# US 9,434,033 B2 · Hole cutter with extruded cap > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,434,033 B2 - Document ID: US9434033B2 - Status: Granted - Kind: B2 - Application number: 12/687,102 - Filed: 2010-01-13 - Published: 2011-07-14 - Granted: 2016-09-06 - Earliest claimed: 2010-01-13 - Assignees: Irwin Industrial Tool Company - Applicants: Joseph Thomas Novak; Robert Richard Zielonka; William B. Korb - Inventors: Joseph Thomas Novak; Robert Richard Zielonka; William B. Korb - Web page: https://patentgrep.com/patent/US9434033B2 ## CPC - B23P 15/28: cutting tools (sawing tools B23D63/00, B23D65/00; files or rasps B23D73/00) - B21K 25/00: Uniting components to form integral members, e.g. turbine wheels and shafts, caulks with inserts, with or without shaping of the components (uniting by interference- or press-fitting B23P11/02, B21K19/02) - B23B 51/04: {Drills} for trepanning - B23B 51/0473: {Details about the connection between the driven shaft and the tubular cutting part; Arbors} - B23B 51/0467: {Details of the tubular body sidewall} - Y10T 29/49: Method of mechanical manufacture - Y10T 408/895: Having axial, core-receiving central portion - B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q) - B21K: MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS (making particular articles by working sheet metal without essentially removing material B21D; processing wire B21F; making pins, needles or nails B21G; making particular articles by rolling B21H; forging machines, pressing machines, hammering machines, in general B21J; making chains B21L; plating B23K) - B23B: TURNING; BORING (arrangements for copying or controlling B23Q) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A hole cutter having an extruded plate cap and methods and apparatuses for making such caps and hole cutters. The plate cap has planar opposing external and internal surfaces with an extruded hub extending axially inwardly from the internal surface. An aperture extends axially through the hub from the external surface. At least a portion of the aperture can be threaded for threaded engagement with a driving arbor. The hub is long enough so that the threaded portion contains at least two full threads. A blade body with a cutting edge is attached to the cap to form a hole cutter. ## Claims ### Claim 1 A hole cutter for cutting a work piece, comprising: a plate steel cap defining substantially planar opposing external and internal surfaces, a periphery defining a flange, an extruded hub extending axially inwardly from the internal surface and defining an aperture extending through the plate cap and hub, wherein the aperture has a threaded portion extending along at least a portion of its length, and the hub extends axially inwardly from the internal surface a sufficient distance such that the threaded portion defines at least two full threads; wherein at least a portion of at least one of the external surface and internal surface is stippled; and an annular blade body extending axially from the cap, the blade body defining a cutting edge at a distal end from the cap. ### Claim 2 (depends on 1) A hole cutter as defined in claim 1, further comprising a recess between the opposing surfaces defining a “B” diameter. ### Claim 3 (depends on 2) A hole cutter as defined in claim 2, wherein the thickness of the cap between the “B” diameter and the hub is at least about 0.134″. ### Claim 4 (depends on 2) A hole cutter as defined in claim 2, wherein the thickness of the cap between the “B” diameter and the hub is between about 0.134″ and about 0.165″. ### Claim 5 (depends on 1) A hole cutter as defined in claim 1, wherein the aperture is configured for engagement with an arbor. ### Claim 6 (depends on 1) A hole cutter as defined in claim 1, wherein the periphery further defines an “A” diameter of the hole cutter that is at least about 3″. ### Claim 7 (depends on 1) A hole cutter as defined in claim 1, wherein the threaded portion is axially-inwardly offset from the external surface. ### Claim 8 (depends on 1) A hole cutter as defined in claim 1, wherein a portion of the external surface surrounding the aperture is not stippled. ### Claim 9 (depends on 1) A hole cutter as defined in claim 1, wherein recesses in the stippled portion define pyramid shapes. ### Claim 10 (depends on 9) A hole cutter as defined in claim 9, wherein the pyramid shapes define 45° angles. ### Claim 11 (depends on 1) A hole cutter as defined in claim 1, wherein the threaded portion extends within a portion of the aperture defined by the hub. ### Claim 12 (depends on 1) A hole cutter as defined in claim 1, wherein at least a portion of the threaded portion extends into a portion of the aperture located axially inwardly from the internal surface. ### Claim 13 (depends on 1) A hole cutter as defined in claim 1, wherein the threaded portion is axially offset from the external surface. ### Claim 14 (depends on 1) A hole cutter as defined in claim 1, wherein a portion of the aperture is unthreaded. ### Claim 15 (depends on 1) A hole cutter as defined in claim 1, wherein the thickness of the plate cap and hub is at least about 0.187 inches. ### Claim 16 A method of manufacturing a hole cutter, comprising: forming a cap blank from plate steel defining generally planar external and internal opposing surfaces; forming a flange at a periphery of the cap blank; forming an aperture though the cap blank extending from the external surface to the internal surface and defining an axis that is substantially perpendicular to the external and internal surfaces; extruding the cap blank at the aperture to form a hub extending along the