Cutting tool

A cutting tool for a power tool. The cutting tool can include a tool body having a first end and a second end and an axis extending therebetween. The second end of the tool body can be engageable with the power tool. A feed screw can be supported in the tool body and can extend outwardly beyond the first end to engage a workpiece. A cutting blade can be removably supported in the tool body for engaging the workpiece.

RELATED APPLICATIONS

The present invention relates to cutting tools and, more particularly, to a rotary cutting tool for a power tool.

SUMMARY

In some embodiments, the invention provides a cutting tool, including a body, a feed screw, and a blade removably supported in the body adjacent to the feed screw. The cutting tool can include teeth positioned circumferentially around and extending outwardly from the body and a locking mechanism for removably securing the blade to the body. In some embodiments, the locking mechanism is movable relative to the body between a locked position, in which the locking mechanism secures the blade to the body, and an unlocked position, in which the blade is removable from the body.

In addition, the present invention provides a cutting tool including a body having a plurality of teeth and a blade removably supported in the body. The cutting tool can also include a locking mechanism, which orients the blade with respect to at least one of the plurality of teeth to maintain a desired spacing between the blade and the at least one of the plurality of teeth.

The present invention also provides a method of operating a cutting tool, including the acts of providing a cutting tool having a tool body and a plurality of teeth positioned along the body, removably securing a blade to the body, and cutting a workpiece with the blade and the teeth. The method can also include the acts of removing the blade from the body and inserting a second blade into the body.

In some embodiments, the invention provides a cutting tool for a power tool, the cutting tool including a tool body having a first end and a second end and an axis extending therebetween, the second end being engageable with the power tool. A feed screw can be supported in the tool body and can extend outwardly beyond the first end to engage a workpiece. A cutting blade can be removably supported in the tool body for engaging the workpiece.

In some embodiments, the invention provides a method of assembling a cutting tool for a power tool. The method includes providing a tool body having a first end and a second end and an axis extending therebetween, the second end being engageable with the power tool. The method further includes coupling a feed screw to the tool body such that the feed screw extends outwardly beyond the first end to engage a workpiece and removably coupling a cutting blade to the tool body for engaging the workpiece.

In some embodiments, the invention provides a cutting tool for a power tool, the cutting tool including a tool body having a first end and a second end and an axis extending therebetween, the second end being engageable with the power tool. A cutting blade can be removably supported in the tool body for engaging a workpiece, and the cutting blade can include a first cutting edge supportable adjacent a radially-outermost portion of the first end of the tool body and a second cutting edge extending radially across the first end of the tool body from the axis toward the radially-outermost portion.

In some embodiments, the invention provides a method of assembling a cutting tool for a power tool. The method includes providing a tool body having a first end and a second end and an axis extending therebetween, the second end being engageable with the power tool. The method further includes removably coupling a cutting blade to the tool body for engaging a workpiece, the cutting blade including a first cutting edge supportable adjacent a radially-outermost portion of the first end of the tool body and a second cutting edge extending radially across the first end of the tool body from the axis toward the radially-outermost portion.

DETAILED DESCRIPTION

In addition, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “front,” “rear,” “top,” “bottom,” “lower”, “up,” “down,” etc.) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. The elements of the present invention can be installed and operated in any orientation desired.1n addition, terms such as “first”, “second,” and “third” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.

FIGS. 1-17illustrate a cutting tool or bit10for use with a power tool, such as, for example, a drill, a driver drill, a screwdriver, and the like. As shown inFIGS. 1-17, the cutting tool10includes a generally cylindrically-shaped body12having a first or workpiece-engaging end14and a second or rearward end16. The second end16includes a base18having an opening20to at least partially facilitate chip removal from the body12of the cutting tool10.

A connecting structure22is supported on the second end16of the body12and includes an elongated rearwardly-extending drive shaft24configured to be received in a tool holder or chuck of a power tool. In the illustrated embodiment ofFIGS. 1-17, the drive shaft24has a substantially hexagonal cross-sectional shape and includes six flat sides26. In other embodiments, the drive shaft24can have other cross-sectional shapes, such as, for example, round, triangular, rectangular, trapezoidal, or any other polygonal shape, oval, irregular, and the like and can include one or more flat sides26.

A feed shaft30extends forwardly from the first end14of the body12. In the illustrated embodiment ofFIGS. 1-17, the feed shaft30is generally aligned with the drive shaft24along a longitudinal axis30A (shown inFIG. 10). In other embodiments, the feed shaft30and the drive shaft24can have other relative orientations.

