CA2055945C - Chemically machined sheet metal cutting tools and method - Google Patents
Chemically machined sheet metal cutting tools and method Download PDFInfo
- Publication number
- CA2055945C CA2055945C CA002055945A CA2055945A CA2055945C CA 2055945 C CA2055945 C CA 2055945C CA 002055945 A CA002055945 A CA 002055945A CA 2055945 A CA2055945 A CA 2055945A CA 2055945 C CA2055945 C CA 2055945C
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- Canada
- Prior art keywords
- metal blank
- tooth
- front surface
- back surface
- exposed areas
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
- B23D73/00—Making files or rasps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
- B24D11/00—Constructional features of flexible abrasive materials; Special features in the manufacture of such materials
- B24D11/001—Manufacture of flexible abrasive materials
- B24D11/003—Manufacture of flexible abrasive materials without embedded abrasive particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
- C23F1/00—Etching metallic material by chemical means
- C23F1/02—Local etching
- C23F1/04—Chemical milling
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/44—Filing
Abstract
A method is shown for manufacturing a sheet metal tool from a metal blank in which a predetermined pattern of etching resistant material is applied to the back surface of the metal blank to define exposed areas separated by resist areas. A layer of etching resistant material is also applied to the front surface of the metal blank which overlies at least the exposed areas on the back surface of the metal blank. The exposed areas on the back surface are then subjected to etching treatment through the exposed areas to form a tooth shape with a cutting edge. The etching treatment is applied solely from the back surface of the metal blank, whereby the cutting edge is so formed terminate in sharpened surfaces in the plane of the front surface, protected by the layer of the etching resistant material on the front surface of the metal blank.
Description
2~~~~~~
BACKGROUND OF THE INVENTION
a 3 1. Field of the Invention:
BACKGROUND OF THE INVENTION
a 3 1. Field of the Invention:
The present invention relates to sheet metal tools 6 of the type used for cutting and abrading operations 7 and, specifically, to a method for chemically machining 8 such tools to provide cutting teeth of unique and 9 highly efficient shapes.
11 2. Description of the Prior Art:
13 Thin cutters and files, 'by their very design, have 14 traditionally been very dull. They tend to load with the material being cut and clog. This necessitates 16 cleaning before .more material can be removed from the 17 work surface. Because of this loading condition, most 18 users rub material off the work surface by friction 19 instead of actually removing material by creating. a chip. It was very difficult to create a sharp cutting 21 edge on prior art cutters and files because of the 22 manufacturing techniques utilized. The problem was 23 increased if the cutter or file in question had a 24 multiplicity of cutting edges. The prior art also required that most cutters or files be stiff or rigid, 26 which generally prohibited the cutter or file from 27 conforming to a curved shape. Although abrasive papers 28 were introduced in an attempt to solve this problem, 29 the paper or cloth abrasive media tended to rub off material and create heat rather than cut material from 31 the work surface.
2~~~~~
1 Many of the cutters or files that are manufactured 2 at the present time are punched out of a suitable sheet 3 metal material. The material is passed through a punch 4 and die, thereby imparting holes in the metal that are bent to provide the ~~set" which is necessary to make 6 the desired tooth profile. The state-of-the-art 7 cutters and files lack a preferred degree of sharpness.
8 This is partially the result of the cutting edges being 9 formed by the ragged die cuts in the metal blank. More expensive cutters and files have ground edges, however 11 this grinding process is limited in application and 12 limited in possible tooth arrangements because the 13 grinding wheel or broach is required to enter and exit 14 the tooth in a straight line. As a result, the available tooth patterns are relatively simple and 16 linear.
18 Because of the high cost of tooling and grinding, 19 attempts have been made in the prior art to manufacture sheet metal files by means of chemical etching 21 processes. These endeavors have not generally met with 22 commercial success because the end product tended to do 23 more rubbing than cutting. This is primarily due to 24 lack of side, frontal and/or top relief in the etched individual tooth patterns. United States Patent No.
26 3,045, 321 to McDenaott is an example of such an 27 abrading device. Etching through duplicate patterns of 28 resists applied to opposite sides of a metal blank so 29 that the etched cavities penetrate completely through the blank from opposite sides works very poorly in 31 practice. As will be explained, the resulting reliefs 32 or clearances extend in the wrong direction, causing 33 the tool to rub more than it will cut.
t ~~a~~~~
2 United States Patent No. 4,240,806 to Francen, is 3 an improvement over the McDermott manufacturing method 4 and makes use of special resist patterns on the metal blank. However, this patent also lacks sufficient top 6 relief or clearance due to the geometry created by the 7 chemical breakdown of metal as it is removed from the 8 metal blank during the etching process. As a result, 9 the tool tends to rub the work surface rather than cut and has the undesirable characteristic loading or 11 clogging previously discussed.
13 It is an object of the present invention to 14 provide an improved chemical machining method for manufacturing cutting tools which overcomes the 16 previously mentioned shortcomings.
18 Another object of the invention is to provide a 19 greater array of tooth designs for such tools that more efficiently cut a work material than the presently 21 available designs.
23 Another object of the invention is to provide a 24 linear file blade which can be mounted in a tensioned state within a frame to be used as an improved rasp or 26 as a hacksaw.
28 Another object of the invention is to provide an 29 improved linear or circular file which can be used with a backing plate for the purpose of providing required 31 stiffness or rigidity.
1 Another object of the invention is to provide an 2 improved flexible etched file that can be used to work 3 irregularly shaped work surfaces.
Another object of the invention is to provide an 6 improved sheet metal file and method of manufacture 7 that eliminates the necessity of grinding the cutting 8 edges or the use of expensive dies and fixtures.
18 Another object of the invention is to provide a 11 manufacturing method which provides the top and side 12 tooth relief angles necessary to efficiently remove 13 material from a Work surface.
11 2. Description of the Prior Art:
13 Thin cutters and files, 'by their very design, have 14 traditionally been very dull. They tend to load with the material being cut and clog. This necessitates 16 cleaning before .more material can be removed from the 17 work surface. Because of this loading condition, most 18 users rub material off the work surface by friction 19 instead of actually removing material by creating. a chip. It was very difficult to create a sharp cutting 21 edge on prior art cutters and files because of the 22 manufacturing techniques utilized. The problem was 23 increased if the cutter or file in question had a 24 multiplicity of cutting edges. The prior art also required that most cutters or files be stiff or rigid, 26 which generally prohibited the cutter or file from 27 conforming to a curved shape. Although abrasive papers 28 were introduced in an attempt to solve this problem, 29 the paper or cloth abrasive media tended to rub off material and create heat rather than cut material from 31 the work surface.
2~~~~~
1 Many of the cutters or files that are manufactured 2 at the present time are punched out of a suitable sheet 3 metal material. The material is passed through a punch 4 and die, thereby imparting holes in the metal that are bent to provide the ~~set" which is necessary to make 6 the desired tooth profile. The state-of-the-art 7 cutters and files lack a preferred degree of sharpness.
