saw blade of FIG. 81.

[0095] FIG. 86 is a perspective view of a saw blade according to another embodiment of the present invention.

[0096] FIG. 87 is an enlarged perspective view of cutting teeth of the saw blade of FIG. 86.

[0097] Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.DETAILED DESCRIPTION

[0098] FIGS. 1-3 illustrate a saw blade 10. The illustrated saw blade 10 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 10 includes a body 18, an attachment portion 22, a cutting portion 26 formed on the body 18 and having a plurality of cutting teeth 30, and a plunge point 34. The attachment portion 22 is configured to couple the blade 10 to the reciprocating saw 14. The plunge point 34 may be used to initiate a plunge cut during operation. In the illustrated embodiment, the body 18, the attachment portion 22, the cutting portion 26, and the plunge point 34 are all integrally formed as a single piece such that the saw blade 10 is a single unitary structure. In other embodiments, the saw blade 10 may be formed from several pieces that are welded or otherwise secured together. During operation, the saw blade 10 is reciprocated in a cutting direction 38 and a return direction 42 (FIG. 2) to cut through a work piece. In some embodiments, the blade 10 and the saw 14 may be used to cut through work pieces composed of wood having nails extending through or embedded therein.

[0099] The body 18 of the saw blade 10 include a first end portion 44 and a second end portion 46 opposite the first end portion 44. The attachment portion 22 is coupled to (e.g., formed at) the first end portion 44 of the body 18. The plunge point 34 is coupled to (e.g., formed at) the second end portion 46 of the body 18. A back portion 50 extends between theAttorney Docket No. 066042- 1973 -WOO 1 attachment portion 22 and the plunge point 34 on a side of the body 18 opposite the cutting portion 26. The back portion 50 includes four stepped surfaces 54a-d at different distances from the cutting portion 26. In other embodiments, the back portion 50 may have fewer or more stepped surfaces or other configurations. The body 18 of the saw blade 10 also defines a longitudinal axis 58 extending through the first end portion 44 and the second end portion 46.

[0100] The attachment portion 22 extends from the first end portion 44 of the body 18 and includes a tang 62 and an aperture 66. The tang 62 and the aperture 66 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely and releasably couple the saw blade 10 to the saw 14. The illustrated attachment portion 22 is angled relative to the longitudinal axis 58 by a tang angle Al. In the illustrated embodiment, the tang angle Al is approximately 6.5 degrees. In other embodiments, the tang angle Al may be larger or smaller.

[0101] With reference to FIGS. 2, 6, and 7, the plurality of cutting teeth 30 extends along the body 18 in a direction parallel to the longitudinal axis 58 and defines a tooth form on the body 18 of the saw blade 10. In the illustrated embodiment, the cutting teeth 30 are unset (i.e., not bent). In other embodiments, the cutting teeth 30 may be set (i.e., bent) in a right direction of the body 18 of the saw blade 10 and / or a left direction of the body 18 of the saw blade 10 such that the cutting teeth 30 alternate between a cutting tooth 30 set in the right direction and a cutting tooth 30 set in the left direction. Each cutting tooth 30 includes a tip 70, a rake face 74, a gullet 78, a relief surface 82, and a protrusion 86. The rake face 74 of each cutting tooth 30 extends from the tip 70 generally toward the longitudinal axis 58. The relief surface 82 of each cutting tooth 30 extends from the tip 70 opposite the rake face 74. The relief surface 82 extends toward the second end portion 46 of the body 18 and is slightly angled, but near parallel to the longitudinal axis 58. The protrusion 86 extends from the relief surface 82 such that the protrusion 86 is spaced from the tip 70. In the illustrated embodiment, the protrusion 86 extends from an end of the relief surface 82 that is opposite the tip 70. In addition, each cutting tooth 30 includes a pocket 98 defined along the tip 70. In the illustrated embodiment, the pocket 98 of each cutting tooth 30 has a curvilinear shape. In other embodiments, the pocket 98 may have other shapes. The pocket 98 is positioned between the rake face 74 and the relief surface 82. As such, each rake face 74 extends between the pocket 98 and the gullet 78 such that the rake face 74 is positioned to at leastAttorney Docket No. 066042- 1973 -WOO 1 partially define the gullet 78. The relief surface 82 of each cutting tooth 30 extends between the pocket 98 and the protrusion 86.

[0102] Each cutting tooth 30 further includes a cutting insert 102 that forms at least a portion of the tip 70. The cuting inserts 102 can be coupled to respective pockets 98 byvarious welding methods and formed of various materials. In the illustrated embodiment, the cuting insert 102 is formed of carbide, while the remaining portion of the cuting tooth, as well as the body 18 of the saw blade 10, is formed of steel (e.g., high speed steel). Each cuting insert 102 is coupled to a respective pocket 98 by resistance welding. The tips 70 of the cutting teeth 30, specifically the cutting inserts 102, define a plane 106 (FIG. 2) that is generally parallel to the longitudinal axis 58. In other embodiments, the cuting teeth 30 may have different heights such that all of the tips 70 do not define the plane 106.

[0103] In an initial state, the cutting insert 102 is formed as a cylindrical piece. In other embodiments, the cuting insert 102 may take the form of other shapes. After the cuting insert 102 is secured to the cutting tooth 30, the cuting insert 102 may then be ground to a desired shape to be in a final state (e.g., the cuting insert 102 of FIGS. 6-10).

[0104] With reference to FIGS. 6-8, the final state of a respective cuting insert 102 is illustrated. In the final state, the cuting insert 102 includes a top portion 110 and a front portion 114. The top portion 110 may also be referred to as a top edge. The front portion 114 may also be referred to as a front edge. The top portion 110 of each cuting insert 102 serves as a relief face for the cuting insert 102. Also, the top portion 110 of each cuting insert 102 is positioned along the pocket 98 such that the relief surface 82 is overlapped by at least a portion of the top portion 110. In the illustrated embodiment, the top portion 110 of each cuting insert 102 is generally flush or coplanar with the corresponding relief surface 82. In other embodiments, the top portion 110 of each cuting insert 102 may be offset from the corresponding relief surface 82. The front portion 114 of each cuting insert 102 serves as a rake face for the cuting insert 102. In the illustrated embodiment, the front portion 1 14 of each cuting insert 102 is offset and oriented at a different angle from the corresponding rake face 74. In other embodiments, the front portion 114 of each cuting insert 102 may be generally flush or coplanar with the corresponding rake face 74. Each cuting insert 102 includes side surfaces 118a, 118b (FIG. 8) extending between the top portion 1 10 and the front portion 114.Attorney Docket No. 066042- 1973 -WOO 1

[0105] Each cutting insert 102 is ground until the top portion 110 is obliquely oriented at an insert angle A2 (FIG. 6) relative to the longitudinal axis 58 and the front portion 114 is obliquely oriented at an insert angle A3 (FIG. 6) relative to the longitudinal axis 58. The insert angle A2 ranges between 6 and 10 degrees, and is preferably 8 degrees. The insert angle A3 ranges between 86 and 90 degrees, and is preferably 88 degrees. In other embodiments, the insert angle A2 and / or the insert angle A3 may have other values.

[0106] With reference to FIGS. 9A, 9B, and 10, each cutting insert 102 is ground such that the side surfaces 118a, 118b overlap a portion of the cutting tooth 30. In other words, the side surfaces 118a, 118b of each cutting insert 102 is not flush with an outer surface 122a, 122b of a corresponding cutting tooth 30. In the illustrated embodiment, the side surfaces 1 18a, 118b extends a first distance DI (FIG. 10) of 0.001 inches from the outer surfaces 122a, 122b. In other embodiments, the side surfaces 118a, 118b of each cutting insert 102 may be flush with the outer surfaces 122a, 122b of a corresponding cutting tooth 30. In addition, each side surface 118a. 118b of the cutting inserts 102 is formed with a chamfer 126a, 126b extending between the front portion 114 and the relief surface 82. The illustrated chamfers 126a, 126b are also at least partially formed on the corresponding cutting tooth 30. The chamfers 126a, 126b are obliquely oriented at an insert angle A4 (FIG. 9 A) relative to the outer surface 122a. 122b of a corresponding cutting tooth 30. In the illustrated embodiment, the insert angle A4 ranges between 43 and 47 degrees, and is preferably 45 degrees. In some embodiments, the insert angle A4 ranges between 38 and 42 degrees, and is preferably 40 degrees. In other embodiments, the insert angle A4 ranges between 33 and 37 degrees, and is preferably 35 degrees.

[0107] With reference back to FIGS. 6-8, the gullet 78 of each cutting tooth 30 is defined by a corresponding rake face 74 and a gullet surface 128. Each gullet surface 128 extends from the corresponding rake face 74 to the protrusion 86 of an adjacent tooth 30. The gullet surfaces 128 includes a base 130 at a bottommost point of the gullet 78. The gullet surfaces 128 are defined by a gullet radius Rl. In some embodiments, the gullet radius R1 may be between 0.02 inches and 0.05 inches, and is preferably 0.0325 inches. The plurality of cutting teeth 30 is arranged along the body 18 of the saw blade 10 such that a second distance D2 (FIG. 3) is defined between adjacent gullets 78. In the illustrated embodiment, the second distance D2 is preferably 0.187 inches.Attorney Docket No. 066042- 1973 -WOO 1

[0108] The protrusion 86 of each cutting tooth 30 is defined by a first protrusion radius R2. a first protrusion face 134. an apex 138, and a second protrusion face 140. The first protrusion radius R2 transitions from the relief surface 82 and the first protrusion face 134 extends from the first protrusion radius R2. The apex 138 extends from the first protrusion face 134 and has a second protrusion radius R3. The second protrusion face 140 extends from the apex 138 to a corresponding gullet surface 128 (FIG. 8). As such, the apex 138 of each protrusion 86 is illustrated with a curvilinear shape such that the protrusions 86 are generally rounded. In other embodiments, the protrusions 86 may have other shapes or forms. The second protrusion face 140 is obliquely oriented relative to the plane 106. In some embodiments, the first protrusion radius R2 may be between 0.01 inches and 0.03 inches, and the second protrusion radius may be between 0.01 inches and 0.03 inches. In illustrated embodiment, the first protrusion radius R2 is approximately 0.020 inches, and the second protrusion radius R3 is approximately 0.020 inches. Such an arrangement helps inhibit nails from entering the gullets 78 of the cutting teeth 30 during cutting operations, as further discussed below.

[0109] With reference to FIGS. 8 and 10, side surfaces 143a, 143b of each apex 138 are respectively formed with chamfers 144a, 144b. In the illustrated embodiment, the chamfers 144a. 144b are continuous with the chamfers 126a, 126b. The chamfers 144a, 144b are respectively oriented at a protrusion angle A5 relative to the outer surfaces 122a, 122b. In the illustrated embodiment, the protrusion angle A5 ranges between 43 and 47 degrees, and is preferably 45 degrees. In some embodiments, the protrusion angle A5 ranges between 38 and 42 degrees, and is preferably 40 degrees. In other embodiments, the protrusion angle A5 ranges between 33 and 37 degrees, and is preferably 35 degrees. The chamfers 126a, 126b of a respective cutting insert 102 and the chamfers 144a, 144b of respective protrusion 86, together form a single continuous chamfer that extends along the cutting insert 102, at least a portion of the relief surface 82, and the apex 138 of the protrusion 86 on each side of a corresponding cutting tooth 30. The single continuous chamfer of each cutting tooth 30 extends along the cutting insert 102, at least a portion of the relief surface 82, and the apex 138 of the protrusion 86. More specifically, the continuous chamfers of each cutting tooth 30 begins at the front portion 114 of the cutting insert 102 and then tapers along each side surface 118a, 118b of the cutting insert 102 to terminate at an interconnecting portion defined between the relief surface 82 and the protrusion 86. Then the continuous chamfer of each cutting tooth 30 continues along each side surfaces 143a, 143b of the apex 138 such that aAttorney Docket No. 066042- 1973 -WOO 1 portion of the protrusion 86 is also ground. In additional embodiments, the chamfers 144a, 144b may be omitted such that the side surfaces 143a. 143b of each apex 138 are flat.

[0110] The protrusions 86 of the cutting teeth 30 inhibit nails (not shown), or other hard objects, imbedded in a work piece (not shown) from entering the gullets 78 and contacting the rake faces 74 of the teeth 30 during cutting operations. As the saw blade 10 moves in the cutting direction 38, the tips 70 of the cutting teeth 30 engage and cut through the work piece. The protrusions 86 are hidden behind the tips 70 of adjacent teeth 30 such that the protrusions 86 do not cut the work piece during the cutting operation.

[0111] When the saw blade 10 encounters the nail, the rake faces 74 of the cutting teeth 30 typically would contact the nail. Such contact may chip, break, or otherwise damage the cutting teeth 30, significantly reducing the usable life of the saw blade 10. However, the protrusions 86 inhibit the nail from impacting the rake faces 74. Instead, as the saw blade 10 moves in the cutting direction 38, the nail contacts one of the protrusions 86 before contacting the adjacent rake face 74. The protrusion 86 displaces (e g., lifts) the saw blade 10, which repositions the nail with respect to the gullet 78 in an improved cutting position. In the improved cutting position, the protrusion 86 inhibits the nail from entering the gullet 78 and the tip 70 is allowed to cut into the nail. When the saw blade 10 is reciprocated in the return direction 42, the nail can ride along the corresponding cutting insert 102 and over the tip 70.

[0112] In the illustrated embodiment, the protrusions 86 of the cutting teeth 30 are designed to inhibit a standard framing nail from entering the gullets 78. The protrusions 86 may be optimized to inhibit various size nails from entering the gullets 78 and increase durability of the cutting teeth 30 by offsetting a center of the framing nail. That is, the protrusions 86 are sized and positioned to prevent approximately 80% of the nail from entering the area above the plane 106. Such a configuration results in an increase in durability compared to a similar saw blade without protrusions on the cutting teeth. As used herein, the term ‘durability7’ refers to the average number of cuts a saw blade makes before fracturing a cutting tooth.

[0113] FIGS. 3-5 illustrate the plunge point 34 of the saw blade 10. The plunge point 34 is formed on the second end portion 46 of the body 18 opposite the attachment portion 22. The illustrated plunge point 34 includes a leading tooth 146 and a second tooth 150. TheAttorney Docket No. 066042- 1973 -WOO 1 leading tooth 146 includes a tip 154, a rake face 158 extending from the tip 154 generally toward the longitudinal axis 58 and at least partially defining a leading gullet 162, and a relief surface 166 extending from the tip 154 to an end 170 of the body 18. A pocket 174 (FIG. 5) of the leading tooth 146 is defined along the tip 154 and has a curvilinear shape. The pocket 174 of the leading tooth 146 is positioned between the rake face 158 and the relief surface 166. The leading tooth 146 also includes a cutting insert 178 secured to the pocket 174 via resistance welding. The cutting insert 178 is similar to the cutting inserts 102 of each cutting tooth 30 of FIGS. 6-10.

