METHOD AND APPARATUS FOR SHARPENING HARDENED TOOLS

Abstract

An application for an apparatus for sharpening a cutting blade includes a source of high pressure water stream capable of cutting steel and a sharpening jig for positioning and holding the cutting blade perpendicular to the high pressure water stream, the sharpening jig provides a mechanism for moving the cutting blade so that a cutting edge of the cutting blade predictably passes beneath the high pressure water.

Description

FIELD OF THE INVENTION

This invention relates to the field of hardened tools and more particularly to a method for sharpening hardened tools such as diamond alloy tool bits.

BACKGROUND OF THE INVENTION

Stone, such as marble and granite, is often cut using a rotating blade made with diamond. In order for such a blade to efficiently cut stone, its cutting edge must be sharp or, approximately at right angles. As such a blade is used, the edges often round resulting in a dull blade that is less effective in cutting stone or, more significant, a blade that places undue stress on the attached saw, causing stalling or a burned-out motor.

Prior to the present invention, to extend the life of these expensive blades, the blades were sharpened by using a hard grinding wheel. Such a process improves the life of the blade, but does not completely and evenly sharpen the blade. Because the blade is so hard, the grinding wheel develops ruts as it sharpens the blade. The ruts are usually curved, therefore, do not sharpen the blade edge at a right angle. Parts of the blade that are sharpened when the grinding wheel is new are often sharper (flatter, right angled) than parts that are sharpened when the grinding wheel is worn and has these ruts. This often results in an unbalanced blade that vibrates or wobbles when used.

Water jet or fluid jet cutting systems are known as evidenced by U.S. Pat. No. 5,782,673 to Warehime. This patent describes a fluid jet cutting and shaping system with an X-Y table beneath the fluid jet for positioning and moving the object to be cut.

What is needed is a method and apparatus for sharpening diamond edge blades and other very hard blades that repeatedly and consistently sharpens the surfaces of the blade.

SUMMARY OF THE INVENTION

In one embodiment, an apparatus for sharpening a cutting blade including a source of a high pressure water stream capable of cutting steel and a sharpening jig for positioning and holding the cutting blade perpendicular to the high pressure water stream, the sharpening jig provides a mechanism for moving the cutting blade so that a cutting edge of the cutting blade predictably passes beneath the high pressure water stream.

In another embodiment, a method of sharpening a diamond cutting tool is disclosed including providing a diamond cutting tool having a dull cutting edge. A source of high pressure water capable of cutting steel is provided. A sharpening jig positioned beneath the high pressure water holds the cutting blade of the diamond cutting tool perpendicular to the high pressure water while the diamond cutting tool is rotated. As the cutting edge of the diamond cutting tool passes beneath the high pressure water, the dull cutting edge is cut sharp by the high pressure water, thereby sharpening the diamond cutting tool.

In another embodiment, an apparatus for sharpening a cutting blade is disclosed including a source of a high pressure water stream capable of cutting steel and a device for positioning and holding the cutting blade perpendicular to the high pressure water stream. The device for positioning and holding the cutting blade is capable of moving the cutting blade so that a cutting edge of the cutting blade predictably passes beneath the high pressure water stream.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a plan view of a diamond cutting blade of the prior art.

FIG. 2 illustrates a side view of a sharpened diamond cutting blade of the prior art.

FIG. 3 illustrates a side view of a dulled diamond cutting blade of the prior art.

FIG. 4 illustrates a grinding wheel used to sharpen a diamond cutting blade of the prior art.

FIG. 5 illustrates a system of the present invention for sharpening a diamond cutting blade.

FIG. 6 illustrates a plan view of a diamond cutting tool of the prior art.

FIG. 7 illustrates a system of the present invention for sharpening a diamond cutting tool.

FIG. 8 illustrates a system of the present invention for sharpening a diamond edging tool.

FIG. 9 illustrates an adapter of the present invention for holding diamond edging tools within the system of the present invention during sharpening.

FIG. 10 illustrates a system of the present invention for sharpening a curved diamond edging tool.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures.

Referring to FIG. 1, a plan view of a diamond cutting blade of the prior art will be described. A typical diamond cutting blade 10 of the art has a cutting surface 14 and a plurality of cutting points 16. The cutting blade 10 has a center hole 12 for installing the cutting blade 10 on a saw hub (not shown). For proper cutting, the cutting blade 10 must be as close to round as possible to prevent vibration and wobble on the saw and must be as sharp as possible, especially when cutting hard stone such as marble and granite.

