Bandsaw blade

Abstract

A bandsaw blade, including a main tooth group formed by nine sawteeth arranged in sequence, including three sub-tooth groups including a first sawtooth (1,4,7) of straight tooth, a second sawtooth (2,5,8) of left set tooth and a third sawtooth (3,6,9) of right set tooth. Each of sawteeth (1) and (4)-(6) has chamfers on two sides. Sawtooth (1) has a first height, sawtooth (4) has a second height and sawtooth (7) has a third height. Sawteeth (5) and (6) have the same fourth height. Sawteeth (2), (3), (8) and (9) have the same fifth height. The first through fifth heights are sequentially decreased. A top plane width of sawtooth (4) is larger than that of sawtooth (1). A top plane width of sawtooth (7) is larger than that of sawtooth (4). By using the bandsaw blade, more chips can be produced to reduce total cutting force and improve cutting efficiency.

Claims

1. A bandsaw blade, comprising a saw blade body and sawteeth located on the saw blade body, wherein nine sawteeth arranged in sequence form a main tooth group; each main tooth group comprises a first sub-tooth group, a second sub-tooth group and a third sub-tooth group; and each sub-tooth group comprises a first sawtooth, a second sawtooth and a third sawtooth which are sequentially arranged, the first sawtooth is a straight tooth, and the second sawtooth and the third sawtooth are a left set tooth and a right set tooth respectively; a first sawtooth of the first sub-tooth group has a first height, and is provided with chamfers on two sides; a first sawtooth of the second sub-tooth group has a second height, and is provided with chamfers on two sides, and the width of the top plane of the first sawtooth of the second sub-tooth group is larger than that of the first sawtooth of the first sub-tooth group; a first sawtooth of the third sub-tooth group has a third height, and the width of the top plane of the first sawtooth of the third sub-tooth group is larger than that of the first sawtooth of the second sub-tooth group; second and third sawteeth of the first sub-tooth group and second and third sawteeth of the third sub-tooth group have a same fifth height; the second and third sawteeth of the second sub-tooth group have a fourth height, and are provided with chamfers on the outer sides; and the first height, the second height, the third height, the fourth height and the fifth height are sequentially decreased.

2. The bandsaw blade according to claim 1, wherein a cutting edge of each sawtooth comprises hard alloy.

3. The bandsaw blade according to claim 1, wherein the first height, the second height, the third height, the fourth height and the fifth height are sequentially decreased in an arithmetic progression.

4. The bandsaw blade according to claim 1, wherein the width of the top plane of the first sawtooth of the first sub-tooth group is equal to 20-30% of the thickness of the saw blade.

5. The bandsaw blade according to claim 1, wherein the width of the top plane of the first sawtooth of the second sub-tooth group is equal to 60-70% of the thickness of the saw blade.

6. The bandsaw blade according to claim 1, wherein the first sawtooth of the third sub-tooth group is not provided with chamfer.

7. The bandsaw blade according to claim 1, wherein none of the second and third sawteeth of the first sub-tooth group and the second and third sawteeth of the third sub-tooth group is provided with chamfer.

8. The bandsaw blade according to claim 1, wherein all the chamfers are chamfers of 45 degrees; and the widths of the chamfers of the second and third sawteeth of the second sub-tooth group are ½ of the tooth set.

9. The bandsaw blade according to claim 1, wherein a rear angle of the sawtooth is between 10 and 30 degrees; and a rake angle of the sawtooth is between 0-15 degrees.

10. The bandsaw blade according to claim 1, wherein the bandsaw blade adopts fixed tooth pitch or variable tooth pitch.

11. The bandsaw blade according to claim 1, wherein the width of the top plane of the first sawtooth of the first sub-tooth group is equal to 25% of the thickness of the saw blade.

12. The bandsaw blade according to claim 1, wherein the width of the top plane of the first sawtooth of the second sub-tooth group is equal to 66% of the thickness of the saw blade.