[0114] In the illustrated embodiment, the end 170 of the body 18 is generally rounded. In other embodiments, the end 170 of the body 18 may be, for example, a sharp point or a flat edge. A top edge 180 extends from the end 170 to the back portion 50 of the body 18. The top edge 180 is obliquely oriented relative to the back portion 50 (e.g., relative to a fourth stepped surface 54d). The top edge 180 may be oriented at approximately 5 to 50 degrees relative to the fourth stepped surface 54d.

[0115] The leading gullet 162 is defined by the rake face 158 of the leading tooth 146 and extends to the nearest, or first, cutting tooth 30. The leading gullet 162 is significantly larger than the gullets 78 of the cutting teeth 30 and has a leading gullet width W1 (FIG. 3). In some embodiments, the leading gullet 162 is at least twice as large as each gullet 78. In the illustrated embodiment, the leading gullet 162 is approximately four times larger than each gullet 78. As such, the leading tooth 146 is spaced further apart from the nearest cutting tooth 30 than the cutting teeth 30 are spaced apart from each other. In the illustrated embodiment, a ratio between a first tip distance D3 from the tip 154 of the leading tooth 146 to the tip 70 of the nearest cutting tooth 30, measured generally parallel to the longitudinal axis 58, and a second tip distance D4 between the tips 70 of adjacent cutting teeth 30 (i.e., the tooth pitch) is approximately 2.0. The enlarged leading gullet 162 improves plunge cut performance by allowing the leading tooth 146 to penetrate further into a work piece before the plurality of cutting teeth 30 engage the work piece, thereby improving cut quality and finish. The enlarged leading gullet 162 also improves cut speed by allowing for greater chip removal.

[0116] With continued reference to FIGS. 3-5, the illustrated second tooth 150 has a curvilinear shape and is defined by a plunge point radius R5 (FIG. 4). In some embodiments, the plunge point radius R5 may be between 0.01 inches and 0.02 inches, and preferably isAttorney Docket No. 066042- 1973 -WOO 10.012 inches. The second tooth 150 includes a tip 182, a rake face 186 extending from the tip 182 generally toward the longitudinal axis 58. and a relief surface 190 extending from the tip 182 generally toward the leading tooth 146. The second tooth 150 is positioned within the leading gullet 162 adjacent the leading tooth 146 such that the second tooth 150 is closer to the leading tooth 146 than to the nearest cutting tooth 30. In the illustrated embodiment, the tip 182 of the second tooth 150 is spaced a third tip distance D5, measured generally perpendicular to the longitudinal axis 58, from the tip 182 of the leading tooth 146. The third tip distance D5 ranges between 0.050 inches and 0.060 inches, and is preferably 0.0545 inches.

[0117] The illustrated second tooth 150 is generally smaller than the leading tooth 146 and each of the cutting teeth 30. The second tooth 150 extends from the leading gullet 162 and is spaced apart from the plane 106 defined by the tips 70, 182 of the cutting teeth 30 and the leading tooth 146. In other words, the plane 106 does not intersect or extend through any portion of the second tooth 150. In the illustrated embodiment, the second tooth 150 extends less than halfway from the body 18 to the plane 106. As such, the tip 182 of the second tooth 150 is spaced a fourth tip distance D6, measured generally perpendicular to the longitudinal axis 58, from the leading gullet 162. The fourth tip distance D6 ranges between 0.025 inches and 0.040 inches, and is preferably 0.032 inches. In other embodiments, the second tooth 150 may extend to a position nearer the plane 106 such as, for example, three-quarters the distance to the plane 106.

[0118] The second tooth 150 improves plunge cut performance by breaking up chip material, thereby reducing the load on the leading tooth 146 and facilitating chip removal. Such an arrangement also increases cutting speed and saw blade life. In the illustrated embodiment, the plunge point 34 includes a single second tooth 150 positioned within the leading gullet 162. In other embodiments, the plunge point 34 may include multiple second teeth positioned within the leading gullet 162. In such embodiments, one or more of the second teeth may be set. Additionally, or alternatively, the second teeth may have different geometries and / or sizes. In still other embodiments, the second tooth 150 may be omitted from the plunge point 34.

[0119] With reference to FIG. 9B, the saw blade 10 includes a coating 192. In the illustrated embodiment, the coating 192 is a ceramic coating overlaying only the cutting insert 102. In some embodiments, the coating 192 may be disposed on the entirety of eachAttorney Docket No. 066042- 1973 -WOO 1 cuting tooth 30. In other embodiments, the coating 192 may be disposed on the entire saw blade 10. including the cuting teeth 30 and the body 18. In additional embodiments, the saw blade 10 may be provided without a coating. The coating 192 overlays the cuting insert 102, such that the cuting insert 102 acts as the weak point due to the coating 192 being significantly stronger than the cuting insert 102. In other words, failure or degradation of the cuting insert 102 may cause the coating 192 to also fail. In some embodiments, the coating 192 may be applied via physical vapor deposition (PVD), which is a variety of vacuum deposition methods. In other embodiments, the coating 192 may be applied via additional methods such as hot-dip galvanizing, thermal spraying, electroplating, sherardizing, and the like.

[0120] The coating 192 permits the saw blade 10 to dissipate heat beter than a conventional saw blade without a coating. As such, the saw blade 10 is able to perform an efficient cuting operation on materials such as cast iron, stainless steel, and other difficult to cut materials. The coating 192 in combination with the tooth form of the cuting teeth 30, provides the saw blade 10 with a cutting life three times longer than a conventional reciprocating saw blade with carbide cuting teeth.

[0121] In the illustrated embodiment, the coating 192 has a thickness T1 measured between a respective side surface 118a, 118b of the cuting insert 102 and an outer surface 194 of the coating 192. In some embodiments, the thickness T1 of the coating 192 is at least 2.0 micrometers. In other embodiments, the thickness T1 of the coating 192 is at least 3.0 micrometers. In still other embodiments, the thickness T1 of the coating 192 is between 2.0 and 5.0 micrometers. In other embodiments, the thickness T1 of the coating 192 is between 3.0 and 4.0 micrometers. In additional embodiments, the thickness T1 of the coating 192 is preferably about 3.5 micrometers.

[0122] In some embodiments, the coating 192 is composed of aluminum titanium nitride (AlTiN). The AlTiN coating increases oxidation resistance at elevated temperatures due to the formation of a protective aluminuim-oxide layer at the surface. In addition, the AlTiN coating increases hardness in deposited films due to micro-structure changes and solid solution hardening. Further, the AlTiN coating age hardens at temperatures typical during operation of the saw blade 10. In other embodiments, the coating 192 is composed of aluminum chromium nitride (AlCrN). The AlCrN coating includes a high hot hardness with high wear resistance in extreme mechanical stresses. The AlCrN coating is particularlyAttorney Docket No. 066042- 1973 -WOO 1 beneficial at high-speed applications, such as those experienced by the saw blade 10. In further embodiments, the coating 192 is composed of aluminum titanium chromium nitride (AlTiCrN). The AlTiCrN coating includes a high hardness, toughness, and oxidation temperature. The AlTiCrN coating is particularly beneficial for machining hardened steels, stainless steels, superalloys, and other difficult to machine materials. Still, in other embodiments, the coating 192 is composed of a titanium-based material. For example, the coating 192 is composed of titanium molybdenum nitride (TiMoN). The TiMoN coating is a ceramic material. Moreover, the coating 192 may include other thickness values, materials, or characteristics than what is described herein.

[0123] FIG. 11 illustrates the manufacturing process of the present embodiment. During step 196, the saw blade 10 is formed to include the body 18 and the plurality of cutting teeth 30. The body 18 and the teeth 30 of the reciprocating saw blade 10 are formed from, for example, coil stock via stamping, laser cutting, grinding, or the like.

[0124] During step 200, the cutting inserts 102 are secured onto the teeth 30. In the illustrated embodiment, each cutting insert 102 is secured onto each of the cutting teeth 30 via resistance welding. In some embodiments, each cutting insert 102 may be secured onto each of the cutting teeth 30 via other welding processes or brazing. In other embodiments, the cutting inserts 102 may be secured onto the cutting teeth 30 via an adhesive or other suitable securing means. The cutting inserts 102 may be formed into their desired shapes prior to or after being secured to the cutting teeth 30.

[0125] During step 204, each cutting tooth 30 is ground to a desired shape. In no particular order, each cutting tooth 30 is ground such that the top portion 110 of each cutting insert 102 is oriented at the insert angle A2 and overlaps a corresponding relief surface 82, the side surfaces 118a, 118b of each cutting insert 102 are oriented to overlap a portion of the cutting tooth 30, the chamfers 126a. 126b of each cutting insert 102 are formed, and the chamfers 144a, 144b of each protrusion 86.

[0126] During step 208, a final geometry' of the saw blade 10 is formed to include the final shape of the body 18 and the tang 62. The final geometry of the saw blade 10 is formed by a stamping process.

[0127] During step 212, the coating 192 is applied to the saw blade 10. In some embodiments, the coating 192 may be applied to solely the cutting inserts 102. In otherAttorney Docket No. 066042- 1973 -WOO 1 embodiments, the coating 192 may be applied to each cutting tooth 30 including the cutting insert 102, but not including the body 18 of the saw blade 10. In further embodiments, the coating 192 may be applied to the entire cutting portion 26, but not including the body 18 of the saw blade 10. In additional embodiments, the coating 192 may be applied to the entirety of the saw blade 10, including the body 18. In still other embodiments, the coating 192 maybe omitted.

[0128] FIGS. 13-17 illustrate another saw blade 310. The saw blade 310 is similar to the saw blade 10 of FIGS. 1-10; therefore, like structure will be identified by like reference number plus “300" and only the difference will be discussed hereafter.

[0129] The saw blade 310 includes a body 318, an attachment portion 322, a cutting portion 326 formed on the body 318 and having a plurality7of cutting teeth 330, and a plunge point 334. In the illustrated embodiment, the cutting teeth 330 are unset (i.e., not bent). In other embodiments, the cutting teeth 330 may be set (i.e.. bent) in a right direction of the body 318 of the saw blade 310 and / or a left direction of the body 318 of the saw blade 310 such that the cutting teeth 330 alternate between a cutting tooth 330 set in the right direction and a cutting tooth 330 set in the left direction. Each cutting tooth 330 includes a tip 370, a rake face 374, a gullet 378, a relief surface 382, and a protrusion 386. The rake face 374 of each cutting tooth 330 extends from the tip 370 generally toward the longitudinal axis 358. The relief surface 382 of each cutting tooth 330 extends from the tip 370 opposite the rake face 374. The relief surface 382 extends toward the second end portion 346 of the body 318 and is obliquely oriented relative to the longitudinal axis 358. The protrusion 386 extends from the relief surface 382 such that the protrusion 386 is spaced from the tip 370. In the illustrated embodiment, the protrusion 386 extends from an end of the relief surface 382 that is opposite the tip 370. In addition, each cutting tooth 330 includes a pocket 398 defined along the tip 370. In the illustrated embodiment, the pocket 398 of each cutting tooth 330 has a curvilinear shape. In other embodiments, the pocket 398 may have other shapes. The pocket 398 is positioned between the rake face 374 and the relief surface 382. As such, each rake face 374 extends between the pocket 398 and the gullet 378 such that the rake face 374 is positioned to at least partially define the gullet 378. The relief surface 382 of each cutting tooth 330 extends between the pocket 398 and the protrusion 386.

[0130] Each cutting tooth 330 further includes a cutting insert 402 that forms at least a portion of the tip 370. The cutting inserts 402 can be coupled to respective pockets 398 byAttorney Docket No. 066042- 1973 -WOO 1 various welding methods and formed of various materials. In the illustrated embodiment, the cutting insert 402 is formed of carbide, while the remaining portion of the cutting tooth, as well as the body 318 of the saw blade 310, is formed of steel (e.g., high speed steel). Each cutting insert 402 is coupled to a respective pocket 398 by resistance welding.

[0131] The cutting insert 402 includes a top portion 410 and a front portion 414. The top portion 410 may also be referred to as a top edge. The front portion 414 may also be referred to as a front edge. The top portion 410 of each cutting insert 402 serves as a relief face for the cutting insert 402. In the illustrated embodiment, the top portion 410 of each cutting insert 402 is generally flush or coplanar with the corresponding relief surface 382. In other embodiments, the top portion 410 of each cutting insert 402 may be offset from the corresponding relief surface 382. The front portion 414 of each cutting insert 402 serves as a rake face for the cutting insert 402. In the illustrated embodiment, the front portion 414 of each cutting insert 402 is offset and oriented at a different angle from the corresponding rake face 374. In other embodiments, the front portion 414 of each cutting insert 402 may be generally flush or coplanar with the corresponding rake face 374. Each cutting insert 402 includes side surfaces 418a, 418b (FIG. 16) extending between the top portion 410 and the front portion 414.

[0132] Each cuting insert 402 is ground until the top portion 410 is obliquely oriented at an insert angle A6 (FIG. 15) relative to the longitudinal axis 358 and the front portion 414 is obliquely oriented at an insert angle A7 (FIG. 15) relative to the longitudinal axis 358. The insert angle A6 ranges between 6 and 10 degrees, and is preferably 8 degrees. The insert angle A7 ranges between 86 and 90 degrees, and is preferably 88 degrees. In other embodiments, the insert angle A6 and / or the insert angle A7 may have other values.

[0133] With reference to FIGS. 16 and 17, each cuting insert 402 is ground such that the side surfaces 418a. 418b overlap a portion of the cuting tooth 330. In other words, the side surfaces 418a, 418b of each cuting insert 402 are not flush with outer surfaces 422a, 422b of a corresponding cutting tooth 330. In the illustrated embodiment, each side surface 418a, 418b extends an insert distance D7 (FIG. 17) of 0.001 inches from the corresponding outer surfaces 422a, 422b. In other embodiments, the side surfaces 418a, 418b of each cuting insert 402 may be flush with the outer surfaces 422a, 422b of a corresponding cutting tooth 330. In addition, the illustrated cuting teeth 330 are non-chamfered cuting teeth 330. As such, the side surfaces 418a, 418b of each cuting tooth 330 are formed as flat surfacesAttorney Docket No. 066042- 1973 -WOO 1 extending between a corresponding top portion 410 and a corresponding front portion 414. Also, an apex 438 of each protrusion 386 is formed with flat side surfaces 443a, 443b.