8 This is partially the result of the cutting edges being 9 formed by the ragged die cuts in the metal blank. More expensive cutters and files have ground edges, however 11 this grinding process is limited in application and 12 limited in possible tooth arrangements because the 13 grinding wheel or broach is required to enter and exit 14 the tooth in a straight line. As a result, the available tooth patterns are relatively simple and 16 linear.
18 Because of the high cost of tooling and grinding, 19 attempts have been made in the prior art to manufacture sheet metal files by means of chemical etching 21 processes. These endeavors have not generally met with 22 commercial success because the end product tended to do 23 more rubbing than cutting. This is primarily due to 24 lack of side, frontal and/or top relief in the etched individual tooth patterns. United States Patent No.
26 3,045, 321 to McDenaott is an example of such an 27 abrading device. Etching through duplicate patterns of 28 resists applied to opposite sides of a metal blank so 29 that the etched cavities penetrate completely through the blank from opposite sides works very poorly in 31 practice. As will be explained, the resulting reliefs 32 or clearances extend in the wrong direction, causing 33 the tool to rub more than it will cut.
t ~~a~~~~
2 United States Patent No. 4,240,806 to Francen, is 3 an improvement over the McDermott manufacturing method 4 and makes use of special resist patterns on the metal blank. However, this patent also lacks sufficient top 6 relief or clearance due to the geometry created by the 7 chemical breakdown of metal as it is removed from the 8 metal blank during the etching process. As a result, 9 the tool tends to rub the work surface rather than cut and has the undesirable characteristic loading or 11 clogging previously discussed.
13 It is an object of the present invention to 14 provide an improved chemical machining method for manufacturing cutting tools which overcomes the 16 previously mentioned shortcomings.
18 Another object of the invention is to provide a 19 greater array of tooth designs for such tools that more efficiently cut a work material than the presently 21 available designs.
23 Another object of the invention is to provide a 24 linear file blade which can be mounted in a tensioned state within a frame to be used as an improved rasp or 26 as a hacksaw.
28 Another object of the invention is to provide an 29 improved linear or circular file which can be used with a backing plate for the purpose of providing required 31 stiffness or rigidity.
1 Another object of the invention is to provide an 2 improved flexible etched file that can be used to work 3 irregularly shaped work surfaces.
Another object of the invention is to provide an 6 improved sheet metal file and method of manufacture 7 that eliminates the necessity of grinding the cutting 8 edges or the use of expensive dies and fixtures.
18 Another object of the invention is to provide a 11 manufacturing method which provides the top and side 12 tooth relief angles necessary to efficiently remove 13 material from a Work surface.
20~~9~5 3 The manufacturing method of the invention is used 4 to form a sheet metal tool, such as an abrading or cutting tool, from a metal blank of the type having a 6 generally flat, front surface, an opposite back surface 7 and a peripheral edge. A predetermined pattern of 8 etching resistant material is applied to the back 9 surface of the metal blank, defining exposed areas separated by resist areas. A layer of etching 11 resistant material is applied to the front surface of 12 the metal blank which overlies at least the exposed 13 areas on the back surface of the metal blank. The 14 exposed areas on the back surface of the metal blank are subjected to etching treatment through the exposed 16 areas to form a tooth shape with a cutting edge, the 17 etching treatment being applied solely from the back 18 surface of the metal blank, whereby the cutting edges 19 so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of 21 etching resistant material on the front surface of the 22 metal blank.
24 Preferably, the exposed areas on the back surface of the metal blank are subjected to etching treatment 26 to form a tooth shape and an associated tooth opening 27 in each of the exposed areas. Each tooth shape is 28 preferably formed with a cutting edge opposite a tooth 29 base. At least selected teeth are bent along their respective bases to bring their respective cutting 31 edges above the plane of the front surface of the metal 32 blank.
2~~594~
1 In certain embodiments, the teeth are formedwith 2 cutting edges opposite a also tooth base, the teeth 3 having opposing side edges.In order to reduce stress 4 at the base region, the a proximate the toothside are edges can be etched equallyfrom the direction both of 6 the front surface of the metal blank and the rear 7 surface. The cutting edge f the tooth continues o to be 8 etched from the direction the rear surface of only.
In another embodiment of the invention, the 11 previously described resist pattern is alternated on 12 the front and back surfaces of the metal blank, so that 13 alternating exposed areas on the back surface are 14 overl2~id by a layer of resist on the front surface and so that alternating exposed area on the front surface 16 are overlaid by a layer of resist on the back surface.
17 The exposed areas on the back surface of the metal 18 blank are then subjected to etching treatment through 19 the exposed areas to force a tooth shape and an associated tooth opening as previously described. The 21 exposed areas on the front surface of the metal blank 22 are subjected to etching treatment through the exposed 23 areas to form a tooth shape, with the etching treatment 24 being applied from the opposite direction of the etching treatment applied to the back surface.
27 Those teeth formed with their sharpened surfaces 28 in the plane of the back surface are then bent along 29 their respective bases to bring their respective cutting edges above the plane of the back surface of 31 the metal blank and those teeth formed with their 32 sharpened surfaces in the plane of the front surface 33 are bent along their respective bases to bring their 1 respective cutting edges above the plane of the front 2 surface of the metal blank. By applying the resist 3 pattern unevenly to the front and rear surfaces of the 4 metal blank, a tooth image is formed which is slightly smaller on one side of the metal blank than the other 6 allowing the back rake angle of the tooth to be 7 controlled and optimized for cutting various materials.
9 A sheet metal file, manufactured by the_process of the invention, includes a plurality of photochemically 11 machined teeth. Any given tooth is etched solely from 12 one side of a metal blank. Alternate teeth or groups 13 of teeth may be etched from opposite sides to create a 14 file that cuts on both sides. Each tooth is bent at its base to bring the cutting edge of the tooth above 16 the surface of the blade. In the case of a circular or 17 linear saw blade, every other tooth of the blade is 18 etched from the opposite side of the metal blank. All 19 of the etching of any particular tooth, however, is accomplished from the same side of the metal blank.
22 Additional objects, features and advantages will 23 be apparent in the written description which follows.
_ g _ 3 Figure 1 is a partial, cross-sectional schematic 4 illustration of the prior art chemical etching process in which the etchant is applied from both sides of the 6 metal blank to form a cutting tooth;
8 Figure 2 is a similar view of another prior art 9 technique in which the etchant is applied from a single direction to form a cutting tooth;
12 Figure 3 is a partial, cross-sectional view of a 13 metal blank used in the method of the invention showing 14 the resist pattern thereof:
16 Figure 4 is a view similar to Figure 3 showing the 17 next step in the method of the invention in which 18 etchant is applied from one side of the metal blank 19 only to form the desired tooth pattern:
21 Figure 5 is a plan view of a sheet metal tool 22 manufactured by the method of the invention:
24 Figure 6 is an enlarged, isolated view of the cutting teethof the tool of Figure 5:
27 Figure 7 is a simplified, top view of a single 28 tooth of the of Figure 5 manufactured according tool to 29 the method theinvention:
of 31 Figure 8 is a partial, cross-sectional view taken 32 along lines II.-VIII.