Referring to FIG. 2, a side view of a sharpened diamond cutting blade of the prior art will be described. The cutting points 16 of the cutting blade 10 are visible. The edge 14a of the cutting blade 10 is sharp being that it is substantially flat and at substantially a right angle with a 90 degree tangent of the rotation of the blade.

Referring to FIG. 3, a side view of a dulled diamond cutting blade of the prior art will be described. The cutting points 16 of the cutting blade 10 are visible. The edge 14b of the cutting blade 10 is dull being that it is substantially curved and its edges are not at substantially a right angle with a 90 degree tangent of the rotation of the blade.

Referring to FIG. 4, a grinding wheel used to sharpen a diamond cutting blade of the prior art will be described. In the past, a grinding wheel 22 or other suitable grinding device was used to flatten the rounded edges 14a of a cutting blade 10 to restore its ability to cut. In this example, the grinding wheel 22 is affixed to a shaft 24 by a fastener 26 and rotates on the shaft 24. The shaft 24 is coupled to a source of rotation (not shown). The flat edge of the grinding wheel 22 contacts the rounded edge 14a of the dull cutting blade 10 and grinds away the rounded edge 14a until it is flat as in FIG. 2. Unfortunately, this method is very time consuming and creates an uneven cutting blade 10 because of difficulties in grinding the blade into a balanced, round blade. Such difficulties are a result of uneven wear of the grinding wheel 22. The grinding wheel 22 begins flat, but as it contacts the edge of the dull blade 10, it wears proportionately to the surface area that must be removed from the edge 14a of the cutting tool 10, thereby forming ruts in the grinding wheel 22.

Referring to FIG. 5, a system of the present invention for sharpening a diamond cutting blade will be described. High pressure water 52 is used to cut hard materials such as marble and granite. The water jet 52 is a very high pressure directed stream of water, usually in the range of 20,000 to 55,000 psi. The water is forced through an orifice in a jewel. The orifice is typically 0.010″ to 0.015″ in diameter. Some water jet cutters 50 use abrasives suspended in the water to cut harder materials or cut faster. The present invention works with many known water jet cutters and is not limited to any particular type or style of water jet cutter.

In the exemplary sharpening system of FIG. 5, a diamond cutting blade 10 is rotatably affixed to a sharpening jig 30. The sharpening jig 30 has a base 32 and a holding arm 36 attached to the base 32 by a threaded fastener 34 such as a bolt, etc. In this way, the sharpening jig 30 is easily affixed to the bed of the water jet cutting system (not shown). The cutting blade 10 to be sharpened is affixed to a hub 42/44/46/48 consisting of an upper hub 44 and a lower hub 46 and optionally, washers or spacers 44, all held together by a bolt 42 that threads into the base 32. The cutting blade turns freely on the hub 42/44/46/48. To reduce bending of the cutting blade 10 under the stress of the high pressure water stream, a standoff 40 is affixed to the base 32 between the top surface of the base 32 and the cutting blade 10. As shown, the water jet 52 from the water jet source 50 (as known in the industry) is directed substantially perpendicular to the cutting blade 10. The sharpening jig 30 is positioned on the table of the water jet cutting device (not shown) and the water jet is aligned to cut the rounded edge 14a off of the cutting blade 10, forming a sharp edge 14a. As the rounded edge 14a is cut from one section of the cutting blade 10, the cutting blade 10 is rotated on the hub 42/44/46/48 until the entire cutting blade 10 has sharp edges 14b as shown in FIG. 2.

Referring to FIG. 6, a plan view of a diamond cutting tool of the prior art will be described. Other diamond cutting tools are known in the industry for cutting holes in stone, for example the cutting tool 60 for cutting faucet holes in stone counter tops. This cutting tool 60 has a cutting edge 62 and cutting surfaces 64 as known in the industry.

Referring to FIG. 7, a system of the present invention for sharpening a diamond cutting tool will be described. To sharpen a diamond cutting tool 60, the cutting tool 60 is threaded onto a threaded shaft 82 that is connected to a source of rotation, in this example a crank handle 84. Other sources of rotation are known in the industry and all such sources are included here within. The threaded shaft 82 passes through and is rotatable held in position by a riser 80 attached to a base 72. The base 72 has a holding arm 76 attached to the base 72 by a threaded fastener 74 such as a bolt, etc. In this way, the sharpening jig 70 is easily affixed to a bed of the water jet cutting system (not shown). The cutting tool 60 to be sharpened is threaded onto the threaded shaft 82 and positioned under the water jet 52 from the water jet source 50 far enough that the rounded edge of the cutting tool 60 is cut off by the water jet 52. The cutting tool 60 is rotated by the source of rotation (e.g., the crank 84) until the entire cutting surface of the cutting tool 60 is sharp.

