Reciprocating Saw Blade Geometry for Accurate Plunge Cutting
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Solution Overview
Problem
Existing reciprocating saw blades with plunge noses often create an enlarged, inaccurate kerf when plunged into a workpiece, leading to slow and uncontrolled cutting, which hampers efficiency and accuracy.
Innovation Solution
A reciprocating saw blade design featuring a full raker tooth with a relief face angle of 35° to 50° and an enlarged gullet, 1.5 to 5.5 times the size of standard gullets, along with a plunging end surface at 35° to 45°, allows for precise and fast plunge cutting by creating a sharp cutting edge and enhancing chip removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional plunge nose design is used, then the blade can plunge into the workpiece, but it creates an enlarged inaccurate kurf and provides little control
Solution Approach 1:
The patent applies local quality by giving the first tooth (plunge tooth) different characteristics from the remaining teeth. Specifically, the first tooth has a relief face angle of 35° to 50° and an enlarged gullet 1.5 to 5.5 times larger than other gullets, while the plunging end face angle is optimized at 35° to 45°. These localized modifications to the first tooth and its surrounding geometry enable precise plunge cutting without affecting the overall blade structure.
2Productivity
If the blade plunges into the workpiece, then cutting can begin, but the cutting process is slow and uncontrolled
Solution Approach 1:
The patent applies parameter changes by optimizing specific geometric parameters of the first tooth and plunging end. The relief face angle of the first tooth is set to 35° to 50°, the plunging end face angle is 35° to 45°, and the first gullet size is increased to 1.5 to 5.5 times the size of other gullets. These parameter modifications enable the blade to plunge quickly and controllably, improving both cutting speed and operator control.
3Productivity
If standard gullet size is used, then the blade structure is simple, but swarf removal from the kurf is slow
Solution Approach 1:
The patent applies local quality by enlarging only the first gullet (adjacent to the plunge tooth) to 1.5 to 5.5 times the size of the remaining gullets, while keeping other gullets at standard size. This localized enlargement of the first gullet specifically improves swarf removal from the plunge kurf without significantly increasing overall blade complexity or affecting the uniformity of the remaining tooth structure.
Data Source
AI summary
A reciprocating saw blade includes a body with a shank end configured to secure the blade with a reciprocating saw, a plunging end configured to enter a workpiece, and a cutting edge and opposite back edge extending between the shank end and the plunging end. The cutting edge is formed to include a plurality of teeth arranged in a repeating pattern that includes left set teeth and right set teeth, the plurality of additional teeth being substantially the same size as each other and as the third tooth, wherein the plurality of additional gullets are substantially the same size as each other, and wherein the enlarged first gullet is longer in an axial direction than each of the plurality of additional gullets.