Saw Blade Tooth Setting Before Grinding to Prevent Deformation
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Solution Overview
Problem
Traditional saw blade manufacturing processes often result in undesirable deformations and inconsistencies due to the setting process, which can damage the cutting teeth and lead to variations in tooth shape and size, affecting cutting performance.
Innovation Solution
A method where the coil stock is first set in opposing directions before forming cutting teeth, using a press with specific die inserts to create a consistent set pattern, thereby avoiding direct contact with the cutting teeth during the setting process, and then forming the teeth using grinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cutting teeth are formed on coil stock before setting, then the setting process can be performed, but undesirable deformations occur along the side face of the saw blade body and at the tip of the cutting tooth
Solution Approach 1:
The coil stock is set in opposing directions before the cutting teeth are formed. This preliminary setting action creates the necessary kerf and clearance in the blade body prior to tooth formation, eliminating the need to set already-formed teeth and preventing the deformations that occur when inserts contact tooth tips during setting.
2Reliability
If the insert presses against the cutting tooth to generate force higher than the yield strength, then the cutting tooth is set properly, but the process creates undesirable deformations at the tip of the cutting tooth
Solution Approach 1:
The setting action is performed on the coil stock material itself before tooth formation. The insert presses against the unset coil stock to create the wave pattern and kerf, achieving proper tooth set without subsequently contacting or deforming the formed tooth tips.
3Force
If the insert contacts the cutting tooth tip during setting, then the setting force can be applied, but the surface area is smallest causing concentrated stress and deformation
Solution Approach 1:
The setting operation is performed on the coil stock before tooth formation, when the material has a larger, more distributed surface area. This avoids the concentrated stress problem that occurs when the same setting force is applied to the smaller surface area of formed tooth tips.
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
This approach reduces deformations, ensures consistent cutting tooth shape and size, and improves cutting performance by maintaining parallel planes at the tooth tips, leading to a smoother cut, increased durability, and reduced capital expenditures by simplifying the setting machinery.
Implementation Method 1
setting a first portion of the coil stock in a first direction, setting a second portion of the coil stock in a second direction opposite the first direction
Data Source
AI summary
A saw blade blank includes a body having an edge and an attachment portion formed on the body. The attachment portion is configured to connect to a power tool. A first portion of the edge is set in a first direction relative to the body. A second portion of the edge is set in a second direction opposite the first direction relative to the body. No cutting teeth are formed on the edge of the body.