13. The bandsaw blade according to claim 1, wherein a rear angle of the sawtooth is 25 degrees; and a rake angle of the sawtooth is 10 degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram of the cross section of the tooth profile of a bandsaw blade provided by the present invention;

(2) FIG. 2(a) is a front view of a band saw blade provided by the present invention (the height of each sawtooth is not indicated);

(3) FIG. 2(b) is a top view of a bandsaw blade of the present invention;

(4) FIG. 3 is a front view of each tooth of the present invention after grinding;

(5) FIG. 4 is a chart of the paper “the relationship between cutting force and chip thickness” published at the 12th International Flexible Automation Conference;

(6) FIG. 5 is a standardized chart of the relationship between force and cutting depth;

(7) FIG. 6 is a schematic diagram of per-tooth cutting of a standardized flat tooth;

(8) FIG. 7 is a schematic diagram of per-tooth cutting of a standardized triple set tooth;

(9) FIG. 8 is a schematic diagram of standardized per-tooth cutting of Bahco 3881 THQ and Bichamp CB PRO type teeth;

(10) FIG. 9 is a schematic diagram of standardized per-tooth cutting of Lenox Cast Master;

(11) FIG. 10 is a schematic diagram of standardized per-tooth cutting of Wikus 542 non-set tooth profile;

(12) FIG. 11 is a schematic diagram of standardized per-tooth cutting of standard triple chip non-set tooth profile;

(13) FIG. 12 is a schematic diagram of standardized per-tooth cutting of a tooth profile provided by the present invention; and

(14) FIG. 13 refers to comparison between tooth setting torsion angles of tooth tips of a bimetal bandsaw blade and a hard alloy bandsaw blade.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(15) The present invention is described in further detail below in combination with accompanying drawings:

(16) Referring to FIG. 1-FIG. 3, and FIG. 12, in a hard alloy bandsaw blade provided by the present invention, nine sawteeth forms a main period (nine sawteeth forms a main tooth group), each three sawteeth form a sub-period (three sawteeth forms a sub-tooth group), and each sub-period includes a straight guide tooth, a left set tooth, a right set tooth arranged in sequence (in FIG. 2, S: non-set straight tooth, L: leftward set tooth, and R: rightward set tooth). The nine sawteeth have five tooth heights; the tooth heights refer to the heights of tooth tips of the sawteeth, and are divided into a first-level height to a fifth-level height from high to low, preferably, step differences between the levels of height are the same (in FIG. 3, Y1-Y4 refer to the height differences between the teeth, and the height difference of each level is the same), and the nine sawteeth have four tooth tip shapes. The four tooth tip shapes are as follows:

(17) first type: the straight tooth without chamfer;

(18) second type: the straight tooth with chamfers on two sides;

(19) third type: the set tooth with chamfer on the outer side; and

(20) fourth type: the set tooth without chamfer.

(21) In the main period, No. 1 tooth is the highest tooth, the tooth tip height belongs to the first level, the No. 1 tooth is of the second-type tooth tip shape, and the width X2 of the unchamfered part of the No. 1 tooth is 25% of the thickness X1 of the saw blade.

(22) The following No. 2 and No. 3 teeth belong to the fourth type tooth tip type, the heights of the No. 2 and No. 3 belong to the fifth level, and the two teeth are symmetrical left and right set teeth.

(23) No. 4 tooth is the second-type straight tooth, and the height level of the tooth is one less than that of the No. 1 tooth, and belongs to the second level. The width X3 of the unchamfered part of the No. 4 tooth is 66% of the thickness X1 of the bandsaw.

(24) No. 5 and No. 6 teeth are the third type tooth tip type, respectively being a left set tooth and a right set tooth, and the heights of the tooth tips belong to the fourth level that is one more than the height level of the No. 2 and No. 3 teeth. One side of each of the No. 5 and No. 6 teeth is chamfered, and the width X4 of the chamfer is 50% of a tooth set S.

(25) No. 7 tooth is the first-type straight tooth, and the height of the tooth tip belongs to the third level.

(26) No. 8 and No. 9 teeth are the first tooth tip type, respectively being a left set tooth and a right set tooth, the heights of the tooth tips belong to the fifth level, and the tooth sets and heights of the No. 8 and No. 9 teeth are the same as those of the No. 2 and No. 3 teeth.