[0134] Unlike the saw blade 10 shown in FIGS. 1 and 2, the illustrated saw blade 310 may not include a coating, such as the coating 192. In other embodiments, the saw blade 310 may include a coating, similar to the coating 192. For example, in one embodiment, as described herein above, a saw blade 10 may include chamfers 126a-b, 144a-b formed on each cutting tooth 30 and a coating 192 that may be disposed on various portions of the saw blade 10. In another embodiment, as described herein above, a saw blade 310 may include nonchamfered cutting teeth 330 and may not include a coating. In other embodiments, a saw blade may include chamfers (e.g., chamfers 126a-b. 144a-b of the saw blade 10) and may not include a coating. In further embodiments, a saw blade may include non-chamfered cutting teeth and may include a coating (e.g., coating 192 of the saw blade 10).

[0135] FIGS. 18-21 illustrate another saw blade 510. The saw blade 510 is similar to the saw blade 10 of FIGS. 1-10; therefore, like structure will be identified by like reference number plus “500’’ and only the difference will be discussed hereafter.

[0136] With reference to FIGS. 18 and 19, the saw blade 510 includes a body 518, an attachment portion 522, and a cutting portion 526 formed on the body 518 and having a plurality of cutting teeth 530. In the illustrated embodiment, the cutting teeth 530 are unset (i.e., not bent). In other embodiments, the cutting teeth 530 may be set (i.e., bent) in a right direction of the body 518 of the saw blade 510 and / or a left direction of the body 518 of the saw blade 510 such that the cutting teeth 530 alternate between a cutting tooth 530 set in the right direction and a cutting tooth 530 set in the left direction.

[0137] Each cutting tooth 530 includes a tip 570, a rake face 574. a gullet 578, and a relief surface 582. The rake face 574 of each cutting tooth 530 extends from the tip 570 generally toward the longitudinal axis 558. The relief surface 582 of each cutting tooth 530 extends from the tip 570 opposite the rake face 574. The relief surface 582 extends tow ard a second end portion 546 of the body 518 and is obliquely oriented relative to the longitudinal axis 558. The relief surface 582 is obliquely oriented relative to the longitudinal axis 558. In addition, each cutting tooth 530 includes a pocket 598 defined along the tip 570. In the illustrated embodiment, the pocket 598 of each cutting tooth 530 has a curvilinear shape. In other embodiments, the pocket 598 may have other shapes. The pocket 598 is positionedAttorney Docket No. 066042- 1973 -WOO 1 between the rake face 574 and the relief surface 582. As such, each rake face 574 extends between the pocket 598 and the gullet 578 such that the rake face 574 is positioned to at least partially define the gullet 578.

[0138] Each cutting tooth 530 further includes a cutting insert 602 that forms at least a portion of the tip 570. The cutting inserts 602 can be coupled to respective pockets 598 by various welding methods and formed of various materials. In the illustrated embodiment, the cutting insert 602 is formed of carbide, while the remaining portion of the cutting tooth, as well as the body 518 of the saw blade 510, is formed of steel (e.g., high speed steel). Each cutting insert 602 is coupled to a respective pocket 598 by resistance welding.

[0139] The cutting insert 602 includes atop portion 610 and a front portion 614. The top portion 610 may also be referred to as a top edge. The front portion 614 may also be referred to as a front edge. The top portion 610 of each cutting insert 602 serves as a relief face for the cutting insert 602. In the illustrated embodiment, the top portion 610 of each cutting insert 602 is a planar portion positioned along the pocket 598 such that the relief surface 582 is overlapped by at least a portion of the top portion 610. In other embodiments, the top portion 610 of each cutting insert 602 may be offset from the corresponding relief surface 582. In further embodiments, the top portion 610 of each cutting insert 602 may be generally flush or coplanar with the corresponding relief surface 582. The front portion 614 of each cutting insert 602 serves as a rake face for the cutting insert 602. In the illustrated embodiment, the front portion 614 of each cutting insert 602 is offset and oriented at a different angle from the corresponding rake face 574. In other embodiments, the front portion 614 of each cutting insert 602 may be generally flush or coplanar with the corresponding rake face 574. Each cutting insert 602 includes a first side surface 618a and a second side surface 618b (FIG. 19) extending between the top portion 610 and the front portion 614.

[0140] With reference to FIG. 20, each cutting insert 602 is ground until the top portion 610 is obliquely oriented at an insert angle A8 (FIG. 20) relative to the longitudinal axis 558 and the front portion 614 is obliquely oriented at an insert angle A9 (FIG. 20) relative to the longitudinal axis 558. The insert angle A8 ranges between 8 and 12 degrees, and is preferably 10 degrees. The insert angle A9 ranges between 85 and 89 degrees, and is preferably 87 degrees. In other embodiments, the insert angle A8 and / or the insert angle A9 may have other values.Attorney Docket No. 066042- 1973 -WOO 1

[0141] With reference to FIGS. 19 and 21, each cutting insert 602 is ground such that the side surfaces 618a. 618b overlap outer surfaces 622a, 622b of a corresponding cutting tooth 530. As such, the side surfaces 618a, 618b of each cutting insert 602 are not flush with the outer surfaces 622a, 622b. In other embodiments, each cutting insert 602 may be ground such that the side surfaces 618a, 618b are flush with the outer surface 622a, 622b of a corresponding cutting tooth 530. In addition, each side surface 618a, 618b is formed with a round edge 626a, 626b extending between the front portion 614 and the relief surface 582, while the top portion 610 extends between the round edges 626a, 626b. Each round edge 626a, 626b defines an insert radius R4, R5. In the illustrated embodiment, each insert radius R4, R5 ranges between 0.020 and 0.030 inches, and is preferably 0.025 inches. In other embodiments, each insert radius R4. R5 may have other values.

[0142] Also, each cutting insert 602 is ground such that the top portion 610 defines an insert width W2 at an apex of the cutting insert 602 and each round edge 626a, 626b defines a cutting-edge width W3. The insert width W2 extends between the round edges 626a, 626b. The insert width W2 of each round edge 626a, 626b ranges between 0.010 and 0.015 inches, and preferably 0.012 inches. For clarity, FIG. 21 only illustrates the cutting-edge width W3 with respect to the round edge 626a formed on the first side surface 618a of a cutting insert 602. The cutting-edge width W3 of each round edge 626a, 626b extends between the top portion 610 and a corresponding side surface 618a, 618b. The cutting-edge W3 ranges between 0.018 and 0.022 inches, and preferably 0.020 inches.

[0143] FIGS. 22-25 illustrate another saw blade 710. The saw blade 710 is similar to the saw blade 10 of FIGS. 1-10; therefore, like structure will be identified by like reference number plus '‘700” and only the difference will be discussed hereafter.

[0144] With reference to FIGS. 22 and 23, the saw blade 710 includes a body 718, an attachment portion 722, and a cutting portion 726 formed on the body 718 and having a plurality of cutting teeth 730. In the illustrated embodiment, the cutting teeth 730 are unset (i.e., not bent). In other embodiments, the cutting teeth 730 may be set (i.e., bent) in a right direction of the body 718 of the saw blade 710 and / or a left direction of the body 718 of the saw blade 710 such that the cutting teeth 730 alternate between a cutting tooth 730 set in the right direction and a cutting tooth 730 set in the left direction.Attorney Docket No. 066042- 1973 -WOO 1

[0145] Each cutting tooth 730 includes a tip 770, a rake face 774, a gullet 778, and a relief surface 782. The rake face 774 of each cutting tooth 730 extends from the tip 770 generally toward the longitudinal axis 758. The relief surface 782 of each cutting tooth 730 extends from the tip 770 opposite the rake face 774. The relief surface 782 extends toward a second end portion 746 of the body 718 and is obliquely oriented relative to the longitudinal axis 758. In addition, each cutting tooth 730 includes a pocket 798 defined along the tip 770. In the illustrated embodiment, the pocket 798 of each cutting tooth 730 has a curvilinear shape. In other embodiments, the pocket 798 may have other shapes. The pocket 798 is positioned between the rake face 774 and the relief surface 782. As such, each rake face 774 extends between the pocket 798 and the gullet 778 such that the rake face 774 is positioned to at least partially define the gullet 778.

[0146] Each cutting tooth 730 further includes a cutting insert 802 that forms at least a portion of the tip 770. The cutting inserts 802 can be coupled to respective pockets 798 by various welding methods and formed of various materials. In the illustrated embodiment, the cutting insert 802 is formed of carbide, while the remaining portion of the cutting tooth, as well as the body 718 of the saw blade 710, is formed of steel (e.g., high speed steel). Each cutting insert 802 is coupled to a respective pocket 798 by resistance welding.

[0147] The cutting insert 802 includes a top portion 810 and a front portion 814. The top portion 810 may also be referred to as a top edge. The front portion 814 may also be referred to as a front edge. The top portion 810 of each cutting insert 802 sen es as a relief face for the cutting insert 802. In the illustrated embodiment, the top portion 810 of each cutting insert 802 is a planar portion generally flush or coplanar with the corresponding relief surface 782. In other embodiments, the top portion 810 of each cutting insert 802 may be positioned along the pocket 798 such that the relief surface 782 is overlapped by at least a portion of the top portion 810. In further embodiments, the top portion 810 of each cutting insert 802 may be offset from the corresponding relief surface 782. The front portion 814 of each cutting insert 802 serves as a rake face for the cutting insert 802. In the illustrated embodiment, the front portion 814 of each cutting insert 802 is offset and oriented at a different angle from the corresponding rake face 774. In other embodiments, the front portion 814 of each cutting insert 802 may be generally flush or coplanar with the corresponding rake face 774. Each cutting insert 802 includes a first side surface 818a and a second side surface 818b (FIG. 25) extending between the top portion 810 and the front portion 814.Attorney Docket No. 066042- 1973 -WOO 1

[0148] With reference to FIG. 24, each cutting insert 802 is ground until the top portion 810 is obliquely oriented at an insert angle A10 relative to the longitudinal axis 758 and the front portion 814 is obliquely oriented at an insert angle Al 1 relative to the longitudinal axis 758. The insert angle A10 ranges between 8 and 12 degrees, and is preferably 10 degrees. The insert angle Al 1 ranges between 85 and 89 degrees, and is preferably 87 degrees. In other embodiments, the insert angle A10 and / or the insert angle Al 1 may have other values.

[0149] With reference to FIGS. 23 and 25, each cutting insert 802 is ground such that the side surfaces 818a, 818b overlap outer surfaces 822a, 822b of a corresponding cutting tooth 730. As such, the side surfaces 818a, 818b of each cutting insert 802 are not flush with the outer surfaces 822a, 822b. In other embodiments, each cutting insert 802 may be ground such that the side surfaces 818a, 818b are flush with the outer surface 822a, 822b of a corresponding cutting tooth 530. In addition, each side surface 818a, 818b is formed with a round edge 826a, 826b extending between the front portion 814 and the relief surface 782, while the top portion 810 extends between the round edges 826a, 826b. Each round edge 826a, 826b defines an insert radius R6, R7. In the illustrated embodiment, each insert radius R6, R7 ranges between 0.010 and 0.020 inches, and is preferably 0.015 inches. In other embodiments, each insert radius R6, R7 may have other values.

[0150] Also, each cutting insert 802 is ground such that the top portion 810 defines an insert width W4 at an apex of the cutting insert 802 and each round edge 826a, 826b defines a cutting-edge width W5. The insert width W4 extends between the round edges 826a, 826b. The insert width W4 of each round edge 826a, 826b ranges between 0.028 and 0.032 inches, and preferably 0.030 inches. For clarity, FIG. 25 only illustrates the cutting-edge width W5 with respect to the round edge 826a formed on the first side surface 818a. The cutting-edge width W5 of each round edge 826a, 826b extends between the top portion 810 and a corresponding side surface 818a, 818b. The cutting-edge W5 ranges between 0.010 and 0.012 inches, and preferably 0.011 inches.

[0151] FIG. 26 illustrates another saw blade 910. The illustrated saw blade 910 is a pruning saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 910 includes a body 918, an attachment portion 922, and a cutting portion 926 formed on the body 918 and having a plurality of cutting teeth 930. The attachment portion 922 is configured to couple the blade 910 to the reciprocating saw 14. In the illustrated embodiment, the body 918, the attachment portion 922, and the cutting portion 926 are allAttorney Docket No. 066042- 1973 -WOO 1 integrally formed as a single piece such that the saw blade 910 is a single unitary structure. In other embodiments, the saw blade 910 may be formed from several pieces that are welded or otherwise secured together. During operation, the saw blade 910 is reciprocated in a cutting direction 938 and a return direction 942 (FIG. 26) to cut through a work piece. In further embodiments, the saw blade 910 may include a coating, similar to the coating 192 of FIG. 9B.

[0152] The body 918 of the saw blade 910 include a first end portion 944 and a second end portion 946 opposite the first end portion 944. The attachment portion 922 is coupled to (e.g., formed at) the first end portion 944 of the body 918. Also, the body 918 defines a longitudinal axis 958 extending through the first end portion 944 and the second end portion 946. The attachment portion 922 extends from the first end portion 944 of the body 918 and includes a tang 962 and an aperture 966. The tang 962 and the aperture 966 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely and releasably couple the saw blade 910 to the saw 14.

[0153] With reference to FIGS. 27 and 28, the plurality of cutting teeth 930 extends along the body 918 in a direction parallel to the longitudinal axis 958 and defines a tooth form on the body 918 of the saw blade 910. Each cutting tooth 930 includes a tip 970, a rake face 974, a gullet 978, and a relief surface 982. The rake face 974 of each cutting tooth 930 extends from the tip 970 generally toward the longitudinal axis 958. The relief surface 982 of each cutting tooth 930 extends from the tip 970 opposite the rake face 974. The relief surface 982 extends toward the second end portion 946 of the body 918 and is obliquely oriented relative to the longitudinal axis 958. In addition, each cutting tooth 930 includes a pocket 998 defined along the tip 970. In the illustrated embodiment, the pocket 998 of each cutting tooth 930 has a rectangular shape. In other embodiments, the pocket 998 may have other shapes. The pocket 998 is positioned between the rake face 974 and the relief surface 982. As such, each rake face 974 extends between the pocket 998 and the gullet 978 such that the rake face 974 is positioned to at least partially define the gullet 978. The relief surface 982 of each cutting tooth 930 extends between the pocket 998 and the gullet 978. In addition, a ridge 1000 is formed along each cutting tooth 930 and forms a curvilinear bump along an intermediate portion of the relief surface 982.

[0154] Each cutting tooth 930 further includes a cutting insert 1002 that forms at least a portion of the tip 970. The relief surface 982 extends therefrom to form an elongated surfaceAttorney Docket No. 066042- 1973 -WOO 1 rearwardly of the cutting insert 1002. As such, the cutting teeth 930 are each formed with a large tooth body positioned behind a corresponding cutting insert 1002 so that the saw blade 910 can perform pruning tasks. The cutting inserts 1002 can be coupled to respective pockets 998 by various welding methods (e.g., resistance welding) and formed of various materials. Also, each cutting insert 1002 has a parallel welding orientation relative to a corresponding pocket 998. In the illustrated embodiment, the cutting insert 1002 is formed of carbide, while the remaining portion of the cutting tooth 930, as well as the body 918 of the saw blade 910, is formed of steel (e.g., high speed steel).