As shown inFIGS. 1-17, the feed shaft30includes a tapered first end32and a second end33. In some embodiments, threads extend radially outwardly from the first end32of the feed shaft30and extend helically around the first end32for threadably engaging a workpiece. The configuration (size, shape, pitch, number, etc.) of the threads on the first end32and the shape or profile of the first end itself may vary and may be particularly suited for particular applications (e.g., material to be cut). In the illustrated embodiment, a ridge34extends circumferentially around the feed shaft30adjacent to the first end32and a recess36(shown inFIG. 9) extends around at least a portion of circumference of the second end33of the feed shaft30. Tile second end33of the feed shaft30is received in, a cavity, or recess37in the drive shaft24.

A rim38extends circumferentially around the first end14of the body12. As shown inFIGS. 1-17, teeth40extend axially outwardly from the rim38and are spaced circumferentially around the rim38. In the illustrated embodiment ofFIGS. 1-17, five teeth40are spaced circumferentially around the rim38at regular intervals. In other embodiments, one, two, three, four, six, or more teeth40can be spaced circumferentially around the rim38at regular or irregular intervals.

In some embodiments, outer ends of the teeth40are tapered or sloped to provide sharpened cutting edges. In the illustrated embodiment ofFIGS. 1-17, outer surfaces of the teeth40are tapered or sloped from a radial inner side42toward a radial outer side44such that a raised cutting edge46is formed around the outer circumference of each cutting tooth40. Alternatively or in addition, the teeth40can be sloped or tapered in a circumferential direction. As shown inFIGS. 1-17, the teeth40can slope upwardly from a trailing edge48, which extends outwardly away from the base18a first distance, toward a leading edge50, which extends outwardly away from the base18a second larger distance, to provide a sharpened cutting tip52adjacent to the leading edge50of each tooth40. In these embodiments, the cutting edge46can be oriented at an angle α with respect to the base18of the body12.

As shown inFIGS. 1-17, gullets56extend axially through the body12between adjacent cutting teeth40. In some embodiments, such as the illustrated embodiment ofFIGS. 1-17, the base58of each gullet56is oriented at an angle β with respect to the base18of the body12such that a trailing or downstream end of each gullet56is spaced a first distance from the base18of the body12and a leading end or upstream end of each gullet56is spaced a second larger distance from the base18of the body12. In some such embodiments, the angle α of cutting edge46of at least one of the teeth40is substantially equal to the angle β of the base58of at least one of the gullets56.

The cutting tool10also includes a blade62supported in the body12and having a first cutting or lifting edge64and a second cutting or lifting edge66. In the illustrated embodiment ofFIGS. 1-17, the blade62includes a blade body68supported in a slot70formed in the body12. The blade62is oriented at an angle θ (shown inFIG. 10) with respect to the base18of the body12. The body12of the cutting tool10can also include a ramp71for supporting the blade62in a desired orientation in the body12. As shown inFIGS. 6,7, and9-13, the blade body68defines an opening72extending between the first and second edges64,66. In some embodiments, such as the illustrated embodiment ofFIGS. 1-17, and as explained in greater detail below, the feed shaft30is engageable with the blade body68to secure the blade62in the body12of the cutting tool10.

The blade62may be constructed of one or more materials suitable for a cutting operation including, but not limited to, low alloy and alloyed steel and non-ferrous materials and various heat-treated metals, ceramic, composite materials (including some plastics). The first and second edges64and66and/or the blade body68may be coated using various coating technologies, such as, for example chemical vapor deposition (CVD), physical vapor deposition (PVD), etc.

FIGS. 14A and 14Billustrate an alternate blade62A, which includes some generally similar features as the blade62, which are given similar reference numerals, appended by the letter “A”. In some embodiments, such as the illustrated embodiment ofFIG. 14B, the first edge64A of the blade62A extends outwardly from the blade body68A a first distance, and the second edge66A of the blade62A extends outwardly from the blade body68A a second distance greater than the first distance. In some such embodiments, the second edge66A extends about 0.02 inches further than the first edge64A. The difference in the extended lengths of the first edge64A and the second edge66A is labeled D.

Returning now toFIGS. 13 and 14, the thickness of the blade62as illustrated is only exemplary, and in some embodiments, the blade62is provided with a relative thickness that is less than or greater than that shown in the figures. For example, the blade62A of the illustrated embodiment ofFIGS. 14A and 14Bhas a relative thickness that is greater than that of the blade62of the illustrated embodiment ofFIGS. 13 and 14. The slot70in the body12can be sized to receive the blade62or62A with a small clearance therebetween. In some embodiments, the blade62has a thickness of about 0.080 inches. In other embodiments, the blade62or62A and the slot70can have other sizes and dimensions.

