Selectively biased tool and methods of using the same

Abstract
A tool including a working portion with a working member, a side surface and an end surface. The working portion includes a passage passing through the side surface and the end surface. At least one seal is adapted to restrict fluid flow through the side surface and the end surface and at least partially defines a pressure chamber. The working member is adapted to be selectively pivotally positioned by selectively pressurizing the pressure chamber. The tool similarly enables unique methods of working workpieces.
Description




TECHNICAL FIELD OF THE INVENTION




The present invention is directed to an adjustable tool, and more particularly to a selectively biased tool and methods of using the same.




BACKGROUND OF THE INVENTION




A conventional gun reamer tool includes a cutting blade and one or more support members which are supported at intervals around the circumference of a rotary shaft (e.g., the reamer head). The shaft, along with the blade and the support members, rotate so that the physical interference between the rotating blade and the workpiece cause a hole to be either bored or reamed in the workpiece. During this machining operation, the rotating support members are positioned so that they support the inside surface of the hole being machined (e.g., either reamed or bored) by constraining radially directed motion of the blade relative to the workpiece.




In some conventional machining center rotating machine tools, lubricant is supplied to the vicinity of the cutting blade through the rotating shaft. An example is shown in U.S. Pat. No. 5,775,853 issued on Jul. 7, 1998, the disclosure of which is herein incorporated by reference.




This support and constraint supplied by the support members help to control the shape (e.g., cylindricity or circularity) of the hole, and help to maintain a constant alignment of the central axis of the hole along the length of the hole (in other words, the hole is straighter). For this reason, gun reamers are often used in applications where holes need to be precisely and accurately machined. Such precision applications may also be needed in the manufacture of automobile parts such as cylinder bores in engine blocks, connecting rod bores and piston wrist pin bores.




Gun reamers are also especially useful where the hole being cut is relatively long (such as the bore of a gun barrel), because the support members will remain in the proximity of the cutting blade, even when the blade has cut a long distance into the workpiece.




One potential shortcoming of conventional gun reamers is that they cannot be adjusted to cut holes of different sizes. Most conventional gun reamers are designed with support and blade members rigidly constrained to the reamer head so that the head can cut holes of just one predetermined radius. Another potential shortcoming of conventional gun reamers is that the blade and support members wear at different rates, which can cause seizure or variation in the diameter and/or circularity of the holes cut by the gun reamer.




In most machine tool operations, including boring and reaming, the friction between the tool and workpiece generates tremendous amounts of heat energy, which can reach temperatures of 2000° F. (1100° C.) and above. If left uncontrolled, such heat could severely damage (e.g., cracking or fracturing) the tool, thus reducing its tool life, making machine tool operations more dangerous and expensive, and reducing the quality and precision of the workmanship. In addition, heat generated friction can discolor the workpiece, and can damage or remove temper or heat treatments. It is commonly known in the industry that coolant can be introduced to the machining area, such as by spraying, to reduce friction between the tool and workpiece by providing coolant fluid between the cutting tool and the workpiece, and to help remove heat energy generated in machine tool operations.




Although coolant fluid can be supplied to the machining area, it is often difficult to insure that such fluid actually makes its way to the interstices between the tool and all of the workpiece surfaces being machined. Additionally, fluid can evaporate quickly due to the high temperatures involved in machining operations. Thus, larger volumes of coolant fluid must generally be continuously supplied to the machining area for the tool to operate effectively. This need to keep coolant fluid between the tool and wall of the bore hole becomes even more problematic in operations where coolant fluids cannot be introduced in close proximity to the machining areas while the tool is engaged with the interior surface of the workpiece.




During use, the work engaging surface of the tool (e.g., the cutting blade and/or support member) can also become loaded with particles or recently cut chips from the interior surface of the workpiece, which in turn, reduces the accuracy and effectiveness of the tool through deteriorating machining ability, and/or clogging of conventional coolant fluid supply openings. It is obviously preferred that the potential for this undesired loading of particles be reduced, and that any loaded particles be removed from the tool as quickly as possible. Typically, nozzle arrangements, such as an external cleaning jet, are provided independent of the tool, for injecting coolant fluid at increased velocities toward the work engaging surface and the work surfaces of the workpiece to wash away particles, to remove particles already loaded on the work surface, and to cool the tool and the workpiece. As mentioned before, it is often very difficult to insure that the fluid sprayed in this way actually reaches the most critical areas of the tool/workpiece interface.




Other attempts to deliver coolant fluid to the machining area have included air or other pneumatic carriers. As with externally applied liquid coolants, when pneumatic carriers are used, resulting turbulence can hinder the machining operations, and often fluid cannot infiltrate into the actual machining area. Previously, attempts to address these two requirements of cooling and cleaning the tool and workpiece have tended to reduce the accuracy and utility of the tool.




As can be seen, currently available tools have a number of shortcomings that can greatly reduce the accuracy of the tools, the tool's life, and its ability to use these tools with automatic tool changing systems. The current structures and assemblies provide a tool having working surfaces that cannot expand to accommodate varying and different uses and needs. Such assemblies can result in uneven machining, and reduces the assembly's usable life. A need currently exists in the machinery industry for a tool with a work engaging assembly having accurately controlled machining diameters so that holes of different sizes can be cut, so that tools cannot become oversized a result of excessive strokes of the tools, and so that the tool can expand in a radial direction uniformly and selectively.




SUMMARY OF THE INVENTION




It is an object of the present invention to provide a cutting tool that addresses and overcomes the above-mentioned shortcomings and problems in the machine tool industry.




It is another object of the present invention to provide a cutting tool with support members to support a workpiece, where the support member and/or a blade member are selectively biased.




It is another object of the present invention to provide a cutting tool whereby the relative position of the blade and the workpiece can be controlled by the selective control of the bias of the blade member and/or support member.




It is yet another object of the present invention to provide a cutting tool that has an increased tool life.




It is also an object of the present invention to provide a tool that eliminates the need for external coolant fluid jets for cleaning or removing loaded particles from the tool's machining surface during use, and routes fluid in close proximity to the work engaging surface to wash away recently cut particles.




It is yet another object of the present invention to provide a tool where the workload is reliably distributed over substantially the entire work engaging surface.




It is another object of the present invention to provide a tool for accurately and uniformly machining a workpiece.




It is further an object of the present invention to provide a tool that can be selectively adjusted during machine operations.




Yet another object of the present invention is to provide a tool that can compensate for material deformation in a workpiece.




It is still another object of the present invention to provide a tool in which coolant fluid delivery to the working area is not inhibited while the tool is engaged with a surface of the workpiece.




A further object of the present invention is to provide a tool that can compensate for wear and tear.




It is yet an object of the present invention to provide a tool that can be used with a quick change or automatic changeable tool system having a fluid pressure source.




Still another object of the present invention is to provide a tool that can be used to machine holes of different or varying diameters.




It is a further object of the present invention to provide a tool that continuously, selectively, and controllably delivers coolant fluid to the machining area despite the type of tool engagement.




Yet another object of the present invention is to provide a tool which self regulates itself for wear and tear on the abrasive.




Still a further object of the present invention is to provide a device where the work engaging surface can be uniformly varied in a radial direction by selectively applying fluid pressure.




A further object of the present invention is to provide a tool that dissipates thermal energy generated in the machining operations, and reduces thermal expansion of the tool.




Additional objects, advantages and other features of the invention will be set forth and will become apparent to those skilled in the art upon examination of the following, or may be learned with practice of the invention.




In some exemplary embodiments of the present invention, the support member and/or blade member of the cutting tool can be selectively biased by selecting the fluid pressure of a fluid which bears on the support member and/or blade member. For example, the tool may be constructed so that pressurized lubricating fluid, which is supplied near or in the vicinity of the cutting blade, bears on and biases both the blade member and the support member. As another exemplary alternative, the blade member and/or the support member may be selectively biased by air pressure and/or by one or more springs.




In some exemplary embodiments of the present invention, the tool is a reamer which has at least one support member and a blade member, such as a blade cartridge, biased by selectively pressurized fluid. It is an advantage of these exemplary reamer embodiments that the fluid pressure can be selected to compensate for wear of the blade, and also to compensate for the difference in wear between the blade and the support member.




In some exemplary embodiments of the present invention, the tool is a reamer where both the blade member and the support members are biased by selectively pressurized fluid. In these exemplary reamer embodiments, the fluid pressure can be selected to control the diameter of the hole so that a single reamer can ream holes of different diameters. Also, the fluid pressure can be selected to compensate for wear of the cutting blade. Also, the fluid pressure can be selectively controlled as the hole is being reamed to control the longitudinal profile of the hole, or to compensate for workpiece deformation which can occur as the hole is reamed.




