JP7578680B2 - Tip saw - Google Patents

Description

One aspect of the present disclosure relates to a tipped saw. The tipped saw cuts a workpiece, such as a siding board made of a ceramic material used as an exterior wall material for a house.

A chip saw has a disk-shaped base metal and multiple cutting tips attached to the outer periphery of the base metal. The cutting tips are made of high-hardness materials such as cemented carbide and polycrystalline diamond (PCD). This reduces wear on the cutting edge when cutting siding boards and the like, allowing for a longer life for the cutting tips.

As a blade type for this type of cutting tip, for example, a flat blade in which the cutting edge at the radially outer tip of the base metal is horizontal is known. Siding boards used as exterior wall materials generally have a design surface with decorative uneven shapes. When cutting a siding board with a tipped saw having a flat blade, defects called pattern skips tend to occur on the edges of the design surface of the siding board. For this reason, it has been necessary to repair the edges of the siding board after cutting, such as by applying paint.

The cutting tip disclosed in Registered Utility Model Publication No. 3183126 has a mountain-shaped or trapezoidal cutting edge. The radially outer tip of the cutting edge, i.e., the apex of the mountain shape or the upper side of the trapezoid, is located near the center of the thickness direction of the base metal. Both left and right edges of the cutting edge are inclined radially outward toward the center of the thickness direction of the base metal. This makes it possible to suppress chipping and other defects that occur at the edge of the cut surface of the workpiece. However, the cutting edge line length per cutting tip is longer than that of a flat blade. Therefore, the net cutting power is higher than that of a flat blade. This type of chip saw is attached to a rechargeable tool such as a portable electric circular saw and used. If the cutting power increases, the number of cuts per charge of the rechargeable tool will decrease.

The cutting tip disclosed in Registered Utility Model No. 3211231 has two types of tips: a first tip whose radially outer tip is on the left side of the thickness direction of the base metal, and a second tip whose radially outer tip is on the right side of the thickness direction of the base metal. The two types of tips are arranged alternately in the circumferential direction of the base metal. These two types of tips also have inclined left and right edges of the cutting edge, which can suppress chipping and other defects at the edge of the cut surface of the workpiece. However, the first and second tips receive cutting resistance that is biased to the left and right in the thickness direction of the base metal. Therefore, when the first and second tips cut the workpiece alternately, the base metal to which each tip is joined is likely to vibrate periodically from side to side. This can cause noise, deterioration of the cut surface, and increase in net cutting power.

As described above, with the cutting tips of conventional tipped saws, it has been difficult to simultaneously prevent damage to the workpiece, such as the handle coming off, and reduce the net cutting power of the tipped saw. Therefore, there has been a need for a tipped saw equipped with a cutting tip that can reduce the net cutting power while preventing damage to the workpiece.

According to one feature of the present disclosure, the chip saw has a right chip, a left chip, and a middle chip. The right chip is joined to the outer periphery of the base metal and has a radially outer tip toward the right in the thickness direction of the base metal when the rake face is viewed from the front in the rotation direction as shown in FIG. 3. The left chip is joined to the outer periphery of the base metal and has a radially outer tip toward the left in the thickness direction of the base metal. The middle chip is joined to the outer periphery of the base metal and has a radially outer tip near the center in the thickness direction of the base metal. The right chip has a first right cutting edge that extends from the tip to the right end at a first right angle. A first left cutting edge is provided that extends from the tip toward the left side surface at a first left angle smaller than the first right angle. A first left shoulder cutting edge is provided that extends from the first left cutting edge to the left end at a first left shoulder angle larger than the first left angle. In detail, the first right angle is the angle between a first reference line extending from the tip of the right chip in the thickness direction of the chip saw and the first right cutting edge. The first left angle is the angle between the first reference line and the first left cutting edge. The first left shoulder angle is the angle between the first left shoulder cutting edge and a second reference line extending from the left end of the first left cutting edge in the thickness direction of the chip saw.

The left tip has a second left cutting edge that extends from the tip to the left end at a second left angle. A second right cutting edge is provided that extends from the tip toward the right side at a second right angle smaller than the second left angle. A second right shoulder cutting edge is provided that extends from the second right cutting edge to the right end at a second right shoulder angle larger than the second right angle. In detail, the second left angle is the angle between a third reference line extending from the tip of the left tip in the thickness direction of the chip saw and the second left cutting edge. The second right angle is the angle between the third reference line and the second right cutting edge. The second right shoulder angle is the angle between a fourth reference line extending from the right end of the second right cutting edge in the thickness direction of the chip saw and the second right shoulder cutting edge.

Therefore, the right tip, the left tip, and the middle tip each have a tip and an inclination angle at the left and right ends. Moreover, the right tip and the left tip have a shoulder cutting edge with a relatively large shoulder angle at one end edge. Therefore, each tip processes the design surface of the siding board with cutting edges located near both side surfaces with a relatively large inclination angle. As a result, chipping of the design surface by the edge of the cutting edge of the chip is effectively suppressed. The right tip and the left tip have a first left cutting edge or a second right cutting edge with a relatively gentle angle. Therefore, the cutting edge line length of the entire chip is shortened by the first left cutting edge and the second right cutting edge. Moreover, the cutting edge line of the first left cutting edge and the second right cutting edge is likely to intersect with the cutting edge line of the middle tip. This shortens the effective cutting edge line length of the middle tip. This reduces the overall net cutting power. Note that each cutting edge of the right tip, left tip, and middle tip may be straight, curved, or a compound line of straight and curved lines.

According to another feature of the present disclosure, the tip of the middle tip is a mountain type having an apex, or a flat type having a length in the thickness direction of the base metal. The middle tip has a third right cutting edge extending from the tip to the right end at a third right angle. It has a third left cutting edge extending from the tip to the left end at a third left angle. The middle tip is arranged so as to be located between the right tip and the left tip on the outer periphery of the base metal. In detail, the third right angle is the angle between a fifth reference line extending from the tip of the middle tip in the thickness direction of the chip saw and the third right cutting edge. The third left angle is the angle between the fifth reference line and the third left cutting edge.