Referring to FIG. 8, a system of the present invention for sharpening a diamond edging tool will be described. This system has a base 91 onto which a drive motor 90 is mounted. The shaft 92 of the drive motor 90 is stabilized by a bearing 94 that is affixed to the base 91 by fasteners 95 as known in the industry. A chuck 96 holds the edging tool 98. In this example, the edging tool 98 is a flat surface edging tool 98 having angled cutting surfaces 99. To sharpen such a edging tool 98, the edging tool 98 in the chuck 96 is rotated by the drive motor 90 and the water jet 52 is positioned to cut the rounded edges of the cutting surfaces 99. The water jet 52 is controlled at the water jet system to pass across the entire cutting edge of the edging tool 98 as the edging tool 98 rotates, thereby sharpening all edges 99 of the edging tool 98.

Referring to FIG. 9, an adapter of the present invention for holding diamond edging tools within the system of the present invention during sharpening will be described. The adapter 104 has a bit end 102 for insertion into the chuck 96 (see FIG. 8) and a body 100 that has a hollowed, threaded portion for accepting a threaded cutting tool (not shown).

Referring to FIG. 10, a system of the present invention for sharpening a curved diamond edging tool will be described. Curved diamond edging tools 110 are known in the industry and used to create bull-nosed edges or rounded edges for countertops and the like. The sharpening system of FIG. 8 is used to sharpen curved diamond edging tools 110 by tightening the bit end 112 of the curved diamond edging tool 110 in the chuck 96 and, as the curved diamond edging tool 110 is rotated by the drive motor 90, the water jet 52 passes along the curved cutting surface of the curved diamond edging tool 110. The travel of the water jet 52 is programmed into the water jet system to track the curvature of the curved diamond edging tool 110.

Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.

It is believed that the system and method of the present invention and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely exemplary and explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.

Claims

1. An apparatus for sharpening a cutting blade, the apparatus comprising:

a source of a high pressure water stream, the high pressure water stream capable of cutting steel; and

a sharpening jig for positioning and holding the cutting blade substantially perpendicular to the high pressure water stream, the sharpening jig providing a means for moving the cutting blade so that a cutting edge of the cutting blade predictably passes beneath the high pressure water stream.

2. The apparatus for sharpening a cutting blade of claim 1, wherein the cutting blade is a diamond steel circular blade and the sharpening jig comprises:

a base platform;

a clamp for holding the base platform to a work table of the source of high pressure water stream; and

a hub for holding the diamond steel circular blade perpendicular to the high pressure water stream, the hub enabling rotation of the diamond steel circular blade.

3. The apparatus for sharpening a cutting blade of claim 2, further comprising a standoff affixed to the base platform between the hub and the high pressure water, the standoff supporting a bottom surface of the diamond steel circular blade.

4. The apparatus for sharpening a cutting blade of claim 1, wherein the cutting blade is a diamond steel hole cutting bit and the sharpening jig comprises:

a base platform;

a clamp for holding the base platform to a work table of the source of high pressure water stream;

a riser affixed to the platform and rising above the platform;

a threaded shaft rotatably interfaced with the riser for holding the diamond steel hole cutting bit perpendicular to the high pressure water stream; and

a means for rotating the threaded shaft, thereby rotating the diamond steel hole cutting bit beneath the high pressure water stream.

5. The apparatus for sharpening a cutting blade of claim 1, wherein the cutting blade is a diamond steel edging tool and the sharpening jig comprises:

a base platform;

a clamp for holding the base platform to a work table of the source of high pressure water stream;

a motor affixed to the base platform, the motor having a shaft;

a chuck for holding the diamond steel edging tool perpendicular to the high pressure water stream, the motor rotating the diamond steel edging tool situated in the chuck.

6. The apparatus for sharpening a cutting blade of claim 5, further comprising a bearing, the bearing affixed to the base platform between the chuck and the motor, the shaft passing through the bearing whereas the bearing supports the shaft.

7. The apparatus for sharpening a cutting blade of claim 5, wherein the source of the high pressure water stream is programmed to travel over the cutting edge of the diamond steel edging tool while the diamond steel edging tool is rotated by the motor.

