Cutting tool with integrated abrasive trimming elements

Abstract

An integrated cutting and trimming tool including a cutter tool body having, in one embodiment, a plurality of spaced-apart cutting elements on its cutting face, channel extensions extending between the spaced-apart cutting elements and abrasive coated radially projecting trimming elements. The abrasive coated radially projecting trimming elements are sized and shaped to fit within the confines of the channel extensions and can be fixedly or removably secured to the cutter body. The abrasive coated radially projecting trimming elements may be attached to a ring-shaped body to allow for unitary attachment to the cutter body. The integrated cutting and trimming tool may be adapted for edge cutting and trimming and overcomes the necessity of having two machines and processes to accomplish the cutting and trimming of materials by condensing the manufacturing process into one step.

Description

TECHNICAL FIELD

This present invention relates to multi-edge material cutting tools. More particularly it relates to a new and improved diamond and carbide cutting tool specially adapted to receive integrated abrasive grit trimming elements for accomplishing cutting and trimming operations in one step and a method of using same.

BACKGROUND OF THE INVENTION

In the past, diamond and carbide cutting tools, such as wood working cutters, have been utilized for cutting a variety of materials, including wood, nonferrous metals, rubber drive belts and plastic. An example of a cutting tool of the known prior art such as is useful in the manufacture of V-belts is shown in FIG. 1. A cutting tool 1 of the known prior art consists of a generally disc-shaped cutter body 2 with a central bore 3. An outer periphery 4 of a cutting face 5 of the cutter body 2 is adapted to receive a plurality of radially arranged and spaced-apart cutting elements 6. These cutting elements 6 are diamond-edged and project from the cutting face 5 of the cutter body 2 at predetermined angles found beneficial in the cutting of the material at hand. The plurality of diamond or carbide edged cutting elements 6 are fixedly brazed on to the cutting face 5 of the disc-shaped cutter body 2 near its outer periphery 4 at calculated spaced-apart intervals 7.

FIG. 2 shows the arrangement of the prior art cutting tool 1 during the manufacture of V-belts. In the manufacture of V-belts, the cutting tool 1 is connected to an arbor 8 that is connected to an energy source. A second cutting tool 9 is mounted upon the arbor 8 in face-to-face relation with first cutting tool 1. In this orientation the cutting elements 6, 10 of the two cutting tools 1, 9 are arranged so that their cutting elements 6, 10 are positioned opposite, but at angles, to each other. It is to be appreciated at this point that due to the face-to-face orientation of the two cutting tools 1, 9 along the common arbor 8, cutting tools 1, 9 are identical in manufacture except for the fact that their cutting elements 6, 10 are oriented in opposite directions on their respective cutter bodies 2, 11. When cutting tools 1, 9 are mounted upon the common arbor 8 in this fashion, a V-shaped channel 12 is formed between the opposing cutting elements 6, 10 of the cutting tools 1, 9. When the cutting tools 1, 9 are powered to rotate, stock V-belt material 13 is drawn through the V-shaped channel 12 formed by the opposed rotating cutting elements 6, 10. By this manner the drawn stock V-belt material 13 is cut to size. The stock V-belt material 13 may contain woven or wound binding materials such as nylon or Kevlar to increase the strength, resiliency or useful working life of the manufactured V-belt. It will be appreciated that other materials apart from stock V-belt material, such as wood, non-ferrous metal and plastic material, could be cut or trimmed to varying patterns as desired using this construction of cutting tool.

In the manufacture of V-belts containing woven or wound binding materials a problem arises in that when a V-belt is cut to size, threads of the binding material project from resulting edges of the cut V-belt such that the edges are rough and in need of trimming. The prior art method of V-belt manufacture thus requires that a secondary trimming operation be performed upon the cut V-belt to remove the rough edges and threads. This secondary trimming operation is accomplished by one of two methods: grinding or slicing. When trimming is accomplished by way of grinding, another machine dedicated to grinding the edges of the rough-hewn V-belts must be used. When trimming is accomplished by way of slicing, a separate slicing machine employing thin rotary steel or carbide blades that dull quickly is used. This slicing operation is slow, costly and relatively dangerous. Accordingly, the current state of the art of V-belt manufacturing involves the two-step process of cutting stock V-belt material and then trimming the rough edges of the cut V-belt by means of grinding or slicing. The first step of the manufacturing operation involves cutting the belt to dimension using a cutting tool as is described above. The second step involves using an abrasive wheel or slicing knife to trim the binding material threads left after the initial cut. There is thus a need in the art for a cutting tool that reduces the steps and production time involved in cutting and trimming V-belts. Therefore, any tool or method that would increase the rapidity of V-belt production is desirable. By extension, any manufacturing process that requires primary cutting and then secondary grinding, sanding, polishing or slicing will benefit from a cutting tool design that combines these processes in a manner that provides decreased manufacturing cycle time in production.

