Multi-chip facet cutting saw blade and related method

A saw blade comprising:

• a plurality of cutting teeth defining a substantially central plane, a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other;
• (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other;
• and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other, wherein the first height is greater than the second and third heights;
• and
• first means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through a workpiece.

A saw blade comprising:

• a plurality of cutting teeth defining a substantially central plane, a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other;
• (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other;
• and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other, wherein the first height is greater than the second and third heights;
• first means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through a workpiece;
• and
• second means for balancing the cutting loads on the teeth in the repeating tooth pattern relative to each other.

A saw blade for cutting a work piece, comprising:

• a plurality of cutting teeth defining a cutting direction, and a repeating pattern of non-overlapping groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other at first acute angles relative to the first upper surface, wherein the first upper surface, and positions of the first side surfaces contiguous to the first upper surface define a first cutting surface fin cutting first chips from the work piece;
• (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height less than the first height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other at second acute angles relative to the second upper surface that are less than the first acute angle, and wherein portions of the second side surfaces extending laterally outwardly relative to the first cutting surface define second cutting surfaces for cutting second chips from the work piece;
• and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height that is less than the first height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other at third acute angles relative to the third upper surface that are less than the first acute angle, and wherein portions of the third side surfaces extending laterally outwardly relative to the second cutting surfaces define third cutting surfaces for cutting third chips from the work piece.

A saw blade comprising:

• a plurality of cutting teeth defining a substantially central plane, a cutting direction, and a repeating pattern of groups of successive teeth, each group including (1) a first tooth defining a first laterally-extending upper surface having a first width and a first height, and first side surfaces extending laterally and downwardly on opposite sides of the first upper surface relative to each other (2) a second tooth located rearwardly of the first tooth with respect to the cutting direction of the saw blade, and including a second laterally-extending upper surface defining a second width and a second height, and second side surfaces extending laterally and downwardly on opposite sides of the second upper surface relative to each other;
• and (3) a third tooth located rearwardly of the first and second teeth with respect to the cutting direction of the saw blade, and including a third laterally-extending upper surface defining a third width and a third height, and third side surfaces extending laterally and downwardly on opposite sides of the third upper surface relative to each other, wherein the first height is greater than the second and third heights, and the first, second and third teeth are located on the saw blade without any additional teeth therebetween;
• first means for creating cutting forces that are directed laterally inwardly substantially toward the central plane and, in turn, forming a substantially straight cut through a workpiece;
• and
• second means for balancing the cutting loads on the teeth in the repeating tooth pattern relative to each other.

A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece, comprising:

• a plurality of cutting teeth defining a cutting direction of the band saw blade, a feed direction of the band saw blade that is transverse to the cutting direction of the band saw blade, and a repeating pattern of groups of successive teeth, wherein each group of successive teeth includes:
• a lead tooth defining a first laterally-extending cutting surface facing the cutting direction of the band saw blade for cutting at least one first chip from the metal work piece, wherein the first laterally-extending cutting surface is oriented substantially normal to a central plane of the band saw blade and defines a first height, and the lead tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining an acute secondary clearance angle greater than the primary clearance angle;
• and
• a plurality of trailing teeth following the lead tooth, wherein each trailing tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining a secondary clearance angle greater than the primary clearance angle, and the plurality of trailing teeth define:
• a second laterally-extending cutting surface facing the cutting direction of the band saw blade, located to one side of the first laterally-extending cutting surface, oriented at a second acute angle relative to the first laterally-extending cutting surface, and defining a second height different than the first height, for cutting at least one second chip from the metal cutting work piece;
• and
• a third laterally-extending cutting surface facing the cutting direction of the band saw blade, located to one side of the first laterally-extending cutting surface and on an opposite side of the first laterally-extending cutting surface relative to the second laterally-extending cutting surface, oriented at a third acute angle relative to the first laterally-extending cutting surface, and defining a third height different than the first height, for cutting at least one third chip from the metal cutting work piece;
• and
• an aluminum titanium nitride coating overlying each of the first, second and third cutting surfaces.

A multi-chip, aluminum titanium nitride coated, metal cutting band saw blade for cutting a metal work piece, comprising:

• a plurality of cutting teeth defining a cutting direction of the band saw blade, a feed direction of the band saw blade that is transverse to the cutting direction of the band saw blade, and a repeating pattern of groups of successive teeth, wherein each group of successive teeth includes:
• a lead tooth including first means extending laterally on the lead tooth and facing the cutting direction of the band saw blade for cutting at least one first chip from the metal work piece, wherein the first means is oriented substantially normal to a central plane of the band saw blade and defines a first height, and the lead tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining an acute secondary clearance angle greater than the primary clearance angle;
• and
• a plurality of trailing teeth following the lead tooth, wherein each trailing tooth defines a primary clearance surface defining an acute primary clearance angle, and a secondary clearance surface defining an acute secondary clearance angle greater than the primary clearance angle, and the plurality of trailing teeth define:
• second means for cutting at least one second chip from the metal cutting work piece, wherein the second means is located to a first side of the first means, is oriented at a second acute angle relative to the first means, and defines a second height different than the first height;
• and
• third means for cutting at least one third chip from the metal cutting work piece, wherein the third means faces the cutting direction of the band saw blade, is located to a second side of the first means that is opposite the first side, is oriented at a third acute angle relative to the first means, and defines a third height different than the first height;
• and
• an aluminum titanium nitride coating physical vapor deposition coated over each of the first, second and third means.