In another exemplary embodiment, the tool includes a working portion with a working member, a side surface and an end surface. The working portion includes a passage passing through the side surface and the end surface. The tool further includes at least one seal adapted to restrict fluid flow through the side surface and the end surface and at least partially defining a pressure chamber. The working member is adapted to be selectively pivotally positioned to any of a variety of working positions in use by selectively pressurizing the pressure chamber.




Still another exemplary embodiment of the invention involves a method of removing material from a workpiece. With such method, a tool is provided including a working portion with a working member. Fluid pressure is provided to pivot the working member outwardly to at least one of a plurality of alternative use positions. The tool is then moved towards the workpiece such that the working member selectively removes material from the workpiece as the working member is applied to the workpiece. It will be understood that the tool can be moved before, during and/or after adjustment of the working member to the use position.




Still other objects of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described an exemplary embodiment of this invention, simply by way of illustration, of one of the best modes contemplated for carrying out this invention. As will be realized, the invention is capable of other different embodiments, and its several details are capable of modification in various aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature, and not as restrictive.











BRIEF DESCRIPTION OF THE DRAWINGS




The present invention as set forth in the detailed description will be more fully understood when viewed in connection with the drawings in which:





FIG. 1

shows a schematic elevational view of a machining center and tool of the present invention with through spindle coolant fluid communication between a tool of the present invention and a fluid supply;





FIG. 1A

is a cross-sectional view of a tool according to the present invention;





FIG. 2

is an end view of the tool of

FIG. 1

;





FIG. 3

is a partial cross-sectional view of an alternative embodiment of a tool according to the present;





FIG. 4

is an end view of the tool of

FIG. 3

;





FIG. 5

is a partial cross-sectional view of an alternative embodiment of a tool according to the present invention;





FIG. 5A

is a partial cross-sectional view of another alternative embodiment of a tool according to the present invention;





FIG. 5B

is a partial cross-sectional view of yet another alternative embodiment of a tool according to the present invention;





FIG. 6

is an end view of the tool of

FIG. 5

;





FIG. 7

is a cross-sectional view of another alternative embodiment of a tool according to the present invention;





FIG. 8

is a side view of yet another embodiment of a tool according to the present invention;





FIG. 9

shows the tool boring a hole in a workpiece;





FIG. 10

shows the tool boring a hole in a workpiece;





FIG. 11

shows the tool boring a hole in a workpiece;





FIG. 12

shows an embodiment of a tool with strain relief;





FIG. 13

shows a portion of a blade of the tool which acts as a support member due to its wide cylindrical margin;





FIG. 14

shows an exploded prospective view of another alternative embodiment of the tool according to the present invention;





FIG. 15

shows an elevational view of the tool of

FIG. 14

;





FIG. 16

shows a side elevational view of a blade cartridge used with the present invention;





FIG. 17

shows a sectional view taken along line


17





17


of the tool of

FIG. 15

;





FIG. 18

is a partial view of a tool with a jacket in accordance with another embodiment of the present invention;





FIG. 19

is a partial sectional view taken along line


19





19


of the tool of

FIG. 18

;





FIG. 20

is a partial exploded perspective view of the tool of

FIG. 18

;





FIG. 21

is a partial view of a tool with an elongated end seal in accordance with yet another embodiment of the present invention;





FIG. 22

is a sectional view taken along line


22





22


of the tool of

FIG. 21

;





FIG. 23

is an exploded perspective view of the tool of

FIG. 21

;





FIG. 24

is a rear view of an end cap in accordance with the present invention;





FIG. 25

is a schematic illustration of a portion of a method of boring as the tool is inserted in accordance with the present invention;





FIG. 26A

is a schematic illustration of a portion of a method of removing the tool without contacting the interior service of the bore in accordance with the present invention;





FIG. 26B

is a schematic illustration of a portion of a method of boring while removing the tool in accordance with the present invention;





FIG. 27A

is a schematic illustration of a portion of a method of changing boring diameters as the tool is inserted in the bore; and





FIG. 27B

is a schematic illustration of a portion of a method of removing the tool from without contacting the frustoconical surface of the bore in accordance with the present invention.











DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS




Referring now to the drawings in detail, wherein like numerals indicate the same elements throughout the Figures,

FIG. 1

illustrates working area


10


which typically comprises a machining station


20


and a work head


12


having a workpiece


14


attached thereto using fixtures and techniques known in the industry. Workpiece


14


is illustrated as a single exemplary structure having a bore hole or similar hollow interior portion which requires honing or finishing. In operation, the tool


100


and workpiece


14


are generally rotated or moved respectively to each other as tool


100


is brought into contact with the workpiece


14


(see arrow “Y”) in order to enable machining operations such as honing.




The present invention may be adapted for use with a machining station or center


20


having a machine spindle


24


which can be rotated at varying speeds by a power source (not shown), and which can quickly and easily receive and secure one of a plurality of tools for various operations (i.e., rotating, vibrating or oscillating). A machining station


20


typically has a synchronized system, such as an automatic tool changer (not shown), for quickly and easily interchanging and utilizing multiple matching tools at one machining station or center


20


, thereby allowing machining station


20


to provide greater utility or range of operations, (i.e., they are not dedicated to a single operation or use of a single type of tool).




Any engaging assembly (e.g.,


25


) (i.e., clamping or otherwise securing) the proximal end


104


of the tool


100


in a generally cantilevered fashion with the machine spindle


24


, such as a drawbar, a collet, a mandrel device, or other device known in the industry, can be used, so long as fluid can be provided to the tool


100


adjacent the spindle/tool interface


28


while the tool


100


is in use. An exemplary engaging assembly


25


allows for quick interchange of tools and provision of fluid communication between the spindle passage


26


and the fluid distribution passageway


108


at tool/spindle interface


28


without the need for separately hooking up hydraulic lines or other fluid connections. As will be understood, the tool


100


could also be utilized in conventional applications and dedicated operations as well.




One embodiment of a tool


100


will now be described with reference to

FIGS. 1A

,


2


, and


9


to


11


. The tool


100


can include a cutting reamer (e.g., head


101


, which can be detachably chucked to a spindle


24


. Cutting head


101


generally includes a proximal portion


104


, a middle portion


106


and a cutting portion


107


.




The tool


100


may comprise a body and is made of a rigid material (e.g., heat treated steel or the like) configured in a longitudinally extended generally cylindrical shape. The tool


100


can be of any desired length, however, it is preferably sufficiently long to accomplish the desired machining operation. A variety of standard materials available in the industry can be used to form the tool


100


so that it is sufficiently rigid and maintains its structural integrity in the desired form during the machining operations at rotational speed from about 200 to about 20,000 revolutions per minute, and so that adverse material deformation does not occur as fluid pressure in the hollow conduit or fluid distribution system


108


increases to levels from about 200 pounds per square inch (“psi”) to about 1,000 psi (1.38×10


6


n/m


2


to 6.89×10


6


n/m


2


). Illustrative examples of materials which might be used include aluminum, steel, or the like. For example, an aluminum alloy might be used where there is a need for a lighter weight tool, which might be desirable when the tool


100


is interchanged in a machine spindle


24


using an automatic tool changing system.




The cutting portion


107


can include blade


126


and/or support pad


124


. When the cutting head


101


, is driven to rotate in the angular direction A about its longitudinal axis L by spindle


24


, blade


126


can be used to drill, cut, ream, bore or otherwise machine an opening, cut-out or hole in a workpiece (e.g.,


14


), while support pad


124


helps to support the cutting head


101


within the hole being machined. More specifically, support pad


124


can rotate along the inner wall of the hole that is being machined by blade


126


, in order to help maintain alignment between the longitudinal axis L of the cutting head


101


and the central axis of the hole, which is being machined by blade


126


, despite the force which the physical interference between the workpiece (e.g.,


14


) and blade


126


exerts on the cutting head


101


.




This support function of support pad


124


can be especially useful when the depth of the hole being bored is quite long relative to the diameter of the hole. The hole in the barrel of a gun is one example of this type of application. The support provided by support pad


124


can also be important in boring high precision holes, for example holes with close tolerances on diameter or cylindricity. Some examples of precision holes are cylindrical bores in engine blocks, spool valves, valve bodies, precision bores and connecting rods, and wrist pin bores.




