Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B24—GRINDING; POLISHING
  • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
  • B24D5/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting only by their periphery; Bushings or mountings therefor
  • B24D5/12—Cut-off wheels
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28D—WORKING STONE OR STONE-LIKE MATERIALS
  • B28D1/00—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor
  • B28D1/02—Working stone or stone-like materials, e.g. brick, concrete or glass, not provided for elsewhere; Machines, devices, tools therefor by sawing
  • B28D1/12—Saw-blades or saw-discs specially adapted for working stone
  • B28D1/121—Circular saw blades

Definitions

• the present invention relates to a saw blade capable of rapid cutting for various objects, such as jewelry, ferrite materials, stone, metallic materials or ceramic tiles. More particularly, the present invention relates to a structure of a cutting tip and a saw blade having the tip. The shape of the tip and blade are modified such that the cutting performance and the life time of the saw blade can be improved. Further the manufacturing process for the saw blade can be simplified and also reduced the manufacturing cost for the saw blade.
• a saw is equipped with a plurality of saw teeth, which are continuously aligned so as to cut various materials, such as wood, synthetic resin, or metals.
• Such a saw is classified into an automatic saw and a manual saw according to the operational manner thereof.
• the manual saw operates at a low speed and is mainly used to cut materials having relatively low hardness, so that saw teeth of the manual saw are less damaged than those of the automatic saw during the operation.
• the saw teeth of the automatic saw may collide to objects being cut with very high speed that the saw teeth of the automatic saw are easily broken and worn out. For this reason, the cutting performance of the automatic saw may be significantly lowered as it being used continuously.
• an automatic saw having a cutting tip in the form of segments including a hard metal or diamond powder.
• FIGS. 1 and 2 are front views illustrating a conventional circular saw blade 9.
• the circular saw blade 9 is installed in a cutting device (not shown), that is, a saw that includes a driving unit and a control unit for cutting an object, such as stone or metallic materials.
• the circular saw blade 9 includes a disc plate 10 formed at the center portion thereof with a shaft hole 11 to be coupled with a rotating shaft of a motor, which is the driving unit of the cutting device (not shown), and a cutting tip 20 in the form of segments, which are aligned at an outer peripheral portion of the disc plate 10 at a uniform pitch so as to cut an object made from a hard material.
• the conventional circular saw blade includes a disc- shaped steel shank having a shaft hole to be coupled with a driving shaft, and a cutting tip in the form of segments, which are aligned at an outer peripheral portion of the steel shaft with a predetermined width and consist of a metal bond and diamond powder.
• a thickness of the cutting tip must be thicker than that of the steel shank such that the cutting tip can be easily introduced into the object to be cut.
• the high speed rotating saw blade approaches to the object to be cut while forming a right angle with respect to a cutting surface of the object.
• 1999-12871 discloses a circular saw for cutting the objects to be cut, such as stone and metals.
• a plurality of the cooling holes 2 are formed symmetrically at upper and lower portions of a disc plate 10 in order to reduce thermal load.
• the circular blade still has the problem derived from heat generations occurred from the cutting tip itself and from friction of the steel shank during the cutting process.
• a first object of the present invention is toprovide a cutting tip having an improved structure capable of enhancing the cutting performance by 30% as compared with that of a conventional cutting tip, and a saw blade having the cutting tip.
• a second object of the present invention is to provide a cutting tip having an improved structure capable of facilitating initial cutting work without grinding an outer peripheral portion of an object to be cut, and a saw blade having the cutting tip.
• a third object of the present invention is to provide a cutting tip having an improved structure and a saw blade having the cutting tip, in which the life time of the saw blade can be expanded by attenuating load applied to the saw blade during the cutting process.
• a fourth object of the present invention is to provide a cutting tip having an improved structure suitable for various objects to be cut and a saw blade having the cutting tip, in which the life time of the cutting tip can be controlled by adjusting the content of diamond powder contained in the segment on the basis of hardness of a metal bond, regardless of the chemical composition and composition ratio of the metal bond contained in the segment in order to form the cutting tip.
• a fifth object of the present invention is to provide a cutting tip and a saw blade having the cutting tip, in which the cutting tip has an improved structure capable of simplifying the manufacturing process and significantly reducing the manufacturing cost for the saw blade.