Therefore, the middle tip has a cutting edge with an inclination angle at the left and right ends, whether the tip is mountain-shaped or flat. The right tip receives a larger cutting resistance on the right side than on the left side when cutting the workpiece. Therefore, the right tip applies a force to the left on the base metal. The left tip receives a larger cutting resistance on the left side than on the right side when cutting the workpiece. Therefore, the left tip applies a force to the right on the base metal. If the right and left tips were arranged alternately, the base metal would be more likely to vibrate periodically from side to side. In contrast, in this feature, the middle tip is arranged between the right and left tips. Therefore, the middle tip suppresses the periodic vibration from side to side of the base metal. Alternatively, the middle tip suppresses the increase in the amplitude of vibration due to periodic vibration. As a result, the middle tip reduces the net cutting power and reduces noise.

According to another feature of the present disclosure, the right tip and the left tip have the same cutting edge angle at the right end and the left end of each tip. The multiple tips that the tip saw has are either the right tip, the left tip, or the middle tip. Therefore, the tip saw has only three types of tips. This can reduce the complexity of the tip saw manufacturing process. Alternatively, the cost of the tip saw can be reduced. Alternatively, the operation simulation of the tip saw can be easily analyzed. Alternatively, the grinding work can be made more efficient because the angle of the grindstone can be kept constant when grinding the three types of tips.

FIG. 2 is a front view of the tip saw according to the first embodiment. FIG. 2 is an enlarged front view of a portion II in FIG. 2 is a diagram showing each tip of the tip saw of the first embodiment as viewed from the front in the direction of rotation. FIG. FIG. 4 is a diagram in which the chips shown in FIG. 3 are superimposed. FIG. 11 is a front view of a tip saw according to a second embodiment. 13 is a diagram showing each tip of a tip saw of a third embodiment as viewed from the front in the direction of rotation. FIG. FIG. 7 is a diagram in which the chips shown in FIG. 6 are superimposed. 13 is a view of each tip of the tip saw of the second comparative example viewed from the front in the direction of rotation. FIG. FIG. 9 is a diagram in which the chips shown in FIG. 8 are superimposed. 1 is a graph comparing the net cutting power of chip saws. This is a graph comparing the surface area of chipped parts of different tipped saw blades. 13 is a view of each tip of a tip saw of a fourth embodiment as viewed from the front in the direction of rotation. FIG. FIG. 13 is a diagram in which the chips shown in FIG. 12 are superimposed. 13 is a view of each tip of a tip saw of a fifth embodiment as viewed from the front in the direction of rotation. FIG. FIG. 15 is a diagram in which the chips shown in FIG. 14 are superimposed. 13 is a view of each tip of a tip saw of a sixth embodiment as viewed from the front in the direction of rotation. FIG. 17 is a diagram in which the chips shown in FIG. 16 are superimposed.

One embodiment of the present disclosure will be described in detail below with reference to the drawings. The same reference numbers in the description refer to the same elements having the same functions, without duplicate description. A first embodiment of the present disclosure will be described based on FIGS. 1 to 4. As shown in FIG. 1, the chip saw 1 has a disk-shaped base metal 2 and a plurality of cutting tips 11 joined to the outer periphery of the base metal 2. The chip saw 1 is rotatably mounted on a cutting tool such as a battery-powered electric circular saw or a stationary chip saw cutting machine. The chip saw 1 rotates the base metal 2 to form grooves in the workpiece with each cutting tip 11, and finally cuts the workpiece. The workpiece is, for example, a ceramic material such as a siding board, or wood and wood materials, resin materials, or composite materials. Alternatively, the workpiece is a steel material such as carbon steel, general structural rolled steel, chromium molybdenum steel, stainless steel, or cast iron, or a non-ferrous metal such as aluminum and aluminum alloys, copper and copper alloys.

As shown in FIG. 1, a substantially circular mounting hole 3 is provided in the center of the base metal 2, penetrating the base metal 2 in the plate thickness direction. The rotating shaft of the cutting tool is inserted into the mounting hole 3, and the chip saw 1 is attached to the cutting tool. When the rotating shaft of the cutting tool rotates, the chip saw 1 rotates clockwise in FIG. 1 around the center 2a of the base metal 2. On the periphery of the base metal 2, a plurality of protruding portions 4 are provided at predetermined intervals, protruding radially outward from the base metal 2. A tooth chamber 5 recessed in the circumferential direction is formed between adjacent protruding portions 4. The protruding portion 4 has a chip sheet 6 that is notched in a rectangular shape at the end forward in the rotation direction of the chip saw 1. A cutting chip 11 is joined to the chip sheet 6. The cutting chip 11 is formed of, for example, cemented carbide, cermet, polycrystalline diamond, or the like.

As shown in FIG. 1, the cutting tip 11 is one of three types of tips: a middle tip 12, a left tip 13, and a right tip 14. The middle tip 12, the left tip 13, and the right tip 14 each have a different cutting edge shape. The cutting tip 11 has, for example, three middle tips 12, four left tips 13, and four right tips 14. One of the middle tips 12, the left tips 13, and the right tips 14 is joined to the tip sheet 6. A plurality of external slits 7 extending from the tooth chamber 5 radially inward of the base metal 2 are provided on the disk surface of the base metal 2. In addition, a plurality of serpentine vibration-damping slits 8 are provided on the disk surface of the base metal 2. The external slits 7 and the vibration-damping slits 8 do not have to be provided, and only one of them may be provided.

As shown in FIG. 2, the cutting tip 11 joined to the base metal 2 has a rake face 11a forward in the direction of rotation of the chip saw 1. The cutting tip 11 has a clearance face 11b radially outward of the base metal 2. A cutting edge 11c is formed at the intersection of the rake face 11a and clearance face 11b. The multiple cutting tips 11 are arranged circumferentially at a pitch 15. The pitch 15 is a circumferential angle centered on the center 2a of the base metal 2 (see FIG. 1). The pitch 15 is the angle between adjacent imaginary lines, for example, when imaginary lines passing through the center 2a and the cutting edges 11c of each cutting tip 11 are imagined.