[0155] In an initial state, the cutting insert 1002 is formed as a cylindrical piece. In other embodiments, the cutting insert 1002 may take the form of other shapes. When secured to a respective pocket 998, each cutting insert 1002 longitudinally extends in a direction perpendicular to the longitudinal axis 958. After the cutting insert 1002 is secured to the cutting tooth 930, the cutting insert 1002 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 1002 of FIGS. 26-30).

[0156] In the final state, the cutting insert 1002 includes a top portion 1010 and a front portion 1014. The top portion 1010 may also be referred to as a top edge. The front portion 1014 may also be referred to as a front edge. The top portion 1010 of each cutting insert 1002 serves as a relief face for the cutting insert 1002. In the illustrated embodiment, the top portion 1010 of each cutting insert 1002 is generally flush or coplanar with the corresponding relief surface 982. In other embodiments, the top portion 1010 of each cutting insert 1002 may be offset from the corresponding relief surface 982. The front portion 1014 of each cutting insert 1002 serves as a rake face for the cutting insert 1002. In the illustrated embodiment, the front portion 1014 of each cutting insert 1002 is offset and oriented at a different angle from the corresponding rake face 974 such that the cutting insert 1002 overlaps a corresponding rake face 974. In other embodiments, the front portion 1014 of each cutting insert 1002 may be generally flush or coplanar with the corresponding rake face 974. Each cutting insert 1002 includes side surfaces 1018a, 1018b (FIG. 27) extending between the top portion 1010 and the front portion 1014.

[0157] With reference to FIG. 28, each cutting insert 1002 is ground until the top portion 1010 is obliquely oriented at an insert angle A12 relative to the longitudinal axis 958 and the front portion 1014 is obliquely oriented at an insert angle A13 relative to the longitudinal axis 958. The insert angle A12 ranges between 18 and 22 degrees, and is preferably 20 degrees.Attorney Docket No. 066042- 1973 -WOO 1The insert angle Al 3 ranges between 81 and 85 degrees, and is preferably 83 degrees. In other embodiments, the insert angle A12 and / or the insert angle A13 may have other values.

[0158] With reference to FIGS. 29 and 30, each cutting insert 1002 is ground such that the side surfaces 1018a, 1018b overlap a portion of the cutting tooth 930. In other words, the side surfaces 1018a, 1018b of each cutting insert 1002 is not flush with an outer surface 1022a, 1022b of a corresponding cutting tooth 930. In other embodiments, the side surfaces 1018a, 1018b of each cutting insert 1002 may be flush with the outer surfaces 1022a, 1022b of a corresponding cutting tooth 930. In addition, each side surface 1018a, 1018b of the cutting inserts 1002 is formed with a chamfer 1026a, 1026b extending between the front portion 1014 and the relief surface 982. The chamfers 1026a, 1026b are obliquely oriented at an insert angle A14 (FIG. 29) relative to the outer surfaces 1022a, 1022b of a corresponding cutting tooth 930. In the illustrated embodiment, the insert angle Al 4 ranges betw een 43 and 47 degrees, and is preferably 45 degrees.

[0159] In addition, each cutting insert 1002 is ground such that each chamfer 1026a, 1026b defines a cutting-edge width W6. For clarity, FIG. 29 only illustrates the cutting-edge width W6 with respect to the chamfer 1026a formed on the first side surface 1018a of the illustrated cutting insert 1002. The cutting-edge width W6 of each chamfer 1026a. 1026b extends between the top portion 1010 and a corresponding side surface 1018a, 1018b. The cutting-edge W6 ranges between 0.007 and 0.019 inches, and is preferably 0.013 inches.

[0160] FIGS. 31 and 32 illustrate another saw blade 1110. The saw blade 1110 is similar to the saw blade 910 of FIGS. 26-30; therefore, like structure will be identified by like reference number plus “200” and only the difference will be discussed hereafter.

[0161] The saw blade 1110 includes a plurality of cutting teeth 1130. Each cutting tooth 1130 has a tip 1170, a rake face 1174, a gullet 1178, a relief surface 1182, and a cutting insert 1202 that forms at least a portion of the tip 1170. Each cutting insert 1202 is ground such that the side surfaces 1218a, 1218b are each formed w ith round edges 1226a, 1226b. Each round edge 1226a, 1226b defines an insert radius R8, R9. In the illustrated embodiment, each insert radius R8, R9 ranges between 0.011 and 0.015 inches, and is preferably 0.013 inches. In further embodiments, the saw blade 11 10 may include a coating, similar to the coating 192 of FIG. 9B.Attorney Docket No. 066042- 1973 -WOO 1

[0162] FIGS. 33 and 34 illustrate another saw blade 1310. The saw blade 1310 is similar to the saw blade 910 of FIGS. 26-30; therefore, like structure will be identified by like reference number plus '‘400’’ and only the difference will be discussed hereafter.

[0163] The saw blade 1310 includes a plurality of cutting teeth 1330. Each cutting tooth 1330 has a tip 1370, a rake face 1374, a gullet 1378, a relief surface 1382, and a cutting insert 1402 that forms at least a portion of the tip 1370. The cutting inserts 1402 can be coupled to respective pockets 1398 by various welding methods (e.g., resistance welding) and formed of various materials. In the illustrated embodiment, each pocket 1398 has a curvilinear shape. In other embodiments, the pockets 1398 may have other shapes. Moreover, the cutting inserts 1402 have a perpendicular welding orientation relative to a corresponding pocket 998. In further embodiments, the saw blade 1310 may include a coating, similar to the coating 192 of FIG. 9B.

[0164] In an initial state, the cutting insert 1402 may be formed as a cylindrical piece. When the cutting insert 1402 is secured to a respective pocket 1398, the cutting insert 1402 longitudinally extends in a direction transverse to a longitudinal axis 1358. After the cutting insert 1402 is secured to the respective pocket 1398, the cutting insert 1402 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 1402 of FIGS. 33 and 34). In the final state, each cutting insert 1402 has a top portion 1410 and a front portion 1414. The top portion 1410 is generally flush or coplanar with a corresponding relief surface 1382. The front portion 1414 is generally flush or coplanar with a corresponding rake face 1374. In comparison to the cutting inserts 1002, 1202 of FIGS. 26-32, the cutting inserts 1402 form a smaller portion of each tip 1370 of the cutting teeth 1330.

[0165] FIGS. 35 and 36 illustrate another saw blade 1510. The saw blade 1510 is similar to the saw blade 910 of FIGS. 26-30; therefore, like structure will be identified by like reference number plus ”600“ and only the difference will be discussed hereafter.

[0166] The saw blade 1510 includes a plurality of cutting teeth 1530. Each cutting tooth 1530 has a tip 1570, a rake face 1574, a gullet 1578, a relief surface 1582, and a cutting insert 1602 that forms at least a portion of the tip 1570. The cutting inserts 1602 can be coupled respective pockets 1598 by various welding methods (e g., resistance welding) and formed of various materials. In the illustrated embodiment, each pocket 1598 has a curvilinear shape. In other embodiments, the pockets 1598 may have other shapes. Moreover, the cuttingAttorney Docket No. 066042- 1973 -WOO 1 inserts 1602 have a perpendicular welding orientation relative to a corresponding pocket 1598. In further embodiments, the saw blade 1510 may include a coating, similar to the coating 192 of FIG. 9B.

[0167] In an initial state, the cutting insert 1602 may be formed as a cylindrical piece. The cutting insert 1602 is secured to a respective pocket 1598 and longitudinally extends in a direction transverse to the longitudinal axis 1558. After the cutting insert 1602 is secured to the respective pocket 1598, the cutting insert 1602 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 1602 of FIGS. 35 and 36). In the final state, each cutting insert 1602 has a top portion 1610 and a front portion 1614. The top portion 1610 is generally flush or coplanar with a corresponding relief surface 1582. The front portion 1614 is generally flush or coplanar with a corresponding rake face 1574. In comparison to the cutting inserts 1002, 1202 of FIGS. 26-32, the cutting inserts 1602 form a smaller portion of each tip 1570 of the cutting teeth 1530. Also, each cutting insert 1602 is ground such that the side surfaces 1618a, 1618b are each formed with round edges 1626a, 1626b. Each round edge 1626a, 1626b defines an insert radius R10, R1 1. In the illustrated embodiment, each insert radius R10, R11 ranges between 0.011 and 0.014 inches, and is preferably 0.013 inches.

[0168] FIGS. 37 and 38 illustrate another saw blade 1710. The illustrated saw blade 1710 is a hole saw constructed before being fully assembled into a cylindrical body to perform cutting operations. The saw blade 1710 may be used with a power tool such as a power drill. The saw blade 1710 includes a body 1718 with apertures 1720 defined therein and a cutting portion 1726 formed on the body 1718. The cutting portion 1726 has a plurality of cutting teeth 1730. During operation, the saw blade 1710 is operable to cut holes of different sizes in a work piece and / or remove plugs from the work piece. In further embodiments, the saw blade 1710 may include a coating, similar to the coating 192 of FIG. 9B.

[0169] With reference to FIGS. 38 and 39, the plurality of cutting teeth 1730 extends along the body 1718 in a direction parallel to a longitudinal axis 1758 of the body 1718 and defines a tooth form on the body 1718 of the saw blade 1710. Each cutting tooth 1730 includes a tip 1770, a rake face 1774, a gullet 1778, and a relief surface 1782. The rake face 1774 of each cutting tooth 1730 extends from the tip 1770 generally toward the longitudinal axis 1758. The relief surface 1782 of each cutting tooth 1730 extends from the tip 1770 opposite the rake face 1774. The relief surface 1782 is obliquely oriented relative to theAttorney Docket No. 066042- 1973 -WOO 1 longitudinal axis 1758. In addition, each cutting tooth 1730 includes a pocket 1798 defined along the tip 1770. In the illustrated embodiment, the pocket 1798 of each cutting tooth 1730 has a rectangular shape. In other embodiments, the pocket 1798 may have other shapes. The pocket 1798 is positioned between the rake face 1774 and the relief surface 1782. As such, each rake face 1774 extends between the pocket 1798 and the gullet 1778 such that the rake face 1774 is positioned to at least partially define the gullet 1778. The relief surface 1782 of each cutting tooth 1730 extends between the pocket 1798 and the gullet 1778. Each cutting tooth 1730 further includes a cutting insert 1802 that forms at least a portion of the tip 1770. The cutting inserts 1802 can be coupled to respective pockets 1798 by various welding methods (e g., resistance welding) and formed of various materials. Also, the cutting inserts 1802 have a parallel welding orientation relative to a corresponding pocket 1798. In the illustrated embodiment, the cutting insert 1802 is formed of carbide, while the remaining portion of the cutting tooth 1730, as well as the body 1718 of the saw blade 1710, is formed of steel (e.g., high speed steel).

[0170] In an initial state, the cutting insert 1802 is formed as a cylindrical piece. In other embodiments, the cutting insert 1802 may take the form of other shapes. When secured to a respective pocket 1798, each cutting insert 1802 longitudinally extends in a direction perpendicular to the longitudinal axis 1758. After the cutting insert 1802 is secured to the cutting tooth 1730, the cutting insert 1802 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 1802 of FIGS. 37-40).

[0171] In the final state, the cutting insert 1802 includes a top portion 1810 and a front portion 1814. The top portion 1810 may also be referred to as a top edge. The front portion 1814 may also be referred to as a front edge. The top portion 1810 of each cutting insert 1802 serves as a relief face for the cutting insert 1802. In the illustrated embodiment, the top portion 1810 of each cutting insert 1802 is generally flush or coplanar with the corresponding relief surface 1782. In other embodiments, the top portion 1810 of each cutting insert 1802 may be offset from the corresponding relief surface 1782. The front portion 1814 of each cutting insert 1802 serves as a rake face for the cutting insert 1802. In the illustrated embodiment, the front portion 1814 of each cutting insert 1802 is slightly offset and oriented at a different angle from the corresponding rake face 1774. As such, the front portion 1814 extends outwardly over the gullet 1778. In other embodiments, the front portion 1814 of each cutting insert 1802 may be generally flush or coplanar with the corresponding rake faceAttorney Docket No. 066042- 1973 -WOO 11774. Each cutting insert 1802 includes side surfaces 1818a, 1818b (FIG. 38) extending between the top portion 1810 and the front portion 1814.

[0172] With reference to FIG. 39, each cutting insert 1802 is ground until the top portion 1810 is obliquely oriented at an insert angle Al 6 relative to a relief axis 1820a extending rearwardly from the tip 1770 and oriented parallel to the longitudinal axis 1758. The front portion 1814 is obliquely oriented at an insert angle Al 7 relative to a rake axis 1820b extending downw ardly from the tip 1770 and oriented perpendicular to the longitudinal axis 1758. The insert angle A16 ranges between 24 and 28 degrees, and is preferably 26 degrees. The insert angle A17 ranges between 14 and 18 degrees, and is preferably 16 degrees. In other embodiments, the insert angle A16 and / or the insert angle A17 may have other values.

[0173] With reference to FIG. 40, each cutting insert 1802 is ground such that the first side surface 1818a overlaps an outer surface 1822a of a corresponding cutting tooth 1730, while the second, opposite side surface 1818b overlaps an opposite outer surface 1822b of the corresponding cutting tooth 1730 at an extent less than the one side surface 1818a. In addition, the cutting insert 1802 is offset relative to body 1718 toward an inside of hole saw (i.e., tow ard a center of the cylindrical body when the saw' blade 1710 is wrapped to form a cylinder). As such, the side surface 1818a is further from the outer surface 1822a than the side surface 1818b is from the outer surface 1822b. In other embodiments, each side surface 1818a, 1818b may be flush or overlap a portion of a corresponding cutting tooth 1730. In addition, each side surface 1818a, 1818b of the cutting inserts 1802 is formed w ith a chamfer 1826a, 1826b. Each chamfer 1826a, 1826b is solely formed along an apex of cutting insert 1802 and does not extend along an entire length of the top portion 1810 defined betw een the front portion 1814 and the relief surface 1782. The chamfers 1826a, 1826b are obliquely oriented at an insert angle Al 8 (FIG. 40) relative to the side surfaces 1818a, 1818b of a corresponding cutting insert 1802. In the illustrated embodiment, the insert angle Al 8 ranges between 43 and 47 degrees, and is preferably 45 degrees.

