Saw Blade Tooth Stamping With Undercut Gullets
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Solution Overview
Problem
Conventional saw blade manufacturing methods are inefficient and require additional grinding steps to sharpen cutting tip portions, which increases production time and costs.
Innovation Solution
A method involving the use of stamping dies to form gullets and tooth bodies in a saw blade body, where the gullets have undercut portions and the tooth bodies include rake and relief faces, allowing for the formation of sharp cutting teeth without a separate grinding step, utilizing a two-step stamping process with differently oriented dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used to form saw blade teeth, then the cutting edges can be formed, but additional grinding steps are required to sharpen the cutting tip portions, increasing production time and costs
Solution Approach 1:
The patent combines the tooth formation and cutting edge sharpening operations into a single stamping process. The stamping die simultaneously forms the tooth body and creates the sharp cutting tip portion through the undercut geometry, eliminating the need for separate grinding steps that were previously required to achieve sharp cutting edges.
Solution Approach 2:
The stamping process performs preliminary shaping that pre-forms the cutting edge geometry during the initial tooth formation. By incorporating the undercut portion in the stamping die, the cutting tip is pre-sharpened before final assembly, eliminating the need for subsequent grinding operations to achieve the desired sharpness.
2Manufacturing precision
If conventional manufacturing methods are used to form saw blade teeth, then the cutting edges can be formed, but additional grinding steps are required, increasing production costs
Solution Approach 1:
The patent combines the tooth formation and cutting edge sharpening operations into a single stamping process. The stamping die simultaneously forms the tooth body and creates the sharp cutting tip portion through the undercut geometry, eliminating the need for separate grinding steps that were previously required to achieve sharp cutting edges.
Solution Approach 2:
The stamping die is designed with undercut geometry that automatically forms the sharp cutting tip portion during the normal tooth formation process. The die structure itself provides the sharpening function without requiring additional grinding equipment or operations, making the process self-sufficient and more cost-effective.
3Ease of manufacture
If gullets are formed without undercut portions, then the manufacturing process is simpler, but the tooth bodies cannot be properly formed with correct rake and relief faces
Solution Approach 1:
The patent introduces undercut portions that extend in a direction toward the saw blade body, creating a three-dimensional geometry that enables proper tooth formation. This additional dimensional feature in the gullet structure allows the stamping die to simultaneously form the tooth body with correct rake and relief faces while maintaining process simplicity.
Solution Approach 2:
The gullet is segmented into multiple portions including the undercut portion that extends toward the saw blade body. This segmentation allows different portions of the gullet to serve different functions: the undercut portion enables proper tooth geometry formation, while the rest of the gullet structure maintains manufacturing simplicity.
Data Source
AI summary
A method of manufacturing a saw blade includes providing a saw blade body having an edge, forming a plurality of tooth bodies that defines a plurality of gullets in the saw blade body, coupling a cutting member to the edge of the saw blade body, and shaping the cutting member to form a cutting tooth after the cutting member is coupled to the edge. Each one of the plurality of tooth bodies defines an undercut portion positioned between adjacent tooth bodies. The cutting tooth includes a rake face extending from a tip of the cutting tooth toward the saw blade body and a relief face extending from the tip toward a second end of the cutting tooth sloping toward the saw blade body.