SUMMARY OF THE INVENTION

The present invention fulfills the need for faster V-belt manufacture by providing for an integrated cutting and trimming tool for use in V-belt manufacture. In one embodiment, the integrated cutting and trimming tool comprises a generally disc-shaped cutter body with a plurality of spaced-apart cutting elements at the periphery of the cutter body, combined with a generally ring-shaped abrasive trimming plate having one or more radially projecting trimming elements. Each radially projecting trimming element extends from the outer ring portion of the abrasive trimming plate. Each radially projecting trimming element is selected, arranged and sized such that when the trimming plate is secured to a cutting face of the cutter body, each radially projecting trimming element lies in a specially created channel located in the space between two cutting elements on the cutter body. A further advantage of the present invention is realized by the fact the abrasive plate can be removably secured to the cutter body. By virtue of this feature the abrasive trimming plate is held securely to the cutter body during cutting and trimming operations. Yet, by using mechanical attachment means as opposed to fixed attachment means, the abrasive trimming plate can be easily removed from the cutter body for purposes of replacement and inspection.

In the preferred embodiment, the outer ring portion of the abrasive plate has a radial dimension less than the radial distance of cutting elements on the cutter body (as measured from the center of a central bore to the axial edges of cutting elements). When secured to the cutting face of the cutter body, the abrasive plate is positioned in such fashion such that its one or more radially projecting trimming elements extend into channels formed into the cutter body and extending between the cutting elements of the cutting tool. In the case where the cutting tool utilizes mechanically secured disposable cutting tips such as are explained below, the radial distance of the outer ring portion of the abrasive plate would need to be modified to account for any structural projection from the cutting face of the cutter body serving as part of a cutting element receptacle. These cutting element receptacles receive cutting elements including a clamping wedge and a disposable cutting tip.

When secured to the cutting face of the cutter body, the abrasive plate is positioned in such fashion such that each of its radially projecting trimming elements extend into a channel formed into the cutter body and extend between the cutting element receptacles of the cutting tool. A cutting tool utilizing the present invention can therefore accomplish both the cutting and trimming operations necessary for V-belt manufacture in one operation instead of the two-step operation currently necessitated by the prior art. A further advantage of the present invention lies in the fact that the trimming performance of the integrated cutting and trimming tool can be modulated by altering the shape of the tip portion, including tip edge, of the radially projecting trimming elements. Additionally, the trimming depth of the of the abrasive plate on the integrated cutting and trimming tool of the present invention can be adjusted by means of shims inserted between the abrasive trimming plate and the cutter body.

In another embodiment of the present invention, one or more individual trimming plates (trimming elements without interconnecting ring portion) are each separately secured to the face of the cutter body between the cutting element receptacles. Each radially projecting trimming plate is selected, arranged and sized such that when the trimming plate is secured to a cutting face of the cutter body, each radially projecting trimming plates lies in a specially created channel in the space between two cutting element receptacles on the cutter body. A further advantage of the present invention is realized by the fact these individual trimming plates can be removably secured to the cutter body. By virtue of this feature the individual trimming plates are held securely to the cutter body during cutting and trimming operations. Yet, by using mechanical attachment means as opposed to fixed attachment means, each individual trimming plate can be easily removed from the cutter body for purposes of replacement and inspection. The trimming depth of the individually securable abrasive trimming plate on the integrated cutting and trimming tool of the present invention can be adjusted by means of shims inserted between the abrasive trimming plate and the cutter body.

Furthermore, the present invention is not limited to face cutters and can be adapted for use with other cutting tools such as circular saw blades, whose cutting elements are located on the edge of the tool, as opposed to its face. Hence, in a further embodiment of the present invention, individual trimming elements are secured between the cutting teeth of a circular saw blade and the benefits of the combined cutting and trimming tool realized. As in the case with the face cutting and trimming tool, the use of shims to vary the height of the radially projecting trimming elements, in relation to the cutting elements, provides a means to adjust a single cutting tool for use in cutting a wide variety of materials and combinations of materials. Additionally, the present invention includes not just the integrated cutting and trimming tool, but also an improved cutting tool, face-cutting and edge-cutting, uniquely adapted to accept a removably securable abrasive grit plate or the removably securable individual trimming elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cutting tool of the prior art.

FIG. 2 is a perspective view a prior art cutting tool mounted in arrangement with a second cutting tool during the V-belt manufacturing process.

FIG. 3 is a view of a braze-on cutting element of the prior art.

FIG. 4 is a view of a cutting tool of the present invention capable of receiving a removably secured abrasive plate.

FIG. 5 is an exploded view of a cutting element and cutting element receptacle of a cutting tool used in the preferred face cutting tool embodiment of the present invention.