As shown in Figure 1, the chip saw 1 has a random pitch in which the size of each pitch 15 is different from each other. The middle tip 12 is joined behind the pitches 15b, 15g, and 15j in the rotational direction. The left tip 13 is joined behind the pitches 15a, 15d, 15f, and 15i in the rotational direction. The left tip 13 is joined behind the pitches 15c, 15e, 15h, and 15k in the rotational direction.

As shown in FIG. 3, the middle tip 12 has a left end 12b and a right end 12c of the cutting edge 11c (see FIG. 2). The left end 12b is located at the left end when viewed from the front of the base metal 2 in the direction of rotation with the cutting edge 11c positioned upward. The right end 12c is located at the right end. The middle tip 12 has a left side edge 12d extending from the left end 12b toward the inside of the base metal 2 in the radial direction, and a right side edge 12e extending from the right end 12c toward the inside of the base metal 2 in the radial direction. The left side edge 12df and the right side edge 12ef each have an inclination angle (side centripetal angle) of 0° to 3°, for example 30', relative to the radial direction of the base metal 2. This slight inclination reduces the contact area between the workpiece and the left side edge 12df or the right side edge 12ef, thereby reducing the cutting resistance. Furthermore, the left side surface 12df and the right side surface 12ef are inclined so as not to protrude too much relative to the cut surface of the workpiece, which allows for a smooth finish to the cut surface.

As shown in FIG. 3, the middle tip 12 has a tip 12a between the left end 12b and the right end 12c. The tip 12a protrudes in a mountain shape toward the radially outward direction of the base metal 2 near the center of the thickness direction of the base metal 2. The tip 12a is located approximately halfway between the left end 12b and the right end 12c in the thickness direction of the base metal 2. The middle tip 12 has a third left cutting edge 12f extending from the tip 12a to the left end 12b. The middle tip 12 has a third right cutting edge 12g extending from the tip 12a to the right end 12c. The third left cutting edge 12f is inclined at a third left angle 12h with respect to the thickness direction of the base metal 2. The third right cutting edge 12g is inclined at a third right angle 12i with respect to the thickness direction of the base metal 2. The third left angle 12h and the third right angle 12i are equal to or greater than 30° and equal to or less than 60°, and preferably equal to or greater than 40° and equal to or less than 50°, for example, both are 45°.

As shown in Figure 3, the left tip 13 has a left end 13b and a right end 13c at the left and right ends of the cutting edge 11c (see Figure 2). The left tip 13 has a left side blade 13d and a right side blade 13e that extend radially inward of the base metal 2 from the left end 13b and the right end 12c, respectively. As shown in Figure 4, the left side blade 13d and the right side blade 13e are formed at the same interval as the left side blade 12d and the right side blade 12e of the middle tip 12 and are inclined at the same side centripetal angle. Therefore, the left side blade 13d and the right side blade 13e overlap with the left side blade 12d and the right side blade 12e when viewed from the front in the rotation direction.

As shown in FIG. 3, the left tip 13 has a tip 13a between the left end 13b and the right end 13c. The tip 13a protrudes in a mountain shape radially outward from the base metal 2 near the center of the thickness of the base metal 2. The tip 13a is positioned closer to the left end 13b than to the right end 13c in the thickness direction of the base metal 2. The distance between the tip 13a and the left end 13b in the thickness direction of the base metal 2 is, for example, one-third or less of the distance between the left end 13b and the right end 13c. The distance between the tip 13a and the left end 13b is, for example, 0.45 mm. The distance between the tip 13a and the right end 13c is, for example, 0.95 mm.

3, the left tip 13 has a second left cutting edge 13f extending from the tip 13a to the left end 13b. The second left cutting edge 13f is inclined at a second left angle 13j with respect to the thickness direction of the base metal 2. The second left angle 13j is approximately the same as the third left angle 12h of the middle tip 12, and is 30° or more and 60° or less, preferably 40° or more and 50° or less, for example 45°.

3, the left tip 13 has a second right cutting edge 13g extending from the tip 13a toward the right side surface 13ef. The second right cutting edge 13g is inclined at a second right angle 13k with respect to the thickness direction of the base metal 2. The second right angle 13k is smaller than the second left angle 13j, and is greater than 0° and less than or equal to 40°, preferably greater than or equal to 10° and less than or equal to 30°, for example, 20°.

3, the left tip 13 has a second right shoulder cutting edge 13i that extends from the shoulder edge 13h at the right end of the second right cutting edge 13g to the right end 13c. The second right shoulder cutting edge 13i is inclined at a second right shoulder angle 13m with respect to the thickness direction of the base metal 2. The second right shoulder angle 13m is approximately the same size as the third right angle 12i of the middle tip, and is 30° to 60°, preferably 40° to 50°, for example 45°.

As shown in Figure 3, the right tip 14 is formed symmetrically to the left tip 13 with respect to a plane passing through the center of the thickness direction of the base metal 2. The right tip 14 has a left end 14b and a right end 14c at the left and right ends of the cutting edge 11c (see Figure 2). The right tip 14 has a left side blade 14d and a right side blade 14e that extend radially inward from the left end 14b and the right end 14c, respectively. As shown in Figure 4, the left side blade 14d and the right side blade 14e are formed at the same interval as the left side blade 12d and the right side blade 12e of the middle tip 12, similar to the left side blade 13d and the right side blade 13e of the left tip 13, and are inclined at the same side centripetal angle.

As shown in Figure 3, the right tip 14 has a tip 14a between the left end 14b and the right end 14c. The tip 14a protrudes in a mountain shape radially outward from the base metal 2 near the center of the thickness of the base metal 2. The tip 14a is positioned closer to the right end 14c than the left end 14b in the thickness direction of the base metal 2. The distance between the tip 14a and the right end 14c in the thickness direction of the base metal 2 is, for example, less than one-third of the distance between the left end 14b and the right end 14c.