Hollow conduit


108


can be provided within the body of tool


100


to extend or run along the longitudinal axis L in a predetermined arrangement, for example, from proximal portion


104


to the cutting portion


107


. Both the tool


100


and the conduit


108


may be oriented so that they share the same center longitudinal axis of rotation. As will be better understood from the description herein, this coaxial orientation of the tool


100


and the conduit


108


may be provided so that the interchanging of tools made in accordance herewith (i.e., securing the tool


100


in place and establishing fluid communication between the spindle passage


26


and the hollow conduit


108


) can be accomplished quickly and automatically upon attachment of tool


100


, and to preserve balance in the tool


100


so that eccentricities, which could cause vibrations during use, are held to a minimum. In this regard, off-centered routing of hollow conduit


108


within the tool


100


could be employed, but in such exemplary embodiments, the tubes could be arranged symmetrically relative to the tool


100


to preserve balance during high speed tool rotation.




Forming the fluid distribution system


108


in the tool


100


and having fluid routed therethrough also provides an effective heat sink to dissipate thermal energy generated during machining operations, further minimizing undue thermal expansion. If the tool


100


were to undergo significant or uncontrolled thermal expansion, and particularly in a radial direction, the outer diameter of the tool mandrel


100


would increase and could interfere and hamper machining operations.




Referring back to

FIG. 1

, the work area


10


also includes a fluid supply system


11


that generally provides a source of pressured fluid to be routed through the spindle


24


(via spindle passageway


26


) and through tool


100


(via the fluid distribution system


108


). The fluid supply system


11


, often referred to as a through-spindle coolant or fluid system, also generally includes a compressor or other system (not shown) for pumping fluid at the desired pressure and flow rate. Various fluid supply systems could be used. For instance, each of the embodiments of the present invention may comprise or be connected to a fluid supply system of one of the types described in U.S. patent application Ser. No. 09/392,091 filed Sep. 8, 1999, which is herein incorporated by reference.




The spindle passage


26


has a distal end which can provide an automatically sealing interface with the tool


100


and fluid distribution system


108


at the tool/spindle interface


28


. This seal might be provided in a variety of structural arrangements, including O-ring, seals and the like, and its exact structure may vary among particular applications.




Fluid communication can thereby automatically and immediately established and maintained between the spindle passageway


26


and fluid distribution passageway


108


when the tool


100


is engaged and held in place by the engaging assembly


25


using various assemblies and techniques known in the industry, as discussed previously. It should be noted that when the tool


100


is not engaged with the engaging assembly


25


, mechanisms known in the industry (e.g., shut off valves or the like) can be used to terminate the flow of coolant fluid adjacent the end of the spindle passage


26


.




Conduit


108


can branch into a plurality of delivery conduits for assisting in delivering fluid to either the workpiece (e.g.,


14


) the blade


126


and/or the support pad


124


. The delivery of cooling or lubricating fluid to the machining area can assist in the dissipation of thermal energy build up in the tool


100


and/or workpiece


14


(which resulted from machining operations), the lubrication of machining operations, and/or facilitate chip or particle removal.

FIG. 1A

illustrates delivery conduit including side conduits, such as support side conduit


110


, blade side conduit


112


, and/or exit conduit


114


.




Fluid tight piston


116


can be provided, and can assist in metering or controlling, or even preventing pressurized fluid from escaping out of the cutting head


101


through the side conduits, such as support side conduit


110


. Likewise, fluid tight piston


118


can assist in metering or controlling, or even preventing the pressurized fluid from escaping from the cutting head


101


through the blade side conduit


112


. However, escape conduit


114


may allow pressurized cooling and lubricating fluid to escape from tool


100


, so that the cooling and lubricating fluid splashes out of the cutting head


101


in the directions indicated by the arrows S. (As discussed below in connection with the embodiment exemplified in

FIG. 7

, in some embodiments of the present invention, the piston may allow fluid to leak around the blades and/or support members to help provide cooling and lubrication.)




The cooling and lubricating fluid which splashes out of escape conduit


114


(and also side conduits, as discussed above) serves to assist in cooling the tool


100


and workpiece


14


in order to help counter or dissipate heat build-up caused by the machining operation. The cooling and lubricating fluid also helps to lubricate the interface between support pad


124


and the inside wall of the hole being bored, so that support pad


124


moves more easily and smoothly along the inside walls of the hole, and also the interface between the blade


126


and the inside wall of the hole being bored, so that blade


126


moves more easily and smoothly along the inside walls of the hole. Conventional cooling and lubricating fluids, such as emulsified water or soluble coolant fluid, protein based water soluble coolant fluid, straight oil, mixtures thereof, or other available machining fluids can be used as the coolant fluid.




Blade side piston


118


may reside in blade side conduit


112


. The pressurized cooling and lubricating fluid in the blade side conduit


112


assists in pushing blade side piston


118


generally radially outwardly against a lower part of blade cartridge


122


. Because the blade cartridge


122


is provided with a slot


123


, the lower part of blade cartridge


122


(and the attached blade


126


) will move in the direction generally indicated by R′ when pushed by blade side piston


118


.




In this way, unlike many conventional tools, the blade cartridge


122


and blade


126


are selectively biased in the radial direction, with the amount of bias being determined by the fluid pressure in blade side conduit


112


. The fluid pressure in blade side conduit


112


is primarily determined by how fast fluid is pumped into the hollow conduit


108


by the pump (P) which supplies fluid from supply


11


to conduit


108


. Therefore, the bias or position of blade


126


can be controlled by controlling the speed and pressure of the pump P.




More particularly, when the fluid in blade side conduit


112


is at a relatively high pressure, this high pressure will serve to push blade side piston


118


and the blade


126


relatively far out in the direction R′. (An example of this is shown in

FIG. 10.

) On the other hand, when the fluid pressure in the blade side conduit


112


is relatively low, the blade side piston


118


and the blade


126


will be pushed in the direction R′ to a lesser extent, if at all. (An example of this is shown in

FIG. 9

)




In either case, the location of the blade


126


with respect to the R′ direction will be determined by the balance between the fluid pressure pushing in the R′ direction, the forces pushing in the counter R′ direction, and/or the centrifical force generated by rotation of tool


100


. Specifically, the spring force of the slotted blade cartridge


122


and the force exerted by the workpiece on blade


126


will tend to push the blade


126


in the counter R′ direction.




If the spring force of blade cartridge


122


and the amount of counter R′ force exerted on blade


126


by the workpiece remains fairly constant, then the location of the blade in the R′ direction can be selected and controlled by controlling the bias, which can be accomplished by controlling the fluid pressure in blade side conduit


112


and/or rotational speed of the tool


100


. As such, the fluid pressure in blade side conduit


112


can be selected to determine the radius of the hole being machined and/or selected to compensate for wear of the blade


126


since the displacement direction R′ of the blade


126


is substantially the same as the radial direction R, at least over the limited travel range of blade


126


.




Support pad


124


can be mounted on support cartridge


120


, and may include a slot


121


that can permit the lower part of the blade cartridge


120


and the support pad


124


some range of travel in the R″ direction (which is substantially the same as the radial direction R for the limited range of travel allowed by support cartridge


120


). Fluid pressure in support side conduit


110


tends to push support side piston


116


against the lower part of support cartridge


120


, thereby working to bias support pad


124


in the R″ direction. Therefore, the support pad


124


can be selectively biased in a manner similar to the blade member


126


. Alternatively, a blade, similar to blade


126


, can be mounted on support cartridge


120


. A second blade can assist in supporting tool


100


, and can assist in removing material from workpiece


14


.




The spring force of support cartridge


120


and normal forces exerted by the workpiece (e.g.,


14


) on support pad


124


will tend to push back in the counter R″ direction. The location of support pad


124


in the R″ direction will therefore be determined by the balance of these forces. By controlling the bias of the support pad


124


, its location can be controlled during machining operations.




Tool


100


can compensate to some degree for differences in wear between blade


126


and support pad


124


. In use, both blade


126


and support pad


124


will wear to some extent due to physical interference between these parts


124


and


126


, respectively, and any workpiece (e.g.,


14


). Generally, blade


126


will wear faster than support pad


124


because blade


126


actually does the machining of workpieces (e.g.,


14


). Of course, in a conventional reamer, if the blade member wears faster than the support member(s), then the diameter and/or the alignment of the holes cut by the conventional reamer will generally be adversely affected.




However, if tool


100


is a reaming tool and if the blade


126


loses material through wear, then the biasing fluid pressure in blade side conduit


112


will tend to push blade


126


further out in the R′ direction in order to compensate for this wear to some extent, and to maintain blade


126


at an appropriate radial location. Similarly, if support pad


124


loses material through wear then the biasing fluid pressure in support side conduit


110


will likewise push support pad


124


out further in the R″ direction in order to compensate for the support side wear to some extent. Not only does this feature of the present invention help enhance hole precision and alignment, it also may allow more prolonged use of blades and/or support members by effectively compensating for an increased degree of wear.