FIG. 6 is a view of a face cutting tool embodiment of the integrated cutting and trimming tool of the present invention.

FIG. 7 is an exploded view of the abrasive ring removed from the cutter body.

FIG. 8 is a view of a face cutting tool embodiment of the integrated cutting and trimming cutting tool of the present invention utilizing independent and separately securable trimming plates.

FIG. 9 is a view of an edge cutting tool embodiment of the integrated cutting and trimming cutting tool of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Conventional V-belt cutting tools such as depicted in FIG. 1 cut well, however, they suffer from the short useful lifespan of the cutting elements. This is particularly a concern with cutting tools used in the manufacture of V-belts containing binding material such as nylon or Kevlar strand material. V-belts utilizing such binding materials, incorporate binding materials such as nylon and Kevlar between rubber layers to improve belt wear and prevent expansion. Binding materials such as nylon and Kevlar are, however, relatively difficult to cut.

Prior art cutting tools generally include cutting tool bodies employing braze-on cutting blades for rough cutting V-belt stock material to size. In recent years these cutting blades have utilized diamond cutting edges due to the advantages of diamond-edged tools. In particular, diamond-edged cutting tools are preferred because they provide longer tool life than either steel or carbide cutting edges.

Referring to FIG. 3, there is illustrated a braze-on diamond-edged embodiment of the cutting element 6 of the known prior art. The diamond-edged cutting element 6 of the known prior art is manufactured by the machining of commercially available stock diamond rounds. A diamond round consists of diamond material bonded to a substrate of metal carbide. In order to manufacture a braze-on cutting element, the round is cut through use of wire electrical discharge machining (EDM) or lasers into the desired shape of a cutting tip. With the braze-on diamond cutting element 6, the diamond must cover the entire surface or face of the cutting edge 17 of the cutting element 6 due to the fact that a significant amount of carbide material 18 below the cutting edge 17 must remain to permanently affix the cutting element 6 to the cutter body 2 (shown in FIG. 1) by means of a braze alloy. Prior art cutting tools of the type shown in FIGS. 1 and 2 require expensive and highly specialized carbide or diamond grinding machinery to sharpen and maintain such cutting tools. Accordingly, with the cutting tool 1 using brazed-on cutting elements 6, when the cutting edges 17 become dull, the entire tool body 2 must be shipped to an outside service provider for sharpening. This process takes from one to three weeks to complete, during which time the cutting tool is not available for production use. This length of service establishes the need for at least one, and normally two, complete sets of back-up tooling to insure that manufacturing production can continue without interruption.

Referring now to FIGS. 4 and 5, there is illustrated a cutting tool 20 for use with the present invention that utilizes an improved cutter body 21 as compared, for example, to cutter body 2 of cutting tool 1 depicted in FIG. 1. By use of this improved cutting tool 20 the above-described costs and time delays attendant to cutting tools utilizing brazed-on cutting tips can be overcome.

The cutting tool 20 depicted in FIG. 4 includes a cutter body 21 with central bore 22. As opposed to the cutting tool employing brazed-on cutting elements, the improved cutting tool utilizes disposable cutting tips 23 that are mechanically attached to the cutter body 21. In this fashion dull cutting tips may be easily removed and discarded. When cutting tips 23 become dull, they are then replaced with new, sharp cutting tips. The removal and replacement of cutting tips 23 can be accomplished while the cutter body 21 remains in place on its powering device. Accordingly, by virtue of these advantages, the best mode for practicing the integrated cutting and trimming tool of the present invention disclosed herein utilizes this improved upon cutting tool 20.

Cutter body 21 has a general disc form and is made of an alloy such as aluminum alloy or a steel alloy. The cutter body 21 central bore 22 allows for mounting on an arbor. A plurality of cutting element receptacles 24 are provided along periphery 25 of the cutting face 26 of cutter body 21 to securely hold a plurality of removable cutting elements 27. These cutting element receptacles 24 are adapted to receive the plurality of cutting elements 27 by means of clamping pressure. These receptacles 24 are formed and shaped according to the particular clamping method chosen to attach the cutting elements 27 to the cutting tool body 21. The receptacles 24 and the cutting elements 27 secured therein, are located at spaced-apart intervals 28 along the outer periphery 25 of the cutting face 26 of cutter body 21.

Cutter body 21 is adapted to receive cutting elements 27 that include disposable cutting tips 23 that are mechanically attached to the cutter body 21. FIG. 5 illustrates the attachment method of a cutting element 27 into a cutting element receptacle 24. In the arrangement shown, each cutting element receptacle 24 is machined so as to receive the components of a cutting element 27 and a clamping means for removably securing the cutting element 27 into position. In the embodiment shown, the clamping means is provided by a screw down clamping piece 30.

