Abstract:
A circular saw blade is provided with a first bore of a first size, configured for engagement with a first size arbor. The disk also has a second bore of a second size configured for engagement with a second size arbor. The second bore is disposed concentrically with the first bore, and is placed within a knockout portion of a disk secured to a face of the saw blade. The knockout portion is removable for enlarging an inner transverse dimension of the disk beyond that of the first bore. The second transverse dimension is within an ISO H7 standard tolerance. The disk is thus configured for mounting the second bore on the second size arbor, and alternatively for removing the knockout portion to mount the first bore on the first size arbor.

Description:
BACKGROUND  
     RELATED APPLICATION  
       [0001]     1. Technical Field  
         [0002]     This invention relates to saw blade equipment, and more particularly to an assembly providing circular saw blades with multiple bores of ISO H7 standard tolerances for mounting on arbors of various sizes.  
         [0003]     2. Background Information  
         [0004]     Power saws of the type that utilize circular saw blades come in a variety of sizes, and are produced and sold by many manufacturers. Although these power tools tend to be similar in many respects, distinctions are also present, not the least of which is the size of the spindle on which the saw blades are mounted. As a result, a user must be careful to purchase a saw blade having a central bore that is properly sized for the particular make and model of power tool onto which the blade is to be installed. Oftentimes, however, the user inadvertently purchases a blade having a central bore size that does not fit the user&#39;s machine. Or, the user may simply wish to remove a blade from one tool and reinstall it on another tool, only to find that the spindle of the other tool doesn&#39;t fit the bore of the blade.  
         [0005]     Attempts to mount saw blades onto relatively undersized spindles leave a gap between the bore and the spindle which disadvantageously enables the saw blade to move radially relative to the spindle. Such radial movement tends to generate eccentric rotation (e.g., ‘running untrue’) of the blade during operation, which may result in inaccurate cutting, damage to the saw blade, and potential danger to the user.  
         [0006]     A potential solution to this problem includes the use of reduction rings placed between the bore and the spindle to effectively reduce the bore size and prevent the blade from running untrue during operation. The blade may be secured to the spindle in a conventional manner, e.g., by the use of opposed circular flanges disposed on the spindle, which are tightened towards one another to capture both the saw blade and the reduction ring(s) therebetween.  
         [0007]     However, these opposed flanges are typically concavo-convex or dish shaped, to engage the blade radially outward of its bore. Thus, the reduction ring(s) may not be tightly engaged by the flanges. Unfortunately, this may permit the reduction ring(s) to move axially out of the bore during use. Once such axial movement has occurred, only the friction forces applied by the flanges serve to maintain the blade in concentric orientation with the spindle. In the event these forces are exceeded, the blade moves radially and becomes eccentric to the spindle.  
         [0008]     Another solution that has been popular in the United States includes providing the steel centers of saw blades with concentric knock out rings. In this approach, the blade is-provided with a small bore size, and larger bore sizes are partially cut into the blade by methods such as laser cutting or wire EDM. Then if needed, a larger size bore can be obtained simply by knocking out the portion of the blade interior thereof, e.g., using a hammer or other suitable tool.  
         [0009]     This approach, however, is generally not usable outside of the U.S. because of the relatively loose tolerances typically associated with bores formed upon removal of laser or EDM cut knockout rings. Such knockouts typically provide a bore tolerance within the ISO H9 standard, i.e., of ±0.04 mm. International standards, such as EN13236, used outside the United States, require a tighter bore tolerance of ISO H7 STANDARD, i.e., of ±0.02 mm.  
         [0010]     Thus, a need exists for a device and method for securely attaching a saw blade to spindles of various sizes in a manner that complies with international standards.  