Turning now to

FIGS. 9 and 10

, tool


100


of the present invention can be used to machine (e.g., ream) holes of different or varying diameters. In

FIG. 9

, the biasing fluid pressure in conduit


108


, blade side conduit


112


and support side conduit


110


is maintained at a relatively low level so that the blade


126


and the support pad


124


are not pushed out very far in the R′ and R″ directions, respectively. Under these conditions, a hole machined by tool


100


will have a relatively small diameter.




However, by increasing the biasing fluid pressure in the conduits


108


,


110


and


112


, as shown in

FIG. 10

, the blade


126


and support pad


124


will be pushed further out in the R′ and R″ directions, respectively. This can result in a relatively larger diameter hole. No change in the tool hardware is necessary to accomplish this, rather only the pressure of the supply fluid must be adjusted. Of course, it is generally easier to control the pressure of the cooling and lubricating fluid (by controlling speed and/or pressure of a pump) than it is to change hardware, so the tool


100


according to the present invention objective will generally increase efficiency and productivity in applications which require holes of different diameters.




Also, although the blade


126


and support pad


124


have a limited range of travel and an accordingly limited range of possible hole diameters, fewer tool cutting heads (e.g.,


101


) will generally be necessary for a given application compared to tool heads, which are capable of machining only one hole diameter.




The relative range of travel between the blade


126


and the support pad


124


can vary according to the particular application. For example, finishing tools can have a relative range of adjustment to allow the machining diameter to vary around 250 microns. Roughing tools may have a larger range of adjustment to allow the machining diameter to vary around 500-1000 microns. The greater amount of adjustment for roughing tools is desirable due to the relatively high level of wear experienced by the tool and is permitted since a lower level of precision is necessary during roughing procedures.




Turning now to

FIGS. 9-11

, tool


100


can be used to compensate for material deformation in the workpiece.

FIG. 9

exemplified a hole being machined in workpiece


14


by tool


100


. In the machining operation exemplified by

FIG. 9

, the fluid pressure in conduits


108


,


110


,


112


and the radial location of blade


126


and support pad


124


are maintained at a generally constant value. Under these conditions, workpiece


14


will generally bow inward near the top of the hole at the location denoted by reference numeral


16


, due to material properties inherently present in workpiece


14


.




As exemplified in

FIGS. 10 and 11

, compensation for this phenomenon can be effected by tool


100


. When tool


100


is reaming the top of the hole, the biasing fluid pressure in conduits


108


,


110


,


112


is adjusted so that blade


126


and support pad


124


are pushed out a bit further in the radial direction R. At first, this results in the hole diameter being somewhat larger at the top of the hole as denoted by reference numeral


18


. Then, as shown in

FIG. 11

, as the tool


100


machines (e.g., reams) further down into the workpiece


14


, the biasing pressure in conduits


108


,


110


,


112


is gradually decreased so that the blade


126


and support pad


124


gradually retract to some degree to match the nominal diameter of the hole being machined as the tool


100


moves further down into the workpiece


14


. While this is occurring, the top of the hole


16


will spring back to some degree to occupy the position denoted by reference


18


. In this way, the top of the hole can take on the nominal hole diameter, because it was machined out to a somewhat larger diameter.




Of course, in order to accomplish the machining operation shown in

FIGS. 10 and 11

, the fluid pressure must be continually and carefully controlled with respect to the longitudinal location of the tool


100


within the workpiece


14


. Appropriate control of the fluid pressure can be empirically determined and written into software which controls the tool


100


. On a related note, tool


100


can be also used to machine holes in a workpiece


14


which do not have a constant diameter over or along their entire length. The fluid pressure can be controlled as the machining occurs so that various portions of the hole have larger or smaller diameters as desired. For example, tool


100


can be used to both ream a hole and provide a facing for the hole or a counter sink for the hole at the front and/or back of the workpiece


14


.




Another embodiment of a tool


200


according to the present invention is exemplified in

FIGS. 3 and 4

. In tool


200


, hollow conduit


208


, blade side conduit


212


, escape conduit


214


, blade side piston


218


, blade side cartridge


222


and blade


226


are similar to the corresponding elements of tool


100


. Support members


230


and


232


, respectively, are provided, mounted or otherwise affixed along the cutting portion


207


of tool


200


in a manner similar to that found in conventional tools.




While tool


200


does not provide all of the flexibility of the previously-discussed biased support pad embodiment exemplified in tool


100


, it is somewhat simpler in construction and may be appropriate for applications which do not cause much wear on support members


230


and


232


, respectively. In tool


200


, however, wear on the blade


226


can still be effectively compensated by appropriate adjustment of the fluid pressure in conduits


208


, and


212


, respectively.




Another alternative embodiment of a tool


300


according to the present invention is exemplified by

FIGS. 5 and 6

. In tool


300


, a central conduit


308


can be provided and extends along the tool


300


to the cutting portion


307


where it terminates in fluid communication with a slot


338


disposed across the cutting portion


307


. Blade


326


can be provided on one side of the slot


338


, while support member


330


can be provided on the opposite side of slot


338


(e.g., FIG.


6


). The portion of the cutting portion


307


which includes blade


326


is called blade side


334


. The other portion of the cutting portion


307


having support member


330


affixed thereto is called support side


336


.




As with all of the exemplary embodiments having a slotted cutting or working portion, the slot may be have many thicknesses and shapes in order to divide the working portion into two or more sections. In some exemplary examples, the slot may have a small thickness (e.g., 0.01 inches wide). The slot can be created by many exemplary processes. For instance, the slot could be created by a wire EDM process, a slotting saw, milling, or other process.




It will be appreciated that thicknesses of larger or smaller than 0.01 inches could also be used. A slot with a smaller thickness may be desirable to minimize fluid loss during use of the tool while a slot with a larger thickness can be used in situations where a predetermined amount of fluid loss is desirable (e.g., in situations where additional cooling, lubrication, and/or chip removal, etc., is desired).




In operation, cooling and lubricating fluid can be pumped down conduit


308


and into slot


338


. Depending on the pressure of the fluid, blade side


334


and support side


336


will be biased away from each other to a greater or lesser extent. More specifically, blade side


334


will be biased in the R′ direction by the fluid pressure, while support side


336


will be biased in the R″ direction by the fluid pressure. This, in turn, causes the blade


326


and the support member


330


to be pushed in the R′ and R″ directions, respectively, thereby allowing control of the radial positions of the blade


326


and support member


330


. In this way, the radial position of the blade member


326


and support member


330


can be controlled by controlling fluid pressure in the conduit


308


and slot


338


.




In tool


300


, an area of removed material


340


in the body of tool


300


helps to allow relative radial deflection of the sides


334


and


336


, respectively. Also generally J-shaped slots


342


and


344


, respectively help allow the sides


334


and


336


, respectively to separate in the radial direction (e.g., R′ and/or R″) under the influence of cooling fluid pressure. A slight modification of this embodiment is exemplified in FIG.


12


.

FIG. 12

illustrates head


600


with blade


626


and support pad


630


. Slot


638


can include an alternative configuration, and/or can include a strain relief portion


642


to help provide strain relief of tool


600


in use. As will be appreciated by those skilled in the industry, other shapes and configurations of slots (e.g.,


338


) can be provided in the body of tool


300


in keeping with the teachings and scope of the present invention.




The tool


300


may also include a seal along the longitudinal edges thereof to minimize coolant loss out of the tool


300


, to assist in selectively biasing the tool


300


, and to assist in directing fluid toward the end of cutting portion


307


of the tool


300


. In one embodiment, tool


300


may be provided with bore holes


345


in the body of tool


300


generally along the longitudinal length thereof and positioned toward the edge thereof. Holes


345


can be filled or plugged with a corresponding shaped plug (e.g., generally longitudinally extending)


346


to effectively seal the slots


338


along their respective edges.




Furthermore, a seal


666


(such as an o-ring) and an end cap


668


may be provided on and releasably attached to the end of tool


600


to further assist in creating a pressure chamber within the tool


600


for selectively biasing the blade


626


and/or support


630


(which also can be another cutter or blade) radially outwardly for desired machining operations. So that tool


600


can be biased as desired, exemplary embodiments of the present invention may include an end cap


668


attached with at fastener


670


at one location to either the blade side


634


or the support side


636


of the tool


600


. It will further be appreciated that the end cap


668


could be attached in both locations, with at least one of the locations having a slot or other mechanism to allow the fastener to side relative to the end plate as the blade side


634


and support side


636


expand relative to one another. The fastener may be a screw, bolt, or other suitable attachment means known in the machine industry.




