U.S. patent number 10,981,233 [Application Number 16/486,961] was granted by the patent office on 2021-04-20 for mechanical roughening by a tool with translatable swaging blades.
This patent grant is currently assigned to FORD MOTOR COMPANY. The grantee listed for this patent is Ford Motor Company. Invention is credited to David Alan Stephenson.
United States Patent |
10,981,233 |
Stephenson |
April 20, 2021 |
Mechanical roughening by a tool with translatable swaging
blades
Abstract
A method includes positioning a cylindrical tool having one or
more rows of blades within a cylindrical bore having a surface,
forming annular grooves and peaks into the surface with the
grooving blades when the swaging blades are in the retracted
position, and translating the swaging blades from the retracted
position to the extended position to deform the peaks. The one or
more rows of blades includes fixed grooving blades and translatable
swaging blades having retracted and extended positions.
Inventors: |
Stephenson; David Alan
(Detroit, MI) |
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Motor Company |
Dearborn |
MI |
US |
|
|
Assignee: |
FORD MOTOR COMPANY (Dearborn,
MI)
|
Family
ID: |
1000005498279 |
Appl.
No.: |
16/486,961 |
Filed: |
February 21, 2017 |
PCT
Filed: |
February 21, 2017 |
PCT No.: |
PCT/US2017/018651 |
371(c)(1),(2),(4) Date: |
August 19, 2019 |
PCT
Pub. No.: |
WO2018/156098 |
PCT
Pub. Date: |
August 30, 2018 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20200230839 A1 |
Jul 23, 2020 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23C
5/18 (20130101); B23C 3/34 (20130101); B23B
41/12 (20130101); Y10T 409/307616 (20150115); B23C
2222/52 (20130101); B23B 2220/44 (20130101); Y10T
407/23 (20150115); B23C 2215/242 (20130101); C23C
4/02 (20130101); B23B 2220/123 (20130101); B23C
2222/04 (20130101); Y10T 408/375 (20150115); Y10T
407/1914 (20150115) |
Current International
Class: |
B23B
41/12 (20060101); B23C 5/18 (20060101); B23C
3/34 (20060101); C23C 4/02 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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202388017 |
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103056402 |
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4022579 |
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4402503 |
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2973267 |
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Oct 2012 |
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979803 |
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11010414 |
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JP |
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2009095918 |
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May 2009 |
|
JP |
|
Other References
International Search Report for PCT/US2017/018643 dated May 23,
2017, 2 pages. cited by applicant .
International Search Report for PCT/US2017/018651 dated May 11,
2017, 2 pages. cited by applicant .
First Office Action for Chinese Application No. 201780086959.3,
dated Apr. 23, 2020, 13 Pages. cited by applicant .
First Office Action for Chinese Application No. 201780087018.1,
dated Apr. 29, 2020, 11 Pages. cited by applicant.
|
Primary Examiner: Gates; Eric A.
Attorney, Agent or Firm: Mastrogiacomo; Vincent Brooks
Kushman P.C.
Claims
What is claimed is:
1. A method comprising: positioning a cylindrical tool having a
body with one or more rows of blades within a cylindrical bore
having a surface, the one or more rows of blades including fixed
grooving blades mounted to the body, and translatable swaging
blades having a retracted position within the body and an extended
position with distal ends of the translatable swaging blades being
positioned radially outward from grooving blade distal ends;
forming annular grooves and peaks into the surface with the
grooving blades when the swaging blades are in the retracted
position within the body such that the distal ends are radially
inward of a radius of the body; and translating the swaging blades
from the retracted position to the extended position to deform the
peaks.
2. The method of claim 1, further comprising translating the
swaging blades from the extended position to the retracted position
after the peaks are deformed.
3. The method of claim 1, wherein each deformed peak includes an
undercut.
4. The method of claim 1, further comprising actuating an actuator
configured to translate the swaging blades between the retracted
position to the extended position.