As shown in FIG. 3, the right chip 14 has a first right cutting edge 14i extending from the tip 14a to the right end 14c. The first right cutting edge 14i is inclined at a first right angle 14m with respect to the thickness direction of the base metal 2. The first right angle 14m is the same as the second left angle 13j of the left chip 13. The right chip 14 has a first left cutting edge 14f extending from the tip 14a toward the left side surface 14df. The first left cutting edge 14f is inclined at a first left angle 14j with respect to the thickness direction of the base metal 2. The first left angle 14j is smaller than the first right angle 14m and is the same as the second right angle 13k of the left chip 13. The right chip 14 has a first left shoulder cutting edge 14h extending from the shoulder edge 14g at the left end of the first left cutting edge 14f to the left end 14b. The first left shoulder cutting edge 14h is inclined at a first left shoulder angle 14k with respect to the thickness direction of the base metal 2. The first left shoulder angle 14k is the same as the second right shoulder angle 13m of the left tip 13.

As shown in FIG. 4, the tips 12a, 13a, and 14a have the same radial height of the base metal 2. The left ends 13b and 14b and the right ends 13c and 14c have the same radial height of the base metal 2. The shoulder edges 13h and 14g have the same radial height of the base metal 2. The cutting edges of the left chip 13 and the right chip 14 are symmetrical to each other at the left-right center and have the same radial height. The left end 12b and the right end 12c of the middle chip 12 are located radially inward of the base metal 2 from the left end 13b and the right end 13c of the left chip 13 and the left end 14b and the right end 14c of the right chip 14. The second left cutting edge 13f and the first left shoulder cutting edge 14h overlap each other when viewed from the front in the rotation direction. The third left cutting edge 12f is approximately parallel to the second left cutting edge 13f and the first left shoulder cutting edge 14h. The second right shoulder cutting edge 13i and the first right cutting edge 14i overlap each other when viewed from the front in the rotation direction. The third right cutting edge 12g is substantially parallel to the second right shoulder cutting edge 13i and the first right cutting edge 14i.

As described above, the tipped saw 1 has a right tip 14, a left tip 13, and a middle tip 12, as shown in Figure 3. The right tip 14 is joined to the outer periphery of the base metal 2 and has a radially outer tip 14a on the right side of the thickness direction of the base metal 2. The left tip 13 is joined to the outer periphery of the base metal 2 and has a radially outer tip 13a on the left side of the thickness direction of the base metal 2. The middle tip 12 is joined to the outer periphery of the base metal 2 and has a radially outer tip 12a near the center of the thickness direction of the base metal 2.

The right tip 14 has a first right cutting edge 14i that extends from the tip 14a to the right end 14c at a first right angle 14m. A first left cutting edge 14f is provided that extends from the tip 14a toward the left side surface 14df at a first left angle 14j that is smaller than the first right angle 14m. A first left shoulder cutting edge 14h is provided that extends from the first left cutting edge 14f to the left end 14b at a first left shoulder angle 14k that is larger than the first left angle 14j. The left tip 13 has a second left cutting edge 13f that extends from the tip 13a to the left end 13b at a second left angle 13j. A second right cutting edge 13g is provided that extends from the tip 13a toward the right side surface 13ef at a second right angle 13k that is smaller than the second left angle 13j. A second right shoulder cutting edge 13i is provided, extending from the second right cutting edge 13g to the right end 13c at a second right shoulder angle 13m that is greater than the second right angle 13k.

Therefore, the right tip 14, the left tip 13, and the center tip 12 each have a tip 14a, 13a, 12a, and have an inclination angle at the left end 14b, 13b, 12b and the right end 14c, 13c, 12c. Moreover, the right tip 14 and the left tip 13 have a first left shoulder cutting edge 14h and a second right shoulder cutting edge 13i at one end edge, which have a relatively large shoulder angle. Therefore, each tip 12, 13, 14 processes the design surface of the siding board with each cutting edge 12f, 12g, 13i, 14h located near both side surfaces with a relatively large inclination angle. As a result, pattern skipping, in which the design surface is chipped by the edge of each cutting edge 12f, 12g, 13i, 14h, is effectively suppressed.

Furthermore, the right tip 14 and the left tip 13 have a first left cutting edge 14f or a second right cutting edge 13g with a relatively gentle angle. Therefore, the first left cutting edge 14f and the second right cutting edge 13g shorten the cutting edge line length of the left tip 13 and the right tip 14 as a whole. Moreover, the cutting edge line of the first left cutting edge 14f and the second right cutting edge 13g is likely to intersect with the cutting edge line of the middle tip 12. Therefore, the effective cutting edge line length of the middle tip 12 is shortened. This reduces the net cutting power. The cutting edges 12f, 12g, 13f, 13g, 13i, 14f, 14h, and 14i of the right tip 14, left tip 13, and middle tip 12 may be straight lines, curved lines, or a composite line of straight lines and curved lines.

As shown in Figure 3, the tip 12a of the middle tip 12 is a mountain shape with an apex. The middle tip 12 has a third right cutting edge 12g that extends from the tip 12a to the right end 12c at a third right angle 12i. It has a third left cutting edge 12f that extends from the tip 12a to the left end 12b at a third left angle 12h. The middle tip 12 is arranged so as to be located between the right tip 14 and the left tip 13 on the outer periphery of the base metal 2.

Therefore, the middle tip 12 has a cutting edge with an inclination angle at the left end 12b and the right end 12c. The right tip 14 receives a larger cutting resistance on the right side than on the left side when cutting the workpiece. Therefore, the right tip 14 applies a force to the left on the base metal 2. The left tip 13 receives a larger cutting resistance on the left side than on the right side when cutting the workpiece. Therefore, the left tip 13 applies a force to the right on the base metal 2. If the right tip 14 and the left tip 13 are alternately arranged, the base metal 2 is likely to vibrate periodically from side to side. In contrast, in this feature, the middle tip 12 is arranged between the right tip 14 and the left tip 13. Therefore, the middle tip 12 suppresses the periodic vibration from side to side of the base metal 2. Alternatively, the middle tip 12 suppresses the increase in the amplitude of vibration due to periodic vibration. As a result, the middle tip 12 reduces the net cutting power and reduces noise.

