Chainsaw

Historical osteotome, a medical bone chainsaw

The origin of chain saws in surgery is debated. A "flexible saw", consisting of a fine serrated link chain held between two wooden handles, was pioneered in the late 18th century (c. 1783–1785) by two Scottish doctors, John Aitken and James Jeffray, for symphysiotomy and excision of diseased bone, respectively.[2] It was illustrated in the second edition of Aitken's Principles of Midwifery, or Puerperal Medicine (1785) in the context of a pelviotomy.[3] In 1806, Jeffray published Cases of the Excision of Carious Joints, which collected a paper previously published by H. Park in 1782 and a translation of an 1803 paper by French physician P. F. Moreau, with additional observations by Park and Jeffray.[4] In it, Jeffray reported having conceived the idea of a saw "with joints like the chain of a watch" independently very soon after Park's original 1782 publication, but that he was not able to have it produced until 1790, after which it was used in the anatomy lab and occasionally lent out to surgeons. Park and Moreau described successful excision of diseased joints, particularly the knee and elbow, and Jeffray explained that the chain saw would allow a smaller wound and protect the adjacent muscles, nerves, and veins.[5] While symphysiotomy had too many complications for most obstetricians, Jeffray's ideas about the excision of the ends of bones became more accepted, especially after the widespread adoption of anaesthetics. For much of the 19th century the chain saw was a useful surgical instrument, but it was superseded in 1894 by the Gigli twisted-wire saw, which was substantially cheaper to manufacture, and gave a quicker, narrower cut, without risk of breaking and being entrapped in the bone.[6]

A precursor of the chainsaw familiar today in the timber industry was another medical instrument developed around 1830, by German orthopaedist Bernhard Heine. This instrument, the osteotome, had links of a chain carrying small cutting teeth with the edges set at an angle; the chain was moved around a guiding blade by turning the handle of a sprocket wheel. As the name implies, this was used to cut bone.[7]

Typical of the earliest chainsaws, this gasoline-powered Dolmar saw was operated by two men

Electric chainsaw

A cordless 4 inch chainsaw commonly known as a "Ripper"

One of the earliest patents for an "endless chain saw" comprising a chain of links carrying saw teeth was granted to Frederick L. Magaw of Flatlands, New York in 1883, apparently for the purpose of producing boards by stretching the chain between grooved drums.[8][9] A later patent incorporating a guide frame was granted to Samuel J. Bens of San Francisco on January 17, 1905, his intent being to fell giant redwoods.[10] The first portable chainsaw was developed and patented in 1918 by Canadian millwright James Shand.[11][12] After he allowed his rights to lapse in 1930, his invention was further developed by what became the German company Festo in 1933. The company, now operating as Festool, produces portable power tools. Other important contributors to the modern chainsaw are Joseph Buford Cox and Andreas Stihl; the latter patented and developed an electric chainsaw for use on bucking sites in 1926[13] and a gasoline-powered chainsaw in 1929, and founded a company to mass-produce them. In 1927, Emil Lerp, the founder of Dolmar, developed the world's first gasoline-powered chainsaw and mass-produced them.

World War II interrupted the supply of German chain saws to North America, so new manufacturers sprang up, including Industrial Engineering Ltd (IEL) in 1939, the forerunner of Pioneer Saws Ltd and part of Outboard Marine Corporation, the oldest manufacturer of chainsaws in North America.[14]

In 1944, Claude Poulan was supervising German prisoners cutting pulpwood in East Texas. Poulan utilized an old truck fender and fashioned it into a curved piece utilized to guide the chain. The "bow guide" now allowed the chainsaw to be utilized by a single operator.

McCulloch in North America started to produce chainsaws in 1948. The early models were heavy, two-person devices with long bars. Often, chainsaws were so heavy that they had wheels like dragsaws. Other outfits used driven lines from a wheeled power unit to drive the cutting bar.

After World War II, improvements in aluminum and engine design lightened chainsaws to the point where one person could carry them. In some areas, the chainsaw and skidder crews have been replaced by the feller buncher and harvester.

Chainsaws have almost entirely replaced simple man-powered saws in forestry. They are made in many sizes, from small electric saws intended for home and garden use, to large "lumberjack" saws. Members of military engineer units are trained to use chainsaws, as are firefighters to fight forest fires and to ventilate structure fires.

Three main types of chainsaw sharpeners are used: handheld file, electric chainsaw, and bar-mounted.

