Hole Saw Slot Geometry for Easier Plug Removal
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Solution Overview
Problem
Existing hole saws often require manual removal of the plug, which can be cumbersome and inefficient, as the plug can become trapped within the cylindrical body during the cutting process.
Innovation Solution
The design incorporates a cylindrical body with axially extending slots and apertures, including a first slot portion, a second slot portion, and a connecting slot portion, which allows for easier removal of the plug using a tool, with the second slot portion's wall being axially offset from the cap end to facilitate tool access and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the hole saw uses a solid cylindrical body without slots, then the structural integrity and strength are maintained, but the plug becomes trapped and requires manual removal which is cumbersome and inefficient
Solution Approach 1:
The cylindrical body is segmented by introducing axial slots that divide the solid structure into sections. These slots allow the plug to be accessed and removed without compromising the overall structural integrity of the hole saw body, resolving the contradiction between ease of plug removal and structural strength.
Solution Approach 2:
The design extracts or removes material from the cylindrical body to create slots and apertures. This extraction creates pathways for plug removal while maintaining sufficient structural strength in the remaining material, enabling easy plug extraction without weakening the hole saw body excessively.
2Ease of operation
If the second slot portion wall is positioned flush with the cap end, then manufacturing is simplified, but tool access and alignment for plug removal is hindered
Solution Approach 1:
The slot configuration varies at different locations: the second slot portion wall is axially offset from the cap end by a specific distance (0.010-0.120 inches) to create local access quality that facilitates tool insertion and alignment. This localized modification improves plug removal operations without requiring complex manufacturing throughout the entire structure.
Data Source
AI summary
A hole saw includes a cylindrical body disposed along an axis of rotation with a side wall extending axially from a cap end to a cutting end. The cutting end includes a plurality of cutting teeth. The hole saw also includes a cap coupled to the cap end of the cylindrical body. The side wall defines an elongated aperture configured to receive a tool for removing work piece plugs from within the cylindrical body. The elongated aperture has a first slot portion adjacent the cutting edge. The first slot portion is oriented perpendicular to the axis of rotation. The elongated aperture also has a second slot portion connected to the first slot portion and extending from the first slot portion toward the cap end. The second slot portion is oriented at an oblique angle relative to the axis of rotation.