Pattern cutter, its processing methods and moulds

Abstract

Disclosed here in the present invention is a pattern cutter, including a base and cutting blade. The cutting blade is located on the base. The blade forms the shape of pattern to be cut. The said base and cutting blade are of one-piece structure, which is machined to shape at one go through die-casting process. A method for processing such a pattern cutter, which directly utilizes mould to die cast the base and blade that are joined together. The said cutting blade forms the pattern shape that requires to be cut. A mould that is applied to the aforesaid processing method, inside the mould there is arranged a cavity for blade forming purpose. The said blade-forming cavity is of triangle or combination of triangle and rectangle or combination of triangle and trapezoid. The depth of blade-forming cavity is greater than or equal to 2.5 mm. The included angle at the sharp end of the blade-forming cavity is smaller than or equal to 60°. The present invention is characterized by simple and rational construction, easy to manufacture, low cost, high product accuracy and good consistency, with a wide range of adaptability and better market prospect.

1 . A pattern cutter, comprising: 
 a base; and    a cutting blade where the cutting blade is integrally formed as a one piece structure with the base and the cutting blade forms the shape of the pattern to be cut, said base and cutting blade formed from die-cast metal.    
   
   
       2 . The pattern cutter of  claim 1 , wherein the height of cutting blade is greater than or equal to 2.5 mm and the cutting edge of the ea blade has an angle of less than or equal to approximately 60°.  
   
   
       3 . The pattern cutter of  claim 1 , wherein the cross sectional shape of the blade is of at least one of a triangle, a combination of a triangle and a rectangle or combination of a triangle and a trapezoid.  
   
   
       4 . The pattern cutter of  claim 1 , wherein the surface of the base is in parallel with that of the cutting blade and both of them are of one of a plane or arc curved surface.  
   
   
       5 . A method for forming a pattern cutter, comprising: 
 providing a die-casting machine;    providing a mould having a desired blade forming cavity and a base forming cavity formed therein and in communication with each other;    placing the mould in the die-casting machine;    using the die-casting machine to fill the blade forming cavity and base forming cavity with a metal; and    taking out a pattern cutter after it has formed.    
   
   
       6 . The method of  claim 5  further comprising forming the mould by machining the desired shape of the blade forming cavity and base forming cavity therein.  
   
   
       7 . The method of  claim 5 , further comprising, applying a surface hardening treatment to the pattern cutter.  
   
   
       8 . The method of  claim 5 , wherein the blade-forming cavity has a cross-section which is of triangle or combination of triangle and rectangle or combination of triangle and trapezoid.  
   
   
       9 . The method of  claim 8 , wherein the blade-forming cavity is formed from at least one of a combination of two mould pieces and machining.  
   
   
       10 . The method of  claim 8 , at least one of a cover die or ejector die of the die-casting mould is joined together with a replaceable core piece.  
   
   
       11 . The pattern cutter of  claim 1 , wherein the die-cast metal is comprised of one of a zinc alloy, an aluminum alloy and a metal alloy.  
   
   
       12 . The method of  claim 7 , wherein said applying the surface hardening treatment includes applying at least one of chromium, nickel and zinc.  
   
   
       13 . The method of  claim 7 , wherein said applying the surface hardening treatment comprises raising the hardness of a blade of the pattern cutter from approximately HRC10 to at least approximately HRC30.  
   
   
       14 . The method of  claim 5 , wherein the blade forming cavity is provided with a depth of at least 2.5 mm and an included angle at a sharp end thereof of at approximately 60 degrees or less.  
   
   
       15 . The method of  claim 10 , further comprising drilling the core piece with a hole for fitting an insert block where an end face of the insert block is provided with a blade-forming groove corresponding to the shape of the blade of the pattern cutter.  
   
   
       16 . A mould for forming a pattern cutter, comprising: 
 a mould having a desired blade-forming cavity and a base-forming cavity formed therein and in communication with each other;    the blade-forming cavity having a cross-section which is of triangle or combination of triangle and rectangle or combination of triangle and trapezoid; and    the blade-forming cavity having a depth of at least 2.5 mm with an included angle at its sharp end smaller than at least about 60°.    
   
   
       17 . The mould of  claim 16 , wherein the blade-forming cavity is formed from at least one of a combination of two mould pieces and machining.  
   
   
       18 . The mould of  claim 16 , wherein at least one of a cover die or ejector die of the mould is joined together with a replaceable core piece.  
   
   
       19 . The method of  claim 18 , wherein the core piece has a hole for fitting an insert block where an end face of the insert block is provided with a blade-forming groove corresponding to the shape of the blade of a pattern cutter.