Another alternative exemplary embodiment of a tool


1100


according to the present invention is exemplified in FIG.


5


A. The tool


1100


is similar in construction to tool


300


described in relation of

FIGS. 5 and 6

above and contains the same corresponding parts and operates in a similar manner. For instance, although not shown, it will be understood that tool


1100


includes bore holes and plugs similar to the bore holes


345


and the plugs


346


as illustrated in FIG.


6


. Furthermore, although not shown, the tool


1100


may also include a seal and end cap, such as seal


666


and end cap


668


described in relation of

FIGS. 5 and 6

above. In tool


1100


, a central conduit


1108


can be provided to extend along the tool


1100


to a working portion


1107


. The working portion


1107


is the portion of the tool adapted to remove material from the workpiece. The central conduit


1108


is in fluid communication with slot


1138


disposed along the working portion


1107


.




As depicted in

FIG. 5A

, the slot


1138


is illustrated as being offset a predetermined distance D from the axis L according to the particular application as desired. For instance, the slot


1138


might extend substantially within the blade side


1134


of the working portion


1107


, thereby bifurcating the working portion


1107


into sections with different cross sectional areas. Bifurcating the working portion


1107


in this manner allows the blade


1126


to be biased in the R′ direction a relatively greater distance than the support member


1130


travels in the r″ direction upon pressurization. Biasing the blade side


1134


a greater distance than the support side may better compensate for the greater wear experienced by the working member


1126


. As the working member


1126


wears away during use, the blade side


1134


can more easily bias outward to compensate for the worn away portions of the working member


1126


. In contrast, the support member


1130


can remain relatively stationary which may be desirable due to the high wear resistance of the support member


1130


.




A J-shaped slot


342


A can extend upwardly in the side containing the blade in order to permit further extension of the blade in the R′ direction while reducing stress concentrations. Although not shown, it is understood that an additional J-shaped member, such as J-shaped member


344


illustrated in

FIG. 5

, could be provided within the tool


1100


in order to permit further extension of the support member


1130


in the r″ direction and/or to reduce stress concentrations. In addition, although not shown, the slot


1142


could extend substantially in the support side


1136


rather than the blade side


1134


in order to cause the support member


1130


to travel a larger distance than the blade


1126


.




In an exemplary operation therefore, fluid (e.g., cooling and lubricating fluid) can be pumped down the conduit


1108


and into the slot


1138


. As depicted in the embodiment illustrated in

FIG. 5A

, depending on the pressure of the fluid, the blade side


1134


will be biased away from the support side


1136


in the direction R′. The support side


1136


will be biased to a smaller extent, if at all, in the direction r″. In this manner the fluid pressure acts to allow control of the radial position of the blade


1126


relative to the support side


1136


. As with the other embodiments of the invention, the support member


1130


could comprise another blade


326


or a plurality of blades and/or supports. Although not shown, it is understood that the slot of the other exemplary embodiments described herein could also be offset from its axis according to the particular application as desired.




The various slotted embodiments of the present invention could be provided with one or more seals and may even be designed without a seal. Embodiments including a seal can be used to restrict, or prevent, fluid flow from the tool. For example, one or more seals could be used to restrict, or prevent, fluid flow from the side(s) and/or end of the tool. For instance, the embodiment illustrated in

FIGS. 5 and 6

illustrate at least one seal (i.e., plugs


346


) used to restrict, or prevent, fluid flow from the side of the slot


338


. In this instance, fluid may be substantially prevented through the sides of the tool while being permitted through the end of the tool. The fluid could further be restricted or prevented with an end cap and/or seal as described in relation to many of the following exemplary embodiments of slotted tools. It will further be understood that the end cap and/or seal could be provided without sealing the sides (e.g., with plugs). Allowing a predetermined amount of fluid might be desirable for lubrication, heat reduction and chip removal. Limiting the fluid flow might further be required to enable the tool to bias the working member or blade outwardly.




The slotted tools of the described examplary embodiments might also be provided without any seals as long as the tool is configured to allow pressure build up to allow proper biasing of the working member or blade and/or support member, if provided. For example, the slot geometry (e.g., a slot with an irregular geometry) could be used to interfere with, and therefore restrict fluid flow. Moreover, the slot thickness could be further reduced to the point where the seals would not be necessary.





FIG. 5B

depicts a tool that can function without any sealing members. The tool is fabricated with little, if any, clearance between the first side


1434


and the second side


1436


of the working portion


1407


. As shown in

FIG. 5B

, the first side


1434


and second side


1436


are fabricated separately and then fastened to the shank


1406


. For instance, a plurality of fasteners


1411


may be used to connect the first side


1434


and the second side


1436


to a shoulder


1409


of the shank. It will be understood that other methods could be used to attach the first and second sides to the shank such as welding, brazing, etc. Accordingly, the first side


1434


and second side


1436


are arranged such that there is little or no clearance between the side surface


1435


of the first side


1434


and the side surface


1437


of the second side


1436


. In one embodiment, the first side surface


1435


abuts the second side surface


1437


.




In use, pressurized fluid is introduced through conduit


1408


such that it travels to the working portion


1407


. The pressure causes a predetermined biasing of the first side


1434


and working member


1426


attached thereto, relative to the second side


1436


and support member


1430


attached thereto. The pressure can be changed to vary the effective diameter of the tool


1400


. As with all of the embodiments of the present invention, the support member


1430


, if provided, can be replaced with one or more support members and/or working members or blades.




Yet another embodiment of a tool


400


is exemplified in FIG.


7


. In exemplary tool


400


, conduit


408


extends along the center of the tool


400


to side conduits, e.g., support side conduit


410


and/or blade side conduit


412


. The fluid in support side conduit


410


Will push on and bias support pad


424


in the radial direction R. Similarly, fluid pressure in blade side conduit


412


will push on and bias blade cartridge


422


and blade


426


in the radial direction R. In this way, fluid pressure can be used to control the radial location of the blade


426


and support pad


424


. A stop


425


should be provided to ensure that the blade cartridge


422


and/or support pad


424


included in the cutting portion


407


are not pushed entirely out of the head by the fluid pressure.




In tool


400


, some clearance (e.g.,


427


A) can be provided between support pad


424


and support side conduit


410


so that cooling and lubricating fluid can splash out in the directions indicated by the arrows S. Similarly, clearance (e.g.,


427


B) can be also provided between the blade cartridge


422


and the blade side conduit


412


so that cooling and lubricating fluid may splash out in the direction indicated by the arrow S. Alternatively, the support pad


424


and blade cartridge


422


may be constructed as fluid-tight pistons so that fluid escaping is minimized or eliminated to the outside of tool


400


. Under this alternative, the fluid would be used solely for the purpose of biasing blade


426


and/or support pad


424


.




Another embodiment of a tool


500


according to the present invention will now be described with reference to FIG.


8


. In this embodiment, the blade


526


and support member


530


can be biased in the R′ and R″ directions, respectively, by spring


540


which is located within slot


538


in the cutting portion


507


of tool


500


. Spring


540


is chosen so that its spring force provides an appropriate amount of biasing force on the blade


526


and support member


530


. The spring


540


can be removed and replaced with other springs having other characteristics depending on the desired application. In this way, tool


500


can be used to machine holes of different diameters. For example, a longer spring or a stiffer spring will push out blade


526


and support member


530


further in the R′ and R″ directions, respectively, resulting in a larger diameter hole. Also, springs


540


can be selected to compensate for wear and tear of the blade


526


and/or support member


530


. For example, a longer or stiffer spring


540


can compensate for a worn blade


526


and/or support member


530


.




It is noted that the biasing force on the blades (e.g.,


126


) and/or support members (e.g.,


130


) of tools according to the present invention can be at least one order of magnitude higher than the cutting load or the load caused by friction from the workpiece (e.g.,


14


). In embodiments using fluid pressure, a high bias can be effected by making the active area of the piston (e.g., interface between the fluid and the piston) as large as possible.




It is also noted that support members of tools according to the present invention may be shaped identically to the blade member. For example, if a reamer head is configured to have three “blades” around its circumference, generally the “blade” which protrudes a small amount farther in the radial direction will act as a blade by performing most of the material removal. The other two “blades” will not remove a substantial amount of material and can act instead as support members. In still further examples, a plurality or all of the blades could be arranged to protrude outwardly such that they all remove material while each blade also acts as a support member for the remaining blades.




