Cutting tools such as knives are used in a variety of applications to cut or otherwise remove material from a workpiece. A cutting tool often has one or more laterally extending, straight or curvilinear cutting edges along which pressure is applied to make a cut. The cutting edge is often defined along the intersection of opposing surfaces that intersect along a line that lies along the cutting edge.
Cutting tools can become dull over time after extended use, and thus it can be desirable to subject a dulled cutting tool to a sharpening operation to restore the cutting edge to a greater level of sharpness. A variety of sharpening systems are known in the art, including but not limited to grinding wheels, whet stones, abrasive cloths, abrasive belts and sharpening steels.
Various embodiments of the present disclosure are generally directed to an apparatus and method for sharpening a cutting tool, such as but not limited to a kitchen knife.
In accordance with some embodiments, a flexible abrasive disk is adapted for rotation about a central axis at a selected rotational velocity. Centripetal forces imparted to the disk during rotation urge the disk to a neutral position in which an outer peripheral portion of the disk is extended toward a selected plane. A housing adjacent the flexible disk has a guide slot with a guide surface at a selected bevel angle with respect to the selected plane. The guide surface is adapted to facilitate presentation of a cutting tool in contacting engagement against the disk. The cutting tool is presented at the selected bevel angle to induce curvilinear displacement of the flexible disk during sharpening of a cutting edge that extends along a side of the cutting tool.
These and other features and advantages of various embodiments can be understood with a review of the following detailed description and the accompanying drawings.
The present disclosure is generally directed to an apparatus and method for sharpening a cutting tool. As explained below, in some embodiments the apparatus comprises at least one flexible abrasive disc adapted for rotation at a selected rotational velocity about a central axis. Centripetal force imparted to the disk urges the disk to a neutral position in which a distal circumferential perimeter of the disc is urged toward alignment with a selected plane orthogonal to the central axis.
A housing encloses the disc and has a guide slot with a guide surface aligned along selected bevel and skew angles. The guide surface is adapted to facilitate presentation of a side of a blade of the cutting tool in contacting engagement against the disk at said bevel and skew angles to induce curvilinear displacement of the flexible disc out of the neutral position during a sharpening operation. The innermost perimeter of the disc remains at a fixed position while a portion of the outermost perimeter of the disc is curvilinearly displaced.
Multi-stage sharpening can be performed with different discs having different characteristics such as different levels of abrasiveness and/or flexibility. This can provide a multi-faceted convex grinding geometry to the cutting tool. The sharpening apparatus may be characterized as a hand-held, portable and electrically powered sharpener.
These and other features of various embodiments can be understood beginning with a review of
A sharpening zone is denoted at 106, which generally represents an area against which a cutting tool may be applied to carry out a sharpening operation thereon as the disk is rotated in direction 108. Other locations on the disk surface for the sharpening zone, and other directions of rotation, can be used.
The term “sharpening” and the like will describe an operation carried out to increase a sharpness level of a cutting edge of a tool to improve efficiency of a cutting operation in which a workpiece is penetrated, eroded and/or divided by the tool. Such sharpening may include the removal of material from the tool and/or the alignment of existing material along the cutting edge of the tool. The term “grinding” is encompassed within the meaning of sharpening but is generally directed to the removal of significant amounts of material from the tool. The term “honing” is also encompassed with the meaning of sharpening but is generally directed to the alignment of material without significant amounts of material removal.
The shaft 120 has a diameter sized to closely fit within the central aperture of the disk, and the disk is secured to the shaft via a hub 122. Other disk attachment arrangements can be used, including multiple spaced apart discs and multiple hubs, clamping systems that clamp the disc with a smaller (or no) central aperture extending through the disk, etc.
The attachment mechanism, in this case the hub 122, maintains the innermost periphery of the disk 100 in a fixed position along the shaft 120 (e.g., a selected distance from the motor 116) both while at rest and during rotation.
The flexible nature of the disk 100 may allow the disk to deform under the weight thereof into a non-planar orientation while the disk is at rest, as depicted in
Presentation of a cutting tool for sharpening against the disk 100 during rotation induces localized curvilinear displacement of the disk out of the neutral position. The type and extent of curvilinear displacement can vary depending on a variety of factors including presentation angle, surface pressure, angular and radial location of the sharpening zone (106,
As further shown in
A guide surface (not separately shown in
The bevel angle θ represents a rotation of the knife along a length thereof so that the cutting edge 138 is canted toward the disk abrasive surface during sharpening. Suitable bevel angles may include angles in the range of about 20-25 degrees, and angles greater than or less than this range. In some cases, bevel angles of 45 degrees or greater may be used.
The skew angle α represents a rotation of the knife about a center point passing through the center of gravity of the knife, so that the tip of the blade 136 is pointed away slightly from the plane of the disk 100. Suitable skew angles may include angles in the range of about 5-10 degrees, and other angles greater or less than this range.
Rotation of the convex flexible disk 100 induces centripetal forces 124 which place the disk 100 into a neutral position, illustrated in
The respective first and second bevel surfaces are formed using a two-stage sharpening process. A first stage is represented in
A first bevel angle θ1, such as about 20 degrees, is used to present the blade 136 against the first disk surface. A corresponding first skew angle can also be used, but such is not depicted in
The second-stage processing of
In some embodiments, only a single faceted sharpening operation may be applied to the knife so that the cutting edge takes the general form in
Multi-stage sharpening arrangements can be used so that respective grinding (material removal) and honing (material alignment) operations are carried out upon the tool at different stages. It will be appreciated that the extent to which a given disk grinds or hones a tool depends on a number of factors including presentation geometry, disk stiffness, disk abrasiveness, surface pressure, tool geometry, tool composition, etc.