VI in Figure 7:
1 Figure 9 is a view of a tooth similar to Figure 7 2 but adapted for use as a planning blade for a power 3 tool:
Figure 10 is a partial, cross-sectional view taken 6 along lines X.-X, in Figure 9:
8 Figure 11 is a plan view of a cutting tool 9 manufactured by the method of the invention;
11 Figure 12 is a plan view of another cutting tool 12 manufactured by the method of the invention:
14 Figure 13 is a plan view of a circular saw blade manufactured by the method of the invention:
17 Figure 14 is a simplified, schematic view of the 18 prior art technique for manufacturing circular or 19 linear saw blades: , 21 Figure 15 is a simplified, schematic view, similar 22 to Figure 14, but illustrating the method of the 23 invention: and Figure 16 is a simplified, plan view of teeth for 26 a circular or linear saw blade manufactured according 27 to the method of the invention.
24 Preferably, the exposed areas on the back surface of the metal blank are subjected to etching treatment 26 to form a tooth shape and an associated tooth opening 27 in each of the exposed areas. Each tooth shape is 28 preferably formed with a cutting edge opposite a tooth 29 base. At least selected teeth are bent along their respective bases to bring their respective cutting 31 edges above the plane of the front surface of the metal 32 blank.
2~~594~
1 In certain embodiments, the teeth are formedwith 2 cutting edges opposite a also tooth base, the teeth 3 having opposing side edges.In order to reduce stress 4 at the base region, the a proximate the toothside are edges can be etched equallyfrom the direction both of 6 the front surface of the metal blank and the rear 7 surface. The cutting edge f the tooth continues o to be 8 etched from the direction the rear surface of only.
In another embodiment of the invention, the 11 previously described resist pattern is alternated on 12 the front and back surfaces of the metal blank, so that 13 alternating exposed areas on the back surface are 14 overl2~id by a layer of resist on the front surface and so that alternating exposed area on the front surface 16 are overlaid by a layer of resist on the back surface.
17 The exposed areas on the back surface of the metal 18 blank are then subjected to etching treatment through 19 the exposed areas to force a tooth shape and an associated tooth opening as previously described. The 21 exposed areas on the front surface of the metal blank 22 are subjected to etching treatment through the exposed 23 areas to form a tooth shape, with the etching treatment 24 being applied from the opposite direction of the etching treatment applied to the back surface.
27 Those teeth formed with their sharpened surfaces 28 in the plane of the back surface are then bent along 29 their respective bases to bring their respective cutting edges above the plane of the back surface of 31 the metal blank and those teeth formed with their 32 sharpened surfaces in the plane of the front surface 33 are bent along their respective bases to bring their 1 respective cutting edges above the plane of the front 2 surface of the metal blank. By applying the resist 3 pattern unevenly to the front and rear surfaces of the 4 metal blank, a tooth image is formed which is slightly smaller on one side of the metal blank than the other 6 allowing the back rake angle of the tooth to be 7 controlled and optimized for cutting various materials.
9 A sheet metal file, manufactured by the_process of the invention, includes a plurality of photochemically 11 machined teeth. Any given tooth is etched solely from 12 one side of a metal blank. Alternate teeth or groups 13 of teeth may be etched from opposite sides to create a 14 file that cuts on both sides. Each tooth is bent at its base to bring the cutting edge of the tooth above 16 the surface of the blade. In the case of a circular or 17 linear saw blade, every other tooth of the blade is 18 etched from the opposite side of the metal blank. All 19 of the etching of any particular tooth, however, is accomplished from the same side of the metal blank.
22 Additional objects, features and advantages will 23 be apparent in the written description which follows.
_ g _ 3 Figure 1 is a partial, cross-sectional schematic 4 illustration of the prior art chemical etching process in which the etchant is applied from both sides of the 6 metal blank to form a cutting tooth;
8 Figure 2 is a similar view of another prior art 9 technique in which the etchant is applied from a single direction to form a cutting tooth;
12 Figure 3 is a partial, cross-sectional view of a 13 metal blank used in the method of the invention showing 14 the resist pattern thereof:
16 Figure 4 is a view similar to Figure 3 showing the 17 next step in the method of the invention in which 18 etchant is applied from one side of the metal blank 19 only to form the desired tooth pattern:
21 Figure 5 is a plan view of a sheet metal tool 22 manufactured by the method of the invention:
24 Figure 6 is an enlarged, isolated view of the cutting teethof the tool of Figure 5:
27 Figure 7 is a simplified, top view of a single 28 tooth of the of Figure 5 manufactured according tool to 29 the method theinvention:
of 31 Figure 8 is a partial, cross-sectional view taken 32 along lines II.-VIII.
VI in Figure 7:
1 Figure 9 is a view of a tooth similar to Figure 7 2 but adapted for use as a planning blade for a power 3 tool:
Figure 10 is a partial, cross-sectional view taken 6 along lines X.-X, in Figure 9:
8 Figure 11 is a plan view of a cutting tool 9 manufactured by the method of the invention;
11 Figure 12 is a plan view of another cutting tool 12 manufactured by the method of the invention:
14 Figure 13 is a plan view of a circular saw blade manufactured by the method of the invention:
17 Figure 14 is a simplified, schematic view of the 18 prior art technique for manufacturing circular or 19 linear saw blades: , 21 Figure 15 is a simplified, schematic view, similar 22 to Figure 14, but illustrating the method of the 23 invention: and Figure 16 is a simplified, plan view of teeth for 26 a circular or linear saw blade manufactured according 27 to the method of the invention.
2 The present invention utilizes chemical etching or 3 milling to produce files and cutters that have teeth and 4 slots for material removal, allowing great flexibility in tooth design, arrangement and selection of material for 6 the cutters or files. Cutters and files made by the 7 method of the present invention are thinner, more 8 flexible, sharper and less likely to load than those made 9 with the prior art techniques. The method is well adapted for photochemical etching processes in which the 11 resist patterns used to form the tooth shapes are 12 computer generated. The use of computer automated design 13 for generation of such optical tooling permits custom 14 configurations of teeth spacing and arrangements that optimize tooth geometry.
16 Chemical etching techniques are known in the art 17 for making devices or tools having cutting teeth such as 18 files, rasps, saw blades, and the like. Such techniques 19 are described, e.g., in U.S. Patent No. 4,240,806, issued December 23, 1980, and U.S. Patent No. 3,045,321, issued 21 July 24, 1962. A metal blank is provided with those 22 areas of the blank which are to form teeth, ridges 23 or other cutting elements being selectively coated 24 with a material which prevents the etching fluid from contacting and acting on them and other areas of the 26 blank are left exposed for the etching treatment.
27 The etching fluid first acts on the surface areas 28 which are not protected by the resist material, and 29 as the etching proceeds, the material not protected by the resist is removed. The pattern of the 1 resist material which is coated on the blank is varied 2 according to the character of the cutting elements that 3 are desired. For example, a pattern of isolated areas 4 where the etching is to start may be formed in an otherwise continuous etching resist coating, or 6 isolated areas of the etching resist coating may be 7 formed on the otherwise exposed surface areas of the 8 blank. The actual etching fluids and resist materials 9 utilized will be familiar to those skilled in the art and do not form a part of the present invention.