The first electric chainsaw was invented by Stihl in 1926.[15] Corded chainsaws became available for sale to the public from the 1960s onwards,[16] but these were never as successful commercially as the older gas-powered type due to limited range, dependency upon the presence of an electrical socket, plus the health and safety risk of the blade's proximity to the cable.[17]

For most of the early 21st century petrol driven chainsaws remained the most common type, but they faced competition from cordless lithium battery powered chainsaws from the late 2010s onwards.[18] Although most cordless chainsaws are small and suitable only for hedge trimming and tree surgery,[19] Husqvarna and Stihl began manufacturing full size chainsaws for cutting logs during the early 2020s.[20] Battery powered chainsaws should eventually see increased market share in California due to state restrictions planned to take effect in 2024 on gas powered gardening equipment.[21][22]

Chainsaw engines are traditionally either a two-stroke gasoline (petrol) internal combustion engine (usually with a cylinder volume of 30 to 120 cm³) or an electric motor driven by a battery or electric power cord. In a petrol chainsaw, fuel is generally supplied to the engine by a carburetor at the intake.

To allow use in any orientation, modern gas chainsaws use a diaphragm carburetor, which draws fuel from the tank using the alternating pressure differential within the crankcase. Early engines used carburetors with gravity fed float chambers, which caused the engine to stall when tilted. The carburetor may need to be adjusted to maintain an appropriate idle speed and air-fuel ratio, such as when moving to a higher/lower altitude or as the air filter clogs. Carburetors are adjusted either by the operator or, in some saws, automatically by an electronic control unit.

To prevent vibration induced injury and reduce user fatigue, saws generally have an anti-vibration system to physically decouple the handles from the engine and bar.[23] This is achieved by constructing the saw in two pieces, connected by springs or rubber in the same way an automobile suspension isolates the chassis from the wheels and road.[24] In cold weather, carburetor icing can occur, so many saws have a vent between the cylinders and carburetor which may be opened to allow hot air to pass. Cold temperature can also contribute to vibration-induced injury,[25] and some saws have a small alternator connected to resistive heating elements in the handles and/or carburetor.

Centrifugal clutch

Sprocket

Typically, a centrifugal clutch and sprocket are used. The centrifugal clutch expands with increasing speed, engaging a drum. On this drum sits either a fixed sprocket or an exchangeable one. The clutch has three jobs: When the engine runs idle (typically 2500-2700 rpm) the chain does not move. When the clutch is engaged and the chain stops in the wood for another reason, it protects the engine. Most importantly, it protects the operator in case of a kickback. Here, the chain brake stops the drum, and the clutch releases immediately.

A guide bar, typically an elongated bar with a round end of wear-resistant alloy steel typically 40 to 90 cm (16 to 36 in) in length, is used. An edge slot guides the cutting chain. Specialized, loop-style bars, called bow bars, were also used at one time for bucking logs and clearing brush, although they are now rarely encountered due to increased hazards of operation.

All guide bars have some elements for operation:

The lower part of the chain runs in the gauge. Here, the lubrication oil is pulled by the chain to the nose. This is basically the thickness of the drive links.

• 0.063 in or 1.6 mm
• 0.058 in or 1.5 mm
• 0.050 in or 1.3 mm
• 0.043 in or 1.1 mm

The end of the saw power head has two oil holes, one on each side. These holes must match with the outlet of the oil pump. The pump sends the oil through the hole in the lower part of the gauge.

Saw bar producers provide a large variety of bars matching different saws.

Through this hole, grease is pumped, typically each tank filling to keep the nose sprocket well lubricated.

Here, one or two bolts from the saw run through. The clutch cover is put on top of the bar and it is secured through these bolts. The number of bolts is determined by the size of the saw.

Different bar types are available:

• Laminated bars consist of different layers to reduce the weight of the bar.
• Solid bars are solid steel, intended for professional use. They commonly have an exchangeable nose, since the sprocket at the bar nose wears out faster than the bar.
• Safety bars are laminated bars with a small sprocket at the nose. The small nose reduces the kickback effect. Such bars are used on consumer saws.