As best illustrated inFIG. 14B, the first edge64A and the second edge66A are oriented at different angles with respect to the cutting end of the blade62A. In some embodiments, the first edge64A is oriented at a first angle A1and the second edge66A is oriented at a second angle A2with respect to the cutting end of the blade62A. The first angle A1can be greater than the second angle A2. In some embodiments, the first angle A1is about 55 degrees and the second angle A2is about 20 degrees.

In some embodiments, the blade body68is formed from two materials. In these embodiments, one or both of the first and second edges64,66can be formed from a first material, such as, for example, high-speed steel, machine steel, or the like, and the blade body68can be formed from a second material, such as, for example, spring-steel or another relatively flexible material, which allows for slight elastic deformation during operation of the cutting tool10. In these embodiments, the two materials can be bonded together. For example, in some embodiments, one or both of the first and second edges64,66can be laser welded to the blade body68. In other embodiments, the first and second edges64,66can be coated, hardened, and/or tempered.

FIG. 14Cillustrates a blade62B having a separately-formed first cutting edge64B that is connected to the blade body68B. The blade62B is otherwise generally similar to the blades62and62A described above. Similar reference numerals are used for similar features, those inFIG. 14Cbeing appended with the letter “B”. The first cutting edge64B may be constructed of a first material (e.g., carbide, ceramic, etc.), and the blade body68B may be constructed of a second material different than the first material. The first material may be particularly suited for a cutting operation and may be harder and more rigid than the second material. Additionally, although not illustrated, any of the blades62,62A, and62B shown and described herein may include one or more serrated and/or discontinuous cutting edges and/or tip and edge profiles other than those shown and described herein.

In some embodiments, as shown inFIGS. 6,7,11-13,15, and16, the blade body68includes first and second shoulders on the end opposite the first and second edges64,66. In some such embodiments, the shoulders are formed by notches extending through the blade body68. The shoulders engage corresponding structure on the cutting tool body12to maintain the position of the blade62with respect to the cutting tool body12. Particularly, the shoulders prevent and/or reduce movement of the blade body68relative to the cutting tool body12in a direction substantially perpendicular to the axis of the cutting tool body12.

In the illustrated embodiment, the shoulders are formed by substantially square notches. However, in some embodiments, the shoulders may be formed by notches of a different size, shape, and/or orientation. Furthermore, in some embodiments (such as the blade62A illustrated inFIGS. 14A and 14Band the blade62B illustrated inFIG. 14C), the two shoulders are of dissimilar size, shape, and/or orientation such that the blades62A and62B are insertable into the cutting tool body12in only a single predetermined orientation.

As shown inFIGS. 1-17, the cutting tool10can include a locking mechanism76for securing the blade62in the body12of the cutting tool10. In some embodiments, such as the illustrated embodiment ofFIGS. 1-17, the locking mechanism76can include a locking member78which is supported in the connecting structure22of the cutting tool10and is movable relative to the connecting structure22between a locked position (shown inFIGS. 2-4and8-10and an unlocked position (shown inFIGS. 5-7). The locking mechanism76can also include an actuator80for moving the locking member78between the locked position and the unlocked position.

In the unlocked position, the locking member78is moved away from and out of engagement with the feed shaft30so that the feed shaft30and/or the blade62can be removed from the body12of the cutting tool10so that the feed shaft30and/or the blade62can be replaced or repaired.

As the locking member78is moved toward the locked position, the locking member78cammingly engages the recess36formed on the second end33of the feed shaft30to seat the blade62in the slot70in the body12of the cutting tool10. This camming action can also orient the first edge64of the blade62and/or the second edge66of the blade62in a desired orientation with respect to the cutting edge46of one or more of the teeth40. In the illustrated embodiment ofFIGS. 1-17, this camming action of the locking member78moves the blade body68downwardly along the ramp71into the slot70and toward the base18of the body12so that the first edge64of the blade62extends outwardly from the base18a first distance and the second edge66of the blade along with the cutting edges46of the teeth40extends outwardly from the base18a second greater distance. In some such embodiments, when the locking member78is moved toward the locked position, the second edge66of the blade62and the cutting edges46of the teeth40extend outwardly from the base18of the body12in an axial direction about 0.02 inches beyond the first edge64of the blade62. In these embodiments, the blade62can be replaced and be reset in the body12of the cutting tool10in a desired orientation without requiring the operator to perform any complicated setup or measuring operations.

