Corner cutting shear machine and method for forming inside corners in a one-piece article

A method of forming a one-piece raised panel from a single piece of material, the panel having a plurality of grooves in a face surface thereof defining a central raised portion inwardly of said grooves and an outer raised portion outwardly of said grooves, said grooves having constant and identical cross-sectional shape and each groove meeting at a corner with an adjacent groove to define a miter line, each groove having an outer groove surface that meets with the outer groove surface of an adjacent groove to define an inside corner portion, said method comprising the steps of:

• machining the face surface to form a portion of each groove without damaging an adjacent groove with which it meets,
• after said machining step, positioning a cutter in the groove portion formed by said machining step such that the cutter is seated within the groove portion, the cutter having the same cross-sectional shape as the groove portion in which it is seated to fit within and conform to the shape of said groove portion and having a mitered cutting edge that aligns with a miter line when the cutter is at a corner, the cutter seated within the groove portion with its cutting edge parallel to said miter line,
• moving the cutter relative to said panel along said groove portion toward a corner while holding the cutter in its seated position within said groove portion until the cutter is aligned with said miter line, the cutter shearing the material near the corner to form the remainder of said groove including the inside corner portion, and
• repeating said steps to form the grooves including the inside corner portions.

A machine for forming adjacent first and second grooves in a face surface of a panel material, such that the grooves meet at a corner to define a miter line, each groove having an outer groove surface that meets with an outer groove surface of the other groove to define an inside corner portion, said machine comprising:

• first and second cutter assemblies each having a shear cutter,
• means for mounting each shear cutter for movement along a path between retracted and extended positions, the path of movement of the cutter of the first assembly meeting with the path of movement of the cutter of the second assembly,
• means for mounting said panel having partial grooves formed therein with said cutters positioned and seated in said grooves, the grooves aligned along the paths of movement of said cutters,
• and means for driving each of the cutters along its respective path within the groove in which it is positioned between said retracted and extended positions,
• whereby driving the cutters to the extended positions shears the material near the corner to form the remainder of the grooves including the inside corner portion.

A machine for forming a groove in a face surface of a panel material, said machine comprising:

• a cutter assembly having a shear cutter, means for mounting the shear cutter for movement along a path between retracted and extended positions,
• means for mounting said panel having a partial groove formed therein with said cutter positioned and seated in said groove portion, said groove portion aligned with the path of movement of said cutter, and
• means for driving said cutter along its path within said groove portion in which it is positioned between said retracted and extended positions,
• whereby driving the cutter to its extended position shears the material near the end of the groove.

A machine for forming an inside corner portion in a one-piece article material, the inside corner portion produced by the meeting at a corner of first and second adjacent profiles, and where said profiles define a miter line where they meet at the corner, said machine comprising:

• first and second cutter assemblies each having a shear cutter,
• means for mounting each shear cutter for movement along a path between retracted and extended positions, the path of movement of the cutter of the first assembly meeting with the path of movement of the cutter of the second assembly,
• mean s for mounting said article having partial profiles formed therein with said cutters positioned and seated with said profiles, the profiles aligned along the paths of movement of said cutters,
• and means for driving each of the cutters along its respective path while seated with its respective profile between said retracted and extended positions,
• whereby driving the cutters to the extended positions shears the material near the corner to form the inside corner portion.