Abstract: A saw blade of uniform abrasive segments with undercut protection to prevent loss of segments and to extend blade life. A metal core includes a uniform peripheral contour formed as a series of spaced apart, segment mounting sections separated by radial gullet channels. A diamond cutting segment is securely bonded to each such mounting section at a bonding interface between the segment and the metal core. Adjacent the ends of each segment on opposite sides of successive gullet channels, are upstanding ears which at least register with and extend through the radial arc of the bonding interface between the segments and the metal core. Both the upstanding ears and the region beneath each segment are preferably overcoated with a wear protection material such as carbide. The overcoated region beneath each segment includes a contoured edge to assist in directing swarf away from the cutting groove.

Abstract: A saw blade of uniform abrasive segments with undercut protection to prevent loss of segments and to extend blade life. A metal core includes a uniform peripheral contour formed as a series of spaced apart, segment mounting sections separated by radial gullet channels. A diamond cutting segment is securely bonded to each such mounting section at a bonding interface between the segment and the metal core. Adjacent the ends of each segment on opposite sides of successive gullet channels, are upstanding ears which at least register with and extend through the radial arc of the bonding interface between the segments and the metal core. Both the upstanding ears and the region beneath each segment are preferably overcoated with a wear protection material such as carbide. The overcoated region beneath each segment includes a contoured edge to assist in directing swarf away from the cutting groove.

Abstract: A method is provided for manufacturing a segmented diamond blade. The method includes the steps of placing a core into a mold and pouring a metal mixture into a mold cavity surrounding the core. The metal mixture is cold pressed to the core to form a blade having a continuous outer rim. Thereafter, the core and outer rim are suspended in a free-sintering furnace which is heated to an initial diffusion bonding temperature. The core and outer rim are heated for an initial bonding time period. Thereafter, the furnace is heated to a final diffusion bonding temperature and the core and outer rim are maintained at this temperature for a final diffusion bonding time period. After the blade cools, it is placed in a cutting tool and segmented. During segmentation, a plurality of radially aligned notches are cut through the outer rim and a corresponding plurality of gullets are cut in the core. During cutting, an inert gas, such as helium, argon or the like, is blown under high pressure directly onto the cutting point.

Abstract: A masonry blade adapted for cutting green concrete and asphalt reduces undercutting and extends blade life by generating turbulent flow within the swarf adjacent to the bond line between the cutting segments and the blade core. Turbulence is created by forming the leading surface of at least one of the cutting elements with a radial dimension greater than its trailing surface and greater than corresponding surfaces of standard elements. The opening of the blade gullets is maintained within predetermined limits to prevent blade vibration.