In the illustrated embodiment ofFIGS. 1-17, an operator can pivot the actuator80about a pivot member or pin84defining a pivot axis, which extends radially through the connecting structure22, to move the locking member78between the locked position and the unlocked position. As shown inFIGS. 2-4and8-10, an operator moves the actuator80toward a first position, in which the actuator80is supported in a recess86formed in the connecting structure22and in which the actuator80is generally axially aligned with the drive shaft24of the cutting tool10, to move the locking member78toward the locked position. As shown inFIGS. 5-7, an operator can move the actuator80toward a second position, in which the actuator80is moved out of the recess86and in which at least a portion of the actuator80extends radially outwardly from the connecting structure22of the cutting tool10, to move the locking member78toward the unlocked position.

In some embodiments, a securing member, such as a pin87, is engageable with a corresponding recess88in the connecting structure22and a corresponding recess in the actuator80to maintain the actuator80in the locked position. In other embodiments, the actuator80can include an outwardly extending projection, which is engageable in the recess88to maintain the actuator80in the locked position in the recess86in the connecting structure22. In still other embodiments, the locking mechanism76can include one or more magnets for maintaining the actuator80in the locked position.

In the illustrated embodiment, the engagement between the recess36of the feed shaft30and the locking member78not only fixes the feed shaft30axially, but also prevents relative rotation between the feed shaft30and the cutting tool body12. The feed shaft30and the recess37may additionally be provided with corresponding hexagonal or otherwise inter-engaging cross-sections to prevent relative rotation therebetween. In other embodiments, some of which are described further below, the feed shaft30is fixed axially and rotationally by separate mechanisms.

During operation, an operator secures the connecting structure22of the cutting tool10to a power tool and positions the cutting, tool10above or in front of a work piece. The operator then centers the feed shaft30above the intended cutting location and activates the power tool to rotate the cutting tool10about the axis of the feed shaft30. As the cutting tool10rotates, the threads of the feed shaft30are driven into the workpiece. The engagement between the threads and the workpiece draws the cutting tool10into the workpiece.

Continued rotation of the cutting tool10moves the cutting edges46of the teeth40into engagement with the workpiece. As the teeth40rotate, the teeth40cut a circular path in the workpiece. As the power tool and the threads on the feed shaft30continue to move the cutting tool10into the workpiece, the first cutting edge64and/or the second cutting edge66are moved into engagement with the workpiece and begin to remove chips from the workpiece. In general these chips are formed when the teeth40score the workpiece. The first cutting edge64then lifts the chips from the workpiece and directs the chips upwardly toward the opening20in the base18and away from the cutting tool10and the workpiece.

After performing a number of cutting operations, the first and second edges64,66may become damaged or worn. It has been found that the first and second edges64,66generally wear down and/or are damaged much faster than the cutting edges46of the teeth40. However, to maintain the effectiveness and operational efficiency of the cutting tool10, the cutting edges46of the teeth40and the first and second edges64,66must be sharpened at the same time and must be filed an equal amount. If this is not done, the relative orientation between the cutting edges46of the teeth40and the first and second edges64,66is not maintained and the cutting tool10does not operate efficiently or correctly.

Rather than sharpening the first and second edges64,66, the operator can pivot the actuator80about the pivot axis, moving the locking member78from the locked position toward the unlocked position. The operator can then remove the blade62and replace the blade62with a new blade62.

Once the new blade62is inserted into the slot70, the operator can replace the feed shaft30into the body12of the cutting tool10and move the actuator80and the locking member78toward the locking position. As explained above, as the locking member78moves toward the locked position, the locking member78cammingly engages the feed shaft30and moves the feed shaft30and the blade62toward a desired orientation with respect to the body12of the cutting tool10. The operator can then resume operation of the cutting tool10without having to perform complicated measurements and without adversely affecting the performance of the cutting tool10.

In some embodiments, a cutting tool body12and a number of differently-configured blades62having, for example, differently-oriented or differently-shaped cutting edges64,66, different material properties, etc., can be packaged together and/or offered for sale as a kit. Alternatively, or in addition, a number of differently-sized and/or differently-configured cutting tool bodies12(e.g., having different cutting diameters, material properties, numbers of teeth40, tip profiles, shaft sizes and configurations, etc.) can be packaged together and sold as a kit with two or more blades62of different size and or configuration (e.g., having differently-oriented or differently-shaped cutting edges64,66, different material properties, etc.).

Alternatively, or in addition, a number of differently-sized and/or differently-configured feed shafts30(e.g., having different material, shaft size, thread size, thread orientation, thread pitch, etc.) can be packaged together and sold as a kit with two or more different cutting tool bodies12(e.g., having different cutting diameters, material properties, numbers of teeth40, tip profiles, shaft sizes and configurations, etc.) and/or two or more different blades62(e.g., having different cutting diameters, material properties, number of teeth, tip profiles, etc.).