(27) The No. 1, No. 2 and No. 3 teeth form the first sub-tooth group; the No. 4, No. 5 and No. 6 teeth form the second sub-tooth group; and the No. 7, No. 8 and No. 9 teeth form the third sub-tooth group. It should be noted that the arrangement mode of the first sub-tooth group, the second sub-tooth group and the third sub-tooth group may be randomly combined, and the cutting number or size or cutting capacity may not be affected.

(28) The tooth profile of the present invention is not necessarily related to the tooth profile on a back material formed by tooth milling (or other processing methods) before the hard alloy head is welded; for example, a tooth profile period formed by tooth milling may include seven teeth or five teeth. Therefore, if the tooth profile period after the tooth tip of the back material is shaped includes seven teeth, and a tooth tip grinding period is designed according to the present invention, one tooth profile period of the saw blade actually includes 64 teeth. Due to the fact that the tooth milling period and the tooth grinding period are inconsistent, the No. 1 grinding tooth tip needs to be separated from the other one by 64 teeth in the same tooth profile formed through tooth milling.

(29) Another change of the present application is to adjust the rear angle from the traditional angle of 20 degrees to the angle of 25 degrees; since 1986, the angle of 20 degrees adopted by the tooth tip rear angle of the hard alloy bandsaw blade is mainly for preventing overlarge vibration in sawing caused by large rear angle; however, by trying to cut Inconel 718 on site, the tooth profile designed by the present invention is proved that the rear angle of 25 degrees will not cause overlarge vibration. Increasing the rear angle is also to further reduce the cutting force.

(30) The main objective of the present application is to generate pieces of chips as much as possible so as to reduce the total cutting force. When the tooth profile is used for cutting, under the condition of same cutting efficiency, the average cutting force of each tooth is lower, and the generated chips are narrow and thick.

(31) Another objective of the present application is also different from that of a tooth profile disclosed in U.S. Pat. No. 5,832,803 which can deal with current materials that are larger and more difficult to cut. Of course, the situation that the product of U.S. Pat. No. 5,832,803 can exist in the market for more than 20 years is based on successful design of the product, which is not an update version of the design of U.S. Pat. No. 5,331,871, but another concept.

(32) The design purpose of the tooth profile of the present application is to reduce the cutting force and then reduce the loss of tension on a cutting edge. This improves sawing quality and prolongs the service life of the bandsaw.

(33) Analysis and comparison on the cutting forces of the bandsaw blade tooth profile of the present application and other tooth profiles

(34) Most attention of most tooth profile patent specifications related to reducing the cutting force is to generate various geometrical shapes of teeth with multiple chips but never analyzing principles thereof, and to leave performance assessment to examiners of patent applications and end users, making them to accept these claims as a fact.

(35) The following is to analyze, in principle, how various tooth profiles affect the cutting force. Firstly, the relationship between the chip thickness and the cutting force required to form the chip must be understood. In 2002, M. Sarwar, H. Hellberg, A. R, Doraisingam, and M. Persson proposed a paper titled “Simulation of the Intermittent Cutting Action of a Bandsaw Blade” in the International Conference on Flexible Automation and Intelligent Manufacturing, Dresden, Germany. The study is finished at the Engineering School, University of Northumbria at Newcastle, UK.

(36) The study essentially researches the relationship between the cutting force generated in sawing and the chip thickness. A single tooth cut specimen is mounted on a rotating fixture on a lathe. Instruments mounted on a single tooth holder measure the cutting forces and feeding forces. One figure of the paper is shown in FIG. 4 of the application.

(37) Inventors of the present application are Mr. Hellberg and Mr. Persson, colleagues who worked together for 15 years from 1991 to 2006. During such period, Empirical rule considered that the chip thickness is doubled but the cutting force is only increased by 60%. Sawing tests on all types of materials have proven this theory over the years, and the bandsaw blades in the tests include bimetal and hard alloy tip bandsaw blades. Based on results of the study and results of the tests, a relationship curve between the cutting force and the chip thickness in FIG. 5 is summarized.

(38) In the figure, the chip depth on a transverse axis and the cutting force on a longitudinal axis are standardized. A standard chip thickness value “1.0” represents the recommended per-tooth cutting depth of the bandsaw when a specific material is cut. A standard cutting force “1.0” refers to the force (hereinafter a unit cutting force) required for cutting the standardized chip thickness “1.0” of the specific material by a 1 mm wide single tooth.