       SUMMARY  
       [0011]     In one aspect of the invention, an apparatus is provided for enabling a circular saw blade to be selectively fastened to arbors of various sizes. The apparatus includes a disk configured for being secured in superposed alignment with a face of the saw blade, the saw blade having a first bore of a first transverse dimension configured for concentric engagement with a first size arbor, to substantially maintain concentricity of the first bore with the first size arbor during operational rotation about its central axis. The disk has a second bore of a second transverse dimension configured for concentric engagement with a second size arbor, to substantially maintain concentricity of the second bore with the second size arbor during operational rotation about its central axis. The second bore is configured for concentric disposition with the first bore, and is placed within a knockout portion of the disk. The knockout portion is removable for enlarging an inner transverse dimension of the disk beyond that of the first bore. The second transverse dimension is within an ISO H7 standard tolerance. The disk is thus configured for mounting the second bore on the second size arbor, and alternatively for removing the knockout portion to mount the first bore on the first size arbor.  
         [0012]     Another aspect of the invention includes an apparatus for selectively fastening a circular saw blade to arbors of various sizes. The apparatus includes disk means for being secured in superposed alignment with a face of the saw blade, the saw blade having first bore means of a first size configured for concentric engagement with a first size arbor, to substantially maintain concentricity of the first bore with the first size arbor during operational rotation about its central axis. The disk means includes a second bore means of a second size configured for concentric engagement with a second size arbor, to substantially maintain concentricity of the second bore with the second size arbor during operational rotation about its central axis. The second bore means is configured for concentric disposition with the first bore means, and is disposed within a bore removal means portion of the disk means. The bore removal means is removable for enlarging an inner transverse dimension of the disk beyond that of the first bore means. The second transverse dimension is within an ISO H7 standard tolerance. The disk means is configured for selectively mounting the second bore on the second size arbor, and alternatively for removal of the bore removal means to mount the first bore on the first size arbor.  
         [0013]     A further aspect of the invention includes a method of providing a circular saw blade apparatus for selective fastening to arbors of various sizes. The method includes providing a circular saw blade having a first bore of a first transverse dimension configured for concentric engagement with a first size arbor, to substantially maintain concentricity of the first bore with the first size arbor during operational rotation about its central axis. The method also includes providing a disk configured for being secured in superposed alignment with a face of the saw blade. The disk is provided with a second bore of a second transverse dimension configured for concentric engagement with a second size arbor, to substantially maintain concentricity of the second bore with the second size arbor during operational rotation about its central axis. The second bore is configured for concentric disposition with the first bore, and is disposed within a knockout portion of the disk. The knockout portion is configured for being removable for enlarging an inner transverse dimension of the disk beyond that of the first bore. The second transverse dimension is within an ISO H7 standard tolerance. The disk is configured for mounting the second bore on the second size arbor, and alternatively for removing the knockout portion to mount the first bore on the first size arbor. The method also includes securing the disk in superposed alignment with a face of the saw blade; and disposing the second bore of the disk concentrically with the first bore of the saw blade, so that the saw blade apparatus is configured for being mounted with the second bore on the second size arbor, or alternatively, for having the knockout portion removed and mounting the first bore on the first size arbor.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     The above and other features and advantages of this invention will be more readily apparent from a reading of the following detailed description of various aspects of the invention taken in conjunction with the accompanying drawings, in which:  
         [0015]      FIG. 1  is a schematic plan view, with optional and hidden portions shown in phantom, of a circular blade with which an embodiment of the present invention is installed; and  
         [0016]      FIG. 2  is a cross sectional view, on an enlarged scale with optional portions shown in phantom, taken along  2 - 2  of  FIG. 1 . 
     
    
     DETAILED DESCRIPTION  
       [0017]     In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized. It is also to be understood that structural, procedural and system changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. For clarity of exposition, like features shown in the accompanying drawings shall be indicated with like reference numerals and similar features as shown in alternate embodiments in the drawings shall be indicated with similar reference numerals.  
         [0018]     Briefly, as best shown in  FIGS. 1 and 2 , an embodiment of the present invention includes a saw blade  12  disposed between a pair of disks  16 ,  18  fastened in superposed orientation to opposite faces thereof. The disks  16 ,  18  each have a central bore  17 ,  19 , respectively, oriented concentrically with a central bore  14  of saw blade  12 . As shown in  FIG. 2 , bores  17  and  19  have respective transverse dimensions (e.g., diameters) DD, EE, which are less than that (CC) of central bore  14 . These dimensions DD, EE, and CC are predetermined to receivably engage arbors or spindles (e.g., of power saws) of three discrete sizes.  
