The invention relates generally to hole drilling bits that are used to drill holes in sheet metal and other sheet materials. More specifically, the invention relates to a stepped multiple hole size drill bit, which is commonly known as a unibit or step drill. Unibits are relatively more expensive than single size twist drills and tend to be used frequently because of their versatility of being capable of drilling a variety of hole sizes. This frequent use also causes them to have a relatively short life. Further, unibits are typically not re-sharpened when worn because of the level of effort and expense to sharpen their many cutting facets.
One object of the present invention is to provide a unibit that can economically be resharpened by means of one or more easily replaceable blades.
Accordingly, a unibit with a replacement blade of the invention provides economical refreshing of the many cutting facets of a unibit with a unibit body and replacement blade that is releasably secured to the unibit body by a blade lock without a complicated mechanism. In one preferred embodiment of the invention, a single replacement blade having cutting edges on one or both opposite side edges is secured in a slot in a conical head of a body then are threaded by screws that extend through the body on one side of the slot, then through an opening in the replacement blade, and into the second side of the body the blade can be provided with or without an integral tip drill. The conical head can have straight or stepped sides. In another embodiment of the invention, one or more replacement blades having cutting edges on one side are locked in blade retaining recesses formed in the conical head of the unibit body. The blade lock can be an eccentric cam member that rotates into and out of locking engagement with the blade. In other embodiments of the invention, other types of novel blade locks are employed to lock the replacement blade in place. Another aspect of the invention provides a replaceable tip drill and a fastener that urges the tip drill into a seated position in the unibit body. The unibit of the invention may be provided with one or more replaceable blades.
These and other features or benefits of the invention will be recognized from this specification, including the claims and the drawing figures, by one having ordinary skill in the art and by those who practice the invention.
a is an enlarged fragmentary view of an edge thereof, showing an undercut at a junction between successive steps of a body thereof,
With general reference to the drawing figures, a first embodiment of a unibit with a replacement blade according to the invention 20 has at least a body 22, a replacement blade 24 (sometimes referred to as a replaceable blade), and a blade lock 26. The body is a body of rotation about an axis “A” and has two opposing ends 27 and 29 (
The shaft 28 is adapted to be secured into a rotating machine, such as a drill or the like (not shown). For example, the unibit 20 may be used with one-quarter inch, one half inch or other sizes of drills and the like. Thus, the shaft may be sized accordingly and in consideration of torque loading on the head 30, as is understood by one having ordinary skill in the art. The body 22 may be made of any appropriate cutting tool holding or foundation material, such as 4140 or 6150 steel, with 4140 steel being less hard and generally less expensive. Other types of steel or alloys will work. Unlike conventionally known unibits, which have a cutting edge integral with their body, the cutting edge of the unibit according to the invention is incorporated in a separate replacement blade. Thus, the body does not need to be formed of the same hardened cutting tool material as the blades and their cutting edges. This can reduce the cost of the tool significantly.
In the first embodiment, a blade receiving recess 40 is formed in each side of the head 30 and releasably receives a corresponding replacement blade 24. As shown in the drawings, the blade receiving recess is a generally V-shaped sectional void in the head 30 that resembles a quarter-section-like portion from the head. This is not a true quarter-section, however, in that the sides or walls 42 and 48 of the section are not aligned (coplanar) with the axis of rotation “A.” Rather, as shown in the end view of the
The replacement blade 24 is a generally triangular shaped plate member that is constructed of a suitably hard material, such as 6264 tool steel, for example. In the first embodiment, the blade has two long legs 44 and 45 and a short leg 47. One of the long legs 44 forms an inclined outer edge of the blade. This leg has a stepped cutting edge 46 that is defined by a series of flats 50 and ramps 52. In use, the head and blade will be rotated and the blade cutting edge will be along a leading face or surface 54 of the blade, relative to the direction of rotation.
The flats 50 are generally parallel with the reference axis “A” when the blade 24 is installed in the head 30, and are spaced a progressively increasing distance from the axis. Again, as with the stepped configuration of the head, the ramps 52 of the replacement blade extend between adjacent flats. The flats 50 and ramps 52 of the blade correspond to the steps 32 and ramps 34 of the head but extend slightly radially outward from the head 30. Thus, the cutting edge is exposed to do its job of cutting, while the head is a foundation for the blade and holds and positions the blade.