Many additional combinations of cutting tool components may be packaged together and/or offered for sale as a kit to enable a user to assemble and configure one or more cutting tools10to particularly suit different applications. The uses or applications may be defined by the materials to be cut (e.g., wood, mica on particle board, laminates, fiberglass over particle board, fiberglass over plywood, drywall, etc.). Alternatively, a kit may include components (such as matched feed shafts30and blades62, for example) that are particularly suited for one specific use or application (e.g., material).

FIG. 18illustrates an alternate embodiment of a cutting tool210according to the present invention. The cutting tool210shown inFIG. 18is similar in many ways to the illustrated embodiments ofFIGS. 1-17described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIG. 18and the embodiments ofFIGS. 1-17, reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-17for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIG. 18. Features and elements in the embodiment ofFIG. 18corresponding to features and elements in the embodiments ofFIGS. 1-17are numbered in the200series.

In the illustrated embodiment ofFIG. 18, the cutting tool210includes a locking mechanism276supported on the drive shaft224for securing the feed shaft230and/or a blade262in a recess in the body212of the cutting tool210. In other embodiments, the locking mechanism276can be positioned on other portions of the cutting tool210. In some embodiments, the locking mechanism276can be substantially similar to the quick-change chuck assembly described in U.S. Pat. No. 6,457,916 and/or the tool bit holder described in U.S. Pat. No. 6,561,523, the entire contents of each of which is hereby incorporated by reference.

In some embodiments, a channel extends radially through the drive shaft224and opens into the recess in the feed shaft230. A locking member, such as, for example, a ball, a roller, and the like, is supported in the channel for movement between a locked position, in which the locking member extends outwardly from the channel and into the recess to secure the feed shaft230to the cutting tool body212, and an unlocked position, in which the locking member is movable along the channel and out of the recess.

In some such embodiments, the feed shaft230can include a notch290and the locking member can be engageable in the notch290to secure the feed shaft230in the cutting tool body212. In the illustrated embodiment ofFIG. 18, the notch290extends around a portion of the circumference of the feed shaft230. In other embodiments, the notch290can extend around the entire circumference of the feed shaft230(as shown inFIGS. 31 and 32, which are discussed in further detail below).

In some embodiments, the locking mechanism276can include a biasing member for biasing the locking member toward the locked position. In some such embodiments, the biasing member is supported in the channel adjacent to the locking member and is operable to bias the locking member through the channel toward the recess. In other embodiments, the biasing member can be supported on an exterior surface292of the drive shaft224.

As shown inFIG. 18, the locking mechanism276can also include an actuator280for moving the locking member between the locked position and the unlocked position. In the illustrated embodiment ofFIG. 18, the actuator280is supported on the exterior surface292of the drive shaft224for axial movement along the drive shaft224between a first or forward-most position (shown inFIG. 18) and a second or rearward-most position. In other embodiments, the actuator280is supported on the exterior surface292of the drive shaft224for circumferential (i.e., relative rotational) movement along the drive shaft224between the first position and the second position. In still other embodiments, the actuator280is supported on the exterior surface292of the drive shaft224for circumferential (i.e., relative rotational) movement along the drive shaft224and axial movement along the drive shaft224.

The actuator280can also include a radially-inwardly extending protrusion. In this manner, when the actuator280is moved toward the first position, the protrusion is moved into radial alignment with the channel in the drive shaft224and into camming engagement with the locking member to move the locking member radially inwardly along the channel toward the locked position. When the actuator280is moved toward the second position, the protrusion is moved out of radial alignment with the channel in the drive shaft224and out of engagement with the locking member so that the locking member can move radially outwardly along the channel and toward the unlocked position. The actuator280can also include a biasing member for biasing the actuator280toward the first position, or alternatively, toward the second position.

FIG. 19illustrates an alternate embodiment of a cutting tool310according to the present invention. The cutting tool310shown inFIG. 19is similar in many ways to the illustrated embodiments ofFIGS. 1-18described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIG. 19and the embodiments o fFIGS. 1-18, reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-18for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIG. 19. Features and elements in the embodiment ofFIG. 19corresponding to features and elements in the embodiments ofFIGS. 1-18are numbered in the300series.

In the illustrated embodiment ofFIG. 19, the cutting tool310includes a locking mechanism376including a sleeve394supported on the exterior surface392of the drive shaft324. Channels396extend radially through the drive shaft324and a portion of the sleeve394. As shown inFIG. 19, a first end of each channel396opens into the recess337in the drive shaft324and a second end of each channel396opens axially toward a rear end398of the sleeve394. Locking members378are supported in the channels396for movement between a locked position, in which the locking members378extend radially inwardly from the second end of the channel396and into the recess337to secure the feed shaft to the cutting tool body, and an unlocked position, in which the locking members378are movable along the channels396and out of the recess337.