12 The cutting elements of the invention may be 13 formed on any material that is suited to etching 14~ treatment. Most of the known suitable materials are metals. Steels of various compositions and hard allays 16 are best suited for use as the blank material where 17 long life and adaptability to the cutting of hard 18 substances is required. For example, stainless steel 19 sheets (Rc 30/55, 300/400 Series Stainless Steel) or mild steels adapted to be hardened subsequent to the 21 etching treatment have been used successfully as the 22 blank or body of the abrading devices of the invention.
23 After a blank has been formed with cutting teeth by the 24 etching treatment of the invention, the product may be given a hardening treatment, e.g., case hardening 26 treatment. For abrading wood and forming smooth 27 surfaces on any of the softer materials, the blank may 28 be composed of one of the softer metals, e.g., nickel, 29 aluminum, copper or brass or any suitable allow.
Economy in the use of metal is obtained by using thin 31 sheets or strips of metal as the blank material.
32 Sheets ranging from about 0.002 inch to about 0.02 ~~a~94~
1 inches thick have adequate strength and desirable 2 flexibility for many abrading uses.
4 ' The devices of the invention are preferably photochemically machined from sheet metal. The 6 photochemically machined sheet metal tools are 7 generally divided into two groups: (1) tools with 8 cutting teeth on the flat part of the blade, used for 9 planing or shaping like a file or sandpaper; (2) tools with cutting teeth on the edge of the blade for sawing 11 and grooving. Unlike files and sandpaper, the first 12 group of blades, made by the present method, will not 13 "load" because removed material passes easily through 14 the openings in the blade. Either type of tool may be manufactured as strips, sheets,. disks, belts, tubes or 16 drums to be used as either hand tools or power tools.
18 Figures 1 and 2 illustrate the generally accepted 19 prior art practices for etching cutting tools .from sheet petal. A metal blank 11 has applied .thereto a 21 predetermined pattern of etching resistant material.
22 In the embodiment of Figure 1, the etching resistant 23 material 13, 15 is applied to both the front and back 24 surfaces 17, 19 of the metal blank. The etchant spray, illustrated by the arrows in Figure 1, is apglied in 26 two-sided fashion, creating a relatively small, blunt 27 ridge 21 on the interior of the opening between the 28 etchant resistant materials 13, 15. In the embodiment 29 of Figure 2, a protective resist layer 23 is applied only on the back surface 25 of the metal blank 11.
31 Without the protective resist layer on the front 32 surface of the metal blank, the sharp edge 2'7 is 33 quickly attacked and blunted by the etchant.
~~J~~~J
2 Figure 3 illustrates the etching arrangement used 3 in the method of the invention in which a metal blank 4 11 has a generally flat, front surface 29, an opposite, back surface 31 and a peripheral edge (shown broken 6 away as 33). In the method used to form the cutting 7 tools of the invention, a predetermined pattern of 8 etching resistant material 35 is applied to the back 9 surface 31 of the metal blank 11, the pattern defining exposed areas 37 separated by resist areas 39, 41. A
11 layer of etching resistant material 43 is applied to 12 the front surface 29 of the metal blank 11 which 13 overlies at least the exposed areas 37 on the back 14 surface 31 of the metal blank 11.
16 As shown in Figure 4, the exposed areas 37 on the 17 back surface 31 are then subjected to etching treatment 18 through the exposed areas 37 to form a tooth shape with 19 a cutting edge 45, the etching treatment (as indicated by the arrows in Figure 4)~ being applied solely 'from 21 the back surface 31 of the metal blank 11. In this 22 way, the cutting edges 45 so formed terminate in 23 sharpened surfaces in the plane of the front surface 24 29, protected by the layer 43 of etchant resistant material on the front surface 29 of the metal blank 11.
27 Figure 5 shows a sheet metal tool, designated 28 generally as 47, manufactured by the method of the 29 invention. In the embodiment of Figure 5, the sheet metal tool 47 is a micro-planing strip provided with 31 reinforcing steel eyelets 49, 51'which allow the strig 32 to be mounted within, e.g., a hacksaw frame (not 33 shown). The tooth shapes 51 are formed in the flat, 1 front surface 53 of the metal blank, within the 2 peripheral edge 55.
4 Figure 6 is an isolated view of selected tooth shapes 51 illustrating the thin, cutting edges 57 which 6 are formed in the frontal portion of the tooth shapes.
7 Each tooth shape has an associated tooth opening 61 8 which is fonaed in the metal blank 11. In the 9 embodiment of the invention illustrated in Figures 5-6, at least selected teeth are bent along their respective 11 bases 59 to bring their respective cutting edges 57 12 above the plane of the front surface 53 of the metal 13 blank 11.
Figures 7 and 8 illustrate the preferred tooth 16 shapes of the invention for sheet metal files or 17 planing blades which are especially adapted for use as 18 hand tools. The blade (Figure 5) can be held under 19 tension in a common hacksaw frame (not shown). If not stretched too tightly, the blade will flex to conform 21 to and work rounded or contoured surfaces. Although 22 the tooth design illustrated in Figure 7 is relatively 23 simple, it will be appreciated that the tooth could be 24 of various sizes, shapes or proportions. For instance, the cutting edge of each tooth could be rounded, 26 serrated, pointed, etc., without increasing the 27 manufacturing cost. Although the sheet metal file 28 (Figure 5) is planar in design, it will be understood 29 that, due to the thin nature of the metal blank used to Corm the file, the file could also be formed into a 31 tube, a half round shape, a triangle, or other rigid 32 shape. Figure 8 illustrates the unidirectional 33 application of the etchant spray (illustrated by the _.,, 1 arrow) which is used to form the cutting edge 57 in the 2 metal blank 11.
4 Figures 9 and 10 illustrate a similar tooth shape 63 having a cutting edge 65, the tooth shape being 6 designed for use with a power tool. The power tool 7 tooth illustrated in Figure 9 is identical to the hand 8 tool tooth illustrated in Figure 7 with the exception 9 of the treatment of the root area 67 of the tooth.
Figure l0 is a sectional view of the root area 11 illustrating the application of etchant spray in equal 12 amounts from each side of the metal blank 11, thereby 13 creating straighter walls on the sides of the teeth 69, 14 71 while still generating the necessary, thin cutting edge on the frontal portion 65. Note that the cutting 16 edge 65 of each tooth continues to be formed by 17 applying etchant spray in a single direction from the 18 back to the front of the metal blank. This technique 19 has been found to minimize internal stresses which are exerted at the base of''the~ tooth in~ power tool 21 applications.