FIG. 5 further illustrates the constituent parts of cutting element 27 as removed from the cutting element receptacle 24. The cutting element 27 is comprised of two parts: a clamping wedge 31 and a diamond-edged cutting tip 23. The clamping wedge 31 has a general block shape. The clamping wedge 31 is made of any hard material such as steel or carbide that is capable of accepting clamping pressure without deformation. A back portion 33 of the clamping wedge 31 has a slot 34 adapted to receive fixing projection 35 of screw-down clamping piece 30 that is screwed down into the cutter body 21. In a preferred embodiment, a front face 36 of the clamping wedge 31 contains two posts 37, 38.

Cutting tip 23 includes a cutting edge 40 and is configured with side slots 41, 42 adapted to receive the two posts 37, 38 projecting from the front face 36 of clamping wedge 31. The cutting tip 23 is cut from commercially available diamond rounds using wire EDM in a fashion that minimizes the use of the expensive polycrystalline diamond coating portion 43 to the cutting edge 40 of the cutting tip 23. When the front face 36 of clamping wedge 31 and the cutting face 44 of cutting tip 23 are brought in face-to-face contact with each other, side slots 41, 42 on the cutting tip 23 receive posts 37, 38 on the clamping wedge 31. The now joined clamping wedge 31 and cutting tip 23 form a cutting element 27 that is inserted as a unit into the cutting element receptacle 24 and mechanically attached to the cutter body 21 in the manner described below.

Each cutting element receptacle 24 is formed into the cutting face 26 of the cutter body 21 such that it includes a raised portion 45 with an adjacent trough 46. The raised portion 45 includes an angled clamping face 47 that is ordinarily, but not necessarily radially aligned with the cutter body 21. The angled clamping face 47 of the raised portion 45 is a flat surface that extends from a top portion 48 of the raised portion 45 to the bottom of the trough 46. Trough 46 is shaped to accommodate and hold the cutting element 27 and screw down clamping piece 30.

When the cutting tip 23 is brought into arrangement with the clamping wedge 31 as indicated above, the entire cutting element 27 is then seated as shown in the cutting element receptacle 24 and against the clamping face 47 of raised portion 45. The screw-down clamping piece 30 is then placed into the cutting element receptacle with slot 34 on the back 33 of the clamping wedge 31 snugly receiving clamping piece fixing projection 35. Clamping piece 30 is provided with a threaded screw hole 50. Screw hole 50 receives securing means, such as a hex bore screw 51, which is threaded into screw hole 50 and on into a screw hole 52 in cutting element receptacle 24 until tightened. In this fashion clamping piece 30 is firmly secured to cutter body 21. In the arrangement indicated, posts 37, 38 of the clamping wedge 31 in conjunction with the clamping force exerted by screw down clamping piece 30 pressing the cutting tip 23 against the clamping face 47 of the raised portion 45 supply anti-ejection means for holding cutting element 27 to the cutter body 21. Screw 53 located on radial edge 54 of the cutter body 21 and adjacent to the cutting element receptacle 24 provides additional protection against centrifugal ejection and serves to position the cutting tip 23 in cutting element receptacle 24. When turned clockwise, screw 53 is drawn tight into screw hole 80 in the cutter body 21 such that screw head 82 is drawn into contact with bottom portion 81 of cutting tip 23. In this fashion screw head 82 serves as a barrier against centrifugal ejectment of the clamping wedge 31 and cutting tip 23.

The screw down clamping piece 30 therefore provides means for removably securing the clamping wedge 31 and cutting tip 23 in the cutting element receptacle. Once the cutting element 27 is secured in the cutting receptacle 24, the cutting edge 40 of the cutting tip 23 is disposed at a predetermined angle found sufficient to cut V-belt material to the desired dimension. By repeating the above procedure all of the cutting element receptacles 24 on the cutter body 21 can be outfitted with cutting elements 27.

Referring now to FIG. 7, cutting face 26 of the cutter body 21 has a ring-shaped channel 60 with channel projections 61 machined into it. The channel 60 and the channel projections 61 are preferably formed by machining the cutter body 21. The outer edge of ring-shaped channel 60 has a radial dimension, as measured from the center of central bore 22, smaller than the radial distance from the center of the central bore to the axial edges 71 of the cutting element receptacles 24. The channel projections 61 extend from outer edge 64 of the ring-shaped channel into the interval spaces 28 between the spaced-apart cutting element receptacles 24.

The integrated cutting and trimming tool of the present invention is explained below and by referring to FIGS. 6 and 7. FIG. 6 shows a top angle view of the integrated cutting and trimming tool. FIG. 7 shows an exploded view of the abrasive trimming plate 62 removed from the cutter body 21. In FIGS. 6 and 7, the individual members are denoted by the following numbers: 21: cutter body, 22: central bore, 60: ring-shaped channel, 24: cutting element receptacle, 27: cutting element, 61: channel projection, 62: ring-shaped abrasive trimming plate, 63: radially projecting trimming element.