axis inwardly from the external surface and past the internal surface, wherein the aperture extends through the hub; and threading at least a portion of the aperture to form a threaded portion configured for engagement with an arbor; stippling at least a portion of at least one of the external and internal surfaces; attaching an axially-extending annular blade body to the cap blank, wherein the blade body defines a cutting edge at a distal end from the cap blank; and wherein the extruding step comprises extruding the hub sufficiently past the internal surface such that the threaded portion defines at least two full threads. ### Claim 17 (depends on 16) A method as defined in claim 16, wherein, after extruding, the hub has a length in a direction of the axis of at least about 0.187″. ### Claim 18 (depends on 16) A method as defined in claim 16, wherein the threaded portion is formed axially offset from the first surface in a direction toward the internal-sec-end surface. ### Claim 19 (depends on 16) A method as defined in claim 16, further comprising forming a “B” diameter between the external and internal surfaces. ### Claim 20 (depends on 19) A method as defined in claim 19, wherein the “B” diameter is formed by coining the cap blank with a die. ### Claim 21 (depends on 20) A method as defined in claim 20, wherein after the coining step, the thickness of the cap blank between the “B” diameter and the hub is at least about 0.134″. ### Claim 22 (depends on 21) A method as defined in claim 21, wherein the thickness of the cap blank between the “B” diameter and the hub is between about 0.134″ and about 0.165″. ### Claim 23 (depends on 16) A method as defined in claim 16, further comprising forming an “A” diameter at the periphery of the cap blank. ### Claim 24 (depends on 23) A method as defined in claim 23, wherein the “A” diameter is formed by trimming the periphery with a die. ### Claim 25 (depends on 16) A method as defined in claim 16, wherein a portion of the first surface surrounding the aperture is not stippled. ### Claim 26 (depends on 16) A method as defined in claim 16, wherein the stippling step comprises forming surface recesses defining pyramid shapes. ### Claim 27 (depends on 26) A method as defined in claim 26, wherein the pyramid shapes define 45° angles. ### Claim 28 (depends on 16) A method as defined in claim 16, wherein the stippling is formed using a punch. ### Claim 29 A hole cutter for cutting a work piece formed by a method comprising the steps of: forming a cap blank from plate steel defining generally planar external and internal opposing surfaces; forming a flange at a periphery of the cap blank; forming an aperture though the cap blank extending from the external surface to the internal surface and defining an axis that is substantially perpendicular to the external and internal surfaces; extruding the cap blank at the aperture to form a hub extending along the axis inwardly from the external surface and past the internal surface, wherein the aperture extends through the hub; threading at least a portion of the aperture to form a threaded portion configured for engagement with an arbor; stippling at least a portion of at least one of the external and internal surfaces; attaching an axially-extending annular blade body to the cap blank, wherein the blade body defines a cutting edge at a distal end from the cap blank; wherein the extruding step comprises extruding the hub sufficiently past the internal surface such that the threaded portion defines at least two full threads. ### Claim 30 (depends on 29) A hole cutter as defined in claim 29, wherein attaching the axially extending annular blade body to the cap blank comprises welding the annular blade body to the cap blank. ### Claim 31 (depends on 29) A hole cutter as defined in claim 29, wherein the hub has a length in a direction of the axis of at least about 0.187″. ### Claim 32 (depends on 29) A hole cutter as defined in claim 29, wherein the threaded portion is axially-offset from the external surface in a direction toward the internal surface. ### Claim 33 (depends on 29) A hole cutter as defined in claim 29, the method further comprising forming a “B” diameter between the external and internal surfaces. ### Claim 34 (depends on 33) A hole cutter as defined in claim 33, wherein the “B” diameter is formed by coining the cap blank with a die. ### Claim 35 (depends on 33) A hole cutter as defined in claim 33, wherein the thickness of the cap blank between the “B” diameter and the hub is between about 0.134″ and about 0.165″. ### Claim 36 (depends on 33) A hole cutter as defined in claim 33, the method further comprising forming an “A” diameter at the periphery of the cap blank. ### Claim 37 (depends on 36) A hole cutter as defined in claim 36, wherein the “A” diameter is formed by trimming the periphery with a die. ### Claim 38 (depends on 36) A hole cutter as defined in claim 36, wherein the “A” diameter is at least about 3″. ### Claim 39 (depends on 33) A hole cutter as defined in claim 33, wherein the thickness of the cap blank between the “B” diameter and the hub is at least about 0.134″. ### Claim 40 (depends on 29) A hole cutter as defined in claim 29, wherein a portion of the first surface surrounding the aperture is not stippled. ### Claim 41 (depends on 29) A hole cutter as defined in claim 29, wherein recesses in the stippled portion define pyramid shapes. ### Claim 42 (depends on 41) A hole cutter as defined in claim 41, wherein the pyramid shapes define 45° angles. ### Claim 43 (depends on 29) A hole cutter as defined in claim 29, wherein the stippling is formed using a punch.