23 Figures 11, 12 and l3 illustrate various cutting 24 tools manufactured according to the method of the invention in which the cutting edges 71, 73, 75 are on 26 the peripheral edge of the tool, rather than being on 27 the flat surface within the peripheral edge. Figure 14 28 illustrates the prior art manufacturing technique in 29 which etchant (illustrated by the arrows in Figure 14) is applied in identical manner on bath sides of the 31 metal blank 77 thereby leaving a ridge 79 in the center 32 of each tooth 81.
1 Figures 15 and 16 illustrate the improved method 2 of the invention. In the case of teeth formed along 3 the peripheral edge of the cutting tool, a 4 predetermined pattern of etching resistant material is applied to the back surface of the metal blank to 6 define exposed areas separated by resist areas. A
7 layer of etching resistant material is also applied to 8 the front surface of tha metal blank which overlies the 9 exposed areas on the back surface of the metal blank.
The previously described resist pattern is alternated 11 on the front and back surfaces so that alternating I2 exposed areas on the back surface are overlaid by a 13 layer of resist on the front surface and so that 14 alternating exposed areas on the front surface are overlaid by a layer of resist on the back surface. The 16 exposed areas on the back surface of the metal blank 17 are subjected to etching treatment through the exposed 18 areas to form a tooth shape 83 having a cutting edge 19 85. The exposed areas on the front surface of the metal blank are subjected to etching treatment through 21 the exposed areas to form a tooth shape 87 having a 22 cutting edge 89, the etching treatment being applied 23 solely from the front surface of the metal blank.
24 Selected cutting teeth can then be bent so that those teeth formed with their sharpened surfaces in the plane 26 of the back surface are bent along their respective 27 bases to bring their respective cutting edges above the 28 plane of the back surface of the metal blank and those 29 teeth formed with their sharpened surfaces in the plane of the front surface are bent along their respective 31 bases to bring their respective cutting edges above the 32 plane of the frcnt surface of the metal blank.
17 _ _ 2~5~~~5 1 Preferably, the resist pattern which is applied to 2 the front and rear surfaces of the metal blank is 3 applied unevenly (illustrated by the dotted lines in 4 Figure 16), thereby forming a tooth image which is slightly smaller on one side of the metal blank than 6 the other. If the resist images on opposite sides are 7 unequal and the metal is etched through from the side 8 with the smaller image (89 in Figure 16), a razor sharp 9 edge (89 in Figure 15) is formed on the side of the metal blank with the larger image. This technique 1l allows each tooth to be formed with a selected back 12 rake. Note that image size and etch direction are 13 reversed from tooth 91 to tooth 93.
Figure 13 shows a circular saw blade 95 having its 16 cutting edge 103 which is oriented 90' froa the cutting 17 edges of the sheet metal file illustrated in Figure 5.
18 By applying the etch pattern with a smaller resist 19 pattern on the backside of the tooth than on the front side, it is possible to provide the necessary top 21 clearance, side clearance and clearance on the outside 22 diameter of the saw. This side differential in the 23 etching resist pattern is necessary in order to create 24 a series of etched teeth that have the proper amount of relief on the sides of the tooth profile so that the 26 teeth can cleanly remove material from a work surface.
28 As illustrated in Figure 15, the resist patterns 29 are alternated from tooth 83 to tooth 87 with every other tooth being etched from the opposite side. All 31 of the etching of any particular tooth is, however, 32 accomplished from the same side. In the embodiment of 33 Figure 13, the circular saw blade 95 is provided with ._, 2~~~~~5 l planing teeth 97, 99, 101 which eliminate the necessity 2 of bending every tooth on the blade. The long, sharp 3 points (illustrated in Figure 15) of the unequally 4 etched teeth give these blades a slicing action that is quite different from the scrapping or chipping action 6 of conventional saw blades and leave an exceptionally 7 smooth finish on the work surface. Although the teeth 8 in Figure 15 are only moderately curved, it will be 9 understood that they could have any desired form. In contrast, conventional stamping and grinding methods 11 have traditionally restricted the design of the prior 12 art teeth to straight-edged forms.
14 An invention has been provided with several advantages. The photochemically machined cutting tools 16 of the invention have tooth shapes which can be made in 17 any conceivable size, shape or pattern without the use 18 of expensive dies or fixtures. The cutting edges of 19 the tooth shapes are razor sharp, without the necessity of grinding or honing. The cutting tools of the 21 invention are well adapted for use as sheet metal 22 cutting tools including circular and linear wood 23 cutting saw blades, micro-planing blades for hand tools 24 and micro-planing blades for power tools. The files ~ and cutters produced by the method of the invention 26 have teeth with associated slots for removal of 27 material from the work surface. The cutters and files 28 made by the method of the invention are thinner, more 29 flexible, sharper and less likely to load than those made with the prior art techniques.
32 While the invention has been shown in only one of 33 its forms, it is not thus limited but is susceptible to 1 various changes and modifications without departing 2 from the spirit thereof.
16 Chemical etching techniques are known in the art 17 for making devices or tools having cutting teeth such as 18 files, rasps, saw blades, and the like. Such techniques 19 are described, e.g., in U.S. Patent No. 4,240,806, issued December 23, 1980, and U.S. Patent No. 3,045,321, issued 21 July 24, 1962. A metal blank is provided with those 22 areas of the blank which are to form teeth, ridges 23 or other cutting elements being selectively coated 24 with a material which prevents the etching fluid from contacting and acting on them and other areas of the 26 blank are left exposed for the etching treatment.
27 The etching fluid first acts on the surface areas 28 which are not protected by the resist material, and 29 as the etching proceeds, the material not protected by the resist is removed. The pattern of the 1 resist material which is coated on the blank is varied 2 according to the character of the cutting elements that 3 are desired. For example, a pattern of isolated areas 4 where the etching is to start may be formed in an otherwise continuous etching resist coating, or 6 isolated areas of the etching resist coating may be 7 formed on the otherwise exposed surface areas of the 8 blank. The actual etching fluids and resist materials 9 utilized will be familiar to those skilled in the art and do not form a part of the present invention.
12 The cutting elements of the invention may be 13 formed on any material that is suited to etching 14~ treatment. Most of the known suitable materials are metals. Steels of various compositions and hard allays 16 are best suited for use as the blank material where 17 long life and adaptability to the cutting of hard 18 substances is required. For example, stainless steel 19 sheets (Rc 30/55, 300/400 Series Stainless Steel) or mild steels adapted to be hardened subsequent to the 21 etching treatment have been used successfully as the 22 blank or body of the abrading devices of the invention.
23 After a blank has been formed with cutting teeth by the 24 etching treatment of the invention, the product may be given a hardening treatment, e.g., case hardening 26 treatment. For abrading wood and forming smooth 27 surfaces on any of the softer materials, the blank may 28 be composed of one of the softer metals, e.g., nickel, 29 aluminum, copper or brass or any suitable allow.
Economy in the use of metal is obtained by using thin 31 sheets or strips of metal as the blank material.
32 Sheets ranging from about 0.002 inch to about 0.02 ~~a~94~
1 inches thick have adequate strength and desirable 2 flexibility for many abrading uses.