In the currently understood best mode for practicing the invention, ring-shaped channel 60 and channel projections 61 provide a recessed seat in the cutting face 26 of the cutter body 21 to receive the similarly shaped (generally ring-shaped) abrasive coated trimming plate 62. As shown in FIGS. 6 and 7, the abrasive trimming plate 62 has a first face 76 and a second face 77 and is seated in the ring-shaped channel 60 such that one or more radially projecting trimming elements 63 of the abrasive coated trimming plate 62 are received by and lie in the channel projections 61. In the preferred embodiment, the abrasive trimming plate 62 is provided with through holes 66 through which screws 67 are inserted and used to secure the plate 62 down to the cutter body 21 by means of screw holes 70 in the cutter body. Once screwed down, the abrasive coated trimming plate 62 is removably secured in the ring-shaped channel 60 and channel projections 61.

The abrasive trimming plate 62, particularly the one or more radially projecting trimming elements 63, may be formed of any durable material such as steel and then coated with abrasive material 68, such as steel, carbide or diamond. The performance of the trimming plate 62 may be adjusted by altering the shape of tip portion 73 of the radially projecting trimming element 63. In this regard, grinding surface 74 of tip portion 73 may be beveled. Additionally or alternatively, sides 75 of tip portion 73 may be tapered. An abrasive trimming plate depicting trimming elements 63 with beveled and tapered tip portions 73 is depicted in FIGS. 6 and 7. The performance of trimming element 63 may also be modulated by providing for a tip edge 79 that is curved (not shown), as opposed to straight (shown), along its width.

For economy's sake only the tip portion 73 of the trimming elements 63 need be coated with abrasive material 68. In the preferred embodiment of the present invention both sides of each trimming element 63 are coated with abrasive material 68. In this fashion when one side of the abrasive trimming plate 62 becomes worn from use it can be quickly removed from the cutter body 21 and flipped over exposing new abrasive material. The abrasive trimming plate 62 can then be quickly re-installed to the cutter body 21, exposing fresh abrasive coating. Additionally, each side of the coated abrasive plate can be coated with different grade or type of grit so as to allow for modulating trimming speed and performance or to accommodate differences in materials being cut.

It is to be appreciated at this point that the abrasive plate 62 may be fixedly attached to cutter body 21 by brazing or other means and the advantages of one step cutting and trimming of V-belts realized. Additionally, however, cutting tool 20 of the present invention may be purchased and used strictly as a cutting tool without the integrated abrasive tool feature described herein. By virtue of channel 60, channel projections 61 and screw holes 70, cutting tool 20 is uniquely adapted to securely receive a later purchased or replacement abrasive coated trimming plate 62, which may be secured to cutter body 21 by use of screws 67. Thus, the end user is afforded the choice of purchasing the cutting tool 20 with or without the integrated abrasive trimming plate 62 feature. The end user also has the choice of removing the abrasive trimming plate 62 when cutting materials that do not require its use. It is also to be appreciated at this point that the integrated cutting and trimming tool of the present invention may be made without channel 60 and that utilizing a cutter body with channel 60 in the cutter body 21 merely represents a preferred embodiment for practicing the invention.

The integrated cutting and trimming tool accomplishes both the cutting and trimming operations necessary for one-step V-belt manufacture in one operation. Moreover, it is a further advantage of the present invention that the trimming depth of the integrated cutting and trimming tool can be easily adjusted. In this regard the integrated cutting and trimming tool provides for a shim or shims 72 to be inserted between the cutter body 21 and the abrasive coated ring-shaped plate trimming 62. By adding and removing shims 72 the depth of trim of the abrasive trimming plate 62 can be varied in relation to the cutting tips 23.

