Abstract:
An ultrasonic blade includes a blade body and a cutting edge. The blade body is defined about a generally axial line. The cutting edge is on the blade body and is defined by the intersection of a first surface and a second surface. The first surface includes a first incident angle of about 0° to 35° from the axial line and a first curve of about 10° to 20° formed at the first incident angle. The second surface includes a second incident angle of about 0° to −35° from the axial line and a second curve of about 10° to 20° formed at the second incident angle.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention generally relates to cutting devices and methods of generating cutter geometry. More particularly, the present invention pertains to a cutting blade, a device to generate an edge of the cutting blade, and a method of generating the edge.  
       BACKGROUND OF THE INVENTION  
       [0002]     When cutting a variety of sheet materials such as carbon fiber, various other fibers, metal foils and composites, an edged cutting tool is generally utilized. In the case of particularly tough and/or abrasive sheet materials, the useful life of the edge of the cutting tool may be relatively short. To overcome this relatively short useful life of edged tools a variety of conventional cutting devices have been utilized. For example, high speed cutting discs are conventionally used to cut such sheet materials. However, high speed cutting discs generate dust that may negatively effect composite layups. Another conventional method of cutting relatively difficult sheet materials is to utilize standard edged cutting tools and replace these cutting tools at a greater frequency.  
         [0003]     A disadvantage associated with utilizing conventional edged cutting tools or cutters is that production is generally stopped while the cutter is being replaced. Thus, as the frequency of replacement increases, down time also increases. Another disadvantage associated with cutting certain relatively tough materials such as titanium foil and titanium graphite composites is that the edge of the cutter may chip. Chipped cutters generally do not cut and may drag material. Materials so dragged may be unusable and thus further increase delays and expense.  
         [0004]     Accordingly, it is desirable to provide a cutting tool, an apparatus to generate an edge, and a method of generating the edge capable of overcoming the disadvantages described herein at least to some extent.  
       SUMMARY  
       [0005]     The foregoing needs are met, to a great extent, by the present invention, wherein in some embodiments a cutting tool, an apparatus to generate an edge, and a method of generating the edge is provided.  
         [0006]     An embodiment of the present invention pertains to an ultrasonic blade. The ultrasonic blade includes a blade body and a cutting edge. The blade body is defined about a generally axial line. The cutting edge is on the blade body and is defined by the intersection of a first surface and a second surface. The first surface includes a first incident angle of about 0° to 35° from the axial line and a first curve of about 10° to 20° formed at the first incident angle. The second surface includes a second incident angle of about 0° to −35° from the axial line and a second curve of about 10° to 20° formed at the second incident angle.  
         [0007]     Another embodiment of the present invention relates to a device to generate a profile for a cutting tool. The device includes a base and a chuck. The base include a top surface. The chuck includes a bore to detachably secure the cutting tool, a first angled surface to mate with the top surface, and a second angled surface to mate with the top surface. Mating the first angled surface and the top surface disposes the cutting tool at a first incident angle. Mating the second angled surface and the top surface disposes the cutting tool at a second incident angle. In addition, the chuck is rotatably secured to the base.  
         [0008]     Yet another embodiment of the present invention pertains to a device for generating a profile of an ultrasonic blade. The device includes a means for introducing a first side of a blade body to an abrasive surface at a first incident angle. The blade body is defined about a generally axial line. The first incident angle is 0° to 35° from the axial line. In addition, the device includes a means for rotating the blade body relative to the abrasive surface and at the first incident angle. The rotation is about 10° to 20°. The device further includes a means for withdrawing the blade body from the abrasive surface and a means for introducing a second side of the blade body to the abrasive surface at a second incident angle. The second incident angle is 0° to 35° from the axial line. The device further includes a means for rotating the blade body relative to the abrasive surface and at the second incident angle. The rotation is about 10° to 20°.  
         [0009]     Yet another embodiment of the present invention relates to a method of generating a profile of an ultrasonic blade. In this method, a first side of a blade body is introduced to an abrasive surface at a first incident angle. The blade body is defined about a generally axial line and the first incident angle is 0° to 35° from this axial line. In addition, the blade body is rotated relative to the abrasive surface and at the first incident angle. This rotation is about 10° to 20°. Furthermore, the blade body is withdrawn from the abrasive surface and a second side of the blade body is introduced to the abrasive surface at a second incident angle. The second incident angle is 0° to 35° from the axial line. Moreover, the blade body is rotated relative to the abrasive surface and at the second incident angle. This rotation is about 10° to 20°.  