(39) The curve in FIG. 5 will be closely validated if the graph in FIG. 4 is normalized. The graph in FIG. 5 can be used for comparing relative cutting forces of various tooth profiles regardless of the materials to be cut.

(40) Comparative analysis on the tooth profile designs of predecessors and the tooth profile of the present application will take sawing Inconel 718 as an example. The analysis is based on following parameters: the same cutting speed, the same feeding rate, the same kerf width that is equal to 2.6 mm, the same material and the same tooth pitch.

(41) FIG. 6 is a schematic diagram of cutting of a flat tooth, in which C1 refers to the first piece of generated chip, and the chip thickness tc=1.0,

(42) F=1.0 f/mm f: one unit cutting force represented by the chip width per mm

(43) Ft=(2.6)×F=2.6 f

(44) the average per-tooth cutting force is 2.6 f.

(45) FIG. 7 is a schematic diagram of cutting of triple set tooth profiles such as Bahco 3868 TSX, Lenox Tri Tech and Bichamp CB MP, in which C1-C3 refer to three pieces of generated chips,

(46) Ft=((2)×(0.65)×(2.1)+(1.3)×(2.1)) f

(47) Ft=2.73+2.73=5.46 f

(48) the average per-tooth cutting force=the total cutting force/the total number of teeth=5.46 f/3=1.82 f.

(49) FIG. 8 is a schematic diagram of cutting of sextuple set tooth profiles such as Bahco 3881 THQ and Bichamp CB PRO, in which C1-C7 refer to seven pieces of generated chips,

(50) Ft=(2.6)×(3.35)=9.1 f

(51) the average per-tooth cutting force=the total cutting force/the number of teeth=9.1 f/6=1.516 f.

(52) FIG. 9 is a schematic diagram of a three-tooth non-set type tooth profile of Lenox Cast Master, in which C1-C5 refer to five pieces of generated chips,

(53) Ft=(2.6)×(2.1)=5.46 f

(54) the average per-tooth cutting force=the total cutting force/the number of teeth=5.46 f/3=1.82 f.

(55) FIG. 10 is a schematic diagram of cutting of the non-set type tooth profile of Wikus 542, in which C1-C7 refer to seven pieces of generated chips, Ft=((1)×(2.56)+(2)×(0.45)×(2.56)+4×(0.35)×(2.1)) f=(2.56+2.304+2.24) f

(56) Ft=7.104 f

(57) the average per-tooth cutting force=the total cutting force/the number of teeth=7.104 f/4=1.776 f

(58) FIG. 11 is a schematic diagram of cutting of a standard triple chip non-set tooth profile, in which C1-C3 refer to three piece of generated chips, Ft=(2.6)×(1.6)=4.16 f

(59) the average per-tooth cutting force=the total cutting force/the number of teeth=4.16 f/2=2.08 f

(60) FIG. 12 is a schematic diagram of cutting of a tooth profile provided by the present application, in which C1-C11 refer to eleven pieces of generated chips, the chip thickness is tc

(61) chip (3, 4, 5, 6, 7, 8, 9) tc=9, F=4.5 f

(62) chip (2,10) tc=6, F=3.35 f

(63) chip (1,11) tc=3, F=2.1 f

(64) Ft=((2.1)×(4.5)+(2)×(0.25)×(2.1)+(2)×(0.25)×(3.3.5)) f=(9.45+1.05+1.675) f

(65) Ft=12.175 f

(66) the average per-tooth cutting force=the total cutting force/the number of teeth=12.175 f/9=1.352 f

(67) At last, the average per-tooth cutting force of each tooth profile is compared. The results are based on the lowest cutting forces of cutting tools, and the average per-tooth cutting forces of the seven tooth profiles are ranked from low to high, as shown in Table 1.

