Multi-chip facet cutting saw blade and related method

Abstract

A metal cutting band saw blade has a plurality of cutting teeth defining a cutting direction, and a repeating tooth pattern of between 3 and 7 teeth. Each tooth defines a laterally-extending upper surface having a width and a height with respect to the back edge of the blade, and side surfaces extending laterally and downwardly on opposite sides of the upper surface relative to each other at acute angles relative to the upper surface. The teeth located rearwardly of the first tooth with respect to the cutting direction of the saw blade define progressively lower heights and progressively smaller acute angles of the side surfaces, and the widths of the upper surfaces of these teeth are greater than the width of the upper surface of the respective first tooth.

What is claimed is: 
     
       1. A saw blade comprising:
 a plurality of cutting teeth defining a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other at first acute angles relative to the first upper surface; (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other at second acute angles relative to the second upper surface; and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other at third acute angles relative to the third upper surface; and wherein the first height is greater than the second and third heights, the first width is less than the second and third widths, and the first acute angle is greater than the second and third acute angles.   
     
     
       2. A saw blade as defined in  claim 1 , wherein the first height is greater than the second height, and the second height is greater than the third height. 
     
     
       3. A saw blade as defined in  claim 2 , wherein the first angle is greater than the second angle, and the second angle is greater than the third angle. 
     
     
       4. A saw blade as defined in  claim 3 , wherein the second and third widths are approximately equal to each other. 
     
     
       5. A saw blade as defined in  claim 1 , wherein the saw blade is a band saw blade. 
     
     
       6. A saw blade as defined in  claim 5 , wherein the saw blade is a metal cutting band saw blade. 
     
     
       7. A saw blade as defined in  claim 1 , wherein the teeth are carbide tipped. 
     
     
       8. A saw blade as defined in  claim 1 , wherein each group in the repeating tooth pattern includes from about 3 teeth through about 7 teeth. 
     
     
       9. A saw blade as defined in  claim 1 , wherein each tooth includes an aluminum titanium nitride coating on at least the respective upper and side surfaces thereof. 
     
     
       10. A saw blade as defined in  claim 9 , wherein the aluminum titanium nitride coating is a physical vapor deposition coating. 
     
     
       11. A saw blade as defined in  claim 1 , wherein the first, second and third teeth are located on the saw blade without any additional teeth therebetween. 
     
     
       12. A saw blade as defined in  claim 1 , wherein the first, second and third acute angles are each with the range of about 5° through about 50°. 
     
     
       13. A saw blade as defined in  claim 12 , wherein the first angle is about 45°. 
     
     
       14. A saw blade as defined in  claim 12 , wherein the second angle is within the range of about 20° through about 30°. 
     
     
       15. A saw blade as defined in  claim 12 , wherein the third angle is within the range of about 5° through about 15°. 
     
     
       16. A saw blade as defined in  claim 1 , wherein each of the first, second and third teeth is unset. 
     
     
       17. A saw blade as defined in  claim 16 , wherein each tooth in the repeating tooth pattern is unset. 
     
     
       18. A saw blade as defined in  claim 1 , wherein the difference in height between any of the three upper surfaces relative to any of the other two upper surfaces is within the range of about 0 and about 0.045 inch. 
     
     
       19. A saw blade as defined in  claim 18 , wherein the height of each upper surface is measured with respect to a back edge of the saw blade. 
     
     
       20. A saw blade as defined in  claim 1 , wherein the heights of the teeth in the repeating tooth pattern are progressively lower in a direction opposite the cutting direction of the saw blade. 
     
     
       21. A saw blade as defined in  claim 1 , wherein the repeating tooth pattern is defined by three teeth, the saw blade defines a predetermined kerf the first width of the first upper surface is less than about ¼ of the predetermined kerf, and the second and third widths of the second and third upper surfaces, respectively, are each greater than about ¼ of the predetermined kerf. 
     
     
       22. A saw blade as defined in  claim 1 , wherein the predetermined tooth pattern is defined by (n) teeth, the saw blade defines a predetermined kerf, the first width of the first upper surface is less than about (1/(n+1)) of the predetermined kerf and the widths of the upper surfaces of the other teeth in the pattern are each substantially equal to or greater than about (1(n+1)) of the predetermined kerf. 
     
     
       23. A saw blade comprising:
 a plurality of cutting teeth defining a substantially central plane, a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other; (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other; and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other, wherein the first height is greater than the second and third heights; and   first means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through a workpiece.   
     
     
       24. A saw blade as defined in  claim 23 , wherein the first means is defined by the first, second and third side surfaces being oriented at acute angles with respect to the first, second and third upper surfaces, respectively. 
     
     
       25. A saw blade as defined in  claim 24 , wherein the first side surfaces are each located at a first acute angle with respect to the first upper surface, the second side surfaces are each located at a second acute angle with respect to the second upper surface, and the third side surfaces are each located at a third acute angle with respect to the third upper surface. 
     