The construct of the invention may be further varied depending on a number of factors, such as, in the case of V-belt manufacture, the size of belt stock and also, the type and composition of belt stock, including binding fibers. As shown in FIG. 8, the cutter body may be adapted such that instead of receiving a generally ring-shaped trimming plate with radially projecting trimming elements, the cutter body 83 could be adapted to receive one or more individually securable trimming plates 92 (trimming elements without the interconnecting ring) that are located between the cutting elements. The individually securable trimming plates 92 can be fixedly secured or removably secured to cutter body 83. Several means can be employed to removably secure each individually securable trimming plate to the cutter body, including without limitation, a screw or screws, clamping force or retaining slot. In the embodiment shown, trimming plates 92 are removably secured to cutter body 83 by means of screws 97. Though the present invention has particular application in the cutting and trimming of V-belts, the invention may also be used to cut and trim a variety of materials. Accordingly, while specific embodiments have been shown and described, many variations are possible. The shape of the cutter body and trimming plate may be changed as desired to suit the equipment with which it is used. In particular, the novel integration of combining trimming elements with a cutting tool of the present invention may be adapted for use with other cutter bodies, such as those used for circular saw blades that have cutting elements located on the edge of the tool, as opposed to its face. A view of the invention in this embodiment is shown in FIG. 9. In this edge-cutting embodiment of the present invention, edge cutting tool 84 with cutter body 85 and cutting teeth 86 located on peripheral edge 93 is adapted to receive the separately securable, edge-mounted and abrasive coated trimming elements 87 in the peripheral spacing segments 88 on peripheral edge 93 of cutter body 85. In this embodiment the peripheral spacing segments 88 are machined so as to accept trimming elements 87, which in the preferred embodiment may be L-shaped or U-shaped. Each trimming element 87 is secured to cutter body 85 by means of a screw 89. Surface 90 of trimming element 87 is coated with abrasive 91 to accomplish the trimming function of the tool. When the described abrasive coated trimming elements are combined with an edge-cutting tool such as is depicted in FIG. 9, the benefits of the combined cutting and trimming tool are realized. As in the case with the face cutting and trimming tool, the height of the trimming elements, in relation to the cutting elements, may be varied. In one embodiment, shims (not shown) between the trimming elements and the cutter body provide a means to adjust a single cutting and trimming tool for use in cutting and trimming a wide variety of materials and combinations of materials.

The shape and dimensions of the cutter body and trimming plate may also be changed to suit the operating speed of the tool or the speed at which stock is fed through the tool. Those of ordinary skill in the art will appreciate that the invention can be carried out with various other minor modifications from that disclosed herein, and same is deemed to be within the scope of this invention.

Claims

1. An integrated cutting and trimming tool comprising:

(a) a disc-shaped cutter body with a central bore and a cutting face;

(b) a plurality of spaced-apart cutting elements each mounted on the cutting face at the periphery of the cutter body;

(c) the cutter body having a plurality of radially projecting channels, each channel located between two spaced-apart cutting elements;

(d) an abrasive coated trimming plate having a ring-shaped body with a first face, a second face and one or more radially projecting trimming elements;

(e) the number of radially projecting trimming elements being equal to or less than the number of radially projecting channels; and

(f) the abrasive coated trimming plate being secured to the cutter body such that one face of the abrasive coated trimming plate is brought in contact with the cutting face and each radially projecting trimming element lies in a radially projecting channel and extends between two spaced-apart cutting elements.

2. The integrated cutting and trimming tool of claim 1 wherein each cutting element has an axial edge and is located at a radial distance R1 as measured from the center of the central bore in the cutter body to the axial edge of the cutting element and the ring-shaped body of the abrasive coated trimming plate has an outer radial distance of less than R1.

3. The integrated cutting and trimming tool of claim 1 wherein the abrasive coated trimming plate is removably secured to the cutter body.

4. The integrated cutting and trimming tool of claim 2 wherein the abrasive coated trimming plate is removably secured to the cutter body.

5. The integrated cutting and trimming tool of claim 3 wherein the abrasive coated trimming plate is coated on both faces with abrasive.

6. The integrated cutting and trimming tool of claim 5 wherein each face of the abrasive coated trimming plate is coated with a different type or grade of abrasive.

7. The integrated cutting and trimming tool of claim 1 wherein each radially projecting trimming element has a tip portion, the tip portion being a section of the trimming element generally distal from the ring-shaped body and only the tip portion of one or more of the radially projecting trimming elements is coated with abrasive.

8. The integrated cutting and trimming tool of claim 3 wherein each radially projecting trimming element has a tip portion, the tip portion being a section of the trimming element generally distal from the ring-shaped body and only the tip portion of one or more of the radially projecting trimming elements is coated with abrasive.

9. The integrated cutting and trimming tool of claim 3 wherein the trimming depth of the abrasive coated trimming plate is adjustable.

10. The integrated cutting and trimming tool of claim 8 wherein the trimming depth of the abrasive coated trimming plate is adjustable.

11. The integrated cutting and trimming tool of claim 6 wherein the trimming depth of the abrasive coated trimming plate is adjustable.

12. The integrated cutting and trimming tool of claim 9 wherein the trimming depth of the abrasive coated trimming plate is adjustable by shims receivable between the cutter body and the abrasive coated trimming plate.

13. The integrated cutting and trimming tool of claim 10 wherein the trimming depth of the abrasive coated trimming plate is adjustable by shims receivable between the cutter body and the abrasive coated trimming plate.

14. The integrated cutting and trimming tool of claim 11 wherein the trimming depth of the abrasive coated trimming plate is adjustable by shims receivable between the cutter body and the abrasive coated trimming plate.