In the illustrated embodiment, the locking mechanism376includes two locking members378supported for movement along two channels396. In other embodiments, the locking mechanism376can include one, three, or more locking members378supported for movement along one, three, or more channels396.

As shown inFIG. 19, the locking mechanism376can include an actuator380supported on the exterior surface392of the drive shaft324for axial movement along the drive shaft324between a first or forward-most position (shown inFIG. 19) and a second or rearward-most position. In the illustrated embodiment ofFIG. 19, the actuator380can also include a forwardly-extending protrusion400.

In this manner, when the actuator380is moved toward the first position, the protrusion400is moved into camming engagement with each of the locking members378to move the locking members378forwardly and radially inwardly along the channels396toward the locked positions in the recess337. When the actuator380is moved toward the second position, the locking members378can be moved radially outwardly along the channels396and away from the recess337so that the feed shaft can be removed from the cutting tool body.

In the illustrated embodiment ofFIG. 19, the locking mechanism376also includes a biasing member402for biasing the actuator380toward the first position. As shown inFIG. 19, the biasing member402can be supported on the exterior surface392of the drive shaft324between a collar406and an interior shoulder408of the actuator380.

As also shown inFIG. 19, a rearward portion410of the actuator380can extend rearwardly across the biasing member402to substantially enclose the biasing member402and to prevent debris from entering the locking mechanism376.

In some embodiments, the outer surface412of the actuator380can be knurled and/or can include outwardly extending protrusions to provide a slip-resistant gripping surface. In these and other embodiments, the outer surface412of the actuator380or a portion of the outer surface412of the actuator380can include or be formed from an elastic material to provide a cushion grip.

FIG. 20illustrates an alternate embodiment of a cutting tool510according to the present invention. The cutting tool510shown inFIG. 20is similar in many ways to the illustrated embodiments ofFIGS. 1-19described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIG. 20and the embodiments ofFIGS. 1-19, reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-19for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIG. 20. Features and elements in the embodiment ofFIG. 20corresponding to features and elements in the embodiments ofFIGS. 1-19are numbered in the500and600series.

In the illustrated embodiment ofFIG. 20, the cutting tool510includes a locking mechanism576including an actuator580supported on the exterior surface592of the drive shaft524. Channels596extend radially through the drive shaft524. As shown inFIG. 20, locking members578are supported in the channels596for movement between a locked position, in which the locking members578extend radially inwardly into the recess537to secure the feed shaft to the cutting tool body, and an unlocked position, in which the locking members578are movable along the channels596and out of the recess537.

As shown inFIG. 20, the locking mechanism576can include an actuator580supported on the exterior surface592of the drive shaft524for axial movement along the drive shaft524between a first or forward-most position (shown inFIG. 20) and a second or rearward-most position. In the illustrated embodiment ofFIG. 20, the actuator580can also include a recess600extending circumferentially around an interior surface616of the actuator580. In still other embodiments, the actuator580can also or alternatively include a recess600extending in a serpentine path or threaded around the drive shaft524.

In this manner, when the actuator580is moved toward the first position, the interior surface616of the actuator580is moved into camming engagement with each of the locking members578to move the locking members578radially inwardly along the channels596toward the locked positions (shown inFIG. 20). When the actuator580is moved toward the second position, the recess600is moved into radial alignment with the channels596so that the locking members578can be moved radially outwardly along the channels596and away from the recess537so that the feed shaft can be removed from the cutting tool body.

In the illustrated embodiment ofFIG. 20, the locking mechanism576also includes a biasing member602for biasing the actuator580toward the second position. As shown inFIG. 20, the biasing member602can be supported on the exterior surface592of the drive shaft524between an outwardly-extending shoulder620of the drive shaft524and an interior shoulder608of the actuator580.

FIGS. 21 and 22illustrate an alternate embodiment of a cutting tool710according to the present invention. The cutting tool710shown inFIGS. 21 and 22is similar in many ways to the illustrated embodiments ofFIGS. 1-21described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIGS. 21 and 22and the embodiments ofFIGS. 1-20, reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-20for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIGS. 21 and 22. Features and elements in the embodiment ofFIGS. 21 and 22corresponding to features and elements in the embodiments ofFIGS. 1-20are numbered in the700and800series.