         [0019]     Bores  17  and  19  are respectively disposed within knockouts  20 ,  22 , defined by conventional score lines or partial cuts  21 ,  23 . These knockouts may be selectively removed by a user, such as to remove bore  17  and/or  19  to provide clearance for a larger arbor/spindle.  
         [0020]     For example, blade  12  may be secured to a power saw having a relatively small diameter arbor, using bore  19 . In the event blade  12  is to be installed to a power saw having a larger, medium sized arbor, knockout  22  may be removed, to provide clearance for engagement of the arbor with bore  17 . Similarly, in the event blade  12  is to be engaged to a relatively large arbor, cutout  20  may also be removed to provide clearance for engagement of this large arbor with bore  14 .  
         [0021]     Advantageously, this embodiment enables a single saw blade to be safely fastened to arbors of three distinct sizes, in a tightly toleranced (e.g., ISO H7 standard) fashion. Such tight tolerances are enabled by pre-forming each bore, rather than forming them in the field upon removal of knockouts as described hereinabove. This aspect advantageously tends to reduce the number of saw blades that need to be kept in stock by retailers and users. In addition, the use of disks  16  and/or  18  has been found to advantageously provide a significant noise dampening effect during use. It is suspected that this noise dampening effect is due to the increased mechanical support provided to the blade by the disks  16 ,  18 , and/or the change in resonance frequency relative to conventional single thickness saw blades.  
         [0022]     The term “axial” when used in connection with an element described herein, refers to a direction relative to the element, which is substantially parallel to its center of rotation when the element is installed on an arbor. Similarly, the term “transverse” refers to a direction other than substantially parallel to the axial direction. The term “transverse cross-section” refers to a cross-section taken along a transverse plane.  
         [0023]     Various embodiments of the invention will now be described in greater detail, with reference to  FIGS. 1-2 . Referring initially to  FIG. 1 , embodiments of the present invention may be used with substantially any type of circular saw blade known to those skilled in the art. For convenience, these embodiments are shown and described with a superabrasive (e.g., diamond) saw blade  12  having a plurality of cutters  24  spaced along its periphery. An example of such a saw blade is disclosed in U.S. Patent Publication No. US2004/019114 to Saint-Gobain Abrasives, Inc., which is fully incorporated by reference herein.  
         [0024]     These superabrasive tools are particularly useful in applications where other tools lack the strength and durability to be practical substitutes. For example, diamond saws are routinely used to cut concrete, asphalt, stone, and other hard materials.  
         [0025]     In the embodiments shown, cutters  24  take the form of conventional superabrasive-laden segments spaced along the periphery thereof, including abrasive grain brazed or otherwise secured to the surface of core  28 . For example, these superabrasive tools may be manufactured by mixing superabrasive particles such as diamond or cubic boron nitride (CBN) with a suitable metal matrix powder (bond). The mixture is then compressed in a mold to form the desired shape (e.g., segment  24 ). The “green” form is then consolidated by sintering at a suitable temperature to form a single body with a plurality of superabrasive particles disposed therein. The consolidated body or segment is attached (e.g., by brazing or laser welding) to a tool body, such as to the round core  28  of a circular saw, to form the final product.  
         [0026]     Other exemplary superabrasive saw blades include a continuous superabrasive-laden rim  26  adhered to the perimeter of a circular steel core as shown in phantom. This abrasive rim  26  may be formed substantially as described above with respect to segments  24 , or by simply brazing, electroplating or electroforming a layer of abrasive grain onto the outer perimeter of the tool body or core  28 .  