         [0010]     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
         [0011]     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.  
         [0012]     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a side view of an ultrasonic cutting tool according to an embodiment of the invention.  
         [0014]      FIG. 2  is a front view of the ultrasonic cutting tool according to  FIG. 1 .  
         [0015]      FIG. 3  is another side view of the ultrasonic cutting tool according to  FIG. 1 .  
         [0016]      FIG. 4  is a perspective view of the ultrasonic cutting tool according to  FIG. 1 .  
         [0017]      FIG. 5  is a cut away view of a chuck device according to an embodiment of the invention.  
         [0018]      FIG. 6  is top view of the chuck device shown in  FIG. 5 .  
         [0019]      FIG. 7  is a flow diagram according to an embodiment of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0020]     The present invention provides, in some embodiments, an ultrasonic cutting tool, a device to generate a profile for the ultrasonic cutting tool and method for generating the profile. In an embodiment, the invention provides for an ultrasonic cutting tool for cutting a variety of suitable materials. Examples of suitable materials generally include sheet materials such as fiber mat, fiber tape, composite material, metal foil, and the like. More particularly, suitable materials include titanium graphite composites, titanium foil, graphite composite prepreg, and the like. This ultrasonic cutting tool or stylus is typically disposed upon an ultrasonic transducer. The ultrasonic transducer generates vibrational energy that induces vibration of the stylus. The frequency of this vibration is generally based upon the mass of the stylus, a stylus base if present, the material being cut, and the like. As such, depending upon the particular system, the vibrational energy generated may range from a few Hertz (Hz) to 100 Mega Hz (MHz) or more.  
         [0021]     In another embodiment, the invention provides a device to generate the profile of the ultrasonic cutting tool. The device includes a base and a chuck. The base include a top surface on to which the chuck is mounted. The chuck includes a bore to detachably secure the cutting tool, a first angled surface to mate with the top surface, and a second angled surface to mate with the top surface. Mating the first angled surface and the top surface disposes the cutting tool at a first incident angle. Mating the second angled surface and the top surface disposes the cutting tool at a second incident angle. In addition, the chuck is rotatably secured to the base. In an embodiment of the invention, the first angled surface is mated to the base and an abrasive surface is introduced to the cutting tool. By introducing the abrasive surface parallel to an axis of rotation of the chuck, one surface of the cutting tool is generated. This surface is further defined by rotating the chuck and thus, generating a camber in the surface of the cutter. To generate the other surface of the cutting tool, the second angled surface of the chuck is mounted to the base, the cutting tool is re-introduced to the abrasive surface, and the chuck is rotated.  
         [0022]     The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. As shown in  FIGS. 1-4  an ultrasonic cutting tool (cutter)  10  includes a stylus  12  and a cutter base  14 . The stylus  12  includes an edge  16  and an axial line A. The edge  16  forms a substantially continuous profile spanning the distance from a side  18  of the stylus  12  to a side  20  of the stylus  12 . That is, there are essentially no facets in the edge  16 . In an embodiment of the invention, the edge  16  includes a plurality of substantially straight portions  22  and  24  and a curved portion  26 . As shown in  FIG. 1 , the straight portions  22  and  24  are at an angle B relative to one another. Also shown in  FIG. 1 , the straight portion  22  is at an angle C relative to a line perpendicular to the axial line A and the straight portion  24  is at an angle D relative to a line perpendicular to the axial line A. In a substantially smooth manner, the curved portion  26  transitions the edge  16  from the angle of the straight portion  22  to the angle of the straight portion  24 . In a particular embodiment the angle B is 60°, the angles C and D are 30°, and the curved portion  26  has a radius of 0.04 inches. However, in various other embodiments, the angles B, C, D, and/or the curved portion  26  may be different. In general, the angles B, C, D, and the curved portion  26  are based upon a variety of factors. These factors include: the material composition and/or temperature profile (heat/cold treatment) of the stylus  12 ; characteristics of material to be cut; frequency of an ultrasonic transducer; system setup; optimization of the system; and the like.  
         [0023]     The cutter base  14  includes a bore  28  and a shank  30 . The bore  28  mates with the stylus  12  in any suitable manner. For example, the stylus  12  may be press fit, threaded, secured with a set screw, or the like. The shank  30  mates with an ultrasonic transducer or similar device. As such, the configuration of the shank is dependent upon the configuration of the ultrasonic transducer utilized.  