A housing 172 encloses the disks 100A-C as well as other components such as a motor 116A and a battery power pack 174. The battery power pack may use rechargeable batteries which can be recharged using a separate power plug (not shown) that can be plugged in to supply power from a domestic electric grid. A user activated switch 176 initiates operation of the motor and rotation of the disks. A removable cover 178 provides access to the interior of the housing 172.
Three respective sharpening stages are denoted at 180A-C. Each stage includes one of the disks 100A-C as well as a pair of opposing guide slots 182A-B with associated guide surfaces 184A-B to provide each stage with associated bevel and skew angles.
To sharpen a cutting tool such as the knife 130, the user sequentially subjects the knife 130 to each of the sharpening stages 180A-C in turn. In some sharpening sequences, less than all of the stages may be used.
Beginning with stage 180A, the user grasps the knife by the handle 140, inserts the blade 136 into the first guide slot 182A so as to contactingly engage the associated guide surface 184A, and draws the knife back against the associated disk 100A while maintaining the side of the blade against the guide surface. The user may repeat this a number of times, such as 3-5 times. This will sharpen a first side of the blade 136 to form a first curvilinear bevel, as generally depicted in
The user next repeats the process using the second guide slot 182B of the first stage 180A. The knife may be inserted from the same side as with guide slot 182A, or may be inserted from the opposing side of the housing 172. As before, the knife blade is contactingly aligned against the guide surface 184B and drawn back across the disk 100A. It will be noted that the knife is sharpened against opposing sides of the same disk 100A during the first stage sharpening.
At the conclusion of the first stage sharpening, the blade will generally have opposing elongated curvilinear bevels as generally depicted in
The sharpener 200 includes a housing 202 which encloses a motor 116B and a power pack 174A. A user activated switch 176A activates the motor to rotate disks 100D-G. The disks in
The housing 200 includes first and second sharpening stages 210A-210B. Each stage has a pair of guide slots 212A-B and with associated guide surfaces (not separately designated). As before, a cutting tool such as the knife 130 can be sharpened against the associated disks by inserting the tool into the respective slots of the respective stages in turn.
A housing 224 supports the disks with an adjustable height support member 226 and includes first and second stage sharpening ports 228A-B with respective guide slots and associated guide surfaces (not separately designated). A suitable coupling mechanism is used to couple a shaft 120A to the tool to enable a motor of the tool 116C to rotate the discs 100H, 1001 at a selected rotational velocity. The knife 130 or other tool is sharpened using the respective stages 228A-B as described above.
The blade 136 is at selected bevel and skew angles relative to the disks as before, but these angles are accommodated by displacement of the respective disks within a housing (not separately shown). An advantage of the arrangement of
As variously embodied, the sharpener of the present disclosure may be characterized without limitation as including elements such as a flexible disk coupled to a motor driven shaft and a guide surface which orients a blade of a cutting tool in a desired position as the blade is presented against the flexible, rotating disk. The disk and guide are configured in a manner such that as the blade is placed and advanced along the guide surface, the blade contacts an abrasive surface of the disk to deform the disk out of a neutral position otherwise occupied by the disk during rotation.
The disk and the associated support structure can be constructed such that the resilience of the disk and/or the forces of rotation acting upon the disk tend to maintain the disk in the neutral position. The local deformation of the disk induced by contacting engagement with the blade provides a controlled sharpening geometry, facilitating grinding and/or honing of the blade. The guide surface is configured such that the blade is presented to the disk at a desired bevel angle and deforms the disk to the desired displacement. The guide may be further configured to skew the blade at a second angle so that the blade only contacts the disk on a selected side, such as on the side of the facing surface of the disk nearest the user.
The disclosed sharpener as embodied herein may provide a number of benefits. It has been found that sharpeners configured as embodied herein can achieve relatively high levels of operational efficiency as compared to current generation sharpeners, and can sharpen standard sized blades using as little as around six watts (6W) of electrical power. The flexible and thin nature of the disk(s) means that power is not unnecessarily wasted turning heavy wheels, larger armatures or extra gears and bearings.
The sharpeners configured as embodied herein have been found to safely sharpen at speeds higher than current generation sharpeners. In many cases, no cooling mechanisms are required for speeds up to around 5,000 surface feet/minute (SFM). By contrast, many current generation sharpeners tend to require cooling at speeds or around 2,000 SFM or less.
Because of the flexible nature of the disks, each disk type can be individually tailored to provide its own optimal surface pressures, neutral position characteristics and sharpening geometries versus abrasiveness. No separate springs, bias members or other adjustment mechanisms are required.
Many different sharpening applications can be accommodated simply by changing disk(s). Disks can be configured to sharpen highly curved blades (bellies, hooks, recurves, etc.) blades with straight profiles (e.g., scissors, cleavers, etc.), blades with serrations, etc.
The high efficiency design of the sharpeners as embodied herein provide a compact, low power consumption and portable sharpening solution. Multiple stages of sharpening can be offered without the need for multiple guides, spring/disk combinations, etc. Because of their collapsible nature, extra and alternate disks can be easily stored in a small compartment within the sharpener housing.
Because the disk flexibility largely controls the applied surface pressure, a significant amount of compliance can be provided. The angle guide positions the blade relative to the disk while the disk flexes to conform to the blade profile. This provides a fault tolerant and highly repeatable sharpening operation that requires relatively little skill by the user.
Various additional alternatives and configurations will readily occur to the skilled artisan after reviewing the present disclosure, and all such alternatives and configurations are encompassed by the present application and the following claims.
This application makes a claim of domestic priority to U.S. Provisional Application No. 61/653,870 filed May 31, 2012. The contents of this provisional application are hereby incorporated by reference.
Number | Date | Country | |
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61653870 | May 2012 | US |