         [0027]     As discussed above, these superabrasive blades are intended for relatively difficult cutting operations, which tend to generate high stresses in the blades. As such, any eccentricity in their rotation during cutting would tend to increase these stresses, possibly to the point of dislodging the abrasive segments from the core, and/or increasing the difficulty of the cutting operation. Any eccentricity may thus be particular problematic when the blades are used in hand-held saws. Accordingly, embodiments of the present invention may be particularly useful with superabrasive saw blades used in hand held power saws.  
         [0028]     As a further variation, saw blade  12  may be provided with cutters in the form of teeth  24 ′, such as shown in phantom. Teeth  24 ′ may be of nominally any size and shape commonly used on saw blades, e.g., to cut relatively soft materials such as wood, plastic, and the like. Teeth  24 ′ may be provided with conventional hardened tips, such as fabricated from tungsten carbide, and/or may be provided with the abrasive grain described hereinabove. Example of saw blades having cutters in the form of teeth  24 ′ are described in U.S. Pat. No. 6,817,936 B1.  
         [0029]     As shown, blade  12  includes a metallic core  28 , having a central bore  14  for fastening the blade to the spindle/arbor of a circular saw (not shown) in a conventional manner, e.g., between a pair of opposed machine flanges. Core  28  is substantially circular in shape, and may comprise substantially any material having the requisite strength for the particular cutting application. Examples of suitable core materials are steel, aluminum, titanium, bronze, their composites and alloys, and combinations thereof. Reinforced plastics having sufficient specific strength may also be used to construct the core. Generally desirable metallic core materials include ANSI 4130 steel and aluminum alloys, 2024, 6065 and 7178.  
         [0030]     Referring now to both  FIGS. 1 and 2 , one embodiment of the invention a blade  12  having only a single disk  16  fastened thereto. This disk may be fastened in any convenient manner, such as using spot welds, laser welds, braze, mechanical fasteners (e.g., bolts, screws, rivets, detents) and adhesives, etc.  
         [0031]     As shown, disk  16  is provided with a central bore  17  disposed concentrically with bore  14  of the blade. Bore  17  is provided with predetermined transverse dimension (e.g., diameter) DD, which meets or exceeds ISO H7 standard tolerance standards for saw blade bores.  
         [0032]     Bore  17  is disposed within knockout portion  20 , defined by score lines or partial cuts  21 . This arrangement enables the operative portion (including bore  17 ) of disk  16  to be easily removed, such as by striking the knockout portion with a hammer or other tool as described above. Score lines/cuts  21  are disposed radially outward of bore  14 , e.g., at a transverse dimension GG greater than dimension CC of bore  14 . This disposition is provided so that once knockout  20  is removed, sufficient clearance will be provided for an arbor to pass through and engage bore  14  without interfering with disk  16 .  
         [0033]     In the embodiment shown, disk  16  may be fabricated from steel, with an axial thickness substantially similar to that of blade  12 , as best shown in  FIG. 2 . However, those skilled in the art should recognize that disk  16  may be fabricated from any number of materials, including various metals, polymers, and/or fiber reinforced composites, etc., having substantially any axial thickness, provided such materials have sufficient structural integrity to withstand the stresses of particular cutting operations. Particular embodiments of the present invention may thus be fabricated from metals such as aluminum, bronze, titanium, steel, and alloys and combinations thereof, using conventional fabrication techniques, such as machining, molding and/or forging operations.  
         [0034]     In addition, although not required, in particular embodiments disk  16  may be provided with an outer dimension (e.g., diameter) FF greater than that of a conventional machine flange (not shown) used to secure a saw blade  12  to the arbor of a power saw. Such a configuration enables the flange to engage disk  16  and effectively compress it axially into engagement with the blade  12 . Such compression tends to supplement the aforementioned fastening of disk  16  to blade  12 .  
         [0035]     In addition, although disk  16  is shown with a circular periphery, the skilled artisan should recognize that the disk may be provided with a periphery of substantially any shape, without departing from the spirit and scope of the present invention. For example, the disk  16  may optionally be provided with a polygonal periphery as shown in phantom at  30  in  FIG. 1 .  