The blade lock 26 releasably secures the blade 24 in the receiving recess 40 and is configured in the first embodiment of the invention as an eccentric cam 59 rotatably mounted in the blade receiving recess 40 of the head 30. The blade lock 26 has an eccentric cam head 60 on a pivot shaft 62. The shaft extends into a corresponding hole in the head. Preferably, the shaft and the hole are provided with cooperating screw threads that engage in forced fit. Thus, disengagement or removal of the blade lock from the head in use is resisted by the force fit engagement of the shaft with the head and their screw threading.
Another feature of the first embodiment of the invention is that an inner end 63 of the blade receiving recess 40 in the head 30 of the unibit is curved outwardly. This curved end directs metal shavings radially outwardly from the tool and prevents shavings from collecting in the recess.
In a second embodiment of the invention, shown in
In a third embodiment of the invention, shown in
As an alternative to the use of a cam plate, the replacement blade itself 85 can be formed with an inclined side 87, as shown in blade lock 26′″ in
In a fifth embodiment of the invention, shown for exemplary purposes in
Another feature of the previous embodiments of the invention is a replaceable tip drill 64 that is releasably mounted in the tip of the unibit. The tip drill 64 may be provided either in combination with a unibit having a replacement blade feature, or in a unibit having a fixed, non-replacement blade. Tip drill 64 includes a shaft 66 that is securely and releasably received in a cooperating shaft receptacle 68 in the tip 31 of the unibit head 30. A set screw 70 or the like may be used to secure the tip drill to the unibit head. Other means for non-rotatably securing the tip drill in the head can be employed, including a mating non-circular (e.g., square) shaft and receptacle. The tip drill is formed of a cutting tool material, such as 6240 steel. The tip drill has a sharpened drill point 80 for starting a drill hole. Desirably, the tip drill also has at least one drill step comprising a ramp 82 and a flat 84 at an increased diameter that mates with the smallest diameter flats and ramps at the top of the body. It should be noted that a tip drill is not necessarily employed in every case. In some instances, such as when the bit is employed in sheet material having a pre-formed hole, the bit might not employ a tip drill at all.
The unibit 20 has at least one replacement blade according to the inventive concept. As shown in
A sixth embodiment of the present invention is shown in
The primary difference between the drill in
The screw thus tightens against the sides of the blade as it is advanced inwardly into the tapered screw hole. Another distinctive feature of the embodiment of
In order to provide an even more secure attachment of the replacement blade to the body of the unibit, the recess in which the blade of
The blade formed in the foregoing manner provides a more secure attachment for the replacement blade than that described in the first six embodiments. This embodiment may therefore be preferred for at least some applications where one of the first six embodiments is used.
A seventh embodiment 200 of the present invention is shown in
Shaft 208 includes flattened portions 216 spaced around the periphery of the shaft for non-rotatably mounting the shaft in a driver chuck.
The head 210 of the body is similar to the previous embodiment except that a small undercut portion 217 is formed between the adjacent steps and ramps of each step in the drill, as shown in
Replacement blade 204 is constructed in a manner similar to replacement blade 104 of
Another feature of replacement blade 204 is that the blade includes a groove 226 adjacent and parallel to the leading edge of the blade. This groove improves the operation of the blade.
The replacement blade 204 is held in position by means of clamping screw 228, shown in
The screw fits in a hole 239 having a tapered opening that mates with tapered collar 232. When the screw first enters the hole, the screw threads permit some sideways movement of the screw in the hole but as the screw advances further into the hole, the hole draws the screw into more fixed axial alignment with the hole. When the tapered screw collar engages the tapered opening in the hole, the band on the screw is brought tightly into holding engagement with the side of the blade. Thus, an out of round or cam type of screw connection is not required in this embodiment. To further improve the blade holding power of the screw, the hole can be at a slight angle, so that the collar on the screw is brought into increasingly tight contact with the side of the blade as the screw is advanced into the hole.
Another feature of this embodiment is the tip drill 240 that fits in an opening 242 in the end of the drill. Tip drill 240 has a shank 244, which has an inclined locking surface 246 thereon. A set screw 248 extends at an angle through a threaded hole in the body, such that an end of the set screw bears against the inclined locking surface and urges the shank of the tip drill axially inwardly into the opening in the drill body so as to tighten the engagement of the tip drill in the drill body as the set screw is tightened. The tip drill has a cutting surface and step on the outer end 250 thereof that mates with the steps of the drill formed along the head of the drill body and the outer end of the replacement blade.