5. A method comprising: positioning a cylindrical tool at an axial
location along a length of a cylinder bore having a surface, the
cylindrical tool having a body with fixed grooving blades mounted
about the circumference of the body and defining recesses about the
circumference of the body to receive translatable swaging blades in
a retracted position such that the distal ends of the translatable
swaging blades are radially inward of a periphery of the body;
forming grooves and peaks into the surface at the axial location
with the grooving blades when the swaging blades are in a retracted
position within the recesses; and deforming the peaks with the
swaging blades when the swaging blades are in an extended position
at the axial location, wherein in the extended position, each
distal end of each of the translatable swaging blades extend
radially outward past each distal end of each of the fixed grooving
blades.
6. The method of claim 5, further comprising translating the
swaging blades between the retracted and extended position after
the forming step.
7. The method of claim 6, further comprising actuating an actuator
configured to translate the swaging blades between the retracted
position and the extended position.
8. The method of claim 5, further comprising removing the tool from
the cylinder bore after the deforming step.
9. A method comprising: positioning a cylindrical tool having a
body with one or more rows of elements including grooving elements
and swaging elements, one of the grooving elements and swaging
elements being fixed elements with distal ends positioned radially
outward of a periphery of the body and the other being translatable
elements movable between a retracted position with each of the
translatable elements being housed in a respective recess defined
in the body such that distal ends of the translatable elements are
positioned radially inward of the periphery to an extended position
with distal ends of the translatable elements being radially
outward of the distal ends of the fixed elements; forming grooves
into a cylindrical surface with the grooving elements to form peaks
therebetween; and deforming the peaks with the swaging
elements.
10. The method of claim 9, wherein the swaging elements are
translatable.
11. The method of claim 10, wherein the grooves are formed when the
swaging elements are in the retracted position.
12. The method of claim 11, further comprising translating the
swaging elements to the retracted position after the deforming
step.
13. The method of claim 9, wherein the grooving elements are
translatable.
14. The method of claim 13, wherein the peaks are deformed when the
grooving elements are in the retracted position.
15. The method of claim 14, further comprising translating the
grooving elements to the extended position after the deforming
step.
16. The method of claim 9, further comprising maintaining the tool
at an axial location along the length of a cylinder bore during the
forming and deforming steps.
17. The method of claim 9, further comprising translating one of
the grooving elements and swaging elements having the retracted and
extended positions by actuating an actuator located on the
tool.
18. The method of claim 9, wherein the grooving and swaging
elements in each row are positioned along a circumference of the
tool.
Description
TECHNICAL FIELD
The present disclosure relates to a method for roughening surfaces
of cylinder bores.
BACKGROUND
Cylinder bores of aluminum engine blocks, where an engine piston
travels, may be treated with a thin layer of thermally sprayed
steel for wear resistance. The cylinder bore surface is often
machined, by mechanical roughening, to provide surface roughness to
facilitate bonding of the steel coating. A grooving tool may be
used to roughen a surface by cutting a series of grooves into the
substrate. A rotary swage-wiper (swaging) tool then can deform the
groove tops to produce an undercut. The use of the grooving and
swiper/swager tools results in positional and orientation errors
due to the intermediate tool change, a heavier nominal deformation,
tool run out, and/or swiping depth variation resulting in voids and
unevenness in the thermal spray coating.
SUMMARY
According to an embodiment, a method includes positioning a
cylindrical tool having one or more rows of blades including fixed
grooving blades and translatable swaging blades having retracted
and extended positions within a cylindrical bore having a surface.
The method further includes forming annular grooves and peaks into
the surface with the grooving blades when the swaging blades are in
the retracted position, and translating the swaging blades from the
retracted position to the extended position to deform the
peaks.
In one or more embodiments, the method may further include
translating the swaging blades from the extended position to the
retracted position after the peaks are deformed. Each deformed peak
may include an undercut. The method may further include actuating
an actuator configured to translate the swaging blades between the
retracted position to the extended position. The method may also
include translating the swaging blades to the extended position
such that a distal end of each of the swaging blades extends beyond
a distal end of each of the grooving blades.