Another way to help ensure that a member having a “blade” geometry will act as a support member rather than a blade is to use a blade with a relatively wide cylindrical margin relative to the diameter of the bore. This is shown in

FIG. 13

, where blade


702


has a wide cylindrical margin


704


relative to bore


715


. Due to its wide margin, blade


702


does not remove substantially any material from the workpiece


14


and acts a support member, rather than as a blade.




In still further examples, the blade


702


can be arranged to remove a substantial amount of material while also acting as a supporting member for cutting material.




Turning now to

FIGS. 14-17

, the present invention can also include a chip evacuation chamber


852


in the body of a tool for assisting in removing cut particles and/or chips from the machining area in a hole, and from interfering with further machining operations, especially in blind holes. Chamber


852


includes at least inlet


854


adjacent the cutting portion


807


, a corresponding outlet


858


positioned proximally away from the inlet


854


, such as along the middle portion


806


and/or proximal portion


804


, and a corresponding passageway


856


between inlet


854


and outlet


858


. The chamber


852


can also have a larger diameter when machining an aluminum workpiece since the cut particles tend to ball up, and could easily interfere with particle removal or clog the inlet


854


, outlet


858


, and/or passageway


856


.




One or more blade cartridges


822


and/or support cartridges (see, e.g.,

FIG. 17

) can each be mounted or attached to tool


800


within chamber


852


using techniques and equipment known in the machine tool industry. When more than one blade cartridge and blade


826


are used, they can be arranged so that the cut radius of each varies. For example, one of the blade (e.g.,


826


A) may machine the inner portion of a hole whereas the other blade (


826


B) may machine the outer portion of the hole. As will be appreciated by those skilled in the art, there should be some slight overlap between blades


826


A and


826


B, respectively, so that the hole is machined appropriately, especially in drilling operations. As exemplified in

FIG. 16

, when blade cartridge


822


has an extended longitudinal length, which may be need for stability and support in machining operation, the shaft


822


A of cartridge


822


may be tapered to assist in providing for chip removal through chip removal passageway


852


.




The tool


800


may also include a seal (e.g., plug


846


) along the longitudinal edges (e.g., within holes


845


extending along the edges) thereof to minimize coolant loss out of the tool


800


, to assist in selectively biasing the tool


800


, and to assist in directing fluid toward the end of cutting portion


807


of the tool


800


. In one embodiment, as shown in

FIG. 14

, tool


800


may be provided with bore holes


845


in the body of tool


800


generally along the longitudinal length thereof and positioned toward the edge thereof. Holes


845


can be filled or plugged with a corresponding shaped plug


846


(e.g., generally longitudinally extending) to effectively seal the slots


838


along their respective outer longitudinal edges. As with other exemplary embodiments having plugs, an end cap may also be provided to help secure the plugs in place.




Another alternative embodiment of the tool


900


is illustrated in

FIGS. 18-20

. A central conduit


908


, as best seen in

FIG. 19

, can be provided to extend along the tool


900


to a working portion


907


. As illustrated in

FIG. 18

, the working portion


907


of the tool


900


is bifurcated with a slot


938


extending laterally through the sidewall. The embodiment of tool


900


includes a seal


980


, such as a jacket, or bladder, with an at least partially open end


982


facing the conduit


908


and a closed end


983


facing away from the conduit


908


. The jacket


980


is positioned within a cavity


974


defined in the working portion


907


of the tool


900


. The jacket


980


acts to at least partially form or sealingly define a pressure chamber


975


and is adapted to restrict, or substantially prevent, fluid from traveling outwardly through the slot


938


. An end cap


968


, having a first section


976


and a second section


978


are shown as being secured with fasteners (see


970


in

FIG. 20

) to the cutting portion


907


of the tool


900


in order maintain the jacket


980


within the cavity


974


while allowing selective radial flexing of the first side


934


and the second side


936


of the tool


900


to adjust the effective working diameter of the tool in use.




The jacket


980


may include one or more apertures


984


for communicating with one or more corresponding escape conduits or passages


914


defined in the cutting portion


907


to allow fluid to pass therethrough and be dispensed by a nozzle


915


for lubrication, heat reduction, and/or chip removal adjacent the corresponding working member or blade


926


. As with any of the other embodiments of the invention described herein, the working member or blade may comprise a cutting edge (e.g., see the edge of the working member


926


). In addition, the working member or blade may comprise an abrasion surface, or other member adapted to remove material from a workpiece by cutting, grinding, reaming, boring or other mechanical method. Moreover, the working member or blade may be replaced by one or more support members, such as support member


330


depicted in FIG.


5


.




The jacket


980


can be comprised of flexible materials such as plastic and may be impermeable to the pressurized fluid. In other embodiments, the jacket


980


might be comprised of a material that is at least partially permeable to the fluid, such as a fluid permeable membrane, to provide sufficient resistance to fluid flow in order to allow pressurization of the pressure chamber


975


while allowing predetermined limited seepage of fluid laterally through the slots


938


and/or through the escape conduit or passage


914


for lubrication, cleaning, cooling, etc. In still further embodiments, the jacket


980


could be perforated with a plurality of small apertures that restrict, rather than prevent, fluid flow. With a fluid permeable material or fluid restricting structure, the aperture


984


in the jacket


980


may be smaller or nonexistent wherein a restricted amount of fluid may escape through the escape conduit or passage


914


is a result of the permeably of the material and/or the permeable structure of the jacket


980


.




In one exemplary embodiment, the jacket


980


could comprise nylon, such as DELRIN nylon, to act as a pressurized jacket or bladder as shown in the figures, especially FIG.


20


. In still other examples, the jacket can comprise a material having comparable modulus and strength of DELRIN nylon. In still further examples, it is understood that the jacket can alternatively comprise a material having a different modulus and strength than that of DELRIN nylon. Indeed, it will be appreciated that a wide range of material will be acceptable to create the jacket of the present invention as long as the modulus is less than the material of the working portion to allow the jacket to expand, and thereby radially flex the sides of the working portion. In addition, it is understood that the jackets of the present invention may be adapted to allow transmission and communication of fluid to the escape conduit or passage


914


and/or the slot


938


.




The jacket


980


, as shown in

FIG. 20

, may have a generally hour-glass shape corresponding to the conformation of the cavity


974


. The hour-glass shape allows the jacket


980


to accommodate a maximum area in the cavity


974


while still allowing for apertures


973


to be formed in the working portion


907


. Moreover, the non-circular shape simplifies alignment of the jacket aperture


984


with the escape conduit or passage


914


, if provided.





FIG. 20

, illustrates an exploded perspective view of the tool


900


in accordance with one embodiment of the present invention. To assemble the tool


900


, the jacket


980


is inserted within the cavity


974


with the closed end


983


facing outwardly and with the aperture


984


, if provided, in communication with the escape conduit or passage


914


of the working portion


907


. The first and second sections


976


,


978


of the end cap


968


are placed over the end of the working portion


907


such that aligning dowels


972


are received in corresponding ones of apertures


971


formed in the end cap


968


and through corresponding ones of the apertures


977


formed in the working portion


907


. Next, the end sections


976


,


978


are fastened to the working portion


907


, for instance with fasteners


970


. Fasteners


970


are received within apertures


969


formed in the end cap and through threaded tapped holes


973


formed in the working portion


907


. The apertures


969


may be counter sunk in order to recess the heads of the fastener


970


. Blade cartridges


922


with corresponding blades


926


are fastened to the working portion


907


.




Although the slot


938


is illustrated as extending along the central plane of the cutting tool


900


, it is understood that the slot


938


may be offset as illustrated in, for example,

FIG. 5A

to allow one of the blades to bias outwardly farther than another blade. In addition, as with all the embodiments of the present invention, the cutter blade could take the form of a singular cutter edge or could be provided with rough working surface for removing material from the interior portion of the workpiece.




Another exemplary tool


1000


of the present invention is depicted in

FIGS. 21-23

.

FIG. 21

is a partial view of a tool


1000


with a bifurcated end having a slot


1038


extending laterally through the cutting portion


1007


. The tool


1000


includes at least one seal (e.g., plugs


1046


and elongated end seal


1066


as best seen in

FIGS. 22 and 23

) adapted to restrict or prevent fluid flow through the side surface


1009


and the end surface


1013


of the working portion


1007


.





FIG. 22

is a sectional view of along line


22


of FIG.