8. A method of sharpening a diamond cutting tool, the method comprising:

providing a diamond cutting tool having a dull cutting edge;

providing a source of high pressure water, the high pressure water capable of cutting steel; and

providing a sharpening jig for positioning and holding the cutting blade substantially perpendicular to the high pressure water;

rotating the diamond cutting tool whereas a cutting edge of the diamond cutting tool passes beneath the high pressure water and the dull cutting edge is cut sharp by the high pressure water.

9. The method of claim 8, wherein the cutting blade is a diamond steel circular blade and the sharpening jig comprises:

a base platform;

a clamp for holding the base platform to a work table of the source of high pressure water; and

a hub for holding the diamond steel circular blade perpendicular to the high pressure water, the hub enabling the rotating of the diamond steel circular blade.

10. The method of claim 9, further comprising a standoff affixed to the base platform between the hub and the high pressure water, the standoff supporting a bottom surface of the diamond steel circular blade.

11. The method of claim 8, wherein the cutting blade is a diamond steel hole cutting bit and the sharpening jig comprises:

a base platform;

a clamp for holding the base platform to a work table of the source of high pressure water;

a riser affixed to the platform and rising above the platform;

a threaded shaft rotatably interfaced with the riser for holding the diamond steel hole cutting bit perpendicular to the high pressure water; and

a means for rotating the threaded shaft, thereby rotating the diamond steel hole cutting bit beneath the high pressure water.

12. The method of claim 8, wherein the cutting blade is a diamond steel edging tool and the sharpening jig comprises:

a base platform;

a clamp for holding the base platform to a work table of the source of high pressure water;

a motor affixed to the base platform, the motor having a shaft;

a chuck for holding the diamond steel edging tool perpendicular to the high pressure water, the motor rotating the diamond steel edging tool.

13. The method of claim 12, further comprising a bearing, the bearing affixed to the base platform between the chuck and the motor, the shaft passing through the bearing whereas the bearing supports the shaft.

14. The method of claim 12, wherein the source of high pressure water is programmed to travel over the cutting edge of the diamond steel edging tool while the diamond steel edging tool is rotated by the motor.

15. An apparatus for sharpening a cutting blade, the apparatus comprising:

a source of a high pressure water stream, the high pressure water stream capable of cutting steel; and

a means for positioning and holding the cutting blade substantially perpendicular to the high pressure water stream, the means for positioning and holding the cutting blade perpendicular having a means for moving the cutting blade so that a cutting edge of the cutting blade predictably passes beneath the high pressure water stream.

16. The apparatus for sharpening a cutting blade of claim 15, wherein the cutting blade is a diamond steel circular blade and the means for positioning and holding the cutting blade perpendicular comprises:

a base platform;

a means for holding the base platform to a work table of the source of high pressure water stream; and

a means for holding the diamond steel circular blade perpendicular to the high pressure water stream, the means for holding enabling rotation of the diamond steel circular blade.

17. The apparatus for sharpening a cutting blade of claim 16, further comprising a standoff affixed to the base platform between the means for holding and the high pressure water stream, the standoff supporting a bottom edge of the diamond steel circular blade.

18. The apparatus for sharpening a cutting blade of claim 15, wherein the cutting blade is a diamond steel hole cutting bit and the means for positioning and holding the cutting blade substantially perpendicular comprises:

a base platform;

a means for holding the base platform to a work table of the source of high pressure water stream;

a riser affixed to the platform and rising above the platform;

a means for holding the diamond steel hole cutting tool, the means for holding rotatably interfaced with the riser thereby holding the diamond steel hole cutting bit perpendicular to the high pressure water stream; and

a means for rotating the a means for holding, permitting rotation of the diamond steel hole cutting bit beneath the high pressure water stream.

19. The apparatus for sharpening a cutting blade of claim 15, wherein the cutting blade is a diamond steel edging tool and the means for positioning and holding the cutting blade perpendicular comprises:

a base platform;

a means for holding the base platform to a work table of the source of high pressure water stream;

a means for rotating the diamond steel edging tool affixed to the base platform;

a means for holding the diamond steel edging tool interfaced to the means for rotating, the means for holding maintaining the diamond steel edging tool substantially perpendicular to the high pressure water stream, the means for rotating adapted to rotate the diamond steel edging tool.

20. The apparatus for sharpening a cutting blade of claim 19, wherein the source of high pressure water stream is programmed to travel over a cutting edge of the diamond steel edging tool while the diamond steel edging tool is rotated by the means for rotating.