15. An integrated cutting and trimming tool comprising:

(a) a disc-shaped cutter body with a central bore and a cutting face;

(b) a plurality of spaced-apart cutting elements mounted on the cutting face at its periphery;

(c) the cutter body having a plurality of radially projecting channels, each channel located between two spaced-apart cutting elements;

(e) an abrasive coated trimming plate having a ring-shaped body, a first face, a second face and one or more radially projecting trimming elements;

(f) the number of radially projecting trimming elements being equal to or less than the number of radially projecting channels;

(g) the abrasive coated trimming plate being secured to the cutter body such that one face of the abrasive coated trimming plate is brought in contact with the cutting face and each radially projecting trimming element lies in a radially projecting channel and extends between two spaced-apart cutting elements; and

(h) each radially projecting trimming element on at least one face of the abrasive coated trimming plate having a tip portion and tip edge, the tip portion being a section of the trimming element generally distal from the ring-shaped body and having sides and a grinding surface, and the tip edge having a certain width and being located on the tip portion of the radially projecting trimming element at a point that is radially farthest from the ring-shaped body of the abrasive coated trimming plate.

16. The integrated cutting and trimming tool of claim 15 wherein the tip portion of one or more of the radially projecting trimming elements is shaped in accordance with one or more of the following characteristics:

a. the grinding surface is beveled;

b. the sides of the tip portion reducedly taper in the direction of the tip edge; or

c. tip edge is curved along its width.

17. The integrated cutting and trimming tool of claim 15 wherein the abrasive coated trimming plate is removably secured to the cutter body.

18. The integrated cutting and trimming tool of claim 17 wherein the tip portion of one or more of the radially projecting trimming elements is shaped in accordance with one or more of the following characteristics:

a. the grinding surface is beveled;

b. the sides of the tip portion reducedly taper in the direction of the tip edge; or

c. tip edge is curved along its width.

19. The integrated cutting and trimming tool of claim 15 wherein each cutting element has an axial edge and is located at a radial distance R1 as measured from the center of the central bore in the cutter body to the axial edge of the cutting element and the ring-shaped body of the abrasive coated trimming plate has an outer radial distance of less than R1.

20. The integrated cutting and trimming tool of claim 19 wherein the tip portion of one or more of the radially projecting trimming elements is shaped in accordance with one or more of the following characteristics:

a. the grinding surface is beveled;

b. the sides of the tip portion reducedly taper in the direction of the tip edge; or

c. tip edge is curved along its width.

21. An integrated cutting and trimming tool comprising:

(a) a disc-shaped cutter body with a central bore and a cutting face;

(b) a plurality of spaced-apart cutting elements mounted at the periphery of the cutting face;

(c) the cutter body having a plurality of radially projecting channels, each channel located between two spaced-apart cutting elements;

(d) one or more abrasive coated trimming plates, each plate having a first face and a second face;

(e) the number of abrasive coated trimming plates being equal to or less than the number of radially projecting channels; and

(f) each abrasive coated trimming plate being secured to the cutter body such that one face of the abrasive coated trimming plate is brought in contact with the cutting face and the abrasive coated trimming plate lies in a radially projecting channel and extends between two spaced-apart cutting elements.

22. The integrated cutting and trimming tool of claim 21 wherein one or more of the abrasive coated trimming plates is removably secured to the cutter body.

23. The integrated cutting and trimming tool of claim 22 wherein one or more of the removably secured abrasive coated trimming plates are coated on both faces with abrasive.

24. The integrated cutting and trimming tool of claim 23 wherein one or more of the removably secured abrasive coated trimming plates that are coated on both sides with abrasive are coated with a different type or grade of abrasive on each face.

25. The integrated cutting and trimming tool of claim 22 wherein the trimming depth of one or more of the abrasive coated trimming plates is adjustable.

26. The integrated cutting and trimming tool of claim 23 wherein the trimming depth of one or more of the abrasive coated trimming plates is adjustable.

27. The integrated cutting and trimming tool of claim 25 wherein the trimming depth of one or more of the trimming-depth adjustable abrasive coated trimming plates is adjustable by shims receivable between the cutter body and the abrasive coated trimming plate.

28. The integrated cutting and trimming tool of claim 26 wherein the trimming depth of one or more of the trimming-depth adjustable abrasive coated trimming plates is adjustable by shims receivable between the cutter body and the abrasive coated trimming plate.

29. A cutting tool comprising:

(a) a disc-shaped cutter body with a central bore and a cutting face;

(b) a plurality of spaced-apart cutting elements each with an axial edge and mounted at the periphery of the cutting face;

(c) each of the plurality of spaced-apart cutting elements being located at a radial distance R1 as measured from the center of the central bore to the axial edge of each of the cutting elements;

(d) the cutter body having a having a plurality of radially projecting channels, each channel located between two spaced-apart cutting elements; and

(e) the cutter body being adapted to removably receive and secure an abrasive coated trimming plate having a ring-shaped body with an outer radial distance of less than R1, a first face, a second face and one or more radially projecting trimming elements such that when one face of the abrasive coated trimming plate is secured to the cutting face of the cutter body each radially projecting trimming element lies in a radially projecting channel and extends between two spaced-apart cutting elements.