According to an embodiment, a method includes positioning a
cylindrical tool having translatable swaging blades and grooving
blades at an axial location along the length of a cylinder bore
having a surface, forming grooves and peaks into the surface with
the grooving blades when the swaging blades are in the retracted
position at the axial location, and deforming the peaks with the
swaging blades when the swaging blades are in the extended position
at the axial location.
In one or more embodiments, the method may further include
translating the swaging blades between the retracted and extended
position after the forming step. The method may further include
actuating an actuator configured to translate the swaging blades
between the retracted position and the extended position. The
method may include translating the swaging blades to the extended
position such that a distal end of each of the swaging blades
extends beyond a distal end of each of the grooving blades. The
method may also include removing the tool from the cylinder bore
after the deforming step.
According to an embodiment, a method includes positioning a
cylindrical tool having one or more rows of elements including
grooving elements and swaging elements, one of the grooving
elements and swaging elements being translatable between a
retracted position to an extended position, forming grooves into a
cylindrical surface with the grooving elements to form peaks
therebetween, and deforming the peaks with the swaging
elements.
In one or more embodiments, the swaging elements may be
translatable. The grooves may be formed when the swaging elements
are in the retracted position. The method may further include
translating the swaging elements to the retracted position after
the deforming step. In another embodiment, the grooving elements
may be translatable. The peaks may be deformed when the grooving
elements are in the retracted position. The method may further
include translating the grooving elements to the extended position
after the deforming step. In one or more embodiments, the method
may further include maintaining the tool at an axial location along
the length of a cylinder bore during the forming and deforming
steps. The method may further include translating one of the
grooving elements and swaging elements having the retracted and
extended positions by actuating an actuator located on the tool.
The grooving and swaging elements in each row may be positioned
along a circumference of the tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a perspective view of the surface roughening tool
showing the grooving blades and swaging blades with the swaging
blades extended.
FIG. 2A depicts a partial cross-section of the swaging blades and
grooving blades of FIG. 1 taken along line 2A, 2B with the swaging
blades retracted.
FIG. 2B depicts a partial cross-section of the swaging blades and
grooving blades of FIG. 1 taken along line 2A, 2B with the swaging
blades extended.
FIG. 3A depicts a partial and isolated schematic view of the
surface roughening tool with the swaging blade retracted.
FIG. 3B depicts a partial and isolated schematic view of the
surface roughening tool of with the swaging blade extended.
FIG. 4A is a side view of the surface roughening tool depicting one
swaging blade retracted according to one or more embodiments.
FIG. 4B is a top view of the surface roughening tool depicting one
swaging blade retracted according to one or more embodiments.
FIG. 5A is a side view of the surface roughening tool depicting one
swaging blade extended according to one or more embodiments.
FIG. 5B is a top view of the surface roughening tool depicting one
swaging blade extended according to one or more embodiments.
FIG. 6 is a side view of the surface roughening tool according to
one or more embodiments.
FIG. 7 is a side view of the surface roughening tool according to
one or more embodiments.
DETAILED DESCRIPTION
As required, detailed embodiments of the present invention are
disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention that
may be embodied in various and alternative forms. The figures are
not necessarily to scale; some features may be exaggerated or
minimized to show details of particular components. Therefore,
specific structural and functional details disclosed herein are not
to be interpreted as limiting, but merely as a representative basis
for teaching one skilled in the art to variously employ the present
invention.
Automotive engine blocks include a number of cylindrical engine
bores. Cylinder bores may be formed and defined by a cylindrical
wall of metal material, including steel iron, and aluminum. In
certain instances, cylinder bores formed from and defined by
relatively light weight metals, such as aluminum or magnesium, may
be used instead of steel or iron cylinder bores to reduce engine
size and/or weight and improve engine power output and fuel
economy. When aluminum is used to construct such blocks, certain
processes are known to enhance strength and wear resistance of the
aluminum engine cylinder bores.