     
       26. A saw blade as defined in  claim 25 , wherein the first angle is greater than the second angle, and the second angle is greater than the third angle. 
     
     
       27. A saw blade as defined in  claim 23 , wherein the first height is greater than the second height, and the second height is greater than the third height. 
     
     
       28. A saw blade as defined in  claim 23 , wherein the second and third widths are approximately equal to each other. 
     
     
       29. A saw blade as defined in  claim 23 , wherein the first, second and third teeth are located on the saw blade without any additional teeth therebetween. 
     
     
       30. A saw blade comprising:
 a plurality of cutting teeth defining a substantially central plane, a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other; (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other; and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other, wherein the first height is greater than the second and third heights;   first means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through a workpiece; and   second means for balancing the cutting loads on the teeth in the repeating tooth pattern relative to each other.   
     
     
       31. A saw blade as defined in  claim 30 , wherein the first means is defined by the first, second and third side surfaces being oriented at acute angles with respect to the first, second and third upper surfaces, respectively. 
     
     
       32. A saw blade as defined in  claim 30 , wherein the second means is defined by the first, second and third upper surfaces being located at progressively lower heights relative to each other, and the first, second and third side surfaces being oriented at progressively smaller acute angles with respect to the respective upper surfaces. 
     
     
       33. A saw blade for cutting a work piece, comprising:
 a plurality of cutting teeth defining a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other at first acute angles relative to the first upper surface, wherein the first upper surface, and positions of the first side surfaces contiguous to the first upper surface define a first cutting surface fin cutting first chips from the work piece; (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height less than the first height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other at second acute angles relative to the second upper surface that are less than the first acute angle, and wherein portions of the second side surfaces extending laterally outwardly relative to the first cutting surface define second cutting surfaces for cutting second chips from the work piece; and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height that is less than the first height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other at third acute angles relative to the third upper surface that are less than the first acute angle, and wherein portions of the third side surfaces extending laterally outwardly relative to the second cutting surfaces define third cutting surfaces for cutting third chips from the work piece.   
     
     
       34. A saw blade as defined in  claim 33 , wherein the first width is less than the second and third widths. 
     
     
       35. A saw blade as defined in  claim 34 , wherein the second and third widths are approximately equal to each other. 
     
     
       36. A saw blade as defined in  claim 33 , wherein the first height is greater than the second height, and the second height is greater than the third height. 
     
     
       37. A saw blade as defined in  claim 33 , wherein the first angle is greater than the second angle, and the second angle is greater than the third angle. 
     
     
       38. A saw blade as defined in  claim 33 , wherein the first, second and third teeth are located on the saw blade without any additional teeth therebetween. 
     
     
       39. A saw blade comprising:
 a plurality of cutting teeth defining a substantially central plane, a cutting direction, and a repeating pattern of groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other; and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other, wherein the first height is greater than the second and third heights, and the first, second and third teeth are located on the saw blade without any additional teeth therebetween;   first means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through a workpiece; and   second means for balancing the cutting loads on the teeth in the repeating tooth pattern relative to each other.   
     
     
       40. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece, comprising:
 a plurality of cutting teeth defining a cutting direction of the band saw blade, a feed direction of the band saw blade that is transverse to the cutting direction of the band saw blade, and a repeating pattern of groups of successive teeth, wherein each group of successive teeth includes:   a lead tooth defining a first laterally-extending cutting surface facing the cutting direction of the band saw blade for cutting at least one first chip from the metal work piece, wherein the first laterally-extending cutting surface is oriented substantially normal to a central plane of the band saw blade and defines a first height, and the lead tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining an acute secondary clearance angle greater than the primary clearance angle; and   a plurality of trailing teeth following the lead tooth, wherein each trailing tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining a secondary clearance angle greater than the primary clearance angle, and the plurality of trailing teeth define:
 a second laterally-extending cutting surface facing the cutting direction of the band saw blade, located to one side of the first laterally-extending cutting surface, oriented at a second acute angle relative to the first laterally-extending cutting surface, and defining a second height different than the first height, for cutting at least one second chip from the metal cutting work piece; and 
 a third laterally-extending cutting surface facing the cutting direction of the band saw blade, located to one side of the first laterally-extending cutting surface and on an opposite side of the first laterally-extending cutting surface relative to the second laterally-extending cutting surface, oriented at a third acute angle relative to the first laterally-extending cutting surface, and defining a third height different than the first height, for cutting at least one third chip from the metal cutting work piece; and 
   an aluminum titanium nitride coating overlying each of the first, second and third cutting surfaces.    
     