21


and illustrates plugs


1046


inserted into holes


1045


that extend within the cutting portion


1007


at a depth I


2


that is larger than the depth I


1


of the slot


1038


to help slow or prevent fluid flow through the lateral slot


1038


. As illustrated in

FIGS. 22 and 23

, the elongated end seal


1066


is positioned at the end of the cutting portion


1007


to slow or prevent fluid from escaping through the end of the cutting portion


1007


. The end cap


1068


includes a first end cap section


1076


and a second end cap section


1077


. The end cap sections


1076


,


1077


are shown as being fastened to or otherwise associated with the end of the cutting portion


1007


to help position the elongated end seal


1066


and maintain the plugs


1046


in functional position.





FIG. 23

is an exploded perspective view of the tool


1000


. When assembling one exemplary embodiment of the present invention, the device plugs


1046


are inserted into the holes


1045


. In one embodiment, the end surface


1048


of the inserted plugs


1046


would be generally flush with the end surface


1013


of the working portion


1007


. In still another embodiment of the present invention, the end surface


1048


of the plugs


1046


might extend slightly outwardly from the end surface


1013


of the working portion


1007


to ensure that the plug


1046


extends entirely within the holes


1045


and/or to allow slight compression of the plug


1046


by attachment of end cap


1068


to provide excellent sealing properties. Elongated end seal


1066


is placed over the end surface


1013


of the cutting portion


1007


to at least cover a portion of the end slot


1039


. In one embodiment, as illustrated in

FIG. 23

, the end seal has enlarged ends adapted to extend over the end surface


1048


of the plugs


1046


to further prevent and/or restrict fluid flow. The first end cap section


1076


and the second end cap section


1078


are thereafter placed over the end surface


1013


of cutting portion


1007


such that alignment dowels


1072


are positioned within apertures


1071


in the end cap


1068


and apertures


1077


in the cutting portion.




Moreover, as illustrated in

FIG. 24

, the reverse side of the end cap sections


1076


,


1078


can define a recess


1080


adapted to receive at least a portion of the elongated end seal


1066


. In one embodiment, the depth of the recess


1080


is slightly less than the thickness of the end seal


1066


to cause compression of the end seal


1066


when the end cap sections


1076


,


1078


are fastened to the cutting portion


1007


, for instance, with fasteners


1070


. The fasteners


1070


can pass through apertures


1069


, such as countersunk bores, to be threaded within threaded apertures


1073


defined in the cutting portion


1007


. One or more cartridges


1022


, with corresponding working members


126


, may be fastened to the cutting portion


1007


. In addition, a nozzle


1015


may be inserted into the escape conduit


1014


to direct fluid adjacent each of the working members or blades


1026


.




In use, pressurized fluid is supplied through conduit


1008


to pressurize a pressure chamber


1075


defined in the working portion between the plugs


1046


and the end seal


1066


, thereby causing a first side


1034


and second side


1036


to flex or bias outwardly relative to one another and to thereby select and control the effective machining diameter of the tool


1000


. Fluid may optionally travel through escape conduit


1014


to be dispensed by nozzle


1015


adjacent the working member or blade


1026


to provide lubrication, heat control, and/or chip removal. In addition, a relief portion


1042


may also be provided to reduce stress points within the tool


1000


.





FIGS. 25

,


26


A,


26


B,


27


A, and


27


B are provided as examples illustrating various methods relating to improved and unique procedures used to remove material from a workpiece with any of the above embodiments of the present invention. For illustrative purposes, the tool will be generally referenced with reference character


1200


, however, it is understood that any tool mentioned above could be used in one or more of the below explained procedural steps.





FIG. 25

depicts a method wherein the tool


1200


is expanded to a first effective machining diameter D


e1


. In addition to providing a workpiece


14


, a tool


1200


is provided with a working portion


1207


and a working member


1226


. Fluid pressure is provided to pivot the working member


1226


outwardly to at least one of a plurality of alternative use positions. As further illustrated in

FIG. 25

, the tool is moved towards the workpiece


14


(i.e., in the direction of the arrow) such that the working member


1226


removes material from the workpiece at an effective diameter D


e1


as the working member


1226


is applied to the workpiece


14


.




As depicted in

FIG. 26A

, fluid pressure may be reduced to allow the tool


1200


to at least partially pivot the working member


1226


back to a reduced effective diameter or a non-use position, and then the tool


1200


is moved away (i.e., in the direction of the arrow in

FIG. 26A

) without removing additional material from the workpiece. It will be understood that the tool


1200


could be further moved away until the working member


1226


is radially clear of the workpiece


14


, and thereafter increasing the fluid pressure to obtain another, greater effective diameter, and then moving the tool


1200


towards the workpiece


14


such that the working member


1226


removes additional material from the workpiece


14


.




Alternatively, as illustrated in

FIG. 26B

, after machining the workpiece


14


in accordance with

FIG. 25

, the fluid pressure could be increased to further pivot and adjust the working member


1226


outwardly to at least a second use position having a second effective diameter D


e2


. The tool


1200


could then be moved away from the workpiece


14


such that the working member removes additional material from the workpiece


14


as the working member


1226


is moved in a direction away from the workpiece


14


.




It will be further understood that the pressure could be changed during the machining process of FIG.


25


. For instance, once the tool


1200


is inserted a predetermined distance, the fluid pressure could be increased to likewise increase the effective bore diameter, for instance in a stepped manner. Alternatively, the fluid pressure could be constantly and/or dynamically changed as the tool


1200


is inserted, thereby creating a frustoconical shape.




As illustrated in

FIG. 27A

, the tool


1200


could have a substantially continuously decreasing pressure and correspondingly, decreasing effective working diameter, as the tool is inserted into the workpiece, thereby creating a frustoconical shape. For instance, the tool can initially be adjusted to an effective diameter D


e3


to begin the working process. The fluid pressure could gradually decrease as the tool is moved relative to the workpiece. For example, as shown in

FIG. 27A

, the tool obtains an intermediate effective diameter D


e4


as the tool is creating the frustoconical cavity. As further illustrated in

FIG. 27B

, the final cut is made by the tool having a smaller effective diameter D


e5


. Once finished, as illustrated in

FIG. 27B

, the fluid pressure could be decreased to prevent removal of additional material as the tool is moved in a direction away from the workpiece. As illustrated in

FIGS. 27A and 27B

, a frustoconical cavity can formed with a flared outer end. It will be understood, however, that using this method and a tool of the present invention, a cavity could be formed with a frustoconical shape with an inwardly flared end and/or a reduced outer end by continuously reducing the fluid pressure during the process step depicted in FIG.


26


B.




In still other examples, the tools of the present invention can be used to create a bore having the shape of an hour-glass wherein the tool starts machining the workpiece with a relatively large initial diameter and then reduces the bore diameter to neck the bore down to a minimum intermediate diameter and thereafter increases the bore diameter to a larger final diameter. In other examples, the tools of the present invention could be used to create a substantially “barrel” shaped bore wherein the tool starts machining the workpiece with a smaller initial diameter and then increases the bore diameter to an intermediate maximum diameter and thereafter decreasing the bore diameter again to a smaller final diameter. In one specific example, the “barrel” shape can be approximated by forming two fructoconical cavities formed in succession. For instance, a first frustoconical cavity could be formed by initially machining the workpiece with a first-diameter and then increasing the bore diameter to a final larger diameter as the tool machines the workpiece. Next, the second frustoconical cavity can be formed by decreasing the bore diameter as the tool still further machines the workpiece until a final smaller bore diameter is obtained.




It will be understood that a wide and unlimited variety of bore diameters and shapes can be provided by appropriate fluid pressure control to adjust the effective working diameter in any number of ways during the boring or other working operations. It is therefore understood that a tool


1200


is provided that has a machining diameter that may be controlled as the tool is reciprocated relative to the workpiece to define an interior surface of various shapes.




The foregoing examples and various exemplary embodiments of the present invention set forth herein are provided for illustrative purposes only and are not intended to limit the scope of the invention defined by the claims. For example, each of the tools can be provided as a drilling tool, a reaming tool, a boring tool with the ability to provide counterbores, chambers and other features in a workpiece. Furthermore, the present invention can be used with through holes and/or blind holes. Additional embodiments of the present invention and advantages thereof will be apparent to one of ordinary skill in the art, and are within the scope of the invention defined by the following claims.