(68) TABLE-US-00001 TABLE 1 Comparison on average per-tooth cutting forces of various tooth profiles Tooth Number of Tooth Profile Cutting Tooth Set Number per Generated Rank Name Force Type Period Chip 1 the present 1.352 set type 9 11 application 2 3881 THQ 1.516 set type 6 7 3 Wikus 542 1.776 non-set type 4 7 4 3868 TSX 1.82 set type 3 3 5 Cast Master 1.82 non-set type 3 5 6 Triple chip 2.08 non-set type 2 3 7 Flat tooth 2.6 non-set type 1 1

(69) Obviously, the cutting force of the tooth profile provided by the present application is the lowest. It should be noted that if the cutting force is assumed to be linear, the chip thickness is twice the cutting force, and then all the teeth will have the same 2.6 units of cutting force. In addition, if it is considered that a tip clearance angle of the tooth profile of the present application is increased to 25 degrees, the cutting force is actually lower.

(70) In the publication of US2005/257660A1, the inventor of the present application proposed two three-tooth set tooth profiles, who was a part-time employee of Bahco Tools at the time. Basically, the application is similar to the Bahco 3881 THQ tooth profile, which is labeled as 3868 TSP, using unchamfered flat teeth with smaller tooth sets in addition to chamfered teeth used for generating thin chip set teeth. The three-tooth set tooth profiles are tooth profile design samples proposed according to the standard Bahco 3868 TSX and 3881 THQ and wear resistance testing is carried out. 140 mm square 304 SS is used as a test workpiece. The initial cutting force of each saw blade is consistent with expectation, the TSX saw blade has the maximum force, and the THQ force and the TSP force are reduced by 80%. Interestingly, the new method of comparing tooth tip cutting forces has a similar comparison. TSX tooth profile completes cutting of 55 pieces, THQ completes 90 pieces, and TSP only completes cutting of 27 pieces. The TSP profile is considered to be failed, the item is canceled, and the patent application did not pass the examination. It was not understood at this time that the hard alloy saw blade is doomed to fail under the condition of multiple tooth set combinations, but bimetal does not have such a problem. The root cause is the difference between the rear angles of the saw blades, the rear angle of the hard alloy saw blade is usually 20 degrees, and the rear angle of the bimetal saw blade is 30 degrees. The angle in turn affects a torsion angle of the tooth tip, and the smaller the main rear angle is, the smaller the torsion angle is. The smaller the torsion angle is, the more easily the tooth tip is abraded by the edge, so that a higher transverse force and a lower transverse cutting capacity are caused, which is the reason that the TSP saw blade fails to work due to low tooth set.

(71) The hard alloy saw blade which adopts a special tooth setting mode to set the teeth and keep the normal tooth set may twist tooth tips as much as possible to achieve an enough torsion angle and prevent untimely chip cutting. It is ironic that the concept of only using the chamfered teeth initially is mainly because tooth setting equipment cannot form multiple levels of tooth sets at that time. As further evidence, there is no hard alloy saw blade with multiple tooth setting levels on the market, and the high and low teeth of the bimetal bandsaw blade are multi-level set teeth.

(72) In FIG. 13, the effect of the rear angle and the tooth set on the torsion angle is shown.

(73) Experimental Testing

(74) Experiments are carried out in a major Inconel manufacturer in China. The purpose is to successfully complete the cutting of the large Inconel 718 forging with the dimension exceeding 550 millimeters (21 inches). Previous attempts are made to saw by using a Triple Set type hard alloy blade produced by a U.S. Manufacturer and the task is not accomplished even three saw blades are used. In the test performed by using the Bichamp CB PRO bandsaw, cutting is performed once within 16 hours, but oblique cutting exists at lower third of the cutting.

(75) When the bandsaw blade provided by the present application is used for sawing for the first time, sawing machining of the whole workpiece is successfully completed within 8 hours, and faults such as oblique cutting are avoided. Sawing time is not too long given that a bandsaw operator is very careful and conservative. And then a plurality of similar products are used for testing; and compared with other products, the present application is remarkably improved in sawing efficiency, sawing effect and sawing service life.

(76) The embodiments of the present invention are described above in combination with the accompanying drawings, and embodiments and features of the embodiments of the present invention may be combined with each other in the case of no conflict. The present invention is not limited to the specific embodiments described above, which are merely illustrative and not limiting; and many forms may be made by those of ordinary skilled in the art without departing from the spirit of the present application and the scope of the claims under inspiration of the present invention, and these are all within the scope of the present invention.