4 ' The devices of the invention are preferably photochemically machined from sheet metal. The 6 photochemically machined sheet metal tools are 7 generally divided into two groups: (1) tools with 8 cutting teeth on the flat part of the blade, used for 9 planing or shaping like a file or sandpaper; (2) tools with cutting teeth on the edge of the blade for sawing 11 and grooving. Unlike files and sandpaper, the first 12 group of blades, made by the present method, will not 13 "load" because removed material passes easily through 14 the openings in the blade. Either type of tool may be manufactured as strips, sheets,. disks, belts, tubes or 16 drums to be used as either hand tools or power tools.
18 Figures 1 and 2 illustrate the generally accepted 19 prior art practices for etching cutting tools .from sheet petal. A metal blank 11 has applied .thereto a 21 predetermined pattern of etching resistant material.
22 In the embodiment of Figure 1, the etching resistant 23 material 13, 15 is applied to both the front and back 24 surfaces 17, 19 of the metal blank. The etchant spray, illustrated by the arrows in Figure 1, is apglied in 26 two-sided fashion, creating a relatively small, blunt 27 ridge 21 on the interior of the opening between the 28 etchant resistant materials 13, 15. In the embodiment 29 of Figure 2, a protective resist layer 23 is applied only on the back surface 25 of the metal blank 11.
31 Without the protective resist layer on the front 32 surface of the metal blank, the sharp edge 2'7 is 33 quickly attacked and blunted by the etchant.
~~J~~~J
2 Figure 3 illustrates the etching arrangement used 3 in the method of the invention in which a metal blank 4 11 has a generally flat, front surface 29, an opposite, back surface 31 and a peripheral edge (shown broken 6 away as 33). In the method used to form the cutting 7 tools of the invention, a predetermined pattern of 8 etching resistant material 35 is applied to the back 9 surface 31 of the metal blank 11, the pattern defining exposed areas 37 separated by resist areas 39, 41. A
11 layer of etching resistant material 43 is applied to 12 the front surface 29 of the metal blank 11 which 13 overlies at least the exposed areas 37 on the back 14 surface 31 of the metal blank 11.
16 As shown in Figure 4, the exposed areas 37 on the 17 back surface 31 are then subjected to etching treatment 18 through the exposed areas 37 to form a tooth shape with 19 a cutting edge 45, the etching treatment (as indicated by the arrows in Figure 4)~ being applied solely 'from 21 the back surface 31 of the metal blank 11. In this 22 way, the cutting edges 45 so formed terminate in 23 sharpened surfaces in the plane of the front surface 24 29, protected by the layer 43 of etchant resistant material on the front surface 29 of the metal blank 11.
27 Figure 5 shows a sheet metal tool, designated 28 generally as 47, manufactured by the method of the 29 invention. In the embodiment of Figure 5, the sheet metal tool 47 is a micro-planing strip provided with 31 reinforcing steel eyelets 49, 51'which allow the strig 32 to be mounted within, e.g., a hacksaw frame (not 33 shown). The tooth shapes 51 are formed in the flat, 1 front surface 53 of the metal blank, within the 2 peripheral edge 55.
4 Figure 6 is an isolated view of selected tooth shapes 51 illustrating the thin, cutting edges 57 which 6 are formed in the frontal portion of the tooth shapes.
7 Each tooth shape has an associated tooth opening 61 8 which is fonaed in the metal blank 11. In the 9 embodiment of the invention illustrated in Figures 5-6, at least selected teeth are bent along their respective 11 bases 59 to bring their respective cutting edges 57 12 above the plane of the front surface 53 of the metal 13 blank 11.
Figures 7 and 8 illustrate the preferred tooth 16 shapes of the invention for sheet metal files or 17 planing blades which are especially adapted for use as 18 hand tools. The blade (Figure 5) can be held under 19 tension in a common hacksaw frame (not shown). If not stretched too tightly, the blade will flex to conform 21 to and work rounded or contoured surfaces. Although 22 the tooth design illustrated in Figure 7 is relatively 23 simple, it will be appreciated that the tooth could be 24 of various sizes, shapes or proportions. For instance, the cutting edge of each tooth could be rounded, 26 serrated, pointed, etc., without increasing the 27 manufacturing cost. Although the sheet metal file 28 (Figure 5) is planar in design, it will be understood 29 that, due to the thin nature of the metal blank used to Corm the file, the file could also be formed into a 31 tube, a half round shape, a triangle, or other rigid 32 shape. Figure 8 illustrates the unidirectional 33 application of the etchant spray (illustrated by the _.,, 1 arrow) which is used to form the cutting edge 57 in the 2 metal blank 11.
4 Figures 9 and 10 illustrate a similar tooth shape 63 having a cutting edge 65, the tooth shape being 6 designed for use with a power tool. The power tool 7 tooth illustrated in Figure 9 is identical to the hand 8 tool tooth illustrated in Figure 7 with the exception 9 of the treatment of the root area 67 of the tooth.
Figure l0 is a sectional view of the root area 11 illustrating the application of etchant spray in equal 12 amounts from each side of the metal blank 11, thereby 13 creating straighter walls on the sides of the teeth 69, 14 71 while still generating the necessary, thin cutting edge on the frontal portion 65. Note that the cutting 16 edge 65 of each tooth continues to be formed by 17 applying etchant spray in a single direction from the 18 back to the front of the metal blank. This technique 19 has been found to minimize internal stresses which are exerted at the base of''the~ tooth in~ power tool 21 applications.
23 Figures 11, 12 and l3 illustrate various cutting 24 tools manufactured according to the method of the invention in which the cutting edges 71, 73, 75 are on 26 the peripheral edge of the tool, rather than being on 27 the flat surface within the peripheral edge. Figure 14 28 illustrates the prior art manufacturing technique in 29 which etchant (illustrated by the arrows in Figure 14) is applied in identical manner on bath sides of the 31 metal blank 77 thereby leaving a ridge 79 in the center 32 of each tooth 81.
1 Figures 15 and 16 illustrate the improved method 2 of the invention. In the case of teeth formed along 3 the peripheral edge of the cutting tool, a 4 predetermined pattern of etching resistant material is applied to the back surface of the metal blank to 6 define exposed areas separated by resist areas. A
7 layer of etching resistant material is also applied to 8 the front surface of tha metal blank which overlies the 9 exposed areas on the back surface of the metal blank.
The previously described resist pattern is alternated 11 on the front and back surfaces so that alternating I2 exposed areas on the back surface are overlaid by a 13 layer of resist on the front surface and so that 14 alternating exposed areas on the front surface are overlaid by a layer of resist on the back surface. The 16 exposed areas on the back surface of the metal blank 17 are subjected to etching treatment through the exposed 18 areas to form a tooth shape 83 having a cutting edge 19 85. The exposed areas on the front surface of the metal blank are subjected to etching treatment through 21 the exposed areas to form a tooth shape 87 having a 22 cutting edge 89, the etching treatment being applied 23 solely from the front surface of the metal blank.