3, the right tip 14 and the left tip 13 have the same first right angle 14m of the first right cutting edge 14i at the right ends 14c, 13c and the same second right shoulder angle 13m of the second right shoulder cutting edge 13i. The first left shoulder angle 14k of the first left shoulder cutting edge 14h at the left ends 14b, 13b and the second left angle 13j of the second left cutting edge 13f are the same. The multiple cutting tips 11 that the chip saw 1 has are either the right tip 14, the left tip 13, or the middle tip 12. Therefore, the chip saw 1 has only three types of cutting tips 11. Moreover, the left and right ends of each tip 12, 13, and 14 have the same angle. Therefore, the complexity of the manufacturing process of the chip saw 1 can be suppressed. Or the cost of the chip saw 1 can be reduced. Or the operation simulation of the chip saw 1 can be easily analyzed, etc. Furthermore, since the angle of the grindstone can be made constant when grinding the three types of cutting tips 11, the grinding work can be made more efficient.

Next, a second embodiment of the present disclosure will be described with reference to Figure 5. The chip saw 20 has a pitch 22 that is different in size from the pitch 15 of the chip saw 1 shown in Figure 1. The number and circumferential order of the middle tips 12, left tips 13, and right tips 14 joined to the base metal 2 of the chip saw 20 are the same as those of the chip saw 1. The pitch 22 is equally spaced regardless of the type of cutting tips 11 provided at both circumferential ends. Furthermore, instead of the vibration-damping slits 8 of the chip saw 1, the chip saw 20 has vibration-damping slits 21 on the disk surface of the base metal 2 that meander with a different shape.

As described above, the chip saw 20 has a middle tip 12, a left tip 13, and a right tip 14, as shown in Figure 5. The middle tip 12 is arranged so as to be located between the left tip 13 and the right tip 14 on the outer periphery of the base metal 2. Therefore, by using the chip saw 20, it is possible to obtain the same effects as those described above with the chip saw 1 (see Figure 1).

Next, a third embodiment of the present disclosure will be described with reference to Figures 6 and 7. The chip saw 30 has a middle chip 32 instead of the middle chip 12 of the chip saw 1 shown in Figure 3. The cutting chip 31 is either the middle chip 32, the left chip 13, or the right chip 14. The middle chip (12) 32 also has a cutting edge 11c at the intersection of the rake face 11a and the relief face 11b as shown in Figure 2. The left and right ends of the cutting edge 11c have a left end 32b and a right end 32c as shown in Figure 6. The middle chip 32 has a left side blade 32d and a right side blade 32e that extend radially inward from the left end 32b and the right end 32c, respectively. The left side blade 32d and the right side blade 32e overlap with the left side blades 13d, 14d and the right side blades 13e, 14e when viewed from the front in the rotation direction.

As shown in Figure 6, the middle tip 32 has a tip 32a between the left end 32b and the right end 32c. The tip 32a extends with a certain length in the thickness direction of the base metal 2. The tip 32a is located approximately halfway between the left end 32b and the right end 32c in the thickness direction of the base metal 2. The left edge 32f and the right edge 32h of the middle tip 32 are symmetrical to each other with respect to a plane passing through the center of the base metal 2 in the thickness direction.

As shown in FIG. 6, the middle tip 32 has a third left cutting edge 32g extending from the left edge 32f to the left end 32b. The middle tip 32 has a third right cutting edge 32i extending from the right edge 32h to the right end 32c. The third left cutting edge 32g and the third right cutting edge 32i are inclined at a third left angle 32j and a third right angle 32k with respect to the thickness direction of the base metal 2. The third left angle 32j and the third right angle 32k are approximately the same as the second left angle 13j, the first left shoulder angle 14k, or the second right shoulder angle 13m and the first right angle 14m. The third left angle 32j and the third right angle 32k are 30° or more and 60° or less, preferably 40° or more and 50° or less, for example 45°.

6 and 7, the tip 32a is located at a position higher than the tips 13a and 14a by a height difference 31a in the radial direction of the base metal 2. The left ends 32b, 13b, and 14b and the right ends 32c, 13c, and 14c have the same height in the radial direction of the base metal 2. The third left cutting edge 32g, the second left cutting edge 13f, and the first left shoulder cutting edge 14h overlap each other when viewed from the front in the rotation direction. The third right cutting edge 32i, the second right shoulder cutting edge 13i, and the first right cutting edge 14i overlap each other when viewed from the front in the rotation direction.

As shown in Figs. 10 and 11, a comparative experiment was carried out to measure the net cutting power and the handle skip area when cutting the workpiece using each tipped saw equipped with a different tip. The outer diameter of the base metal 2 of each tipped saw was 125 mm, the blade thickness of the base metal 2 was 1.5 mm, and the number of teeth was 11. The cutting tips equipped in each tipped saw had a rake angle of 10° and were made of polycrystalline diamond. The distance from the left end to the right end of the cutting edge of each cutting tip was set to be the same. The tip height of each tip (the radial position relative to the center 2a of the base metal 2) was set to be the same height. A ceramic siding board was used as the workpiece. Each tipped saw was rotated at a rotation speed of 5000 rpm, and the workpiece was fed at a feed rate of 3.6 [m/min] to cut the workpiece. The net cutting power was obtained by subtracting the idling power from the measured cutting power. The pattern skip area is the area (mm ² ) of the pattern skip when the cutting distance is 400 mm.

In the flat-blade tipped saws shown in Figures 10 and 11, all cutting tips are flat blades. The tip of the cutting edge of the flat-blade cutting tip extends in the thickness direction of the base metal 2 from the left end to the right end. In the ridge-blade tipped saws, all cutting tips have the same shape as the center tip 12 shown in Figure 3. In the tipped saw of comparison product 1, the left tips 13 and right tips 14 shown in Figure 3 are arranged alternately in the circumferential direction. Since there are 11 teeth, either the left tip 13 or the right tip 14 is provided with one more tooth.