In operation, step drill 200 operates in the same manner as the previous embodiments.
The eighth embodiment 300 of the present invention is one of the preferred embodiments, and is shown in
Shaft 308 includes flattened portions 316 spaced around the periphery of the shaft for non-rotatably mounting the shaft in a driver chuck. The unibit body 302 can include an enlarged rim 312 at a base 314 of the conical head 310 to prevent the drill from passing all the way through an opening in sheet material. The enlarged rim is optional and may not be employed in all circumstances.
Head 310 has an axially extending slot 355 therein that extends laterally all the way through the cone substantially from the tip to the base of the head and has open sides at the inclined surfaces on both sides of the head. The head on both sides of the slot forms spaced blade support members 354, which are connected to one another and to the shaft 308 at the base 314. Each blade support member is generally triangular in shape, having two long legs 356 and one short leg 358, and the blade support members are positioned so that the replacement blade can be slid into the slot 355 between the blade support members. The long legs 356 of each blade support member 354 are curved outwardly where the blade support member attaches to the base. This curved end 357 directs metal shavings radially outwardly from the tool. Where the long legs of each prong join at the tip end 307, the prong tips 360 may be blunted to ensure that a tip drill 306 on the blade extends beyond the head.
The replacement blade 304 is a generally triangular shaped plate member that is constructed of a suitably hard material, such as 6264 tool steel, for example. In the eighth embodiment, the blade 304 can include an integral tip drill 306 at a tip end 309 of the blade and a base 314 that is positioned adjacent the shaft 308. The blade 304 has two long legs 318 and a short leg 320. The two long legs 318 join at the tip drill 306, which is formed integrally with the blade when a tip drill is desired. There are some instances where a tip drill is not desired, so the blade also can be formed without a tip drill 306. In such a case, the blade ends at blunt end 309 as shown in phantom in
The blade 304 includes two aligned blade holes 344 that are generally positioned along the axis of the blade and the blade holder body when the blade 304 is installed in the head 310. The blade holes 344 align with the head holes 342 when the blade is installed in the head. The base or short leg 320 of the blade 304 includes a slot 346 that is generally along the axis “A” when the blade is installed in the head. A pin 348 extends through and is wedged or otherwise secured in hole 350 that extends through the conical head and the slot in the head of the drill body to provide proper positioning of the replacement blade. The slot also makes it easier to replace a blade simply by removing screws 330 and sliding the blade 304 out of the head 310.
The flats 324 are generally parallel with the reference axis “A” when the blade 304 is installed in the head 310, and are spaced a progressively increasing distance from the axis. The ramps 325 of the replacement blade extend between adjacent flats. The tip drill 306, flats 324 and ramps 325 of the blade extend outward from the head 310. Thus, the cutting edges are exposed to do their job of cutting, while the head is a foundation for the blade and holds and positions the blade.
The replacement blade 304 is held in position by means of clamping screws 330 (similar to
The screws 330 fit in holes 342. The screws 330 fit through the holes 342 in the near side of the head, extend through blade holes 344 in the blade 304, and then are threaded into threaded holes 342 in the opposite side of the head.
In operation, step drill 300, which is one of the preferred embodiments, operates in the substantially the same manner as the previous embodiments but provides simplified construction, an integral tip drill (when desired) and secured mounting.
One having ordinary skill in the art and those who practice the invention will understand that various modifications and improvements may be made without departing from the disclosed inventive concept. Various relational terms, including left, right, front, back, top, and bottom, for example, are used in the detailed description of the invention and in the claims only to convey relative positioning of various elements of the claimed invention and are not otherwise used to limit the scope of the invention.
This is a continuation-in-part application of co-pending U.S. patent application Ser. No. 11/430,458, entitled Unibit With Replacement Blade and filed on May 9, 2006, by Scott C. Seeley, now co-pending, the disclosure of which is incorporated here by reference.
Number | Date | Country | |
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Parent | 11430458 | May 2006 | US |
Child | 11842424 | Aug 2007 | US |