Roll Formed Flexible Die Plate For Rotary Cutting Tool

Abstract

A method of making a rotary cutting tool for cutting a web of material comprises the steps of roll forming a first flexible die plate into a cylindrical shape, mounting the cylindrically shaped die plate onto a cylindrically shaped fixture, and machining cutting elements onto the roll formed die plate. The roll formed die plate may then be removed from the fixture and attached to a cylinder. The first die plate can cooperate with a second die plate attached to a second cylinder to cut the thin web of material.

1 . A method of making a rotary cutting tool comprising, in combination, the steps of:
 roll forming a first flexible die plate into a cylindrical shape;   mounting the cylindrically shaped die plate onto a cylindrically shaped fixture; and   machining cutting elements onto the roll formed die plate.   
   
   
       2 . The method of making a rotary cutting tool further comprising the step of attaching the die plate to a corresponding cylinder. 
   
   
       3 . The method of  claim 1  wherein the fixture has a cylindrical, curved surface and the curve of the die plate generally corresponds to the curved surface of the fixture. 
   
   
       4 . The method of  claim 1  further comprising the step of:
 removing the die plate from the fixture and roll forming the die plate a second time, forming the die plate into a generally cylindrical shape.   
   
   
       5 . The method of  claim 4  further comprising a cylinder having a radius, wherein the generally cylindrical shape of the flexible die plate is has a radius which is about the same size as the radius of the cylinder. 
   
   
       6 . The method of  claim 4  further comprising a cylinder having a radius, wherein the generally cylindrical shape of the flexible die plate is has a radius which is slightly larger than the radius of the cylinder. 
   
   
       7 . The method of  claim 1  further comprising the step of heat treating the cutting elements formed on the flexible die plate. 
   
   
       8 . The method of  claim 1  further comprising the step of assembling the flexible die plate and a position adjustment device to a cylinder, wherein the position adjustment device provides for position adjustment of the flexible die plate on the cylinder. 
   
   
       9 . The method of  claim 8  wherein the position adjustment device comprises a yoke which receives a y-slide and at least one eccentric. 
   
   
       10 . The method of  claim 8  further comprising the steps of:
 roll forming a second flexible die plate into a cylindrical shape;   mounting the second die plate onto the cylindrically shaped fixture;   machining cutting elements onto the roll formed die plate;   assembling the second die plate and a second position adjustment device to a second cylinder; and   positioning cylinders with attached die plates in close proximity to one another, allowing the die plates to cooperate to cut a thin web of material.