[0174] In addition, each cutting insert 1802 is ground such that each chamfer 1826a, 1826b defines a cutting-edge width W7. For clarity, FIG. 40 only illustrates the cutting-edge width W7 with respect to the chamfer 1826b formed on the second side surface 1818b. The cutting-edge width W7 of each chamfer 1826a, 1826b extends betw een the top portion 1810 and a corresponding side surface 1818a, 1818b. The cutting-edge W7 ranges betw een 0.20 and 0.30 inches, and preferably 0.25 inches.Attorney Docket No. 066042- 1973 -WOO 1

[0175] FIGS. 41 and 42 illustrate another saw blade 1910 that is a hole saw constructed before being fully assembled into a cylindrical body to perform cutting operations. The saw blade 1910 is similar to the saw blade 1710 of FIGS. 37-40; therefore, like structure will be identified by like reference number plus “200” and only the difference will be discussed hereafter.

[0176] The saw blade 1910 includes a body 1918 and a cutting portion 1926 formed on the body 1918. The cutting portion 1926 has a plurality of cutting teeth 1930. Each cutting tooth 1930 includes a tip 1970, a rake face 1974, a gullet 1978, a relief surface 1982, and a cutting insert 2002 that forms at least a portion of the tip 1970. Each cutting insert 2002 is ground such that the side surfaces 2018a, 2018b are each formed with round edges 2026a, 2026b. Each round edge 2026a, 2026b defines an insert radius R12, R13. In the illustrated embodiment, each insert radius R12, R13 ranges between 0.83 and 0.87 inches, and is preferably 0.85 inches. In further embodiments, the saw blade 1910 may include a coating, similar to the coating 192 of FIG. 9B.

[0177] FIGS. 43 and 44 illustrate another saw blade 2110 that is a hole saw constructed before being fully assembled into a cylindrical body to perform cutting operations. The saw blade 2110 is similar to the saw blade 1710 of FIGS. 37-40; therefore, like structure will be identified by like reference number plus “400” and only the difference will be discussed hereafter.

[0178] The saw blade 2110 includes a body 2118 and a cutting portion 2126 formed on the body 2118. The cutting portion 2126 has a plurality of cutting teeth 2130. Each cutting tooth 2130 includes a tip 2170, a rake face 2174, a gullet 2178, a relief surface 2182, a pocket 2198 defined along the tip 2170, and a cutting insert 2202 that forms at least a portion of the tip 2170. In the illustrated embodiment, the pocket 2198 of each cutting tooth 2130 has a curvilinear shape. In other embodiments, the pocket 2198 may have other shapes. The cutting inserts 2202 can be coupled to respective pockets 2198 by various welding methods (e.g., resistance welding) and formed of various materials. Moreover, the cutting inserts 2202 have a perpendicular welding orientation relative to a corresponding pocket 2198. In further embodiments, the saw blade 2110 may include a coating, similar to the coating 192 of FIG. 9B.Attorney Docket No. 066042- 1973 -WOO 1

[0179] In an initial state, the cutting insert 2202 may be formed as a cylindrical piece. When the cutting insert 2202 is secured to a respective pocket 2198, the cutting insert 2202 longitudinally extends in a direction transverse to a longitudinal axis 2158. After the cutting insert 2202 is secured to the respective pocket 2198, the cutting insert 2202 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 2202 of FIGS. 43 and 44).

[0180] FIGS. 45 and 46 illustrate another saw blade 2310 that is a hole saw constructed before being fully assembled into a cylindrical body to perform cutting operations. The saw blade 2310 is similar to the saw blade 1710 of FIGS. 37-40; therefore, like structure will be identified by like reference number plus "600“ and only the difference will be discussed hereafter.

[0181] The saw blade 2310 includes a body 2318 and a cutting portion 2326 formed on the body 2318. The cutting portion 2326 has a plurality of cutting teeth 2330. Each cutting tooth 2330 includes a tip 2370, a rake face 2374, a gullet 2378, a relief surface 2382, a pocket 2398 defined along the tip 2370, and a cutting insert 2402 that forms at least a portion of the tip 2370. In the illustrated embodiment, the pocket 2398 of each cutting tooth 2330 has a curvilinear shape. In other embodiments, the pocket 2398 may have other shapes. The cutting inserts 2402 can be coupled to respective pockets 2398 by various welding methods (e.g., resistance welding) and formed of various materials. Moreover, the cutting inserts 2402 have a perpendicular welding orientation relative to a corresponding pocket 2398. In further embodiments, the saw blade 2310 may include a coating, similar to the coating 192 of FIG. 9B.

[0182] In an initial state, the cutting insert 2402 may be formed as a cylindrical piece. When the cutting insert 2402 is secured to a respective pocket 2398, the cutting insert 2402 longitudinally extends in a direction transverse to the longitudinal axis 2358. After the cutting insert 2402 is secured to the respective pocket 2398, the cutting insert 2402 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 2402 of FIGS. 45 and 46). Each cutting insert 2402 is ground such that the side surfaces 2418a, 2418b are formed with round edges 2426a. 2426b. Each round edge 2426a. 2426b defines an insert radius R14, R15. In the illustrated embodiment, each insert radius R14, R15 ranges between 0.83 and 0.87 inches, and is preferably 0.85 inches.Attorney Docket No. 066042- 1973 -WOO 1

[0183] FIGS. 47 and 48 illustrate another saw blade 2510. The illustrated saw blade 2510 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 2510 includes a body 2518, an attachment portion 2522, and a cutting portion 2526 formed on the body 2518 and having a plurality of cutting teeth 2530. The attachment portion 2522 is configured to couple the blade 2510 to the reciprocating saw 14. In the illustrated embodiment, the body 2518, the attachment portion 2522, and the cutting portion 2526 are all integrally formed as a single piece such that the saw blade 2510 is a single unitary structure. In other embodiments, the saw blade 2510 may be formed from several pieces that are welded or otherwise secured together. During operation, the saw blade 2510 is reciprocated in a cutting direction 2538 and a return direction 2542 (FIG. 47) to cut through a work piece. In further embodiments, the saw blade 2510 may include a coating, similar to the coating 192 of FIG. 9B.

[0184] The body 2518 of the saw blade 2510 include a first end portion 2544 and a second end portion 2546 opposite the first end portion 2544. The attachment portion 2522 is coupled to (e.g., formed at) the first end portion 2544 of the body 2518. Also, the body 2518 defines a longitudinal axis 2558 extending through the first end portion 2544 and the second end portion 2546. The attachment portion 2522 extends from the first end portion 2544 of the body 2518 and includes a tang 2562 and an aperture 2566. The tang 2562 and the aperture 2566 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely and releasably couple the saw blade 2510 to the saw 14.

[0185] With reference to FIGS. 48 and 49, the plurality of cutting teeth 2530 extends along the body 2518 in a direction parallel to the longitudinal axis 2558 and defines a tooth form on the body 2518 of the saw blade 2510. In the illustrated embodiment, the cutting teeth 2530 are unset (i.e., not bent). In other embodiments, the cutting teeth 2530 may be set (i.e., bent) in a right direction of the body 2518 of the saw blade 2510 and / or a left direction of the body 2518 of the saw blade 2510 such that the cutting teeth 2530 alternate between a cutting tooth 2530 set in the right direction and a cutting tooth 2530 set in the left direction.

[0186] Each cutting tooth 2530 includes a tip 2570, a rake face 2574, a gullet 2578, and a relief surface 2582. The rake face 2574 of each cutting tooth 2530 extends from the tip 2570 generally toward the longitudinal axis 2558. The relief surface 2582 of each cutting tooth 2530 extends from the tip 2570 opposite the rake face 2574. The relief surface 2582 is arched and extends toward the second end portion 2546 of the body 2518. In addition, eachAttorney Docket No. 066042- 1973 -WOO 1 cuting tooth 2530 includes a pocket 2598 defined along the tip 2570. In the illustrated embodiment, the pocket 2598 of each cuting tooth 2530 has a rectangular shape. In other embodiments, the pocket 2598 may have other shapes. The pocket 2598 is positioned between the rake face 2574 and the relief surface 2582. As such, each rake face 2574 extends between the pocket 2598 and the gullet 2578 such that the rake face 2574 is positioned to at least partially define the gullet 2578. The relief surface 2582 of each cuting tooth 2530 extends between the pocket 2598 and the gullet 2578. Each cuting tooth 2530 further includes a cuting insert 2602 that forms at least a portion of the tip 2570. The cuting inserts 2602 can be coupled to respective pockets 2598 by various welding methods (e.g., resistance welding) and formed of various materials. Also, the cuting inserts 2602 have a parallel welding orientation relative to a corresponding pocket 2598. In the illustrated embodiment, the cuting insert 2602 is formed of carbide, while the remaining portion of the cuting tooth 2530, as well as the body 2518 of the saw blade 2510, is formed of steel (e.g., high speed steel).

[0187] In an initial state, the cuting insert 2602 is formed as a cylindrical piece. In other embodiments, the cuting insert 2602 may take the form of other shapes. When secured to a respective pocket 2598, each cuting insert 2602 longitudinally extends in a direction perpendicular to the longitudinal axis 2558. After the cuting insert 2602 is secured to the cuting tooth 2530, the cuting insert 2602 may then be ground to a desired shape to be in a final state (e.g., the cuting insert 2602 of FIGS. 47-50).

[0188] In the final state, the cuting insert 2602 includes a top portion 2610 and a front portion 2614. The top portion 2610 may also be referred to as a top edge. The front portion 2614 may also be referred to as a front edge. The top portion 2610 of each cuting insert 2602 serves as a relief face for the cuting insert 2602. In the illustrated embodiment, the top portion 2610 of each cuting insert 2602 is offset from the corresponding relief surface 2582. In other embodiments, the top portion 2610 of each cuting insert 2602 may be flush with the corresponding relief surface 2582. The front portion 2614 of each cuting insert 2602 serves as a rake face for the cuting insert 2602. In the illustrated embodiment, the front portion 2614 of each cuting insert 2602 is offset and oriented at a different angle from the corresponding rake face 2574. In other words, at least a portion of the cuting insert 2602 overlaps the rake face 2574. In other embodiments, the front portion 2614 of each cuting insert 2602 may be generally flush or coplanar with the corresponding rake face 2574. EachAttorney Docket No. 066042- 1973 -WOO 1 cuting insert 2602 includes side surfaces 2618a, 2618b (FIG. 48) extending between the top portion 2610 and the front portion 2614.

[0189] With reference to FIG. 49, each cuting insert 2602 is ground until the top portion 2610 is obliquely oriented at an insert angle A19 relative to the longitudinal axis 2558 and the front portion 2614 is obliquely oriented at an insert angle A20 relative to the longitudinal axis 2558. The insert angle Al 9 ranges between 6 and 10 degrees, and is preferably 8 degrees. The insert angle A20 ranges between 91 and 95 degrees, and is preferably 93 degrees. In other embodiments, the insert angle A19 and / or the insert angle A20 may have other values.

[0190] With reference to FIG. 50, each cuting insert 2602 is ground such that the side surfaces 2618a, 2618b respectively overlap and extend obliquely relative to an outer surface 2622a, 2622b of a corresponding cuting tooth 2530. In other embodiments, the side surfaces 2618a, 2618b of each cuting insert 2602 may be flush with the outer surfaces 2622a, 2622b of the corresponding cuting tooth 2530. In addition, each side surface 2618a, 2618b of the cuting inserts 2602 is formed with a chamfer 2626a, 2626b extending between the front portion 2614 and the relief surface 2582. The chamfers 2626a, 2626b are obliquely oriented at an insert angle A21 relative to the top portion 2610. In the illustrated embodiment, the insert angle A21 ranges between 43 and 47 degrees, and is preferably 45 degrees.

[0191] Each cuting insert 2602 is ground such that the side surfaces 2618a, 2618b obliquely extend at a side surface angle AA1 relative to the outer surfaces 2622a, 2622b of each cuting tooth 2530. Also, the cuting inserts 2602 are ground such that each chamfer 2626a, 2626b defines a cutting-edge width W8 that extends between the top portion 2610 and a corresponding side surface 2618a, 2618b. For clarity, FIG. 50 only illustrates the side surface angle AA1 with respect to the second side surface 2618b and the cuting-edge with W8 with respect to the first side surface 2618a. The side surface angle AA1 ranges between 3 and 7 degrees, and preferably 5 degrees. The cuting-edge W8 ranges between 0.003 and 0.007 inches, and is preferably 0.005 inches.

[0192] FIGS. 51 and 52 illustrate another saw blade 2710. The saw- blade 2710 is similar to the saw blade 2510 of FIGS. 47-50; therefore, like structure will be identified by like reference number plus '‘200’’ and only the difference will be discussed hereafter.

[0193] The illustrated saw blade 2710 includes a body 2718, an atachment portion 2722, and a cuting portion 2726 formed on the body 2718 and having a plurality of cuting teethAttorney Docket No. 066042- 1973 -WOO 12730. Each cutting tooth 2730 includes a tip 2770, a rake face 2774, a gullet 2778, a relief surface 2782, and a cutting insert 2802 that forms at least a portion of the tip 2770. Each cutting insert 2802 is ground such that the side surfaces 2818a, 2818b are respectively formed with a round edge 2826a, 2826b. Each round edge 2826a, 2826b defines an insert radius R16, R17. In the illustrated embodiment, each insert radius R16, R17 ranges between 0.008 and 0.012 inches, and is preferably 0.01 inches. In further embodiments, the saw blade 2710 may include a coating, similar to the coating 192 of FIG. 9B.

[0194] FIGS. 53 and 54 illustrate another saw blade 2910. The saw' blade 2910 is similar to the saw blade 2510 of FIGS. 47-50; therefore, like structure will be identified by like reference number plus ”400“ and only the difference will be discussed hereafter.

[0195] The illustrated saw blade 2910 includes a body 2918, an attachment portion 2922, and a cutting portion 2926 formed on the body 2918 and having a plurality of cutting teeth 2930. Each cutting tooth 2930 includes a tip 2970, a rake face 2974, a gullet 2978. a relief surface 2982, and a pocket 2998 defined along the tip 2970. In the illustrated embodiment, the pocket 2998 of each cutting tooth 2930 has a curvilinear shape. In other embodiments, the pocket 2998 may have other shapes. In addition, each cutting tooth 2930 further includes a cutting insert 3002 that forms at least a portion of the tip 2970. The cutting inserts 3002 can be coupled to respective pockets 2998 by various welding methods (e.g., resistance welding) and formed of various materials. Also, the cutting inserts 3002 have a perpendicular welding orientation relative to a corresponding pocket 2998. In further embodiments, the saw' blade 2910 may include a coating, similar to the coating 192 of FIG. 9B.

[0196] In an initial state, the cutting insert 3002 may be formed as a cylindrical piece. When the cutting insert 3002 is secured to a respective pocket 2998, the cutting insert 3002 longitudinally extends in a direction transverse to a longitudinal axis 2958. After the cutting insert 3002 is secured to the respective pocket 2998, the cutting insert 3002 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 3002 of FIGS. 53 and 54).

[0197] FIGS. 55 and 56 illustrate another saw blade 3110. The saw blade 3110 is similar to the saw blade 2510 of FIGS. 47-50; therefore, like structure will be identified by like reference number plus “600” and only the difference will be discussed hereafter.Attorney Docket No. 066042- 1973 -WOO 1

[0198] The illustrated saw blade 3110 includes a body 3118, an attachment portion 3122, and a cutting portion 3126 formed on the body 3118 and having a plurality of cutting teeth 3130. Each cutting tooth 3130 includes a tip 3170, a rake face 3174, a gullet 3178, a relief surface 3182, and a pocket 3198 defined along the tip 3170. In the illustrated embodiment, the pocket 3198 of each cutting tooth 3130 has a cur ilinear shape. In other embodiments, the pocket 3198 may have other shapes. In addition, each cutting tooth 3130 further includes a cutting insert 3202 that forms at least a portion of the tip 3170. The cutting inserts 3202 can be coupled to respective pockets 3198 by various welding methods (e.g., resistance welding) and formed of various materials. Also, the cutting inserts 3202 have a perpendicular welding orientation relative to a corresponding pocket 3198. In further embodiments, the saw blade 3110 may include a coating, similar to the coating 192 of FIG. 9B.

[0199] In an initial state, the cutting insert 3202 may be formed as a cylindrical piece. When the cutting insert 3202 is secured to a respective pocket 3198, the cutting insert 3202 longitudinally extends in a direction transverse to a longitudinal axis 3158. After the cutting insert 3202 is secured to the respective pocket 3198, the cutting insert 3202 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 3202 of FIGS. 55 and 56). Each cutting insert 3202 is ground such that the side surfaces 3218a, 3218b are respectively formed with a round edge 3226a, 3226b. Each round edge 3226a, 3226b defines an insert radius R18, R19. In the illustrated embodiment, each insert radius R18, R19 ranges between 0.008 and 0.012 inches, and is preferably 0.01 inches.

[0200] FIGS. 57 and 58 illustrate another saw blade 3310. The illustrated saw blade 3310 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 3310 includes a body 3318, an attachment portion 3322, and a cutting portion 3326 formed on the body 3318. The cutting portion 3326 is formed as a single cutting segment coupled to the body 3318 and having a plurality of cutting teeth 3330. In other embodiments, the cutting portion 3326 may be formed as multiple cutting segments coupled to the body 3318 and spaced from each other. The attachment portion 3322 is configured to couple the blade 3310 to the reciprocating saw 14. In the illustrated embodiment, the body 3318 and the attachment portion 3322 are integrally formed as a single piece, while the cutting portion 3326 is separately formed and coupled to the body 3318. During operation, the saw blade 3310 is reciprocated in a cutting direction 3338 and a returnAttorney Docket No. 066042- 1973 -WOO 1 direction 3342 (FIG. 57) to cut through a work piece. In further embodiments, the saw blade 3310 may include a coating, similar to the coating 192 of FIG. 9B.

[0201] The body 3318 of the saw blade 3310 include a first end portion 3344 and a second end portion 3346 opposite the first end portion 3344. The attachment portion 3322 is coupled to (e.g., formed at) the first end portion 3344 of the body 3318. Also, the body 3318 defines a longitudinal axis 3358 extending through the first end portion 3344 and the second end portion 3346. The attachment portion 3322 extends from the first end portion 3344 of the body 3318 and includes a tang 3362 and an aperture 3366. The tang 3362 and the aperture 3366 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely and releasably couple the saw blade 3310 to the saw 14. In addition, a nose 3368 of the body 3318 is formed along the second end portion 3346 and extends outwardly beyond the cutting portion 3326.

[0202] With reference to FIGS. 58 and 59, the plurality of cutting teeth 3330 extends along the body 3318 in a direction parallel to the longitudinal axis 3358 and defines a tooth form on the body 3318 of the saw blade 3310. Each cutting tooth 3330 includes a tip 3370, a rake face 3374, a gullet 3378, and a relief surface 3382. The rake face 3374 of each cutting tooth 3330 extends from the tip 3370 generally toward the longitudinal axis 3358. The relief surface 3382 of each cutting tooth 3330 extends from the tip 3370 opposite the rake face 3374 and is obliquely oriented relative to the longitudinal axis 3358. As such, each gullet 3378 extends between rake face 3374 of a first cutting tooth 3330 and a relief surface 3382 of an adjacent second cutting tooth 3330. The illustrated tooth form includes 20 teeth per inch (TPI). In other embodiments, the saw blade 3310 can include fewer or more teeth per inch. For example, the tooth form may include 25 TPI.

[0203] During manufacturing of the saw blade 3310, the unitary' structure of the body 3318 and the attachment portion 3322 is formed from a first material (e.g., low-carbon steel) by, for example, a stamping process. The cutting portion 3326 is formed from a second material (e.g., carbide) to provide a single carbide strip secured to the body 3318 of the saw blade 3310. The cutting teeth 3330 are formed in the cutting portion 3326 before the cutting portion 3326 is secured to the body 3318.

[0204] Each cuting tooth 3330 is formed with a top portion 3410 and a front portion 3414. The top portion 3410 may also be referred to as a top edge. The front portion 3414Attorney Docket No. 066042- 1973 -WOO 1 may also be referred to as a front edge. The top portion 3410 serves as a relief face for each cutting tooth 3330. In the illustrated embodiment, the top portion 3410 of each cutting tooth 3330 is generally flush or coplanar with the corresponding relief surface 3382. The top portion 3410 is obliquely oriented at an insert angle A22 (FIG. 59) relative to the longitudinal axis 3358 and the front portion 3414 is obliquely oriented at an insert angle A23 (FIG. 59) relative to the longitudinal axis 3358. The insert angle A22 ranges between 28 and 32 degrees, and is preferably 30 degrees. The insert angle A23 ranges between 95 and 99 degrees, and is preferably 97 degrees. In other embodiments, the insert angle A22 and / or the insert angle A23 may have other values.

[0205] With reference to FIG. 60, each cutting tooth 3330 is ground such that side surfaces 3418a, 3418b of the cutting portion 3326 overlap the body 3318 of the saw blade 3310. In other words, the side surfaces 3418a, 3418b of the cutting portion 3326 is not flush with outer surfaces 3422a, 3422b of the body 3318. In other embodiments, the side surfaces 3418a, 3418b of the cutting portion 3326 may be flush with the outer surfaces 3422a, 3422b of the body 3318. In addition, each cutting tooth 3330 is formed with chamfers 3426a, 3426b extending between the front portion 3414 and the relief surface 3382. The chamfers 3426a, 3426b are obliquely oriented at an insert angle A24 relative to an apex of the top portion 3410 of a corresponding cutting tooth 3330. In the illustrated embodiment, the insert angle A24 ranges between 43 and 47 degrees, and is preferably 45 degrees.

[0206] In addition, each cutting tooth 3330 is ground such that each chamfer 3426a, 3426b defines a cutting-edge width W9. For clarity, FIG. 60 only illustrates the cutting-edge width W9 with respect to the chamfer 3426a formed on the first side surface 3418a. The cutting-edge width W9 of each chamfer 3426a, 3426b extends between the top portion 3410 and a corresponding side surface 3418a, 3418b. The cutting-edge W9 ranges between 0.006 and 0.018 inches, and preferably 0.012 inches.

[0207] FIGS. 61 and 62 illustrate another saw blade 3510. The saw blade 3510 is similar to the saw blade 3310 of FIGS. 57-60; therefore, like structure will be identified by like reference number plus “200"’ and only the difference will be discussed hereafter.

[0208] The illustrated saw blade 3510 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 3510 includes a body 3518, an attachment portion 3522, and a cutting portion 3526 formed on the body 3518. The cuttingAttorney Docket No. 066042- 1973 -WOO 1 portion 3526 is formed as a single cuting segment coupled to the body 3518 and having a plurality of cuting teeth 3530. Each cuting tooth 3530 is formed with round edges 3626a, 3626b. Each round edge 3626a, 3626b defines an insert radius R20, R21. In the illustrated embodiment, each insert radius R20, R21 ranges between 0.01 and 0.016 inches, and is preferably 0.013 inches. In further embodiments, the saw blade 3510 may include a coating, similar to the coating 192 of FIG. 9B.

[0209] FIGS. 63-65 illustrate another saw blade 4110. The illustrated saw blade 4110 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 4110 includes a body 4118, an attachment portion 4122, and a cutting portion 4126 formed on the body 4118 and having a plurality of cutting teeth 4130. The atachment portion 4122 is configured to couple the blade 4110 to the reciprocating saw 14. In the illustrated embodiment, the body 4118, the atachment portion 4122, and the cuting portion 4126 are all integrally formed as a single piece such that the saw blade 4110 is a single unitary structure. In other embodiments, the saw blade 4110 may be formed from several pieces that are welded or otherwise secured together. During operation, the saw blade 4110 is reciprocated in a cutting direction 4138 and a return direction 4142 (FIG. 63) to cut through a work piece. In further embodiments, the saw blade 4110 may include a coating, similar to the coating 192 of FIG. 9B.

[0210] The body 4118 of the saw blade 4110 include a first end portion 4144 and a second end portion 4146 opposite the first end portion 4144. The atachment portion 4122 is coupled to (e.g., formed at) the first end portion 4144 of the body 4118. Also, the body 4118 defines a longitudinal axis 4158 extending through the first end portion 4144 and the second end portion 4146. The atachment portion 4122 extends from the first end portion 4144 of the body 4118 and includes a tang 4162 and an aperture 4166. The tang 4162 and the aperture 4166 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely and releasably couple the saw blade 4110 to the saw 14.

[0211] With reference to FIGS. 64-67, the plurality of cuting teeth 4130 extends along the body 4118 in a direction parallel to the longitudinal axis 4158 and defines a tooth form on the body 4118 of the saw blade 4110. In the illustrated embodiment, the cuting teeth 4130 are unset (i.e., not bent). In other embodiments, the cuting teeth 4130 may be set (i.e., bent) in a right direction of the body 4118 of the saw blade 4110 and / or a left direction of the bodyAttorney Docket No. 066042- 1973 -WOO 14118 of the saw blade 4110 such that the cutting teeth 4130 alternate between a cutting tooth 4130 set in the right direction and a cutting tooth 4130 set in the left direction.

[0212] Each cutting tooth 4130 includes atip 4170, a rake face 4174, a gullet 4178, and a relief surface 4182. The rake face 4174 of each cutting tooth 4130 extends from the tip 4170 generally toward the longitudinal axis 4158. The relief surface 4182 of each cutting tooth 4130 extends from the tip 4170 opposite the rake face 4174. The relief surface 4182 is arched and extends toward the second end portion 4146 of the body 4118. In addition, each cutting tooth 4130 includes a pocket 4198 defined along the tip 4170. In the illustrated embodiment, the pocket 4198 of each cutting tooth 4130 has a rectangular shape. In other embodiments, the pocket 4198 may have other shapes. The pocket 4198 is positioned between the rake face 4174 and the relief surface 4182. As such, each rake face 4174 extends between the pocket 4198 and the gullet 4178 such that the rake face 4174 is positioned to at least partially define the gullet 4178. The relief surface 4182 of each cutting tooth 4130 extends between the pocket 4198 and the gullet 4178. Each cutting tooth 4130 further includes a cutting insert 4202 that forms at least a portion of the tip 4170. The cutting inserts 4202 can be coupled to respective pockets 4198 by various welding methods (e.g., resistance welding) and formed of various materials. Also, the cutting inserts 4202 have a parallel welding orientation relative to a corresponding pocket 4198. In the illustrated embodiment, the cutting insert 4202 is formed of carbide, while the remaining portion of the cutting tooth 4130, as well as the body 41 18 of the saw blade 4110, is formed of steel (e.g., high speed steel). The illustrated cutting portion 4126 includes 6 teeth per inch (TPI). In other embodiments, the saw blade 4110 can include fewer or more teeth per inch. For example, the cutting portion 4126 may include 7.3 TPI.

[0213] In an initial state, the cutting insert 4202 is formed as a cylindrical piece. In other embodiments, the cutting insert 4202 may take the form of other shapes. When secured to a respective pocket 4198, each cutting insert 4202 longitudinally extends in a direction perpendicular to the longitudinal axis 4158. After the cutting insert 4202 is secured to the cutting tooth 4130, the cutting insert 4202 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 4202 of FIGS. 63-67).

[0214] In the final state, the cutting insert 4202 includes a top portion 4210 and a front portion 4214. The top portion 4210 may also be referred to as a top edge. The front portion 4214 may also be referred to as a front edge. The top portion 4210 of each cutting insertAttorney Docket No. 066042- 1973 -WOO 14202 serves as a relief face for the cutting insert 4202. In the illustrated embodiment, the top portion 4210 of each cutting insert 4202 is offset from the corresponding relief surface 4182. In other embodiments, the top portion 4210 of each cutting insert 4202 may be flush with the corresponding relief surface 4182. The front portion 4214 of each cutting insert 4202 serves as a rake face for the cutting insert 4202. In the illustrated embodiment, the front portion 4214 of each cutting insert 4202 is offset and oriented at a different angle from the corresponding rake face 4174. In other embodiments, the front portion 4214 of each cutting insert 4202 may be generally flush or coplanar with the corresponding rake face 4174. Each cutting insert 4202 includes side surfaces 4218a, 4218b (FIG. 67) extending between the top portion 4210 and the front portion 4214.

[0215] With reference to FIG. 66, each cutting insert 4202 is ground until the top portion 4210 is obliquely oriented at an insert angle A25 relative to a relief axis 4220a extending from the tip 4170 and oriented parallel to the longitudinal axis 4158. Also, the front portion 4214 is obliquely oriented at an insert angle A26 relative to a rake axis 4220b extending from a bottom of the cutting insert 4202 and oriented perpendicular to the longitudinal axis 4158. The insert angle A25 ranges between 8 and 12 degrees, and is preferably 10 degrees. The insert angle A26 ranges between 3 and 7 degrees, and is preferably 5 degrees. In other embodiments, the insert angle A25 and / or the insert angle A26 may have other values.

[0216] With reference to FIG. 67, each cutting insert 4202 is ground such that the side surfaces 4218a, 4218b overlap outer surfaces 4222a, 4222b of a corresponding cutting tooth 4130. In other embodiments, the side surfaces 4218a. 4218b of each cutting insert 4202 may be flush with the outer surfaces 4222a, 4222b of the corresponding cutting tooth 4130. In addition, each side surface 4218a, 4218b of the cutting inserts 4202 is formed with a chamfer 4226a, 4226b extending between the front portion 4214 and the relief surface 4182. Each chamfer 4226a, 4226b is obliquely oriented at an insert angle A27 relative to an adjacent side surface 4218a, 4218b. In the illustrated embodiment, the insert angle A27 ranges between 43 and 47 degrees, and is preferably 45 degrees.

[0217] In addition, each cutting insert 4202 is ground such that each chamfer 4226a, 4226b defines a cutting-edge width W10. For clarity. FIG. 67 only illustrates the cutting- edge width W10 with respect to the chamfer 4226b formed on the second side surface 4218b. The cutting-edge width W10 of each chamfer 4226a, 4226b extends between the top portionAttorney Docket No. 066042- 1973 -WOO 14210 and a corresponding side surface 4218a, 4218b. The cutting-edge W10 ranges between 0.010 and 0.014 inches, and preferably 0.012 inches.

[0218] FIGS. 68 and 69 illustrate another saw blade 4310. The saw blade 4310 is similar to the saw blade 4110 of FIGS. 63-67; therefore, like structure will be identified by like reference number plus “200” and only the difference will be discussed hereafter.

[0219] The illustrated saw blade 4310 includes a body 4318, an attachment portion 4322, and a cutting portion 4326 formed on the body 4318 and having a plurality of cutting teeth 4330. Each cutting tooth 4330 includes a tip 4370, a rake face 4374, a gullet 4378. a relief surface 4382, and a cutting insert 4402 that forms at least a portion of the tip 4370. Each cutting insert 4402 is ground such that the side surfaces 4418a, 4418b are respectively formed with a round edge 4426a, 4426b. Each round edge 4426a, 4426b defines an insert radius R22, R23. In the illustrated embodiment, each insert radius R22, R23 ranges between 0.008 and 0.012 inches, and is preferably 0.01 inches. In further embodiments, the saw blade 4310 may include a coating, similar to the coating 192 of FIG. 9B.

[0220] FIGS. 70 and 71 illustrate another saw blade 4510. The saw blade 4510 is similar to the saw blade 4110 of FIGS. 63-67 ; therefore, like structure will be identified by like reference number plus “400” and only the difference will be discussed hereafter.

[0221] The illustrated saw blade 4510 includes a body 4518, an attachment portion 4522, and a cutting portion 4526 formed on the body 4518 and having a plurality of cutting teeth 4530. Each cutting tooth 4530 includes a tip 4570, a rake face 4574, a gullet 4578, a relief surface 4582, and a pocket 4598 defined along the tip 4570. In the illustrated embodiment, the pocket 4598 of each cutting tooth 4530 has a curvilinear shape. In other embodiments, the pocket 4598 may have other shapes. In addition, each cutting tooth 4530 further includes a cutting insert 4602 that forms at least a portion of the tip 4570. The cutting inserts 4602 can be coupled to respective pockets 4598 by various welding methods (e.g., resistance welding) and formed of various materials. Also, the cutting inserts 4602 have a perpendicular welding orientation relative to a corresponding pocket 4598. In further embodiments, the saw blade 4510 may include a coating, similar to the coating 192 of FIG. 9B.

[0222] In an initial state, the cutting insert 4602 may be formed as a cylindrical piece. When the cutting insert 4602 is secured to a respective pocket 4598, the cutting insert 4602 longitudinally extends in a direction transverse to a longitudinal axis 4558. After the cuttingAttorney Docket No. 066042- 1973 -WOO 1 insert 4602 is secured to the respective pocket 4598, the cutting insert 4602 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 4602 of FIGS. 70 and 71).

[0223] FIGS. 72 and 73 illustrate another saw blade 4710. The saw blade 4710 is similar to the saw blade 4110 of FIGS. 63-67; therefore, like structure will be identified by like reference number plus '‘600’’ and only the difference will be discussed hereafter.

[0224] The illustrated saw blade 4710 includes a body 4718, an attachment portion 4722, and a cutting portion 4726 formed on the body 4718 and having a plurality of cutting teeth 4730. Each cutting tooth 4730 includes a tip 4770, a rake face 4774, a gullet 4778. a relief surface 4782, and a pocket 4798 defined along the tip 4770. In the illustrated embodiment, the pocket 4798 of each cutting tooth 4730 has a curvilinear shape. In other embodiments, the pocket 4798 may have other shapes. In addition, each cutting tooth 4730 further includes a cutting insert 4802 that forms at least a portion of the tip 4770. The cutting inserts 4802 can be coupled to respective pockets 4798 by various welding methods (e.g., resistance welding) and formed of various materials. Also, the cutting inserts 4802 have a perpendicular welding orientation relative to a corresponding pocket 4798. In further embodiments, the saw blade 4710 may include a coating, similar to the coating 192 of FIG. 9B.

[0225] In an initial state, the cutting insert 4802 may be formed as a cylindrical piece. When the cutting insert 4802 is secured to a respective pocket 4798, the cutting insert 4802 longitudinally extends in a direction transverse to a longitudinal axis 4758. After the cutting insert 4802 is secured to the respective pocket 4798, the cutting insert 4802 may then be ground to a desired shape to be in a final state (e.g., the cutting insert 4802 of FIGS. 72 and 73). Each cutting insert 4802 is ground such that the side surfaces 4818a, 4818b are respectively formed with a round edge 4826a, 4826b. Each round edge 4826a, 4826b defines an insert radius R24. R25. In the illustrated embodiment, each insert radius R24. R25 ranges between 0.010 and 0.020 inches, and is preferably 0.015 inches.

[0226] FIGS. 74-76 illustrate another saw blade 4910. The illustrated saw blade 4910 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw blade 4910 includes a body 4918, an attachment portion 4922, and a cutting portion 4926 formed on the body 4918 and having a plurality of cutting teeth 4930. The attachment portion 4922 is configured to couple the blade 4910 to the reciprocating saw 14. In theAttorney Docket No. 066042- 1973 -WOO 1 illustrated embodiment, the body 4918, the attachment portion 4922, and the cutting portion 4926 are all integrally formed as a single piece such that the saw blade 4910 is a single unitary structure. In other embodiments, the saw blade 4910 may be formed from several pieces that are welded or otherwise secured together. During operation, the saw blade 4910 is reciprocated in a cutting direction 4938 and a return direction 4942 (FIG. 74) to cut through a work piece. In further embodiments, the saw blade 4910 may include a coating, similar to the coating 192 of FIG. 9B.

[0227] The body 4918 of the saw blade 4910 include a first end portion 4944 and a second end portion 4946 opposite the first end portion 4944. The attachment portion 4922 is coupled to (e.g., formed at) the first end portion 4944 of the body 4918. Also, the body 4918 defines a longitudinal axis 4958 extending through the first end portion 4944 and the second end portion 4946. The attachment portion 4922 extends from the first end portion 4944 of the body 4918 and includes a tang 4962 and an aperture 4966. The tang 4962 and the aperture 4966 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely and releasably couple the saw blade 4910 to the saw 14.

[0228] With reference to FIGS. 75-77, the plurality of cutting teeth 4930 extends along the body 4918 in a direction parallel to the longitudinal axis 4958 and defines a tooth form on the body 4918 of the saw blade 4910. In the illustrated embodiment, the cutting teeth 4930 are unset (i.e., not bent). In other embodiments, the cutting teeth 4930 may be set (i.e., bent) in a right direction of the body 4918 of the saw blade 4910 and / or a left direction of the body 4918 of the saw blade 4910 such that the cutting teeth 4930 alternate between a cutting tooth 4930 set in the right direction and a cutting tooth 4930 set in the left direction.

[0229] Each cutting tooth 4930 includes a tip 4970, a rake face 4974, a gullet 4978, and a relief surface 4982. The rake face 4974 of each cutting tooth 4930 extends from the tip 4970 generally toward the longitudinal axis 4958. The relief surface 4982 of each cutting tooth 4930 extends from the tip 4970 opposite the rake face 4974. The relief surface 4982 extends toward the second end portion 4946 of the body 4918 and slightly angled, but near parallel to the longitudinal axis 4958. In addition, each cutting tooth 4930 includes a pocket 4998 defined along the tip 4970. In the illustrated embodiment, the pocket 4998 of each cutting tooth 4930 has a curvilinear shape. In other embodiments, the pocket 4998 may have other shapes. The pocket 4998 is positioned between the rake face 4974 and the relief surface 4982. As such, each rake face 4974 extends between the pocket 4998 and the gullet 4978Attorney Docket No. 066042- 1973 -WOO 1 such that the rake face 4974 is positioned to at least partially define the gullet 4978. The relief surface 4982 of each cutting tooth 4930 extends between the pocket 4998 and the gullet 4978. Each cutting tooth 4930 further includes a cutting insert 5002 that forms at least a portion of the tip 4970. The cutting inserts 5002 can be coupled to respective pockets 4998 by various welding methods (e.g., resistance welding) and formed of various materials. In the illustrated embodiment, the cutting insert 5002 is formed of carbide, while the remaining portion of the cutting tooth, as well as the body 4918 of the saw blade 4910, is formed of steel (e g., high speed steel). The illustrated cutting portion 4926 includes 14 teeth per inch (TPI). In other embodiments, the saw blade 4910 can include fewer or more teeth per inch.

[0230] In an initial state, the cutting insert 5002 is formed as a cylindrical piece. In other embodiments, the cutting insert 5002 may take the form of other shapes. After the cutting insert 5002 is secured to the cutting tooth 4930, the cutting insert 5002 may then be ground to a desired shape to be in a final state (e g., the cutting insert 5002 of FIGS. 74-78).

[0231] In the final state, the cutting insert 5002 includes a top portion 5010 and a front portion 5014. The top portion 5010 may also be referred to as a top edge. The front portion 5014 may also be referred to as a front edge. The top portion 5010 of each cutting insert 5002 sen es as a relief face for the cutting insert 5002. Also, the top portion 5010 of each cutting insert 5002 is positioned along the pocket 4998 such that the relief surface 4982 is overlapped by at least a portion of the top portion 5010. In the illustrated embodiment, the top portion 5010 of each cutting insert 5002 is generally flush or coplanar with the corresponding relief surface 4982. In other embodiments, the top portion 5010 of each cutting insert 5002 may be offset from the corresponding relief surface 4982. The front portion 5014 of each cutting insert 5002 serves as a rake face for the cutting insert 5002. In the illustrated embodiment, the front portion 5014 of each cutting insert 5002 is offset and oriented parallel to the corresponding rake face 4974. In other embodiments, the front portion 5014 of each cutting insert 5002 may be generally flush or coplanar with the corresponding rake face 4974. Each cutting insert 5002 includes side surfaces 5018a, 5018b (FIG. 75) extending between the top portion 5010 and the front portion 5014.

[0232] Each cutting insert 5002 is ground until the top portion 5010 is obliquely oriented at an insert angle A28 (FIG. 77) relative to a horizontal reference plane 5020 positioned along the cutting teeth 4930 and oriented parallel to the longitudinal axis 4958. Also, the front portion 5014 is perpendicularly oriented at an insert angle A29 (FIG. 77) relative to theAttorney Docket No. 066042- 1973 -WOO 1 horizontal reference plane 5020. The insert angle A28 ranges between 6 and 10 degrees, and is preferably 8 degrees. The insert angle A29 ranges between 88 and 92 degrees, and is preferably 90 degrees. In other embodiments, the insert angle A28 and / or the insert angle A29 may have other values.

[0233] With reference to FIG. 78, each cutting insert 5002 is ground such that the side surfaces 5018a, 5018b respectively overlap and extend obliquely at a side surface angle A14 relative to an outer surface 5022a, 5022b of a corresponding cutting tooth 4930. The side surface angle A14 ranges between 3 and 7 degrees, and is preferably 5 degrees. In other embodiments, the side surfaces 5018a, 5018b of each cutting insert 5002 may be flush with the outer surfaces 5022a, 5022b of a corresponding cutting tooth 4930. In addition, each side surface 5018a, 5018b of the cutting inserts 5002 is formed with a chamfer 5026a, 5026b extending between the front portion 5014 and the relief surface 4982. The chamfers 5026a, 5026b are obliquely oriented at an insert angle A30 relative to a corresponding outer surface 5022a, 5022b. In the illustrated embodiment, the insert angle A30 ranges between 43 and 47 degrees, and is preferably 45 degrees.

[0234] In addition, each cutting insert 5002 is ground such that each chamfer 5026a, 5026b defines a cutting-edge width W11 and an overhang width W12. For clarity, FIG. 78 only illustrates the cutting-edge width W1 1 and the overhang width W12 with respect to the chamfer 5026a formed on the first side surface 5018a. The cutting-edge width W11 of each chamfer 5026a, 5026b extends between the top portion 5010 and a corresponding side surface 5018a, 5018b. The cutting-edge W11 ranges between 0.018 and 0.006 inches, and preferably 0.012 inches. The overhang width W12 of each chamfer 5026a, 5026b extends between a respective side surface 5018a, 5018b of the cutting insert 5002 and a corresponding outer surface 5022a, 5022b of the cutting tooth 4930.

[0235] FIGS. 79 and 80 illustrate another saw blade 5110. The saw blade 51 10 is similar to the saw blade 4910 of FIGS. 74-78; therefore, like structure will be identified by like reference number plus “200” and only the difference will be discussed hereafter.

[0236] The illustrated saw blade 5110 includes a body 5118, an attachment portion 5122, and a cutting portion 5126 formed on the body 5118 and having a plurality of cutting teeth 5130. Each cutting tooth 5130 includes a tip 5170, a rake face 5174, a gullet 5178, a relief surface 5182, and a cutting insert 5202 that forms at least a portion of the tip 5170. EachAttorney Docket No. 066042- 1973 -WOO 1 cuting insert 5202 is ground such that the side surfaces 5218a, 5218b are respectively formed with a round edge 5226a, 5226b. Each round edge 5226a, 5226b defines an insert radius R26, R27. In the illustrated embodiment, each insert radius R26, R27 ranges between 0.007 and 0.017 inches, and is preferably 0.012 inches. In further embodiments, the saw blade 5110 may include a coating, similar to the coating 192 of FIG. 9B.

[0237] FIGS. 81-83 illustrate another saw blade 5310. The illustrated saw blade 5310 is a reciprocating saw blade for use with a power tool such as a reciprocating saw 14 (FIG. 12). The saw- blade 5310 includes a body 5318, an atachment portion 5322, a cuting portion 5326 formed on the body 5318 and having a plurality of cutting teeth 5330, and a plunge point 5334. The atachment portion 5322 is configured to couple the blade 5310 to the reciprocating saw 14. The plunge point 5334 may be used to initiate a plunge cut during operation. In the illustrated embodiment, the body 5318, the atachment portion 5322, the cuting portion 5326, and the plunge point 5334 are all integrally formed as a single piece such that the saw blade 5310 is a single unitary structure. In other embodiments, the sawblade 5310 may be formed from several pieces that are welded or otherwise secured together. During operation, the saw blade 5310 is reciprocated in a cuting direction 5338 and a return direction 5342 (FIG. 81) to cut through a work piece. In further embodiments, the saw blade 5310 may include a coating, similar to the coating 192 of FIG. 9B.

[0238] The body 5318 of the saw blade 5310 include a first end portion 5344 and a second end portion 5346 opposite the first end portion 5344. The atachment portion 5322 is coupled to (e.g., formed at) the first end portion 5344 of the body 5318. The plunge point 5334 is coupled to (e.g., formed at) the second end portion 5346 of the body 5318. A back portion 5350 extends between the atachment portion 5322 and the plunge point 5334 on a side of the body 5318 opposite the cuting portion 5326. The back portion 5350 includes three stepped surfaces 5354a-c at different distances from the cuting portion 5326. In other embodiments, the back portion 5350 may have fewer or more stepped surfaces or other configurations. The body 5318 of the saw- blade 5310 also defines a longitudinal axis 5358 extending through the first end portion 5344 and the second end portion 5346.

[0239] The atachment portion 5322 extends from the first end portion 5344 of the body 5318 and includes a tang 5362 and an aperture 5366. The tang 5362 and the aperture 5366 are configured to engage a blade clamp provided on the reciprocating saw 14 to securely andAttorney Docket No. 066042- 1973 -WOO 1 releasably couple the saw blade 5310 to the saw 14. The illustrated attachment portion 5322 is obliquely oriented relative to the longitudinal axis 5358.

[0240] With reference to FIGS. 82-84, the plurality of cutting teeth 5330 extends along the body 5318 in a direction parallel to the longitudinal axis 5358 and defines a tooth form on the body 5318 of the saw blade 5310. In the illustrated embodiment, the cutting teeth 5330 are unset (i.e. , not bent). In other embodiments, the cutting teeth 5330 may be set (i. e. , bent) in a right direction of the body 5318 of the saw blade 5310 and / or a left direction of the body 5318 of the saw blade 5310 such that the cutting teeth 5330 alternate between a cutting tooth 5330 set in the right direction and a cutting tooth 5330 set in the left direction.

[0241] Each cutting tooth 5330 includes a tip 5370, a rake face 5374, a gullet 5378, and a relief surface 5382. The rake face 5374 of each cutting tooth 5330 extends from the tip 5370 generally toward the longitudinal axis 5358. The relief surface 5382 of each cutting tooth 5330 extends from the tip 5370 opposite the rake face 5374. The relief surface 5382 extends toward the second end portion 5346 of the body 5318 and is obliquely oriented relative to the longitudinal axis 5358. In addition, each cutting tooth 5330 includes a pocket 5398 defined along the tip 5370. In the illustrated embodiment, the pocket 5398 of each cutting tooth 5330 has a curvilinear shape. In other embodiments, the pocket 5398 may have other shapes. The pocket 5398 is positioned between the rake face 5374 and the relief surface 5382. As such, each rake face 5374 extends between the pocket 5398 and the gullet 5378 such that the rake face 5374 is positioned to at least partially define the gullet 5378. The relief surface 5382 of each cutting tooth 5330 extends between the pocket 5398 and the protrusion 86.

[0242] Each cutting tooth 5330 further includes a cutting insert 5402 that forms at least a portion of the tip 5370. The cutting inserts 5402 can be coupled to respective pockets 5398 by various welding methods and formed of various materials. In the illustrated embodiment, the cutting insert 5402 is formed of carbide, while the remaining portion of the cutting tooth, as well as the body 5318 of the saw blade 5310, is formed of steel (e.g., high speed steel). Each cutting insert 5402 is coupled to a respective pocket 5398 by resistance welding.

[0243] In an initial state, the cutting insert 5402 is formed as a cylindrical piece. In other embodiments, the cutting insert 5402 may take the form of other shapes. After the cutting insert 5402 is secured to the cutting tooth 5330, the cutting insert 5402 may then be ground to a desired shape to be in a final state (e g., the cutting insert 5402 of FIGS. 81-85).Attorney Docket No. 066042- 1973 -WOO 1

[0244] In the final state, the cutting insert 5402 includes a top portion 5410 and a front portion 5414. The top portion 5410 may also be referred to as a top edge. The front portion 5414 may also be referred to as a front edge. The top portion 5410 of each cutting insert 5402 serves as a relief face for the cutting insert 5402. Also, the top portion 5410 of each cutting insert 5402 is positioned along the pocket 5398 such that the relief surface 5382 is overlapped by at least a portion of the top portion 5410. In the illustrated embodiment, the top portion 5410 of each cutting insert 5402 is generally flush or coplanar with the corresponding relief surface 5382. In other embodiments, the top portion 5410 of each cutting insert 5402 may be offset from the corresponding relief surface 5382. The front portion 5414 of each cutting insert 5402 sen es as a rake face for the cutting insert 5402. In the illustrated embodiment, the front portion 5414 of each cutting insert 5402 is slightly offset and oriented at a different angle from the corresponding rake face 5374. In other embodiments, the front portion 5414 of each cutting insert 5402 may be generally flush or coplanar with the corresponding rake face 5374. Each cutting insert 5402 includes side surfaces 5418a, 5418b (FIG. 82) extending between the top portion 5410 and the front portion 5414.

[0245] With reference to FIG. 84, each cutting insert 5402 is ground until the top portion 5410 is obliquely oriented at an insert angle A31 relative to the longitudinal axis 5358 and the front portion 5414 is obliquely oriented at an insert angle A32 relative to the longitudinal axis 5358. The insert angle A31 ranges between 6 and 10 degrees, and is preferably 8 degrees. The insert angle A32 ranges between 89 and 93 degrees, and is preferably 91 degrees. In other embodiments, the insert angle A31 and / or the insert angle A32 may have other values.

[0246] With continued reference to FIGS. 84 and 85, each cutting insert 5402 is ground such that the side surfaces 5418a, 5418b overlap outer surfaces 5422a, 5422b of a corresponding cutting tooth 5330. In other embodiments, the side surfaces 5418a, 5418b of each cutting insert 5402 may be flush with the outer surfaces 5422a, 5422b of a corresponding cutting tooth 5330. In addition, each side surface 5418a, 5418b of the cutting inserts 5402 is formed w th a chamfer 5426a, 5426b extending between the front portion 5414 and the relief surface 5382. The chamfers 5426a, 5426b are obliquely oriented at an insert angle A33 (FIG. 85) relative to a corresponding outer surface 5422a, 5422b. In the illustrated embodiment, the insert angle A33 ranges between 43 and 47 degrees, and is preferably 45 degrees.Attorney Docket No. 066042- 1973 -WOO 1

[0247] In addition, each cutting insert 5402 is ground such that each chamfer 5426a, 5426b defines a cutting-edge width W13. For clarity. FIG. 85 only illustrates the cutting- edge width W13 with respect to the chamfer 5426a formed on the first side surface 5418a. The cutting-edge width W13 of each chamfer 5426a, 5426b extends between the top portion 5410 and a corresponding side surface 5418a, 5418b. The cutting-edge W13 ranges between 0.005 and 0.017 inches, and preferably 0.010 inches.

[0248] FIGS. 86 and 87 illustrate another saw blade 5510. The saw blade 5510 is similar to the saw blade 5310 of FIGS. 81-85; therefore, like structure will be identified by like reference number plus “200"’ and only the difference will be discussed hereafter.

[0249] The illustrated saw blade 5510 includes a body 5518, an attachment portion 5522, and a cutting portion 5526 formed on the body 5518 and having a plurality of cutting teeth 5530. Each cutting tooth 5530 includes a tip 5570, a rake face 5574, a gullet 5578, and a relief surface 5582, and a cutting insert 5602 that forms at least a portion of the tip 5570. Each cutting insert 5602 is ground such that the side surfaces 5618a, 5618b are respectively formed with a round edge 5626a, 5626b. Each round edge 5626a, 5626b defines an insert radius R27, R28. In the illustrated embodiment, each insert radius R27, R28 ranges between 0.007 and 0.017 inches, and is preferably 0.012 inches. In further embodiments, the saw blade 5510 may include a coating, similar to the coating 192 of FIG. 9B.

[0250] Although the invention 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 invention as described.

[0251] Various features and advantages of the invention are set forth in the following claims.

Claims

Attorney Docket No. 066042- 1973 -WOO 1CLAIMSWhat is claimed is:

1. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising: a body defining a longitudinal axis; an attachment portion coupled to the body and configured to be coupled to the reciprocating saw; a cutting portion formed on the body, the cutting portion including a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis, each cutting tooth includes a tip having a cutting insert with at least one chamfer oriented at an insert angle relative to a portion of a corresponding cutting tooth, a rake face extending from the tip toward the longitudinal axis, a gullet at least partially defined by the rake face, a relief surface extending from the tip opposite the rake face, and a protrusion extending between the gullet and the relief surface, the protrusion configured to inhibit an object imbedded within a work piece from impacting the rake face; and a ceramic coating overlaying at least the cutting insert of each cutting tooth.

2. The reciprocating saw blade of claim 1, wherein the insert angle is 45 degrees.

3. The reciprocating saw blade of claim 1, wherein the insert angle is 40 degrees.

4. The reciprocating saw blade of claim 1, wherein the insert angle is 35 degrees.

5. The reciprocating saw blade of claim 1, wherein each cutting tooth is set in a right direction or a left direction of the body.

6. The reciprocating saw blade of claim 1 , wherein each cutting tooth is unset.Attorney Docket No. 066042- 1973 -WOO 17. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising: a body defining a longitudinal axis; an attachment portion coupled to the body and configured to be coupled to the reciprocating saw; and a cutting portion formed on the body, the cutting portion including a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis, each cutting tooth includes a rake face, a relief surface, a pocket positioned between the rake face and the relief surface. a cutting insert secured to the pocket, the cutting insert having atop portion obliquely oriented at a first insert angle relative to the longitudinal axis, a front portion obliquely oriented at a second insert angle relative to the longitudinal axis, and at least one side surface extending between the top portion and the front portion, the at least one side surface being formed with a chamfer, and a protrusion extending from the relief surface, the protrusion configured to inhibit an object imbedded within a work piece from impacting the rake face.

8. The reciprocating saw blade of claim 7, wherein the first insert angle is 8 degrees.

9. The reciprocating saw blade of claim 7, wherein the second insert angle is 88 degrees.

10. The reciprocating saw blade of claim 7, wherein the chamfer is oriented at a third insert angle relative to a portion of a corresponding cutting tooth, and wherein the third insert angle is 45 degrees.

11. The reciprocating saw blade of claim 7, wherein each cutting tooth is set in a right direction or a left direction of the body.

12. The reciprocating saw blade of claim 7, wherein each cutting tooth is unset.

13. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising:Attorney Docket No. 066042- 1973 -WOO 1 a body defining a longitudinal axis; an atachment portion coupled to the body and configured to be coupled to the reciprocating saw; a cuting portion formed on the body, the cutting portion including a plurality of cuting teeth extending along the body in a direction parallel to the longitudinal axis, each cuting tooth includes a tip having a cuting insert with at least one chamfer, and a protrusion spaced a distance from the tip, the protrusion having an apex with a curvilinear shape, the protrusion configured to inhibit an object imbedded within a work piece from impacting a rake face of each cuting tooth; and a ceramic coating overlaying at least the cuting insert of each cuting tooth.

14. The reciprocating saw blade of claim 13, wherein the at least one chamfer is oriented at an insert angle relative to a portion of a corresponding cuting tooth, and wherein the insert angle is 45 degrees.

15. The reciprocating saw blade of claim 13, wherein the at least one chamfer is oriented at an insert angle relative to a portion of a corresponding cuting tooth, and wherein the insert angle is 40 degrees.

16. The reciprocating saw blade of claim 13, wherein the at least one chamfer is oriented at an insert angle relative to a portion of a corresponding cuting tooth, and wherein the insert angle is 35 degrees.

17. The reciprocating saw blade of claim 13, wherein the ceramic coating has a thickness ranging between 2.0 and 5.0 micrometers.

18. The reciprocating saw blade of claim 13, wherein the ceramic coating has a thickness ranging between 3.0 and 4.0 micrometers.

19. The reciprocating saw blade of claim 13, wherein the ceramic coating has a thickness of about 3.5 micrometers.Attorney Docket No. 066042- 1973 -WOO 120. The reciprocating saw blade of claim 13, wherein the ceramic coating is applied by physical vapor deposition.

21. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising: a body defining a longitudinal axis; an attachment portion coupled to the body and configured to be coupled to the reciprocating saw; and a cutting portion formed on the body, the cutting portion including a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis, each cutting tooth includes a tip having a cutting insert with at least one round edge, a rake face extending from the tip toward the longitudinal axis, a gullet at least partially defined by the rake face, and a relief surface extending from the tip opposite the rake face.

22. The reciprocating saw blade of claim 21 , wherein the at least one round edge defines a radius of 0.025 inches.

23. The reciprocating saw blade of claim 21, wherein the at least one round edge defines a radius of 0.015 inches.

24. The reciprocating saw blade of claim 21, wherein the at least one round edge is a first round edge, and wherein the cutting insert has a second round edge.

25. The reciprocating saw blade of claim 24, wherein each round edge defines a radius of 0.025 inches.

26. The reciprocating saw blade of claim 24, wherein each round edge defines a radius of 0.015 inches.

27. The reciprocating saw blade of claim 24, wherein the cutting insert has a planar portion formed between the first round edge and the second round edge, and wherein the planar portion of the cutting insert is obliquely oriented relative to the longitudinal axis.Attorney Docket No. 066042- 1973 -WOO 128. The reciprocating saw blade of claim 21, wherein each cutting tooth is set in a right direction or a left direction of the body.

29. The reciprocating saw blade of claim 21, wherein each cutting tooth is unset.

30. A reciprocating saw blade for use with a reciprocating saw, the reciprocating saw blade comprising: a body defining a longitudinal axis; an attachment portion coupled to the body and configured to be coupled to the reciprocating saw; and a cutting portion formed on the body, the cutting portion including a plurality of cutting teeth extending along the body in a direction parallel to the longitudinal axis, each cutting tooth includes a rake face, a relief surface, a pocket positioned between the rake face and the relief surface, and a cutting insert secured to the pocket, the cutting insert having atop portion obliquely oriented relative to the longitudinal axis, a front portion obliquely oriented relative to the longitudinal axis, a first side surface extending between the top portion and the front portion, and a second side surface extending between the top portion and the front portion opposite the first side surface, the first side surface and the second side surface are each formed with a round edge.

31. The reciprocating saw blade of claim 30, wherein the round edge of each side surface defines of radius of 0.015 inches.

32. The reciprocating saw blade of claim 30, wherein the round edge of each side surface defines of radius of 0.025 inches.

33. The reciprocating saw blade of claim 30, wherein the top portion is a planar portion extending between the round edge of each side surface.

34. The reciprocating saw blade of claim 30, wherein each cutting tooth is set in a right direction or a left direction of the body.Attorney Docket No. 066042-1973-W00135. The reciprocating saw blade of claim 30, wherein each cutting tooth is unset.

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