         [0024]     As shown in  FIG. 3 , the edge  16  is generated by the intersection of two surfaces  32  and  34 . These surfaces  32  and  34  are at an angle E relative to one another and at respective angles F and G relative to the axial line A. In addition, the surfaces  32  and  34  are curved or cambered. This curvature in combination with the angles F and G are configured in a manner so as to generate the profile of the edge  16  as described herein. The curvature of the surface  34  is illustrated in  FIG. 4 . According to an embodiment, when viewed edge-on, the surface  34  includes a plurality of substantially straight portions  36  and  38  and a curved portion  40 . The straight portions  36  and  38  are at respective angles Hand J relative to a line tangent to the curved portion  40 . In a substantially smooth manner, the curved portion  40  transitions the surface  34  from the angle H to the angle J. In a particular embodiment the angle H is 7.2°, the angle J is 7.2°, and the curved portion  40  is at a radius of 0.171 inches. However, in various other embodiments, the angles H and/or J, and/or the curved portion  40  may be different. In general, the angles H and J are configured to generate the angles B, C, and D thus, based the those factors discussed herein with reference to the angles B, C, and D, the angle H and J are configured accordingly. Also, the curved portion  40  is configured to generate the curved portion  26  and thus, based the those factors discussed herein with reference to the curved portion  26 , the curved portion  40  is configured accordingly.  
         [0025]      FIG. 5  is a cross sectional view of a device  44  to generate the edge  16  on the cutter  10 . It is to be noted, however, that while the device  44  is illustrated generating the edge  16  in  FIG. 5 , embodiments of the invention are not limited to generating the edge  16  with the device  44  but rather, any suitable manner of generating the edge  16  is within the scope of the invention. In particular, according to another embodiment of the invention, a numerically controlled (NC) milling machine is instructed to generate the edge  16 . Thus, the device  44  shown in  FIG. 5  is for illustrative purposes only. To continue, as shown in  FIG. 5 , the device  44  includes a chuck  46 , an indexing plate  48 , and a chuck base  50 . The chuck  46  is configured to detachably secure the cutter  10 . For example, in an embodiment of the invention, the chuck  46  includes a threaded bore  52  to mate with the threaded shank  30 . The bore  52  includes an axial line K. The chuck  46  further includes a plurality of surfaces  54  and  56 . To generate the various angles of the cutter  10 , the surfaces  54  and  56  are angled with respect to the axial line K. In particular, the surface  54  is angled with respect to the axial line K to generate the angle F and the surface  56  is angled with respect to the axial line K to generates the angle G.  
         [0026]     The chuck  46  is secured to the indexing plate by any suitable fastening device. For example, as shown in  FIG. 5 , the indexing plate  48  includes a hole  60 , through which a bolt  62  is threaded into a threaded bore  64 . In this manner, the surface  54  is mounted to the indexing plate  48 . In addition, to mount the surface  56  to the indexing plate  48 , the bolt  62  is threaded into a threaded bore  66 . Furthermore, although one bolt  62  is shown, in various embodiments of the invention, two or more bolts are utilized to secure the chuck  46  to the indexing plate  48 .  
         [0027]     To pivotally secure the chuck  46  and indexing plate  48  assembly to the chuck base  50 , the indexing plate  48  includes a rim  68 . The rim  68  is configured to engage the chuck base  50  and rotate about the chuck base  50  with a minimal amount of lateral play. The indexing plate  48  rotates upon the chuck base  50  about an axial line L. To modulate the degree to which the chuck  46  may rotate relative to the chuck base  50 , the rim  68  includes a plurality of slots  70  and  72 . These slots  70  and  72  are configured to engage and indexing pin  74 . As shown in  FIG. 6 , the slots  70  and  72  are configured to allow sufficient movement of the indexing pin  74  so as to generate the angles H and J.  
         [0028]     As shown in  FIG. 5 , the axial line L is set back from the surface  32  sufficiently so as to generate the curved portion  40 . In a particular example, the axial line L is offset 0.171 inches from the surface  32  so as to generate a corresponding radius upon the curved portion  40 .  
         [0029]      FIG. 6  is a top view of the chuck base  50  according to the  FIG. 5 . As shown in  FIG. 6 , the slot  70  and indexing pin  74  are configured to allow sufficient rotation of the chuck  46  relative to the chuck base  50  so as to generate the angles H and J.  
         [0030]      FIG. 7  is a flow diagram of a method  78  according to an embodiment of the invention. In the method  78 , a device such as the device  44  is utilized to generate the edge  16  upon the stylus  12 . Prior to initiation of the method  78  a variety of tasks may be performed. These tasks include, in no particular order: secure a stylus blank within the chuck  46 ; mount the chuck  46  to the index plate  48 ; mount the index plate  48  to the chuck base  50 ; power the grinder; and the like. In a particular example, the surface  54  is mounted to the index plate  48 .  