The inner surface of each engine bore is machined so that the
surface is suitable for use in automotive applications, e.g.,
exhibits suitable wear resistance and strength. Internal
cylindrical surfaces where an engine piston travels may be treated
to provide surface roughness to facilitate bonding to a later
applied metallic coating. The machining process may include
roughening the inner surface, subsequently applying the metallic
coating to the roughened surface, and honing the metallic coating
to obtain a finished inner surface with the requisite strength and
wear resistance. A metallic coating may be applied using thermal
spraying. Alternatively, a liner material having requisite strength
and wear resistance characteristics may be applied to the
unfinished inner surface of the engine bore.
FIG. 1 depicts a surface roughening tool 100 for roughening the
surface of a cylinder bore to improve bonding of a thermally
sprayed coating. Generally, the tool 100 is held in a holder
fastened to a tool spindle (not shown). The spindle may be either a
box or motorized spindle. The tool 100 is used to produce grooves
into the surface of the cylinder bore, which run in the
circumferential direction of the cylinder bore, as the tool 100 is
lowered into the cylinder bore. The profile produced on the surface
has grooves with intermediate ridges, or peaks, in between. The
tool spindle has an axis of rotation parallel to the cylinder bore
axis. The longitudinal axis of the tool (along the length) is
offset from the cylinder bore axis. The tool rotates in the spindle
about the tool axis at an angular speed, and precesses around the
bore axis at a separate angular speed. The precession around the
axis is referred to as circular interpolation. The tool 100
interpolates such that the tool blades rotate and move
simultaneously in a circular path around the cylinder bore surface,
moving down the length of the cylinder bore. This permits machining
of grooves in any bore with a diameter larger than the tool 100
such that bores of different diameters can be cut with the same
tool. The interpolation movement permits the formation of a pocket
and the annular parallel grooves within the inner surface of the
cylinder bore. The interpolation of the tool is discussed in U.S.
patent application Ser. No. 13/913,865, filed on Jun. 10, 2013, and
Ser. No. 13/461,160, filed on May 1, 2012, which are incorporated
by reference herein in their entirety.
The grooving blades 110, or grooving elements, are projecting
radially outward from the tool 100 on tool body 130, and are
configured to cut into the surface to form the grooves and peaks.
Cylindrical tool body 130 may be formed of steel or cemented
tungsten carbide. The grooving elements 110 may be dispersed in one
or more axial rows along the length of the tool 100 to provide a
cutting edge. Grooving blades 110 have a distal end 160 and may be
dispersed around the circumference of the tool body 130 and along
the longitudinal axis of the tool 100 to form a desired profile of
grooves and peaks within the cylinder bore. In a non-limiting
example, grooving blades 110 are equally radially spaced apart from
adjacent grooving blades 110. Any number of grooving blades 110 may
be used. The grooving blades 110 may be formed of rows of grooving
elements brazed end to end to form a long cutting edge. The
grooving blades 110 may be formed of a cutting material suitable
for machining aluminum or magnesium alloy. The considerations for
selecting such materials include without limitation chemical
compatibility and/or hardness. Non-limiting examples of such
materials include, without limitation, high speed steel, sintered
tungsten carbide or polycrystalline diamond. The grooving blades
and elements may also include pocket cutting elements.
The surface roughening tool 100 also includes swaging blades 120,
or swaging elements, which deform the peaks formed by the grooving
blades 110 to produce an undercut on the peaks. The swaging
elements may also be referred to as swiping elements because the
tool used for deformation may be a swiper (swage/wiper). The
resulting profile may be a dovetail type shape of the peaks. The
swaging blades are dispersed corresponding to the grooving blades
110 such that the swaging blades 120 can deform the peaks formed by
the grooving blades 110. The swaging elements 110 may be dispersed
in one or more axial rows along the length of the tool 100 to
provide a cutting edge. The swaging blades 120 may be formed of
swaging elements brazed end to end to form a long cutting edge. The
swaging blades may be dispersed around the circumference of the
tool body 130 as well as along the longitudinal axis of the tool
100 to form the desired profile of grooves and undercut peaks
within the cylinder bore. The swaging blades 120 are capable of
projecting radially outward from the tool 100, beyond the grooving
blades 110, and may also be storable in a recess of the tool body
130. The swaging blades 110 may be formed of a cutting material
suitable for machining aluminum or magnesium alloy. The
considerations for selecting such materials include without
limitation chemical compatibility and/or hardness. A non-limiting
example of the swaging blades 120 includes polycrystalline
diamond.