• a sixth object of the present invention is to provide a cutting tip and a saw blade having the cutting tip, in which the cutting tip has an improved structure capable of representing superior cooling efficiency during the cutting process, so that a body of the saw blade, in particular, a shank of a circular saw blade can be prevented from being broken during the cutting process, thereby ensuring safety of the worker.
• the present invention provides a cutting tip of a saw blade for cutting various objects such as jewelry, ferrite materials, stone, metallic materials, or ceramic tiles, by having high hardness.
• the cutting tip comprises: a mesh pattern formed on upper and lower surfaces of the cutting tip.
• the mesh pattern includes a relief section having a plurality of relief lines, which cross each other at a predetermined angle while forming meshes, and an engraving section defined by the relief lines of the relief section.
• the mesh pattern formed on the upper surface of the cutting tip is offset from the mesh pattern formed on the lower surface of the cutting tip.
• the relief section of the mesh pattern formed on the upper surface of the cutting tip corresponds to the relief section of the mesh pattern formed on the lower surface of the cutting tip.
• a relief line of the mesh pattern has a width of about 0.5 to 3.5mm.
• a width of a relief line of the mesh pattern is inversely proportional to a content of diamond powder contained in a segment of the cutting tip.
• a size of the mesh pattern is proportional to a content of diamond powder contained in a segment of the cutting tip.
• the diamond powder includes at least one selected from the group comprising of natural diamond powder, synthetic diamond powder, and cubic boron nitride(CBN).
• the content of the diamond powder contained in the segment is proportional to rockwell hardness (HRc) of a metal bond.
• the diamond powder contained in the segment has a particle size in a range of about 30 to 120 meshes.
• the present invention also provides a saw blade including the cutting tip having the above structure.
• the saw blade includes a body shaped by one selected from the group comprising of a flat type, a disc type, a core-drill type or a grinding cup wheel type.
• a plurality of cooling holes are formed in the disc-shaped body.
• the saw blade is a circular saw blade, a plurality of cooling holes are formed in a body of the circular saw blade.
• the present invention has the following advantages.
• the cutting tip and the saw blade having the cutting tip according to the present invention represent superior cutting performance as compared with that of the conventional saw blade having the conventional cutting tip.
• the cutting tip and the saw blade having the cutting tip according to the present invention can perform initial cutting without grinding an outer peripheral portion of an object to be cut.
• the cutting tip and the saw blade having the cutting tip according to the present invention can expand the life time of the saw blade by attenuating load applied to the saw blade during the cutting process.
• the cutting tip and the saw blade having the cutting tip according to the present invention can easily cut various objects and can control the life time of the cutting tip by adjusting the content of diamond powder contained in the segment on the basis of hardness of a metal bond, regardless of the chemical composition and composition ratio of the metal bond contained in the segment.
• the cutting tip and the saw blade having the cutting tip according to the present invention can simplify the manufacturing process and significantly reduce the manufacturing cost for the saw blade.
• the cutting tip and the saw blade having the cutting tip according to the present invention represent superior cooling efficiency during the cutting process, so that a body of the saw blade, in particular, a shank of a circular saw blade can be prevented from being broken during the cutting process, thereby ensuring safety of the worker.
• FIG. 1 is a front view illustrating a conventional circular saw blade
• FIG. 2 is an enlarged view illustrating a structure of a cutting tip formed in the conventional circular saw blade shown in FIG. 1 ;
• FIG. 3 is a perspective view illustrating a circular saw blade having a cutting tip according to one embodiment of the present invention;
• FIG. 4 is an enlarged view of a cutting tip shown in FIG. 3;
• FIG. 5 is a perspective view illustrating a circular saw blade having a cutting tip according to another embodiment of the present invention
• FIG. 6 is an enlarged view of a cutting tip shown in FIG. 5;
• FIG. 7 is a schematic view illustrating an empty cavity formed in a cutting tip when a cutting process is performed by means of the circular saw blade shown in FIGS. 3 and 5;
• FIG. 8 is a view illustrating a moving direction of diamond powder contained in a segment during a sintering process for the segment, which forms a conventional cutting tip;
• FIGS. 9 and 10 are views illustrating a moving direction of diamond powder contained in a segment during a sintering process for the segment, which forms a cutting tip according to one embodiment of the present invention;