24 Selected cutting teeth can then be bent so that those teeth formed with their sharpened surfaces in the plane 26 of the back surface are bent along their respective 27 bases to bring their respective cutting edges above the 28 plane of the back surface of the metal blank and those 29 teeth formed with their sharpened surfaces in the plane of the front surface are bent along their respective 31 bases to bring their respective cutting edges above the 32 plane of the frcnt surface of the metal blank.
17 _ _ 2~5~~~5 1 Preferably, the resist pattern which is applied to 2 the front and rear surfaces of the metal blank is 3 applied unevenly (illustrated by the dotted lines in 4 Figure 16), thereby forming a tooth image which is slightly smaller on one side of the metal blank than 6 the other. If the resist images on opposite sides are 7 unequal and the metal is etched through from the side 8 with the smaller image (89 in Figure 16), a razor sharp 9 edge (89 in Figure 15) is formed on the side of the metal blank with the larger image. This technique 1l allows each tooth to be formed with a selected back 12 rake. Note that image size and etch direction are 13 reversed from tooth 91 to tooth 93.
Figure 13 shows a circular saw blade 95 having its 16 cutting edge 103 which is oriented 90' froa the cutting 17 edges of the sheet metal file illustrated in Figure 5.
18 By applying the etch pattern with a smaller resist 19 pattern on the backside of the tooth than on the front side, it is possible to provide the necessary top 21 clearance, side clearance and clearance on the outside 22 diameter of the saw. This side differential in the 23 etching resist pattern is necessary in order to create 24 a series of etched teeth that have the proper amount of relief on the sides of the tooth profile so that the 26 teeth can cleanly remove material from a work surface.
28 As illustrated in Figure 15, the resist patterns 29 are alternated from tooth 83 to tooth 87 with every other tooth being etched from the opposite side. All 31 of the etching of any particular tooth is, however, 32 accomplished from the same side. In the embodiment of 33 Figure 13, the circular saw blade 95 is provided with ._, 2~~~~~5 l planing teeth 97, 99, 101 which eliminate the necessity 2 of bending every tooth on the blade. The long, sharp 3 points (illustrated in Figure 15) of the unequally 4 etched teeth give these blades a slicing action that is quite different from the scrapping or chipping action 6 of conventional saw blades and leave an exceptionally 7 smooth finish on the work surface. Although the teeth 8 in Figure 15 are only moderately curved, it will be 9 understood that they could have any desired form. In contrast, conventional stamping and grinding methods 11 have traditionally restricted the design of the prior 12 art teeth to straight-edged forms.
14 An invention has been provided with several advantages. The photochemically machined cutting tools 16 of the invention have tooth shapes which can be made in 17 any conceivable size, shape or pattern without the use 18 of expensive dies or fixtures. The cutting edges of 19 the tooth shapes are razor sharp, without the necessity of grinding or honing. The cutting tools of the 21 invention are well adapted for use as sheet metal 22 cutting tools including circular and linear wood 23 cutting saw blades, micro-planing blades for hand tools 24 and micro-planing blades for power tools. The files ~ and cutters produced by the method of the invention 26 have teeth with associated slots for removal of 27 material from the work surface. The cutters and files 28 made by the method of the invention are thinner, more 29 flexible, sharper and less likely to load than those made with the prior art techniques.
32 While the invention has been shown in only one of 33 its forms, it is not thus limited but is susceptible to 1 various changes and modifications without departing 2 from the spirit thereof.
Claims (13)
1. A method of manufacturing a sheet metal tool from a metal blank of the type having a substantially flat, front surface, an opposite back surface and a peripheral edge, the method comprising the steps of:
applying to the back surface of the metal blank a predetermined pattern of etching resistant material defining exposed areas separated by resist areas; and applying a layer of etching resistant material to the front surface of the metal blank which overlies at least the exposed areas on the back surface of the metal blank;
subjecting the exposed areas on the back surface of the metal blank to etching treatment through the exposed areas to form a tooth shape with a cutting edge, the etching treatment being applied solely from the back surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of etching resistant material on the front surface of the metal blank.
applying to the back surface of the metal blank a predetermined pattern of etching resistant material defining exposed areas separated by resist areas; and applying a layer of etching resistant material to the front surface of the metal blank which overlies at least the exposed areas on the back surface of the metal blank;
subjecting the exposed areas on the back surface of the metal blank to etching treatment through the exposed areas to form a tooth shape with a cutting edge, the etching treatment being applied solely from the back surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of etching resistant material on the front surface of the metal blank.
2. The method of claim 1, wherein the tooth shapes which are formed are formed in the flat, front surface of the metal blank, within the peripheral edge thereof.
3. The method of claim 1, wherein the tooth shapes which are formed are formed along at least a portion of the peripheral edge of the metal blank.
4. A method of manufacturing a sheet metal tool from a metal blank of the type having a substantially flat, front surface, an opposite back surface and opposing side edges, the method comprising the steps of:
applying to the back surface of the metal blank a predetermined pattern of etching resistant material defining exposed areas separated by resist areas; and applying a layer of etching resistant material to the front surface of the metal blank which overlies the exposed areas on the back surface of the metal blank;
subjecting the exposed areas on the back surface of the metal blank to etching treatment through the exposed areas to form a tooth shape and an associated tooth opening in each of the exposed areas, each tooth shape being formed with a cutting edge opposite a tooth base, the etching treatment being applied solely from the back surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of etching resistant material on the front surface of the metal blank;
bending at least selected teeth so formed along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
applying to the back surface of the metal blank a predetermined pattern of etching resistant material defining exposed areas separated by resist areas; and applying a layer of etching resistant material to the front surface of the metal blank which overlies the exposed areas on the back surface of the metal blank;
subjecting the exposed areas on the back surface of the metal blank to etching treatment through the exposed areas to form a tooth shape and an associated tooth opening in each of the exposed areas, each tooth shape being formed with a cutting edge opposite a tooth base, the etching treatment being applied solely from the back surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of etching resistant material on the front surface of the metal blank;
bending at least selected teeth so formed along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
5. The method of claim 4, wherein each tooth shape which is formed has a cutting edge opposite a tooth base and opposing side edges which terminate in a root region of the tooth, the method further comprising the steps of etching the area proximate the root region of each tooth equally from the direction of both the front surface of the metal blank and the rear surface.