FIGS. 2A and 2B show a cross section of the tool taken along line
2A, 2B. Swaging blades 120 are translatable between a retracted
position and an extended position, as shown in FIGS. 2A and 2B,
respectively. When the swaging blades 120 are in the retracted
position, the blades 120 are wholly or partially stored in a recess
in the tool body 130 such that the cutting edge of the swaging
blades 120 are not in contact with the cylinder bore surface.
Distal end 160 of each grooving blade 110 cutting edge extends
beyond the distal end 170 of the swaging blade 120 such that the
grooving blade 110 can cut the grooves and peaks into the cylinder
bore when the swaging blade 120 is in the retracted position. After
the grooves and peaks have been cut, the swaging blades 120
translate to the extended position during rotation 150 such that
distal end 170 of the swaging blade 120 extends radially outwardly
beyond the distal end 160 of grooving blade 110. The distal end 160
of the grooving blade 110 sets a circumference 140 such that the
distal end 170 of the swaging blade 120 extends beyond this
circumference 140 when in the extended position.
Although FIGS. 2A and 2B show that the swaging blades 120 are
translatable between a retracted position and an extended position,
in certain other instances the grooving elements 110 may be
translatable, or both sets of blades may be translatable, to
roughen the surface by producing grooves and peaks, and deforming
the peaks thereafter. Similarly, the orientation of the grooving
blades 110 and swaging blades 120 with respect to the tool rotation
150 may be reversed, as well as the tool rotation itself.
FIGS. 3A and 3B depict an enlarged partial view of the surface
roughening tool 100. Distance D shows the distance swaging blade
120 translates for the distal end 170 of the swaging blade 120 to
extend past the distal end 160 of the grooving blade 110. Swaging
blade 120 is translated by an actuator 200. The actuator 200 may
utilize an eccentric cam, cone and wedge, screw mechanism, or any
similar mechanism. The actuator 200 in some instances includes an
elongated member 220 connected to a cam 210 for translating the
swaging blade 120. The elongated member 220 is connected to a
cartridge 230 which stores the swaging blade 120 in the recess of
the tool body. As the tool 100 rotates through a fixed angle in
direction 150, cam 210 moves the elongated member 220 to push the
cartridge 230 to translate the swaging blade 120 out of the tool
body 130 to the extended position.
FIGS. 4A-B, 5A-B, and 6-7 show schematics of tool 100 utilizing
various actuators 200, such as a cam, screw, or cone and wedge. As
shown in FIGS. 4A-B, 5-AB, and 6-7, one actuator mechanism is shown
for translating one swaging blade for illustrative purposes. In one
embodiment, all axially dispersed swaging blades can be translated
similarly. For example, six axially located swaging blades may be
similarly translated simultaneously by a mechanism for each swaging
blade. FIG. 4A-B shows cam 210 connected to elongated member 220
for pushing an end of cartridge 230, which has a pivot 310, for
translating one swaging blade 120 to the extended position. The
actuator 200 may be activated by a knob 320 on the tool 100 being
rotated in a direction around axis 330. FIGS. 5A-B show one swaging
blade 120 in the extended position, after the cam 210 engages the
elongated member 220 to push the cartridge 230 about pivot 310.