• FIG. 11 is a view illustrating a trail formed by diamond powder, which is contained in a segment according to properties of a metal bond in order to form a conventional cutting tip;
• FIG. 12 is a view illustrating a trail formed by diamond powder, which is contained in a segment according to properties of a metal bond in order to form a cutting tip of the present invention;
• FIGS. 13 and 14 are views for explaining the reason that causes a limitation of the content of diamond powder in a segment, which forms a conventional cutting tip;
• FIG. 15 is a view for explaining the reason that does not cause a limitation of the content of diamond powder in a segment, which forms a cutting tip according to one embodiment of the present invention
• FIGS. 16 and 17 are graphs illustrating the difference of cutting performance and life time between a conventional saw blade having a typical cutting tip and a saw blade having a cutting tip according to one embodiment of the present invention, when an object to be cut is sandstone;
• FIGS. 18 and 19 are graphs illustrating the difference of cutting performance and life time between a conventional saw blade having a typical cutting tip and a saw blade having a cutting tip according to one embodiment of the present invention, when an object to be cut is marble;
• FIGS. 20 and 21 are graphs illustrating the difference of cutting performance and life time between a conventional saw blade having a typical cutting tip and a saw blade having a cutting tip according to one embodiment of the present invention, when an object to be cut is granite. Best Mode for Carrying Out the Invention
• FIG. 3 is a perspective view illustrating a circular saw blade having a cutting tip according to one embodiment of the present invention
• FIG. 4 is an enlarged view of the cutting tip shown in FIG. 3
• FIG. 5 is a perspective view illustrating a circular saw blade having a cutting tip according to another embodiment of the present invention
• FIG. 6 is an enlarged view of the cutting tip shown in FIG. 5
• FIG. 7 is a schematic view illustrating an empty cavity formed in the cutting tip when a cutting process is performed by means of the circular saw blade shown in FIGS. 3 and 5.
• FIGS. 3 to 6 show a circular saw blade 1 used for cutting an object, such as a ferrite material, stone, metallic materials or ceramic tiles.
• the circular saw blade 1 includes a body 100 and a cutting tip 200 formed at an outer peripheral portion of the body 100. Both upper and lower surfaces of the cutting tip 200 are formed with a mesh pattern 211.
• the present invention does not limit the shape of the mesh pattern 211 so long as the mesh pattern 211 consists of a relief section having a plurality of relief lines, which cross each other at a predetermined angle while forming meshes, and an engraving section defined by the relief lines of the relief section.
• the relief lines may be in the form of straight lines, curved lines or straight-curved lines.
• the engraving section can be formed with a lozenge, a circular or an oval shape according to the shape of the relief lines.
• the mesh pattern 211 shown in FIGS. 3 and 4 includes a relief section 21 Ia having a plurality of relief straight lines, which cross each other while forming a predetermined angle therebetween, and an engraving section 21 Ib defined by the relief straight lines in the form of a lozenge shape.
• the mesh pattern 211 shown in FIGS. 5 and 6 includes a relief section 211a having a plurality of relief curved lines, which cross each other, and a curved engraving section 21 Ib defined by the relief curved lines.
• the engraving section 21 Ib when the engraving section 21 Ib is defined by the relief straight lines, the engraving section 21 Ib has a substantially lozenge shape as shown in FIGS. 3 and 4.
• each engraving section 21 Ib gradually expands, as the position of the engraving section 21 Ib is remote from the body 100 of the circular saw blade 1.
• a plurality of lozenge- shaped engraving sections are aligned in a row along the outer peripheral portion of the body 100.
• the mesh pattern 211 having the above structure is preferably formed on both upper and lower surfaces of the cutting tip 200.
• the mesh pattern 211 formed on the upper surface 210 of the cutting tip 200 may correspond to the mesh pattern 211 formed on the lower surface of the cutting tip 200 or can be offset from the mesh pattern 211 formed on the lower surface of the cutting tip 200.
• the relief section of the mesh pattern 211 formed on the upper surface 210 of the cutting tip 200 preferably corresponds to the relief section of the mesh pattern formed on the lower surface of the cutting tip 200 at the end portion of the cutting tip 200.
• the relief section of the mesh pattern 211 formed on the upper surface 210 of the cutting tip 200 may partially or fully correspond to the engraving section of the mesh pattern formed on the lower surface of the cutting tip 200 at the end portion of the cutting tip 200. More preferably, at least a half area or the whole area of the relief section of the mesh pattern 211 formed on the upper surface 210 of the cutting tip 200 may correspond to that of the engraving section of the mesh pattern formed on the lower surface of the cutting tip 200.