Claims
  • 1. A method of removing material from a workpiece comprising the steps of:a) providing a tool extending along an axis, the tool including a cantilevered working portion with a working member; b) pivotally positioning the working member with respect to the tool axis to a plurality of alternative use positions by providing the tool with fluid at predetermined pressures to bend the cantilevered working portion to control the pivotal position of the working member with respect to the tool axis; and c) effectuating relative contacting movement between the tool and the workpiece in the alternative use positions of the working member to remove material from the workpiece at different distances from the tool axis by contacting the working member and the workpiece at the alternative use positions.
  • 2. The method of claim 1, wherein the step of providing the tool with fluid comprises providing the tool with fluid comprising an incompressible fluid.
  • 3. The method of claim 1, wherein the step of providing the tool with fluid comprises providing the tool with fluid comprising a liquid.
  • 4. The method of claim 1, wherein the step of providing the tool with fluid comprises providing the tool with fluid comprising a lubricant.
  • 5. The method of claim 1, wherein the step of providing the tool with fluid comprises providing the tool with fluid selected from the group consisting of emulsified water, water soluble coolant fluid, and oil.
  • 6. The method of claim 1, wherein continuous contact between the working member and the workpiece is maintained as the working member is moved between the alternative use positions.
  • 7. The method of claim 1, wherein a series of machining steps are performed by sequentially pivotally positioning the working member with respect to the tool axis to alternative use positions.
  • 8. The method of claim 1, wherein the working portion further comprises a side surface and an end surface, wherein the working portion defines a passage passing through the end surface and the side surface in at least two locations, thereby dividing the working portion into at least a first section and a second section, wherein the fluid at the predetermined pressure biases a portion of the first section from a portion of the second section to control the pivotal position of the working member with respect to the tool axis.
  • 9. The method of claim 8, wherein the tool further comprises at least one seal adapted to restrict fluid flow through at least one of the side surface and the end surface and at least partially defining a pressure chamber, wherein the pressure chamber is pressurized with the fluid to bias the portion of the first section from the portion of the second section to control the pivotal position of the working member with respect to the tool axis.
  • 10. The method of claim 9, wherein the step of providing a tool extending along an axis with at least one seal comprises providing a tool with at least one seal comprising at least one plug received in an aperture defined in the working portion, wherein the at least one plug restricts fluid flow through at least the side surface.
  • 11. The method of claim 9, wherein the step of providing a tool extending along an axis comprises providing a tool including a working portion with a cavity defined at least partially within the working portion, and providing the seal as a jacket received in the cavity.
  • 12. The method of claim 11, wherein the step of providing the seal as a jacket received in the cavity includes providing the jacket with an open end and a closed end wherein the jacket is received in the cavity such that the closed end is located adjacent an end surface of the working portion.
  • 13. The method of claim 11, further comprising the step of restraining the jacket within the cavity of the working portion with at least one end cap.
  • 14. The method of claim 1, further comprising the steps of reducing the fluid pressure to allow the working member to pivot back toward the tool axis to a non-use position and moving the tool away from the workpiece without removing additional material from the workpiece.
  • 15. The method of claim 14, further comprising the steps of moving the tool away from the workpiece until the working member is radially clear of the workpiece, increasing fluid pressure to pivot the working member outwardly with respect to the tool axis to at least a second use position and again moving the tool towards the workpiece such that the working member removes additional material from the workpiece.
  • 16. The method of claim 1, further comprising the steps of increasing the fluid pressure to further pivot the working member outwardly with respect to the tool axis to at least a second use position and retracting the tool from the workpiece such that the working member removes additional material from the workpiece at a different effective diameter.
  • 17. The method of claim 1, further comprising the steps of increasing the fluid pressure to further pivot the working member outwardly with respect to the tool axis to at least a second use position and moving the tool further towards the workpiece such that the working member removes additional material from the workpiece at a different effective diameter.
  • 18. The method of claim 1, wherein the fluid pressure is changed while the tool is moving, thereby altering the effective diameter of the tool as desired.
  • 19. The method of claim 18, wherein the fluid pressure is substantially continuously changed while the tool is moving.
  • 20. The method of claim 18, wherein the tool forms a frustoconical cavity in the workpiece.
  • 21. The method of claim 1, further comprising the step of disbursing an amount of the fluid from the working portion to facilitate the method of removing material from the workpiece.
  • 22. The method of claim 1, wherein the step of providing a tool extending along an axis comprises providing a tool including a cantilevered working portion comprising a blade cartridge.
  • 23. The method of claim 9, wherein the step of providing a tool extending along an axis with at least one seal comprises providing a tool with at least one seal comprising at least one elongated end seal located adjacent the end surface of the working portion, wherein the at least one elongated end seal restricts fluid flow through an end surface of the working portion.
  • 24. The method of claim 8, wherein the step of providing a tool extending along an axis with a passage comprises providing the passage such that the passage is symmetrically disposed with the first section having approximately the same cross-sectional area as the second section.
  • 25. The method of claim 8, wherein the step of providing a tool extending along an axis with a passage comprises providing the passage such that the passage is disposed with the first section and second section having different cross-sectional areas.
  • 26. The method of claim 8, further comprising the step of disbursing an amount of the fluid from the working portion to facilitate the method of removing material from the workpiece.
  • 27. The method of claim 9, further comprising the step of restraining the seal relative to the working portion with at least one end cap.
  • 28. The method of claim 27, wherein the step of restraining the seal relative to the working portion with at least one end cap comprises restraining the seal relative to the working portion with at least one end cap including a recess formed in the end cap to receive a portion of the seal.
  • 29. The method of claim 27, wherein the step of restraining the seal relative to the working portion with at least one end cap comprises restraining the seal relative to the working portion with at least one end cap comprising at least two end cap sections.
REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 09/810,593 filed Mar. 16, 2001, now U.S. Pat. No. 6,536,998, which claims the benefit of U.S. Provisional Application No. 60/265,015, filed Jan. 30, 2001 and which is a continuation-in-part of U.S. application Ser. No. 09/392,114 filed Sep. 8, 1999, now U.S. Pat. No. 6,270,295, which claims the benefit of U.S. Provisional Application No. 60/099,464 filed Sep. 8, 1998.

US Referenced Citations (52)
Number Name Date Kind
2867139 Caldwell Jan 1959 A
3067637 Horning Dec 1962 A
3115051 Burg Dec 1963 A
3311003 Daugherty Mar 1967 A
3389621 Wear Jun 1968 A
3622247 Greenberg et al. Nov 1971 A
3714537 Bur Jan 1973 A
3735459 Allen May 1973 A
3757637 Eich et al. Sep 1973 A
3864054 Eysel Feb 1975 A
3937586 Watson Feb 1976 A
3966347 Watson Jun 1976 A
3977194 Klee et al. Aug 1976 A
4019246 Tomita et al. Apr 1977 A
4067251 Eckle et al. Jan 1978 A
4087890 Ishizuka et al. May 1978 A
4163624 Eckle Aug 1979 A
4184391 Eckle Jan 1980 A
4200418 Kress et al. Apr 1980 A
4224846 Eysel et al. Sep 1980 A
4245939 Sear Jan 1981 A
4289431 Berstein Sep 1981 A
4350054 Werth, Jr. Sep 1982 A
4387612 Eckle et al. Jun 1983 A
4409721 Tomita et al. Oct 1983 A
4417379 Goode Nov 1983 A
4443140 Boetto Apr 1984 A
4480700 Kieger Nov 1984 A
4489629 D'Andrea Dec 1984 A
4607549 Krempel Aug 1986 A
4634324 Eckle et al. Jan 1987 A
4637285 Mizoguchi Jan 1987 A
4742738 Strand May 1988 A
4762037 Stoffel Aug 1988 A
4786217 Johne Nov 1988 A
4913602 Peter et al. Apr 1990 A
4941782 Cook Jul 1990 A
5033918 Eysel et al. Jul 1991 A
5116171 Gerk et al. May 1992 A
5251511 Muendlein et al. Oct 1993 A
5304019 Klee et al. Apr 1994 A
5307714 Muendlein et al. May 1994 A
5368420 Gerk et al. Nov 1994 A
5427480 Stephens Jun 1995 A
5599146 Scheer Feb 1997 A
5655422 Stolz et al. Aug 1997 A
5713703 Gerk et al. Feb 1998 A
5865573 Kress Feb 1999 A
6196773 Hyatt et al. Mar 2001 B1
6243962 Brock Jun 2001 B1
6270295 Hyatt et al. Aug 2001 B1
6536998 Hyatt et al. Mar 2003 B2
Foreign Referenced Citations (8)
Number Date Country
143046 Jul 1980 DD
212669 Aug 1984 DD
2013539 Aug 1979 GB
14088 Feb 1979 JP
222124 Oct 1968 SU
1196154 Dec 1985 SU
1278118 Dec 1986 SU
1583227 Aug 1990 SU
Provisional Applications (2)
Number Date Country
60/099464 Sep 1998 US
60/265015 Jan 2001 US
Continuation in Parts (1)
Number Date Country
Parent 09/392114 Sep 1999 US
Child 09/810593 US