In the illustrated embodiment ofFIGS. 21 and 22, the cutting tool710includes a locking mechanism776. A channel796extends radially through the drive shaft724and communicates with the recess737in the drive shaft724. An actuator780is supported in the channel796for radial movement between a first position (shown inFIG. 21) and a second position. As shown inFIG. 22, the actuator780can include a slot824and can support a locking member778for movement along the channel796between a locked position, in which the locking member778extends radially inwardly into the recess737to secure the feed shaft730to the cutting tool body, and an unlocked position, in which the locking member778is movable along the channel796and out of the recess737.

In the illustrated embodiment ofFIGS. 21 and 22, the locking member778is supported for movement along the slot824. In other embodiments, the locking member778can be integrally formed with the actuator780for movement with the actuator780between the first position and the second position.

When the actuator780of the illustrated embodiment ofFIGS. 21 and 22is moved along the channel796toward the first position, the locking member778is moved radially inwardly into the recess737to engage the feed shaft730. When the actuator780is moved toward the second position, the locking member778is able to move radially outwardly along the channel796and out of the recess737toward the unlocked position. The actuator780can also include a biasing member802for biasing the actuator780toward the first position.

FIGS. 23-25illustrate an alternate embodiment of a cutting tool910according to the present invention. The cutting tool910shown inFIGS. 23-25is similar in many ways to the illustrated embodiments ofFIGS. 1-22described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIGS. 23-25and the embodiments ofFIGS. 1-22, reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-22for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIGS. 23-25. Features and elements in the embodiment ofFIGS. 23-25corresponding to features and elements in the embodiments ofFIGS. 1-22are numbered in the900and1000series.

In the illustrated embodiment ofFIGS. 23-25, the cutting tool910includes a locking mechanism976. The locking mechanism976can include locking members978and an actuator980supported on the exterior surface992of the drive shaft924for axial movement along the drive shaft924between a first or forward-most position (shown inFIG. 24) and a second or rearward-most position (shown inFIG. 25). In the illustrated embodiment ofFIGS. 23-25, the actuator980can also include a recess1000extending circumferentially around an interior surface1016of the actuator980at its forward end1024. In the illustrated embodiment ofFIGS. 23-25, the recess1000extends to the forward end1024of the actuator980.

Channels996are defined between the base916of the cutting tool body912and a forward end of the drive shaft924. In the illustrated embodiment ofFIGS. 23-25, two channels996are spaced around the circumference of the drive shaft924by about 180 degrees and extend radially through the exterior surface992of the drive shaft924and open into the recess937. In other embodiments, the channels996can have other relative locations and orientations.

In this manner, when the actuator980is moved toward the first position, the interior surface1016of the actuator980is moved into camming engagement with each of the locking members978to move the locking members978radially inwardly along channels996toward the locked positions (shown inFIG. 24). When the actuator980is moved toward the second position, the recess1000is moved into radial alignment with the channels996so that the locking members978can be moved radially outwardly along the channels996and out of the recess936of the feed shaft930so that the feed shaft930can be removed from the cutting tool body912.

In the illustrated embodiment ofFIGS. 23-25, the locking mechanism976also includes a biasing member1002for biasing the actuator980toward the first position. As shown inFIGS. 24 and 25, the biasing member1002can be supported on the exterior surface992of the drive shaft924between an interior shoulder1008of the actuator980and a pair of retaining members1032A and1032B.

A second biasing member1036is positioned in the recess937of the drive shaft924that receives the feed shaft930. A slug1044is positioned in the recess937adjacent the second biasing member1036. When the feed shaft930is inserted into the recess937and the locking mechanism976is moved into a locked position, the slug1044is contacted by the second end933of the feed shaft930, and the second biasing member1036is compressed. When the locking mechanism976is unlocked, the second biasing member1036urges the feed shaft930out of the recess937and away from the drive shaft924so that the feed shaft930is released from the locking engagement with the locking members978.

In some embodiments, the slug1044includes a base portion1044A and an engaging portion1044B. The base portion1044A and the engaging portion1044B may be integrally-formed or alternately, may be separately-formed and coupled together by any suitable means (e.g., adhesive, welded, threaded engagement, etc.). In the illustrated embodiment, the base portion1044A has a larger outer profile than the engaging portion1044B. As such, the base portion1044A may engage the locking members978when the feed shaft930is released to retain the slug1044within the recess937. Alternately, the slug1044may be retained by the second biasing member1036, opposite ends of which can be connected to the base portion1044A and to the recess937.

In some embodiments, the slug1044can be magnetically connected to the feed shaft930. In some such embodiments, the engaging portion1044B can include or support a magnet operable to maintain the feed shaft930connected to the slug1044and to the drive shaft924after the feed shaft930has been released from the locking engagement of the locking members978. To remove the feed shaft930, a user can grasp the feed shaft930and decouple it from the engaging portion1044B of the slug1044.