         [0036]     This embodiment enables blade  12  to be secured to a power saw having a relatively small diameter arbor, using bore  17 . Alternatively, in the event blade  12  is to be installed to a power saw having a larger arbor, knockout  20  may be removed, to provide clearance for engagement of the arbor with bore  14 . Thus, this embodiment advantageously enables blade  12  to be concentrically secured to arbors of two discrete sizes, at relatively tight (e.g., ISO H7 standard) tolerances. These tight tolerances are provided by using pre-formed bores, which may be conveniently held to tighter tolerances than bores formed in the field such upon removal of knockouts defined by score or cut lines as described hereinabove.  
         [0037]     As best shown in  FIG. 2 , as also mentioned hereinabove, an optional embodiment of the invention includes a second disk  18 , shown in phantom, fastened to blade  12  on a face opposite that of disk  16 . In this alternate embodiment, disks  16  and  18  effectively sandwich blade  12  therebetween. Disk  18  is substantially similar to disk  16 , while including a bore  19  having a transverse dimension EE distinct from (e.g., smaller than) dimension DD of disk  16 . Bore  19  is disposed within knockout  22  defined by score lines/cuts  23 , for optional removal in the manner described above with respect to knockout  20 .  
         [0038]     This alternate embodiment enables the saw blade to be concentrically secured to arbors of three discrete sizes, each within relatively tight (e.g., ISO H7 standard) tolerances. In particular, the blade may be secured to a relatively small diameter arbor using bore  19  of disk  18 . Alternatively, in the event blade  12  is to be installed to a power saw having a larger arbor, knockout  22  may be removed, to provide clearance for engagement of the arbor with bore  17  of disk  16 . Still further, knockout  20  may be removed to provide clearance for engagement of a still larger arbor with bore  14 .  
         [0039]     Although bores have been shown and described as being circular in transverse cross-section to receive similarly shaped arbors, those skilled in the art should recognize that the bores may be provided with substantially any cross-sectional geometry, e.g., triangular, rectangular, diamond, square, etc., such as may be required to accommodate shafts of similar cross-sectional geometry, without departing from the spirit and scope of the present invention.  
         [0040]     Moreover, although embodiments having one and two disks fastened to a saw blade have been shown and described, it should be evident that additional disks, e.g., having bores of successively smaller transverse dimension, may be superposed with one another on saw blade  12  to further expand the range of spindle/arbor sizes to which blade  12  may be fastened.  
         [0041]     The following illustrative example is intended to demonstrate certain aspects of the present invention. It is to be understood that this example should not be construed as limiting.  
       EXAMPLE  
       [0042]     A saw blade  12  (NORTON™ PRO LINE, ZDH 500, 300 mm outside diameter, manufactured by Saint-Gobain Abrasives S.A., Bascharage, Luxembourg) was provided with disks  16  and  18  substantially as shown and described hereinabove with respect to  FIGS. 1 and 2 . Disks  16  and  18  were fabricated from steel, having outside diameters FF of 100 mm. Blade  12  had a central bore of 25.4 mm in diameter, while disks  16  and  18  had central bores  17  and  19  of 22.23 mm and 20 mm, respectively. Tolerances of the bore dimensions met or exceeded the ISO H7 standard. Bores  17  and  19  were respectively disposed in knockouts  20 ,  22  having outer diameters GG of 27.8 mm formed by providing laser cuts  21 ,  23 , while leaving small webs sufficient to hold knockouts  20 ,  22  in place as shown.  
         [0043]     Blade  12  was engaged with a power saw having an arbor of 19.99 mm diameter, using bore  19  and tested by cutting a masonry workpiece. Thereafter, knockout  22  was removed, and blade  12  engaged with a 22.22 mm diameter arbor using bore  17 , following by test cutting a masonry workpiece. Knockout  20  was subsequently removed, and blade  12  fastened to a 25.39 mm arbor using bore  14 , followed by test cutting of the masonry workpiece. In each of these test cuts, blade  12  was successfully maintained in concentric orientation with the arbors.  
         [0044]     In the preceding specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.