• each relief line which forms the mesh pattern 211, preferably has a width of about 0.5 to 3.5mm. If the width of the relief line is less than 0.5mm, the cutting tip may be easily worn during the cutting process due to friction between the cutting tip and the object to be cut, so that the life time of the saw blade may be shortened. In contrast, if the width of the relief line exceeds 3.5mm, it is difficult to obtain the cutting tip having a smooth configuration.
• FIG. 7 which shows empty cavities formed in the cutting tip when the cutting process is performed by means of the circular saw blade as shown in FIGS. 3 and 5
• the circular saw blade 1 having the cutting tip 200 formed with the mesh pattern 211 performs the cutting process
• a plurality of empty cavities are formed in the cutting tip 200.
• Heat generated during the cutting process can be effectively cooled due to the empty cavities.
• the performance of the cutting tip can be improved while reducing heat generated during the cutting process.
• the cutting tip 200 has an improved structure capable of facilitating initial cutting work for an object, so that it is possible to directly perform the initial cutting work without grinding an outer peripheral portion of an object to be cut.
• FIG. 8 is a view illustrating the moving direction of diamond powder contained in the segment during the sintering process for the segment, which forms a conventional cutting tip
• FIGS. 9 and 10 are views illustrating the moving direction of diamond powder contained in the segment during the sintering process for the segment, which forms the cutting tip according to one embodiment of the present invention.
• FIG. 11 is a view illustrating a trail formed by diamond powder, which is contained in the segment according to properties of a metal bond (chemical composition and composition ratio of components, additives, etc.) in order to form a conventional cutting tip
• FIG. 12 is a view illustrating a trail formed by diamond powder, which is contained in the segment according to properties of a metal bond in order to form the cutting tip of the present invention.
• the trail formed by the diamond powder is shortened.
• the trail formed by the diamond powder is extended as the hardness of the metal bond contained in the segment of the conventional cutting tip becomes lowered.
• the properties of the metal bond can be adjusted by manufactures or users depending on several factors, such as the material of the object to be cut, and the life time of the saw blade. If the conventional cutting tip is employed, as shown in FIG. 11, it is necessary to properly adjust the length of the trail formed by the diamond powder, which is contained in the segment according to the properties of the metal bond, in order to obtain desired cutting performance and life time. For this reason, the manufactures must make efforts to adjust the properties of the metal bond. This is because the cutting performance and life time of the cutting tip can be improved only when the properties of the metal bond contained in the segment are optimally harmonious with the material of the object to be cut and the content of the diamond powder.
• the trail formed by the diamond powder contained in the segment is forcibly removed. Therefore the content of the diamond powder contained in the segment can beadjusted on the basis of hardness of the metal bond regardless of other properties of the metal bond, so that the saw blade representing superior cutting performance and improved life time can be fabricated according to applications thereof.
• FIGS. 13 and 14 are views for explaining the reason that causes a limitation of the content of diamond powder in the segment, which forms a conventional cutting tip.
• FIG. 15 is a view for explaining the reason that does not cause a limitation of the content of diamond powder in the segment, which forms the cutting tip according to the present invention.
• the content of diamond powder is about 18% relative to the metal bond, regardless of the properties of the metal bond.
• the conventional cutting tip is fabricated by sintering the segment that includes diamond powder of the above content, a predetermined interval is formed between a first diamond and a second diamond, so that the cutting process can be properly performed due to the predetermined interval.
• the third diamond is not provided between the first and second diamonds even if the content of diamond powder increases proportionally to hardness of the object to be cut, so that it is possible to fabricate the cutting tip while increasing the content of diamond powder by two times as compared with that of the conventional cutting tip. Therefore, according to the cutting tip of the present invention, the cutting performance and wear-resistance of the saw blade can be controlled by adjusting the content of diamond powder, so that it is not necessary to take the chemical composition and composition ratio of the metal bond into consideration based on the material of the object to be cut.
• the manufacturing process for the saw blade can be more simplified because the saw blade can be fabricated by simply adjusting the content of diamond powder on the basis of rockwell hardness (HRc) of the metal bond while employing the metal bond having the same property regardless of the material of the object to be cut.
