Saw blade and method of manufacturing the same

Abstract

A method of manufacturing a saw blade includes providing a saw blade body having an edge, forming a plurality of tooth bodies that defines a plurality of gullets in the saw blade body, coupling a cutting member to the edge of the saw blade body, and shaping the cutting member to form a cutting tooth after the cutting member is coupled to the edge. Each one of the plurality of tooth bodies defines an undercut portion positioned between adjacent tooth bodies. The cutting tooth includes a rake face extending from a tip of the cutting tooth toward the saw blade body and a relief face extending from the tip toward a second end of the cutting tooth sloping toward the saw blade body.

1 . A method of manufacturing a saw blade, the method comprising:
 providing a saw blade body having an edge;   forming a plurality of tooth bodies that defines a plurality of gullets in the saw blade body, each one of the plurality of tooth bodies defining an undercut portion positioned between adjacent tooth bodies;   coupling a cutting member to the edge of the saw blade body; and   shaping the cutting member to form a cutting tooth after the cutting member is coupled to the edge, the cutting tooth including a rake face extending from a tip of the cutting tooth toward the saw blade body and a relief face extending from the tip toward a second end of the cutting tooth sloping toward the saw blade body.   
     
     
         2 . The method of  claim 1 , further comprising coupling a plurality of cutting members to the edge of the saw blade, and shaping the plurality of cutting members to form a plurality of cutting teeth after the plurality of cutting members is coupled to the edge, wherein each cutting tooth of the plurality of cutting teeth includes a rake face extending from a tip of each cutting tooth toward the saw blade body and a relief face extending from the tip of each cutting tooth toward a second end of each cutting tooth sloping toward the saw blade body, wherein each of the plurality of cutting members includes the rake face before the plurality of cutting members are shaped into the plurality of cutting teeth. 
     
     
         3 . The method of  claim 2 , wherein the forming the plurality of tooth bodies and the plurality of gullets is performed before the coupling the plurality of cutting members to the edge of the saw blade body. 
     
     
         4 . The method of  claim 1 , wherein the shaping the cutting member to form the cutting tooth includes shaping the cutting member to form a plurality of cutting teeth, and wherein each cutting tooth of the plurality of cutting teeth includes a rake face extending from a tip of each cutting tooth toward the saw blade body and a relief face extending from the tip of each cutting tooth toward a second end of each cutting tooth sloping toward the saw blade body, and wherein the cutting member extends over the plurality of gullets before the cutting member is shaped into the plurality of cutting teeth. 
     
     
         5 . The method of  claim 1 , wherein the plurality of gullets is a first plurality of gullets, and further comprising forming a second plurality of gullets in the saw blade body sized differently than the first plurality of gullets, and wherein each of the second plurality of gullets is positioned between adjacent first plurality of gullets. 
     
     
         6 . The method of  claim 5 , wherein the forming the second plurality of gullets includes forming the second plurality of gullets after coupling the cutting member to the edge of the saw blade body. 
     
     
         7 . The method of  claim 1 , further comprising forming an attachment portion including a tang and an aperture in the saw blade body. 
     
     
         8 . A method of manufacturing a saw blade, the method comprising:
 providing a saw blade body having an edge;   forming a plurality of tooth bodies that defines a plurality of gullets in the saw blade body with a first forming process, each tooth body having a first end and a second end, each of the plurality of gullets defined between two adjacent tooth bodies of the plurality of tooth bodies, at least one of the plurality of tooth bodies defining an undercut portion of a corresponding one of the plurality of gullets at the second end of the at least one of the plurality of tooth bodies;   coupling a cutting member to the edge of the saw blade body; and   shaping the cutting member with a second forming process to form a cutting tooth on the at least one of the plurality of tooth bodies after the cutting member is coupled to the edge, the cutting tooth including a rake face adjacent to the first end of the at least one of the plurality of tooth bodies, the second forming process being a different forming process than the first forming process.   
     
     
         9 . The method of  claim 8 , wherein the first forming process includes a stamping process using a stamping die. 
     
     
         10 . The method of  claim 8 , wherein the second forming process includes a grinding process. 
     