30. A cutting tool comprising:

(a) a disc-shaped cutter body with a central bore and a cutting face;

(b) a plurality of spaced-apart cutting elements mounted on the cutting face of the cutter body and along its periphery;

(c) the cutter body having a having a plurality of radially extending channels, each channel extending between two spaced-apart cutting elements; and

(d) the cutter body being adapted to receive one or more abrasive coated trimming plates wherein each trimming plate can be removably secured to the cutter body between two spaced-apart cutting elements.

31. An integrated cutting and trimming tool comprising:

(a) a disc-shaped cutter body with a central bore, a first face and a second face;

(b) the cutter body having a peripheral cutting edge between the first face and second face;

(c) a plurality of spaced-apart radially projecting cutting elements mounted on the cutting edge;

(d) a plurality of peripheral spacing segments, each segment extending between the spaced-apart cutting elements;

(d) one or more abrasive coated trimming elements; and

(e) the number of abrasive coated trimming elements being equal to or less than the number of peripheral spacing segments and, whereby each of the abrasive coated trimming elements is secured to the cutter body at the location of a peripheral spacing segment.

32. The integrated cutting and trimming tool of claim 31 wherein at least one of the abrasive coated trimming elements is removably secured to the cutter body.

33. The integrated cutting and trimming tool of claim 32 wherein the trimming depth of at least one of the removably secured abrasive coated trimming element is adjustable.

34. The integrated cutting and trimming tool of claim 33 wherein the trimming depth of each removably secured and trimming depth adjustable abrasive coated trimming element is adjustable by shims receivable between the cutter body and the abrasive coated trimming element.

35. A cutting tool comprising:

(a) a disc-shaped cutter body with a central bore, a first face and a second face;

(b) the cutter body having a peripheral cutting edge between the first face and second face;

(c) a plurality of spaced-apart radially projecting cutting elements mounted on the cutting edge;

(d) a plurality of peripheral spacing segments, each segment extending between the spaced-apart cutting elements; and

(e) the cutter body being adapted to receive one or more abrasive coated trimming elements, wherein each trimming element can be removably secured to the cutter body at the location of a peripheral spacing segment.

36. A method of cutting and trimming material comprising:

(a) providing a cutting tool comprised of a disc-shaped cutter body, a central bore, a cutting face, a plurality of spaced-apart cutting elements mounted on the cutting face of the cutter body at its periphery and a plurality of radially projecting channels located between the spaced-apart cutting elements;

(b) securing to the cutting tool an abrasive coated trimming plate having a ring-shaped body with a first face, a second face and one or more radially projecting trimming elements such that one face of the abrasive coated trimming plate is brought in contact with the cutting face of the cutter body and each radially projecting trimming elements lies in a radially projecting channel and extends between two spaced-apart cutting elements;

(c) rotating the cutting tool with the secured abrasive coated trimming plate; and

(d) having the rotating cutting tool with the secured abrasive coated trimming plate make contact with stock material such that the stock material makes contact with one or more of the cutting elements and one or more of the radially projecting trimming elements.

37. A method of cutting and trimming material comprising:

(a) providing a cutting tool comprised of a disc-shaped cutter body, a central bore, a cutting face, a plurality of spaced-apart cutting elements mounted on the cutting face of the cutter body at its periphery and a plurality of radially projecting channels located between the spaced-apart cutting elements;

(b) securing one or more abrasive coated trimming plates to the cutting tool such that each secured abrasive coated trimming plates lies in a radially projecting channel and extends between two spaced-apart cutting elements;

(c) rotating the cutting tool having at least one trimming plate secured to it; and

(d) having the rotating cutting tool with at least one abrasive coated trimming plate secured to it make contact with stock material such that the stock material makes contact with one or more of the cutting elements and at least one trimming plate.

38. A method of cutting and trimming material comprising:

(a) providing a cutting tool comprising a disc-shaped cutter body, a central bore, a first face and a second face, the cutter body having a peripheral cutting edge between the first face and second face, a plurality of spaced-apart radially projecting cutting elements mounted on the cutting edge and a plurality of peripheral spacing segments extending between the spaced-apart cutting elements;

(b) securing one or more abrasive coated trimming elements to the cutting tool such that each secured abrasive coated trimming element is secured to the cutting tool at the location of a peripheral spacing segment;

(c) rotating the cutting tool having at least one abrasive coated trimming element secured to it; and

(d) having the rotating cutting tool with at least one abrasive coated trimming element secured to it make contact with stock material such that the stock material contacts one or more of the cutting elements and at least one abrasive coated trimming element.