         [0031]     As shown in  FIG. 7 , the method  78  may be initiated at step  80  by introducing the stylus blank to a grinding surface. The stylus blank is essentially a stylus such as the stylus  12  that lacks a fully formed edge such as the edge  16 . The grinding surface includes any suitable abrasive, milling, ablative, or other such surface that is operable to remove material from the stylus  12 . This grinding surface is positioned parallel to the axial line L and at a height sufficient to engage the stylus  12 .  
         [0032]     At step  82  the stylus  12  is advanced relative to the grinding surface. In general, the speed at which the stylus is advanced is dependent upon the rate at which material is removed from the stylus  12 . This material removal rate is varies according to the material characteristics of the stylus  12 , grit composition and condition of the abrasive, rotational speed of the grinding surface, and the like. In addition, the stylus  12  is advanced until a sufficient amount of material is removed. In general, the amount of material removal is dependent upon the profile of the edge  16  and various finishing steps that are optionally performed. For example, if the edge  16  is to bisect the axial line A, the stylus  12  is advanced until surface  32  intersects the axial line A. However, if a polishing step is to be performed, the advance of the stylus  12  may be stopped just prior to the surface  32  intersecting the axial line A. In this regard, the generation of the surfaces  32  and/or  34  need not be performed in a single step or pass. Instead, two or more passes may be performed. For example, the surface  32  is roughly formed in a first pass and then finish formed in a second pass. Furthermore, if the stylus  12  includes excess length, the stylus  12  is advanced past the point that the surface  32  intersects the axial line A. Upon removal of sufficient material from the stylus  12 , the stylus  12  is rotated at step  84 .  
         [0033]     At step  84  the stylus  12  is rotated to generate the curvature or camber in the surface  32 . For example, the indexing plate  48  and thus the stylus  12 , is rotated such that the indexing pin  74  contacts one side of the slot  70  and then the other side of the slot  70 . In addition, the steps  82  and  84  need not be performed in the order presented but rather, the steps  82  and  84  may be performed essentially simultaneously, alternating one then the other, or the like.  
         [0034]     At steps  86  and  88  the stylus  12  is withdrawn from the grinding surface and the chuck  46  is repositioned upon the indexing plate  48 . For example, fasteners securing the chuck  46  are removed, the surface  56  is mated to the indexing plate  48 , and the fasteners re-secured. In addition, the grinding surface is optionally de-powered as a safety precaution and/or to prepare the grinding surface for subsequent milling operations. The repositioned chuck and indexing plate assembly is re-mounted upon the chuck base  50  and, at step  90 , re-introduced to the grinding surface.  
         [0035]     At step  90  the stylus  12  is re-introduced to the grinding surface. The step  90  is similar to the step  80 . Thus, the device  44  is positioned relative to the grinding surface and, if de-powered, the grinding surface is powered or otherwise prepared to mill the stylus  12 .  
         [0036]     At step  92  the stylus  12  is advanced relative to the grinding surface. The steps  92  and  94  are similar to the steps  82  and  84 . In this regard, the stylus  12  is advanced until a sufficient amount of material is removed. In general, the amount of material removal is dependent upon the profile of the edge  16  and various finishing steps that are optionally performed. For example, if the edge  16  is to bisect the axial line A, the stylus  12  is advanced until surface  34  intersects the axial line A. However, if a polishing step is to be performed, the advance of the stylus  12  may be stopped just prior to the surface  34  intersecting the axial line A. Upon removal of sufficient material from the stylus  12 , the stylus  12  is rotated at step  94 .  
         [0037]     At step  94  the stylus  12  is rotated to generate the curvature or camber in the surface  34 . For example, the indexing plate  48  and thus the stylus  12 , is rotated such that the indexing pin  74  contacts one side of the slot  72  and then the other side of the slot  72 . In addition, the steps  92  and  94  need not be performed in the order presented but rather, the steps  92  and  94  may be performed essentially simultaneously, alternating one then the other, or the like. Following the method  78  and generation of the edge  16  a variety of finishing and/or evaluation steps are optionally performed. For example, the surfaces  32  and/or  34  may be polished or ground with a relatively finer abrasive to remove burrs or wire-edge structures from the edge  16 . In addition, the cutter  10  in general and edge  16  in particular are optionally inspected to determine if the edge  16  is adequate.  
         [0038]     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.