8 and 9 show the cutting tip 71 of the tip saw 70 of the comparative product 2. The cutting tip 71 is either the center tip 32 shown in FIG. 6 or the left tip 73 or right tip 74 shown in FIG. 8. The left tip 73 and right tip 74 differ from the left tip 13 and right tip 14 shown in FIG. 3 in the presence or absence of the second right shoulder cutting edge 13i or the first left shoulder cutting edge 14h. That is, the tip 73a, left end 73b, left side blade 73d, right side blade 73e, and second left cutting edge 73f of the left tip 73 are configured in the same manner as the tip 13a, left end 13b, left side blade 13d, right side blade 13e, and second left cutting edge 13f, respectively. The tip 74a, right end 74c, left side edge 74d, right side edge 74e, and first right cutting edge 74g of the right tip 74 are configured similarly to the tip 14a, right end 14c, left side edge 14d, right side edge 14e, and first right cutting edge 14i, respectively. The second left cutting edge 73f is inclined at a second left angle 73h that is the same as the second left angle 13j with respect to the thickness direction of the base metal 2. The first right cutting edge 74g is inclined at a first right angle 74i that is the same as the first right angle 14m with respect to the thickness direction of the base metal 2.

As shown in FIG. 8, the tip 32a is located at a position higher than the tips 73a and 74a in the radial direction of the base metal 2 by a height difference 71a. The left tip 73 has a second right cutting edge 73g extending from the tip 73a toward the right end 73c. The second right cutting edge 73g is inclined at a second right angle 73i that is the same as the second right angle 13k (see FIG. 3) with respect to the thickness direction of the base metal 2. The right tip 74 has a first left cutting edge 74f extending from the tip 74a toward the left end 74b. The first left cutting edge 74f is inclined at a first left angle 74h that is the same as the first left angle 14j with respect to the thickness direction of the base metal 2. As shown in FIG. 9, the right end 73c and the left end 74b are located radially outward of the base metal 2 than the right ends 32c and 74c or the left ends 32b and 73b. Therefore, the right end 73c and the left end 74b protrude radially outward relative to the cutting edges 32g, 73f, 32i, and 74g.

As shown in FIG. 10, the net cutting power of the tipped saw with a crest is approximately 14% greater than that of the tipped saw with a flat blade. The cutting edge of the crest is inclined with respect to the thickness direction of the base metal 2. Therefore, the cutting edge line length of the crest is longer than that of the flat blade, and it is considered that the net cutting power is greater. The net cutting power of the comparative product 1 is approximately 13% greater than that of the tipped saw with a flat blade. The comparative product 1 has left tips 13 and right tips 14 alternately in the circumferential direction. The left tip 13 receives a larger cutting resistance on the left side than on the right side, so it applies a force to the right to the base metal 2 during cutting. The right tip 14 receives a larger cutting resistance on the right side than on the left side, so it applies a force to the left to the base metal 2 during cutting. Therefore, the left tip 13 and the right tip 14 alternately cut the workpiece, so that the base metal 2 tends to vibrate periodically in the thickness direction. This is why it is considered that the net cutting power of the comparative product 1 is large.

As shown in Figure 10, the net cutting power of the chip saw 1 is approximately 5% less than that of a flat-blade chip saw. As shown in Figure 4, the right tip 14 and the left tip 13 have the first left cutting edge 14f or the second right cutting edge 13g, which have a relatively gentle angle. This shortens the overall cutting edge line length of the left tip 13 and the right tip 14. Furthermore, the cutting edge line formed by the first left cutting edge 14f and the second right cutting edge 13g is likely to intersect with the cutting edge line formed by the third left cutting edge 12f and the third right cutting edge 12g of the middle tip 12, which have a relatively large angle. This shortens the effective cutting edge line length of the middle tip 12. This is why it is thought that the net cutting power of the chip saw 1 is small.

As shown in FIG. 10, the net cutting power of the chip saw 30 is approximately the same as that of a flat-blade chip saw. As shown in FIG. 7, the third left cutting edge 32g, the second left cutting edge 13f, and the first left shoulder cutting edge 14h overlap each other when viewed from the front in the direction of rotation. The third right cutting edge 32i, the second right shoulder cutting edge 13i, and the first right cutting edge 14i overlap each other when viewed from the front in the direction of rotation. In general, a chip saw advances upward in the figure toward the workpiece as it is fed toward the workpiece. Therefore, the cutting edge line of the cutting tip at the rear of the direction of rotation is located higher in the figure than the cutting edge line of the cutting tip at the front of the direction of rotation. This makes it difficult for the cutting edge lines of the middle tip 32, the left tip 13, and the right tip 14 to cross. Therefore, it is considered that the cutting edge line length is not effectively shortened, and the reduction in net cutting power is small.

As shown in Figure 10, the net cutting power of the comparative product 2 is roughly the same as that of the tipped saw 1. As shown in Figure 9, the right end 73c and the left end 74b of the tipped saw 70 protrude radially outward relative to the cutting edges 32g, 73f, 32i, and 74g. Therefore, the cutting edge lines formed by the middle tip 32, the left tip 73, and the right tip 74 are more likely to intersect than, for example, the cutting edge lines formed by the middle tip 32, the left tip 13, and the right tip 14 of the tipped saw 30 (see Figure 7). This is thought to have resulted in a smaller net cutting power.

As shown in Figure 11, the flat blade tipped saw has a larger handle skip area than the other test products. The cutting edge of the flat blade is not inclined in the thickness direction of the base metal 2 (see Figure 3). In other words, the cutting edge of the flat blade is roughly perpendicular to the cutting surface of the workpiece. Therefore, the left and right ends of the cutting edge are prone to handle skip when cutting the workpiece. The handle skip area of the ridged blade tipped saw and comparison product 2 is roughly 20% of that of the flat blade tipped saw.

As shown in Figure 8, the left tip 73 and right tip 74 of the tipped saw 70 have a second right cutting edge 73g or a first left cutting edge 74f with a relatively gentle inclination angle. The workpiece is cut by the second right cutting edge 73g and the first left cutting edge 74f, which strike the left and right cutting surfaces at a relatively large angle. For this reason, it is believed that the comparative product 2 was not able to effectively suppress handle jumping.