     
       41. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the plurality of trailing teeth further define:
 a fourth laterally-extending cutting surface facing the cutting direction of the band saw blade, located to one side of the second laterally-extending cutting surface and on an opposite side of the second laterally-extending cutting surface relative to the first laterally-extending cutting surface, oriented at a fourth acute angle relative to the first laterally-extending cutting surface, and defining a fourth height different than the first height, for cutting at least one fourth chip from the metal cutting work piece; and   a fifth laterally-extending cutting surface facing the cutting direction of the band saw blade, located to one side of the third trailing laterally-extending cutting surface and on an opposite side of the third laterally-extending cutting surface relative to the first laterally-extending cutting surface, oriented at a fifth acute angle relative to the first laterally-extending cutting surface, and defining a fifth height different than the first height, for cutting at least one fifth chip from the metal cutting work piece; and   wherein the aluminum titanium nitride coating overlies each of the first, second, third, fourth and fifth cutting surfaces.    
     
     
       42. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 41, wherein the first height is greater than each of the second, third, fourth and fifth heights.  
     
     
       43. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 41, wherein the second and third heights are approximately equal, and the fourth and fifth heights are approximately equal.  
     
     
       44. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 43, wherein the second and third heights are lower than the first height, and the fourth and fifth heights are lower than the second and third heights.  
     
     
       45. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 41, wherein the second and third acute angles are approximately equal, and the fourth and fifth acute angles are approximately equal.  
     
     
       46. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 45, wherein the second and third acute angles are greater than the fourth and fifth acute angles.  
     
     
       47. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 45, wherein the second and third acute angles are within the range of about 5° through about 50°, and the fourth and fifth acute angles are within the range of about 5° through about 15°.  
     
     
       48. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the teeth are one of carbide tipped and bi-metal.  
     
     
       49. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the second and third laterally-extending cutting surfaces are defined by a first trailing tooth, and the fourth and fifth laterally-extending cutting surfaces are defined by a second trailing tooth following the first trailing tooth.  
     
     
       50. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the lead tooth and a first and second of the plurality of trailing teeth are located on the band saw blade without any additional teeth therebetween.  
     
     
       51. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the height of each cutting surface is measured with respect to a back edge of the band saw blade.  
     
     
       52. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the aluminum titanium nitride coating is a physical vapor deposition coating.  
     
     
       53. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the groups of successive teeth are non-overlapping.  
     
     
       54. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 40, wherein the primary and secondary clearance angles each are within the range of about 1° through about 40°.  
     
     
       55. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 54, wherein each tooth further includes a tertiary clearance surface defining an acute tertiary clearance angle that is greater than the respective acute secondary clearance angle.  
     
     
       56. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece, comprising:
 a plurality of cutting teeth defining a cutting direction of the band saw blade, a feed direction of the band saw blade that is transverse to the cutting direction of the band saw blade, and a repeating pattern of groups of successive teeth, wherein each group of successive teeth includes:   a lead tooth including first means extending laterally on the lead tooth and facing the cutting direction of the band saw blade for cutting at least one first chip from the metal work piece, wherein the first means is oriented substantially normal to a central plane of the band saw blade and defines a first height, and the lead tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining an acute secondary clearance angle greater than the primary clearance angle; and   a plurality of trailing teeth following the lead tooth, wherein each trailing tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining an acute secondary clearance angle greater than the primary clearance angle, and the plurality of trailing teeth define:
 second means for cutting at least one second chip from the metal cutting work piece, wherein the second means is located to a first side of the first means, is oriented at a second acute angle relative to the first means, and defines a second height different than the first height; and 
 third means for cutting at least one third chip from the metal cutting work piece, wherein the third means faces the cutting direction of the band saw blade, is located to a second side of the first means that is opposite the first side, is oriented at a third acute angle relative to the first means, and defines a third height different than the first height; and 
   an aluminum titanium nitride coating physical vapor deposition coated over each of the first, second and third means.    
     
     
       57. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 56, wherein the plurality of trailing teeth further define:
 fourth means for cutting at least one fourth chip from the metal cutting work piece, wherein the fourth means faces the cutting direction of the band saw blade, is located to one side of the second means on an opposite side of the second means relative to the first means, is oriented at a fourth acute angle relative to the first means, and defines a fourth height different than the first height; and   fifth means for cutting at least one fifth chip from the metal cutting work piece, wherein the fifth means faces the cutting direction of the band saw blade, is located to one side of the third means and is on an opposite side of the third means relative to the first means, is oriented at a fifth acute angle relative to the first means, and defines a fifth height different than the first height; and   wherein the aluminum titanium nitride coating is physical vapor deposition coated over each of the first, second, third, fourth and fifth means.    
     
     
       58. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 57, wherein the first means is a first laterally-extending cutting surface, the second means is a second laterally-extending cutting surface, the third means is a third laterally-extending cutting surface, the fourth means is a fourth laterally-extending cutting surface, and the fifth means is a fifth laterally-extending cutting surface.  
     
     
       59. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 56, further comprising means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through the work piece.  
     
     
       60. A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece as defined in claim 56, further comprising means for balancing the cutting loads on the teeth in the repeating tooth pattern relative to each other.