FIG. 5B shows the top view after one swaging blade 120 is extended
such that the base pivot 310, where the swaging blade 120 was
previously aligned, is stationary. FIG. 6 depicts a cam mechanism
210 for actuator 200. FIG. 7 depicts a wedge mechanism 210 for
actuator 200.
Having described the structure of tool 100 according to one or more
embodiments, the following describes the method of using an
embodiment of the tool 100 to machine a profile into an inner
surface of a cylinder bore. The tool 100 is typically mounted in a
machine tool spindle with an axis of rotation parallel to the
cylinder bore axis, offset from the bore axis. The tool is
positioned within the cylindrical bore, with fixed grooving blades
and translatable swaging blades. The tool interpolates around the
cylinder bore at different angular speeds about the tool axis and
the bore axis. The interpolating movement permits the formation of
a pocket and annular, parallel grooves within the inner surface of
a cylinder bore while the swaging blades are in the retracted
position. After forming the annular profile of grooves and peaks in
the cylinder bore surface, the swaging blades 120 are translated to
the extended position such that the swaging blades 120 interpolate
over the same tool path as the grooving blades 110 to reduce
positional and orientation errors. The tool 100 is maintained at an
axial location along the length of the cylinder bore during the
forming and deforming steps. An actuator 200 is engaged to
translate the swaging blades between the retracted and extended
positions. The swaging blades 120 deform the peaks after they are
translated to the extended position. In the extended position, the
swaging blades 120 have distal ends for deforming, which extend
radially beyond the distal ends of the grooving blades 110, and
produce an undercut on the peaks. Further, after deforming the
peaks, the swaging blades 120 are translated back to the retracted
position. The tool 100 may then be returned to a tool magazine. The
tool 100 may be removed from the cylinder bore for extending and
retracting the swaging blades 120.
In one or more embodiments, one of the grooving elements 110 and
swaging elements 120 are translatable. For example, the grooving
blades 110 may be retractable, and the swaging blades 120 fixed,
such that the grooving blades are translated to the retracted
position after producing the grooves and peaks in the surface. The
retracted position of the grooving blades 120 is radially inward of
the swaging blades 120 so that the swaging blades can deform the
peaks thereafter. Similarly, in other embodiments, both the
grooving blades and the swaging blades may be translatable between
an extended and retracted position to form the grooves and peaks,
and deform the peaks thereafter.
The machined surface after the grooving step and the swaging step
has one or more advantages over other roughening processes. First,
adhesion strength of the metal spray may be improved by using the
swaging step instead of other secondary processes, such as diamond
knurling, roller burnishing, wire brushing, or hydraulic expansion.
The adhesion strength was tested using a pull test. The adhesion
strength may be in the range of 40 to 70 MPa. In other variations,
the adhesion strength may be 50 to 60 MPa. Compared to the adhesion
strength of a diamond knurling process, the adhesion strength of
swiping is at least 20% higher. Further, the Applicants have
recognized that adhesion is independent of profile depth of the
grooves after the first processing step. This may be advantageous
for at least two reasons. The swaging blades cut relatively lower
profile depths compared to conventional processes, such as diamond
knurling, roller burnishing, and brushing. In certain variations,
the reduction in profile depth is 30 to 40%. Accordingly, less
metal spray material is necessary to fill the profile while not
compromising adhesion strength. Also, any variation in the depth of
the grooves does not affect the adhesion strength, which makes the
swaging step more robust than conventional processes. As another
benefit of one or more embodiments, the swaging step can be
operated at much higher operational speeds than other processes,
such as roller burnishing or diamond knurling. In addition,
translating the swaging blades to the extended position for the
swaging step eliminates positional errors and run out due to tool
change between the grooving and swaging steps of roughening the
cylinder bore surface.
While exemplary embodiments are described above, it is not intended
that these embodiments describe all possible forms of the
invention. Rather, the words used in the specification are words of
description rather than limitation, and it is understood that
various changes may be made without departing from the spirit and
scope of the invention. Additionally, the features of various
implementing embodiments may be combined to form further
embodiments of the invention.
* * * * *