As shown in Figure 11, the handle skip area of the chip saws 1 and 30 and the comparative product 1 is sufficiently small, less than 5 mm2. Therefore, the cut surface of the workpiece is good. In particular, the chip saw 1 effectively suppresses handle skipping. The chip saws 1 and 30 and the comparative product 1 all cut the cut surface of the workpiece with cutting edges that have a relatively large inclination angle. Moreover, two or three types of cutting tips are used to share the cutting surface on both the left and right sides. Therefore, it is believed that handle skipping was effectively suppressed. According to the above experimental results, the chip saws 1 and 30 can effectively suppress handle skipping and relatively reduce the net cutting power.

As described above, the chip saw 30 has a middle chip 32, a left chip 13, and a right chip 14 as shown in FIG. 6. The tip 32a of the middle chip 32 is flat and has a length in the thickness direction of the base metal 2. The middle chip 32 has a third right cutting edge 32i that extends from the right edge 32h of the tip 32a to the right end 32c at a third right angle 32k. A third left cutting edge 32g that extends from the left edge 32f of the tip 32a to the left end 32b at a third left angle 32j is provided. The middle chip 32 is arranged so as to be located between the left chip 13 and the right chip 14 on the outer periphery of the base metal 2. The left chip 13 and the right chip 14 are the same as those of the chip saw 1 (see FIG. 1). Therefore, the chip saw 30 can be used to obtain the same effects as those of the chip saw 1.

Next, the fourth embodiment of the present disclosure will be described based on Figures 12 and 13. The chip saw 40 has a center chip 42 instead of the center chip 12 of the chip saw 1 shown in Figure 3. The cutting chip 41 is one of the center chip 42, the left chip 13, and the right chip 14. The center chip 42 has a left end 42b and a right end 42c at the left and right ends of the cutting edge 11c (see Figure 2). The tip 42a is between the left end 42b and the right end 42c. The center chip 42 has the same cutting edge shape as the center chip 12. That is, the left side blade 42d, the right side blade 42e, the third left cutting edge 42f, and the third right cutting edge 42g of the center chip 42 are configured in the same manner as the left side blade 12d, the right side blade 12e, the third left cutting edge 12f, and the third right cutting edge 12g of the center chip 12, respectively. The third left angle 42h and the third right angle 42i are equal in magnitude to the third left angle 12h and the third right angle 12i, respectively.

As shown in Figures 12 and 13, the tip 42a, left end 42b, and right end 42c have different heights in the radial direction of the base metal 2 than the tip 12a, left end 12b, and right end 12c shown in Figure 3. The tip 42a is located lower in the radial direction of the base metal 2 than the tips 13a and 14a by a height difference 41a. Therefore, the height difference between the left end 42b and the right end 42c and the left ends 13b and 14b or the right ends 13c and 14c is larger than that between the left end 12b and the right end 12c.

As described above, the tip 42a of the middle tip 42 is lower in the radial direction of the base metal 2 than the tip 12a of the middle tip 12, as shown in Figures 3 and 12. Therefore, the effective cutting edge line length of the middle tip 42 is shorter. On the other hand, the effective cutting edge line length of the left tip 13 and the right tip 14 tends to be longer. For example, by appropriately setting the pitch 15 (see Figure 1) of each cutting tip 41, the cutting edge line length of the entire tips 42, 13, and 14 can be shortened. This reduces the net cutting power. Moreover, the design surface of the siding board is processed by each cutting edge 42f, 42g, 13i, and 14h located near both side surfaces with a relatively large inclination angle. Therefore, the above-mentioned effect can be obtained by using the chip saw 40, similar to that of the chip saw 1 (see Figure 1).

Next, the fifth embodiment of the present disclosure will be described based on Figures 14 and 15. The chip saw 50 has a center chip 52 instead of the center chip 12 of the chip saw 1 shown in Figure 3. The cutting chip 51 is one of the center chip 52, the left chip 13, and the right chip 14. The center chip 52 has a left end 52b and a right end 52c at the left and right ends of the cutting edge 11c (see Figure 2). The tip 52a is between the left end 52b and the right end 52c. The center chip 52 has the same cutting edge shape as the center chip 12. That is, the left side blade 52d, the right side blade 52e, the third left cutting edge 52f, and the third right cutting edge 52g of the center chip 52 are configured in the same manner as the left side blade 12d, the right side blade 12e, the third left cutting edge 12f, and the third right cutting edge 12g of the center chip 12, respectively. The third left angle 52h and the third right angle 52i are equal in magnitude to the third left angle 12h and the third right angle 12i, respectively.

As shown in Figures 14 and 15, the tip 52a, left end 52b, and right end 52c have different heights in the radial direction of the base metal 2 than the tip 12a, left end 12b, and right end 12c shown in Figure 3. The tip 52a is located at a position that is higher in the radial direction of the base metal 2 than the tips 13a and 14a by a height difference 51a. Therefore, the height difference between the left end 52b and the right end 52c and the left ends 13b and 14b or the right ends 13c and 14c is smaller than that between the left end 12b and the right end 12c.

As described above, the tip 52a of the middle tip 52 is higher in the radial direction of the base metal 2 than the tip 12a of the middle tip 12, as shown in Figures 3 and 14. Therefore, the effective cutting edge line length of the middle tip 52 is longer. Therefore, the overall cutting edge line length of the left tip 13 and the right tip 14 is shorter. This reduces the cutting resistance of the left tip 13 and the right tip 14 against the cut surface of the workpiece. Moreover, the design surface of the siding board is processed by each cutting edge 52f, 52g, 13i, 14h located near both side surfaces with a relatively large inclination angle. Therefore, the above-mentioned effect can be obtained by using the chip saw 50, similar to that of the chip saw 1 (see Figure 1).