     
         11 . The method of  claim 8 , wherein the coupling a cutting member to the edge of the saw blade body includes coupling a single, continuous piece of material to the plurality of tooth bodies; and
 wherein the shaping the cutting member with a second forming process to form a cutting tooth on the at least one of the plurality of tooth bodies after the cutting member is coupled to the edge includes forming a separate cutting tooth on each of the plurality of tooth bodies from the single, continuous piece of material.   
     
     
         12 . The method of  claim 8 , wherein the shaping the cutting member with a second forming process to form a cutting tooth on the at least one of the plurality of tooth bodies includes forming the cutting tooth with the rake face extending parallel and continuous with the first end of the at least one of the plurality of tooth bodies. 
     
     
         13 . The method of  claim 12 , wherein the shaping the cutting member with a second forming process to form a cutting tooth on the at least one of the plurality of tooth bodies includes forming the cutting tooth with a projection having a flat edge adjacent to the second end of the at least one of the plurality of tooth bodies, the flat edge extending parallel to the rake face and extending parallel with a portion of the second end of the at least one of the plurality of tooth bodies. 
     
     
         14 . The method of  claim 13 , wherein the forming the plurality of tooth bodies that defines a plurality of gullets in the saw blade body with a first forming process includes forming the portion of the second end of the at least one of the plurality of tooth bodies that extends parallel with the flat edge at a position between the cutting tooth and the undercut portion. 
     
     
         15 . The method of  claim 8 , wherein the forming a plurality of tooth bodies includes forming a first plurality of tooth bodies that defines a first plurality of gullets and forming a second plurality of tooth bodies that defines a second plurality of gullets;
 wherein each of the first plurality of gullets is defined by a second end of a corresponding one of the first plurality of tooth bodies and a first end of a corresponding one of the second plurality of tooth bodies;   wherein each of the second plurality of gullets is defined by a first end of a corresponding one of the first plurality of tooth bodies and a second end of a corresponding one of the second plurality of tooth bodies; and   wherein the second plurality of gullets is sized differently than the first plurality of gullets.   
     
     
         16 . A method of manufacturing a saw blade, the method comprising:
 providing a saw blade body that extends along an axis and has an edge;   forming a plurality of tooth bodies in the saw blade body, at least one of the plurality of tooth bodies having a first end and a second end, the first end extending linearly, the second end having a first portion that extends linearly and a second portion that extends non-linearly from the first portion of the second end toward the saw blade body;   coupling a cutting member to the edge of the saw blade body; and   shaping the cutting member to form a cutting tooth on the at least one of the plurality of tooth bodies after the cutting member is coupled to the edge.   
     
     
         17 . The method of  claim 16 , wherein the forming the plurality of tooth bodies in the saw blade body includes forming the at least one of the plurality of tooth bodies such that both the first end of the at least one of the plurality of tooth bodies and the first portion of the second end of the at least one of the plurality of tooth bodies extend perpendicularly to the axis. 
     
     
         18 . The method of  claim 17 , wherein the shaping the cutting member to form the cutting tooth on the at least one of the plurality of tooth bodies includes forming a rake face that extends parallel and continuous with the first end of the at least one of the plurality of tooth bodies, and forming a projection having a flat edge that extends parallel and continuous with the first portion of the second end of the at least one of the plurality of tooth bodies. 
     
     
         19 . The method of  claim 16 , wherein the forming the plurality of tooth bodies in the saw blade body includes forming a first plurality of tooth bodies and a second plurality of tooth bodies;
 wherein each of the first plurality of tooth bodies has a first end extending perpendicularly to the axis and a second end having a first portion that extends perpendicularly to the axis and a second portion that extends non-linearly from the first portion of the second end toward the saw blade body; and   wherein each of the second plurality of tooth bodies has a first end extending perpendicularly to the axis and a second end extending perpendicularly to the axis.   
     
     
         20 . The method of  claim 16 , wherein the forming a plurality of tooth bodies in the saw blade body includes a stamping process with a stamping die, and wherein the shaping the cutting member to form a cutting tooth includes a grinding process.