In some embodiments, the cutting tool910ofFIG. 23is provided with an alternate locking mechanism976A as illustrated inFIGS. 26-28. The locking mechanism976A is similar to the locking mechanism976shown in the figures and described above, except for the particular features described below. Additionally, the feed shaft924A may include additional features as compared to the feed shaft924described above.

A pin1050extends radially outwardly from the exterior surface992A of the drive shaft924A and into the interior of the actuator980A. As shown inFIGS. 26 and 2, tie actuator980A can include an interior ledge1054extending around a majority of the circumference of the actuator980A. A gap or slot1058is provided in the interior ledge1054adjacent the pill1050. A biasing member1002A (FIG. 28) is positioned within the actuator980A and around the exterior surface992A of the drive shaft924A. The biasing member1002A is omitted fromFIG. 26for the purpose of clarity. The biasing member1002A includes a first end1062that engages a retaining slot1066in the actuator980A and a second end1070that engages a recess1074(FIG. 26) in the exterior surface992A of the drive shaft924A.

The biasing member1002A can provide a torsion biasing force to bias the actuator980A toward the orientation shown inFIG. 26relative to the drive shaft924A. In this orientation, the slot1058is out of axial alignment with the pin1050, and the actuator980A cannot be axially moved from the first (forward) position to the second (rearward) position to unlock the locking mechanism976A. In some embodiments, the biasing member1002A additionally provides an axially biasing force to bias the actuator980A toward the first position.

In order to move the actuator980A from the first position toward the second position, the actuator980A is rotated against the force of the biasing member1002A and relative to the drive shaft924A to axially align the slot1058with the pin1050and then the actuator980A may be moved axially relative to the drive shaft924A into the second position. In a similar manner to the locking mechanism976described above, the second position of the actuator980A allows the feed shaft930to be released. In addition, the torsional biasing of the actuator980A (counter-clockwise as viewed inFIG. 26) relative to the drive shaft924A inhibits incidental unlocking of the locking mechanism976A. For example, if at any time the actuator980A contacts the workpiece or loose chips of the workpiece during operation, the actuator980A will be prevented from being moved from the first position to the second position. In fact, due to the rotation of the cutting tool910, contact with the workpiece further urges the actuator980A torsionally in the same direction as the biasing member1002A. A pocket1078(FIG. 27) in the interior ledge1054defines a shoulder1082that engages the pin1050and limits the rotational movement of the actuator980A relative to the drive shaft924A.

FIGS. 29-32illustrate an alternate embodiment of a cutting tool1110according to the present invention. The cutting tool1110shown inFIGS. 29-32is similar in many ways to the illustrated embodiments ofFIGS. 1-28described above. Accordingly, with the exception of mutually inconsistent features and elements between the embodiment ofFIGS. 29-32and the embodiments ofFIGS. 1-28, reference is hereby made to the description above accompanying the embodiments ofFIGS. 1-28for a more complete description of the features and elements (and the alternatives to the features and elements) of the embodiment ofFIGS. 29-32. Features and elements in the embodiment ofFIGS. 29-32corresponding to features and elements in the embodiments ofFIGS. 1-28are numbered in the1100and1200series.

As shown inFIGS. 29-32, the feed shaft1130is fixed against rotational movement relative to the cutting tool body1112by a key1286and keyway1290, both of which have circular cross-sections in the illustrated embodiment, but each of which may alternately have a cross-sectional shape that is rectangular, polygonal, elliptical, etc. in other embodiments. The keyway1290can be a blind hole adjacent to and connecting with the recess1137. In the illustrated embodiment, the keyway1290extends axially through the cutting tool body1112in a direction substantially parallel to the recess1137. The keyway1290can be configured to receive the key1286therein. As shown inFIGS. 29 and 30, the key1286is a cylindrical pin having an outer diameter sized to closely and frictionally engage the wall of the keyway1290. In some embodiments, key1286is sized to provide an interference fit with the keyway1290.

The feed shaft1130, as best shown inFIG. 31, may include an axially-extending keyway1294(e.g., slot, scallop, etc.) configured to receive the key1286. In the illustrated embodiment, the keyway1294in the feed shaft1130is a rounded scallop shaped to receive the cylindrical-shaped key1286. In other embodiments, the keyway1294may have another shape, depending on the shape of the key1286.

FIG. 32illustrates another side of the feed shaft1130, which includes a flat1296. The flat1296may provide clearance for the blade1162and/or an engagement surface for the same.FIGS. 31 and 32illustrate a notch or annular groove1190that extends fully around a circumference of the feed shaft1130and is engageable by one or more locking members, as described above.

The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention.