Cutting Blade Teeth Forming for Acute Edge Angles
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Solution Overview
Problem
Conventional methods for manufacturing cutting edges for hair cutting systems, such as trimmers and shavers, fail to produce sharp cutting edges with acute angles smaller than 90 degrees, as stamping results in straight angles and forging leads to blunt edges, while other techniques are complex and costly.
Innovation Solution
A cutting and bending process using a cutting device with a first and second die to form teeth with edge portions that protrude below a plane, followed by a bending process to shape these edges into sharp, robust cutting edges, achieving a wedge angle smaller than 90 degrees without the need for expensive finishing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional stamping is used to form cutting edges, then the manufacturing process is simple, but the cutting edge angle becomes straight (90 degrees) and not sharp
Solution Approach 1:
The method performs preliminary cutting to create teeth with edge portions protruding below the blank plane, then subsequently bends these edge portions back to form the final acute cutting edge angle. This two-step approach (cutting then bending) allows achieving precise acute angles that cannot be obtained by stamping alone, while maintaining manufacturing simplicity.
2Strength
If conventional forging is used to form cutting edges, then the cutting edges become robust, but the cutting edge angle becomes blunt and not sharp
Solution Approach 1:
The cutting device first creates teeth with edge portions that protrude below the blank plane, establishing a preliminary geometry. Then the bending device bends these protruding edge portions back to form the final acute cutting edge angle. This sequence allows the material to maintain robustness from forging while achieving the precise sharp angle through controlled bending, avoiding the bluntness inherent in conventional forging.
3Manufacturing precision
If other manufacturing techniques are used to achieve acute cutting edge angles, then the cutting edge precision is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The invention merges the cutting function and bending function into an integrated two-step process using a cutting device followed by a bending device. The cutting device creates teeth with protruding edge portions, and the bending device bends these portions back to form acute angles. This combined approach achieves precise acute cutting edge angles without requiring complex separate operations or expensive specialized equipment, maintaining manufacturing simplicity while improving precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively forms sharp and robust cutting edges for hair cutting systems, applicable to both linear and rotary systems, at a lower environmental and economic cost compared to existing techniques, ensuring superior hair cutting performance.
Implementation Method 1
moving the first die and second die with respect to each other such that the first plane is moved toward and passes through the second plane, such that each element of the plurality of first elements passes at least partially between adjacent elements of the plurality of second elements
Implementation Method 2
utilizing a bending device to bend edge portions of the teeth of the cutting blade or guard that extend below the plane of the blank after step d) back toward the plane of the blank
Data Source
Figure 1a~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a method (200) of forming a plurality of teeth of a cutting blade or guard, the method comprises: a) taking (210) a blank of material, the blank having an upper outer surface and a lower outer surface, wherein at least a portion of the lower outer surface is substantially planar and forms a plane of the blank; b) utilizing (220) a cutting device (20) comprising a first die (40) and a second die (50), wherein the first die comprises a plurality of first elements (42) and the second die comprises a plurality of second elements (52), wherein a first plane (60) is defined with respect to upper surfaces of the plurality of first elements and a second plane (70) is defined with respect to lower surfaces of the plurality of second elements, and wherein each upper surface of the plurality of first elements has a centre part (44) that lies in the first plane and edge parts (46) that are below the first plane; c) placing (230) the blank in the cutting device, such that the portion of the lower outer surface faces the upper surfaces of the plurality of first elements and the portion of the upper outer surface faces the lower surfaces of the plurality of second elements; d) moving (240) the first die and second die with respect to each other such that the first plane is moved toward and passes through the second plane, such that each element of the plurality of first elements passes at least partially between adjacent elements of the plurality of second elements, and wherein teeth (80) of the cutting blade or guard are formed that correspond to the positions of the plurality of first elements and wherein the teeth have a lower outer surface formed from the lower outer surface of the blank; and e) utilizing (250) a bending device (30) to bend edge portions (82) of the teeth of the cutting blade or guard that extend below the plane of the blank after step d) back toward the plane of the blank.