Next, the sixth embodiment of the present disclosure will be described with reference to Figs. 16 and 17. The chip saw 60 has a chip 62 instead of the chip 12 of the chip saw 1 shown in Fig. 3. The cutting chip 61 is one of the chips of the chip 62, the left chip 13, and the right chip 14. The chip 62 has a left end 62b and a right end 62c at the left and right ends of the cutting edge 11c (see Fig. 2). The tip 62a is between the left end 62b and the right end 62c. The shape of the cutting edge of the chip 62 is the same as that of the chip 12. That is, the left side blade 62d, the right side blade 62e, the third left cutting edge 62f, and the third right cutting edge 62g of the chip 62 are configured in the same manner as the left side blade 12d, the right side blade 12e, the third left cutting edge 12f, and the third right cutting edge 12g of the chip 12, respectively. The third left angle 62h and the third right angle 62i are equal in magnitude to the third left angle 12h and the third right angle 12i, respectively.

As shown in Figures 16 and 17, the tip 62a, the left end 62b, and the right end 62c have different radial heights of the base metal 2 from the tip 12a, the left end 12b, and the right end 12c shown in Figure 3. The tip 62a is located at a position higher than the tips 13a and 14a in the radial direction of the base metal 2 by a height difference 61a. The height difference 61a is greater than the height difference 51a (see Figure 14). The left ends 62b, 13b, and 14b and the right ends 62c, 13c, and 14c have the same radial height of the base metal 2. The third left cutting edge 62f, the second left cutting edge 13f, and the first left shoulder cutting edge 14h overlap each other when viewed from the front in the rotation direction. The third right cutting edge 62g, the second right shoulder cutting edge 13i, and the first right cutting edge 14i overlap each other when viewed from the front in the rotation direction.

As described above, the tip 62a of the middle tip 62 is higher in the radial direction of the base metal 2 than the tip 52a of the middle tip 52, as shown in Figures 14 and 16. Therefore, the effective cutting edge line length of the middle tip 62 is longer, and the effective cutting edge line length of the left tip 13 and the right tip 14 is shorter. Moreover, the design surface of the siding board is processed by each cutting edge 62f, 62g, 13i, 14h located near both side surfaces with a relatively large inclination angle. Therefore, by using the chip saw 60, the above-mentioned effect can be obtained similar to that of the chip saw 1 (see Figure 1).

Various modifications can be made to the chip saws 1, 20, 30, 40, 50, and 60 of the present embodiment described above. For example, a chip saw 1 having 11 cutting tips 11 has been exemplified. Alternatively, the chip saw 1 may have 10 or less cutting tips 11, or 12 or more cutting tips 11. A chip saw 1 having three middle tips 12, four left tips 13, and four right tips 14 has been exemplified. Alternatively, the number of middle tips 12, left tips 13, and right tips 14 may be changed. For example, the number of middle tips 12 may be five, and the number of left tips 13 and right tips 14 may be two each. The number of left tips 13 and right tips 14 does not have to be the same. The circumferential order of the middle tips 12, left tips 13, and right tips 14 may be changed as appropriate.

Three types of cutting tips 11, the middle tip 12, the left tip 13, and the right tip 14, are exemplified. Instead of this, four or more types of cutting tips 11 may be used. For example, there may be multiple types of cutting tips 11 having the same characteristics as the left tip 13, or multiple types of cutting tips 11 having the same characteristics as the left tip 13. The left tip 13 and the right tip 14 may be asymmetric with respect to a plane passing through the center of the thickness direction of the base metal 2. The tip 13a of the left tip 13 and the tip 14a of the right tip 14 may be at different heights in the radial position of the base metal 2. Although the tip saw 1 in which the total angle of the pitches 15a, 15d, 15f, and 15i is approximately the same as the total angle of the pitches 15c, 15e, 15h, and 15k is exemplified, each pitch 15 may be changed as appropriate.

The example shows a chip saw 1 in which the third left angle 12h, the second left angle 13j, and the first left shoulder angle 14k are the same, and the third right angle 12i, the second right shoulder angle 13m, and the first right angle 14m are the same. Alternatively, for example, the angles of each cutting edge may be different. Or the angles of some cutting edges may be different. For multiple cutting tips 11 of the same type, the radial positions of the base metal 2 may be set to different heights.

The various embodiments described in detail above with reference to the accompanying drawings are representative of the present invention and are not intended to limit the present invention. The detailed description is intended to teach one of ordinary skill in the art to make, use and/or implement various aspects of the present teachings and is not intended to limit the scope of the present invention. Moreover, each of the additional features and teachings described above may be applied and/or used separately or together with other features and teachings to provide an improved tip saw and/or method of making and using the same.

Claims (3)

A tip saw,
a right tip that is joined to an outer periphery of the base metal and has a radially outer tip on the right side in the thickness direction of the base metal;
a left tip joined to an outer periphery of the base metal and having a radially outer tip on the left side in a thickness direction of the base metal;
a middle tip that is joined to the outer periphery of the base metal and has a radially outer tip near the center in the thickness direction of the base metal,
The plurality of tips of the tip saw are any one of the three types of tips,
the right tip has a first right cutting edge extending from the tip to the right end at a first right angle, a first left cutting edge extending from the tip toward a left side surface at a first left angle smaller than the first right angle, and a first left shoulder cutting edge extending from the first left cutting edge to the left end at a first left shoulder angle larger than the first left angle,
The left tip has a second left cutting edge extending from the tip to the left end at a second left angle, a second right cutting edge extending from the tip toward the right side surface at a second right angle smaller than the second left angle, and a second right shoulder cutting edge extending from the second right cutting edge to the right end at a second right shoulder angle larger than the second right angle,
The first left shoulder cutting edge and the second left cutting edge overlap each other when viewed from the front in the rotation direction,
The first right cutting edge and the second right shoulder cutting edge overlap each other when viewed from the front in the direction of rotation . The tip saw according to claim 1,
The tip of the middle tip is a mountain type having a vertex, or a flat type having a length in the thickness direction of the base metal,
The middle tip has a third right cutting edge extending from the tip to the right end at a third right angle and a third left cutting edge extending from the tip to the left end at a third left angle,
The center tip is disposed on the outer periphery of the base metal so as to be located between the right tip and the left tip. The tip saw according to claim 1 or 2,
The right tip and the left tip have the same cutting edge angle at the right end of each tip, and the same cutting edge angle at the left end of each tip.

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