6. A method of manufacturing a sheet metal tool from a metal blank of the type having a substantially flat, front surface, an opposite back surface and opposing side edges, the method comprising the steps of:
applying to the back surface of the metal blank a predetermined pattern of etching resistant material defining exposed areas separated by resist areas; and applying a layer of etching resistant material to the front surface of the metal blank which overlies the exposed areas on the back surface of the metal blank;
alternating the previously described resist pattern on the front and back surfaces so that alternating exposed areas on the back surface are overlaid by a layer of resist on the front surface and so that alternating exposed areas on the front surface are overlaid by a layer of resist on the back surface;
subjecting the exposed areas on the back surface of the metal blank to etching treatment through the exposed areas to form a tooth shape and an associated tooth opening in each of the exposed areas, each tooth shape being formed with a cutting edge opposite a tooth base, the etching treatment being applied solely from the back surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of etching resistant material on the front surface of the metal blank;
subjecting the exposed areas on the front surface of the metal blank to etching treatment through the exposed areas to form a tooth shape and an associated tooth opening in each of the exposed areas, each tooth shape being formed with a cutting edge opposite a tooth base, the etching treatment being applied solely from the front surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the back surface and protected by the layer of etching resistant material on the back surface of the metal blank;
bending those teeth formed with their sharpened surfaces in the plane of the back surface along their respective bases to bring their respective cutting edges above the plane of the back surface of the metal blank and bending those teeth formed with their sharpened surfaces in the plane of the front surface along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
applying to the back surface of the metal blank a predetermined pattern of etching resistant material defining exposed areas separated by resist areas; and applying a layer of etching resistant material to the front surface of the metal blank which overlies the exposed areas on the back surface of the metal blank;
alternating the previously described resist pattern on the front and back surfaces so that alternating exposed areas on the back surface are overlaid by a layer of resist on the front surface and so that alternating exposed areas on the front surface are overlaid by a layer of resist on the back surface;
subjecting the exposed areas on the back surface of the metal blank to etching treatment through the exposed areas to form a tooth shape and an associated tooth opening in each of the exposed areas, each tooth shape being formed with a cutting edge opposite a tooth base, the etching treatment being applied solely from the back surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface and protected by the layer of etching resistant material on the front surface of the metal blank;
subjecting the exposed areas on the front surface of the metal blank to etching treatment through the exposed areas to form a tooth shape and an associated tooth opening in each of the exposed areas, each tooth shape being formed with a cutting edge opposite a tooth base, the etching treatment being applied solely from the front surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the back surface and protected by the layer of etching resistant material on the back surface of the metal blank;
bending those teeth formed with their sharpened surfaces in the plane of the back surface along their respective bases to bring their respective cutting edges above the plane of the back surface of the metal blank and bending those teeth formed with their sharpened surfaces in the plane of the front surface along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
7. The method of claim 6, wherein the resist pattern which is applied to the front and rear surfaces of the metal blank is applied unevenly, thereby forming a tooth image which is slightly smaller on one side of the metal blank than the other.
8. A chemically machined, sheet metal file formed from a metal blank of the type having a substantially flat, front surface, an opposite back surface and opposing side edges, comprising:
a plurality of cutting teeth chemically etched in the metal blank, each tooth being defined by a tooth shape and an associated tooth opening which extends completely through the metal blank, each tooth shape being formed with a cutting edge and a tooth base, the etching treatment which is used to form the cutting teeth being applied in one direction only from the back surface toward the front surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface, at least selected teeth so formed being bent along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
a plurality of cutting teeth chemically etched in the metal blank, each tooth being defined by a tooth shape and an associated tooth opening which extends completely through the metal blank, each tooth shape being formed with a cutting edge and a tooth base, the etching treatment which is used to form the cutting teeth being applied in one direction only from the back surface toward the front surface of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces in the plane of the front surface, at least selected teeth so formed being bent along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
9. The chemically machined, sheet metal file of claim 8, wherein the metal blank is a flat, flexible strip which is mounted in a frame to place the strip in a state of tension.
10. The chemically machined, sheet metal file of claim 8, wherein a back plate is affixed to at least one side of the metal blank to provide increased rigidity for the file.
11. The chemically machined, sheet metal file of claim 8, wherein each tooth shape is formed with opposing side edges in addition to a cutting edge and a tooth base, the opposing side edges terminating in root regions which are etched equally from both sides of the metal blank, the cutting edge being etched solely from one side of the metal blank.
12. A chemically machined, circular blade formed from a metal blank of the type having a substantially flat, front surface, an opposite back surface and a peripheral edge, comprising:
a plurality of cutting teeth chemically etched about the peripheral edge of the metal blank, each tooth being defined by a tooth shape and an associated tooth opening which extends completely through the metal blank, each tooth shape being formed with a cutting edge and a tooth base, the etching treatment which is used to form the cutting teeth being applied in one direction only for each tooth being formed, the direction of etching being alternated in a repeating pattern around the peripheral edge of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces which are alternately located in the plane of the front surface and the plane of the back surface of the metal blank, those teeth formed with their sharpened surfaces in the plane of the back surface being bent along their respective bases to bring their respective cutting edges above the plane of the back surface of the metal blank and those teeth formed with their sharpened surfaces in the plane of the front surface being bent along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
a plurality of cutting teeth chemically etched about the peripheral edge of the metal blank, each tooth being defined by a tooth shape and an associated tooth opening which extends completely through the metal blank, each tooth shape being formed with a cutting edge and a tooth base, the etching treatment which is used to form the cutting teeth being applied in one direction only for each tooth being formed, the direction of etching being alternated in a repeating pattern around the peripheral edge of the metal blank, whereby the cutting edges so formed terminate in sharpened surfaces which are alternately located in the plane of the front surface and the plane of the back surface of the metal blank, those teeth formed with their sharpened surfaces in the plane of the back surface being bent along their respective bases to bring their respective cutting edges above the plane of the back surface of the metal blank and those teeth formed with their sharpened surfaces in the plane of the front surface being bent along their respective bases to bring their respective cutting edges above the plane of the front surface of the metal blank.
13. The chemically machined, circular saw blade of claim 12, wherein the resist pattern which is applied to the front and rear surfaces of the metal blank is applied unevenly, thereby forming a tooth image which is slightly smaller on one side of the metal blank than the other.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/621,602 US5100506A (en) | 1990-12-04 | 1990-12-04 | Chemically machined sheet metal cutting tools and method |
| US621,602 | 1990-12-04 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2055945A1 CA2055945A1 (en) | 1992-06-05 |
| CA2055945C true CA2055945C (en) | 2003-07-29 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002055945A Expired - Lifetime CA2055945C (en) | 1990-12-04 | 1991-11-21 | Chemically machined sheet metal cutting tools and method |
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| Country | Link |
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| US (1) | US5100506A (en) |
| CA (1) | CA2055945C (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US107808A (en) * | 1870-09-27 | Improvement in saws | ||
| US297816A (en) * | 1884-04-29 | Island | ||
| US788236A (en) * | 1904-06-22 | 1905-04-25 | Single Stave Barrel Company | Saw. |
| US3045321A (en) * | 1955-04-15 | 1962-07-24 | Buckbee Mears Co | Abrading devices and method of making them |
| US3079669A (en) * | 1960-03-30 | 1963-03-05 | Jess L Massingill | Aluminum removing wheel |
| US4240806A (en) * | 1978-08-16 | 1980-12-23 | Minnesota Micro Metal, Inc. | Abrading material |
-
1990
- 1990-12-04 US US07/621,602 patent/US5100506A/en not_active Expired - Lifetime
-
1991
- 1991-11-21 CA CA002055945A patent/CA2055945C/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| US5100506A (en) | 1992-03-31 |
| CA2055945A1 (en) | 1992-06-05 |
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| EEER | Examination request | ||
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