Usually, each segment in a chain (which is constructed from riveted metal sections similar to a bicycle chain, but without rollers) features small, sharp, cutting teeth. Each tooth takes the form of a folded tab of chromium-plated steel with a sharp angular or curved corner and two beveled cutting edges, one on the top plate and one on the side plate. Left-handed and right-handed teeth are alternated in the chain. Chains are made in varying pitch and gauge; the pitch of a chain is defined as half of the length spanned by any three consecutive rivets (e.g., 8 mm, 0.325 inch), while the gauge is the thickness of the drive link where it fits into the guide bar (e.g., 1.5 mm, 0.05 inch). The conventional "full complement" chain has one tooth for every two drive links. "Full skip" chain has one tooth for every three drive links. Built into each tooth is a depth gauge or "raker", which rides ahead of the tooth and limits the depth of cut, typically to around 0.5 mm (0.025"). Depth gauges are critical to safe chain operation. If left too high, they cause very slow cutting; if filed too low, the chain becomes more prone to kick back. Low depth gauges also cause the saw to vibrate excessively. Vibration is uncomfortable for the operator and is detrimental to the saw.

The tension of the cutting chain is adjusted so that it neither binds on nor comes loose from the guide bar. The tensioner for doing so is either operated by turning a screw or a manual wheel. The tensioner is either in a lateral position underneath the exhaust or integrated into the clutch cover.

Lateral tensioners have the advantage that the clutch cover is easier to mount, but the disadvantage that it is more difficult to reach nearby the bar. Tensioners through the clutch cover are easier to operate, but the clutch cover is more difficult to attach.

When turning the screw, a hook in a bar hole moves the bar either out (tensioning) or in, making the chain loose. Tension is right when it can be moved easily by hand and not hanging loose from the bar. When tensioning, hold the bar nose up and pull the bar nuts tight. Otherwise, the chain might derail.

The underside of each link features a small, metal finger called a "drive link", which locates the chain on the bar, helps to carry lubricating oil around the bar, and engages with the engine's drive sprocket inside the body of the saw. The engine drives the chain around the track by a centrifugal clutch, engaging the chain as engine speed increases under power, but allowing it to stop as the engine speed slows to idle speed.

Consistent improvement to overall chainsaw design, including adding safety features, has taken place over the years. These include chain-brake systems, better chain design, and lighter, more ergonomic saws, including fatigue-reducing antivibration systems.

As chainsaw carving has become more popular, manufacturers are making special short, narrow-tipped bars (called "quarter-tipped" "nickel-tipped", or "dime-tipped" bars, based on the size of their tips). Some chainsaws are built specifically for carving applications.[26] Echo sponsors a carving series.[27]

A chainsaw used to trim the 2016 U.S. Capitol Christmas tree

Today's chainsaws have multiple safety features to protect the operator. These include:

• Chain brake
  • A chain brake activator is located forward of the upper handle and is activated by a kickback event. When triggered, it tensions a band around the clutch drum, stopping the chain within milliseconds.
  • A chain catcher is located between the saw body and the clutch cover. In most cases, it resembles a hook made of aluminum. It is used to stop the chain when it derails from the bar and shortens the length of the chain. When derailing, the chain swings from underneath the saw towards the operator. This prevents the chain from hitting the operator, which hits the rear handle guard instead.
  • A rear handle guard protects the hand of the operator when the chain derails.
• Some chains have safety features as safety links as on micro chisel saws. These links keep the saw close to the gap between two cutting links and lift the chain when the space at the safety link is full with saw chips, which lifts the chain and lets it cut slower. Nonprofessional chains have less aggressive teeth, by having shallower depth gauges.

When fastened into a special guide frame, a chainsaw can be used as a portable sawmill to cut bulk wood into planks or boards. Such usage is called a chainsaw mill or Alaskan sawmill.

A water-cooled chainsaw cutting concrete

Special chainsaws can cut concrete, brick, and natural stone. These use similar chains to ordinary chainsaws, but with cutting edges embedded with diamond grit. They may use gasoline or hydraulic power, and the chain is lubricated with water, because of high friction and to remove stone dust. The machine is used in construction, for example, in cutting deep, square holes in walls or floors, in stone sculpture for removing large chunks of stone during pre-carving, by fire departments for gaining access to buildings, and in restoration of buildings and monuments for removing parts with minimal damage to the surrounding structure. More recently, concrete chainsaws with electric motors of 230 volts have also been developed.[39]

Because the material to be cut is not fibrous, much less kickback occurs. So, the most-used method of cutting is plunge-cutting, by pushing the tip of the blade into the material. With this method, square cuts as small as the blade width can be achieved. Pushback can occur if a block shifts when nearly cut through and pinches the blade, but overall, the machine is less dangerous than a wood-cutting chainsaw.