• HRc rockwell hardness
• the width of the relief line of the mesh pattern is inversely proportional to the content of diamond powder contained in the segment of the cutting tip. If the width of the relief line becomes enlarged, the cutting tip may be rarely worn by load applied thereto during the cutting process, even if the content of diamond powder decreases. That is, the desired content of diamond powder is assumed as 20% when the relief line of the mesh pattern formed in the cutting tip according to the present invention has the width of lmm. In this state, if the width of the relief line is enlarged to 2mm, the life time of the saw blade may not be shortened even if the content of diamond powder is less than 20%.
• the saw blade can maintain the improved cutting performance and life time even if the content of diamond powder is maintained at 20%. Therefore, when the relief lines of the mesh pattern formed in the cutting tip according to the present invention have the same width, the size of the mesh pattern is proportional to the content of diamond powder contained in the segment of the cutting tip.
• the size of the mesh pattern may vary depending on applications thereof.
• the content of diamond powder for each mesh must be constant in order to obtain the optimum cutting performance. That is, when the content of diamond powder is uniform over the whole area of the cutting tip, the life time of the saw blade may be lengthened as the size of the mesh pattern is enlarged.
• the diamond powder contained in the segment of the cutting tip according to the present invention refers to hard abrasives and includes at least one selected from the group comprising of natural diamond powder, synthetic diamond powder, and cubic boron nitride (CBN).
• a particle size of the diamond powder is preferably 30 to 120 meshes. If the particle size of the diamond powder exceeds 30 meshes or is smaller than 120 meshes, the cutting tip cannot achieve the object and effect of the present invention. For this reason, diamond powder having the particle size of 30 to 120 meshes is contained in the segment of the cutting tip according to the present invention. More preferably, the particle size is increased or decreased in a 5-mesh unit within the above range.
• FIGS. 16 to 21 show graphs illustrating the difference of cutting performance and life time between a conventional saw blade having a typical cutting tip and a saw blade having a cutting tip according to one embodiment of the present invention.
• FIGS. 16 and 17 are graphs illustrating the difference of cutting performance and life time between the conventional saw blade having the typical cutting tip and the saw blade having the cutting tip according to one embodiment of the present invention, when an object to be cut is sandstone.
• FIGS. 18 and 19 are graphs illustrating the difference of cutting performance and life time between the conventional saw blade having the typical cutting tip and the saw blade having the cutting tip according to one embodiment of the present invention, when the object to be cut is marble.
• FIGS. 20 and 21 are graphs illustrating the difference of cutting performance and life time between the conventional saw blade having the typical cutting tip and the saw blade having the cutting tip according to one embodiment of the present invention, when the object to be cut is granite.
• the saw blade having the cutting tip according to the present invention represents improved cutting performance and life time as compared with the conventional saw blade having the typical cutting tip.
• the chemical composition and composition ratio of the metal bond may vary depending on the material of the object to be cut.
• the content of diamond powder is adjusted on the basis of rockwell hardness (HRc 28) of the metal bond, regardless of the material of the object to be cut.
• the conventional saw blade is fabricated by taking the chemical composition and composition ratio of the metal bond into consideration, but the saw blade having the cutting tip according to the present invention is fabricated by adjusting the content of diamond powder, so that the manufacturing process for the saw blade can be simplified, and the cutting performance and life time of the saw blade can be improved while ensuring safety during the cutting process.
• a plurality of cooling holes are preferably formed in the body 100 of the saw blade 1.
• air may freely pass through the cooling holes during the cutting process, so that the thermal load applied to the body 100 caused by friction between the object to be cut and the body 100 can be reduced. That is, stability of the body 100 can be improved if the cooling holes are formed in the body 100 of the circular saw blade 1.
• the saw blade may include a body shaped by at least one selected from the group comprising of a flat type, a disc type, a core-drill type, or a grinding cup wheel type etc.
• the effect of the present invention may not be changed even if the shape of the body of the saw blade having the cutting tip is changed.
• the present invention provides a saw blade capable of cutting various objects, such as jewelry, ferrite materials, stone, ceramic tiles or metallic materials.
• the shape of the cutting tip of the saw blade is modified such that cutting performance and life time of the saw blade can be improved.
• the manufacturing process for the saw blade can be simplified, thereby reducing the manufacturing cost for the saw blade.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Mining & Mineral Resources (AREA)
• Polishing Bodies And Polishing Tools (AREA)

Applications Claiming Priority (3)

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• 2006
  • 2006-05-02 WO PCT/KR2006/001649 patent/WO2006118413A1/en active Application Filing
  • 2006-05-02 EP EP06757613A patent/EP1937438A1/de not_active Withdrawn

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