U.S. patent application number 09/899071 was filed with the patent office on 2001-11-29 for method and apparatus for the manufacture of metal components requiring chip removing machining.
Invention is credited to Qvarth, Ingemar.
Application Number | 20010045002 09/899071 |
Document ID | / |
Family ID | 20414414 |
Filed Date | 2001-11-29 |
United States Patent
Application |
20010045002 |
Kind Code |
A1 |
Qvarth, Ingemar |
November 29, 2001 |
Method and apparatus for the manufacture of metal components
requiring chip removing machining
Abstract
Identical ring-shaped metal blanks are machined whereby each
blank forms a plurality of identical components. The blanks are
first machined on both sides, and then a stack of the blanks is
clamped axially adjacent one another on an arbor. Tools machine the
blanks for reshaping the blanks. One of the tools is a slitter
which makes axial cuts through the stack to separate each blank
into a plurality of components distributed around the axis.
Inventors: |
Qvarth, Ingemar; (Valbo,
SE) |
Correspondence
Address: |
Ronald L. Grudziecki, Esq.
BURNS, DOANE, SWECKER & MATHIS, L.L.P.
P.O. Box 1404
Alexandria
VA
22313-1404
US
|
Family ID: |
20414414 |
Appl. No.: |
09/899071 |
Filed: |
July 6, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09899071 |
Jul 6, 2001 |
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09500993 |
Feb 9, 2000 |
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Current U.S.
Class: |
29/558 ;
29/26A |
Current CPC
Class: |
Y10T 29/49998 20150115;
Y10T 29/49996 20150115; B23P 23/02 20130101; Y10T 29/5145 20150115;
Y10T 29/49789 20150115; Y10T 409/305824 20150115; Y10T 409/40525
20150115; Y10T 29/49798 20150115; Y10T 29/49865 20150115; Y10T
83/7763 20150401; Y10T 29/5107 20150115; Y10T 29/5143 20150115;
B23P 13/02 20130101; Y10T 82/10 20150115; Y10T 279/30 20150115;
B23C 5/006 20130101 |
Class at
Publication: |
29/558 ;
29/26.00A |
International
Class: |
B23P 013/04 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 10, 1999 |
SE |
9900440-0 |
Claims
What is claimed is:
1. A method of manufacturing metal components, comprising the steps
of: A) face-machining opposite sides of each of a plurality of
ring-shaped metal blanks; B) securing the face-machined blanks in
axially adjacent relationship along an axis, whereby the blanks are
immovable relative to one another; and C) performing a plurality of
different chip-removing machining operations on each blank for
reshaping the blanks, one of the machining operations comprising
making axial cuts through the blanks in a direction parallel to the
axis to separate each blank into a number of components distributed
around the axis.
2. The method according to claim 1 wherein step B further includes
arranging the blanks concentrically on an arbor, the arbor defining
the axis.
3. The method according to claim 2 wherein step B further includes
pressing the side surfaces of adjacent blanks into direct contact
with one another.
4. The method according to claim 1 wherein step B further includes
pressing the side surfaces of adjacent blanks into direct contact
with one another.
5. The method according to claim 1 wherein the blanks that are
face-machined in step A comprise hardened steel blanks.
6. The method according to claim 1 wherein the one machining
operation which makes axial cuts comprises a slit cutting
operation.
7. The method according to claim 1 wherein the one machining
operation which makes axial cuts makes each of such axial cuts
through all of the blanks from one end-most blank to another
end-most blank.
8. The method according to claim 1 wherein step A comprises
face-machining opposite sides of each of a plurality of ring-shaped
metal blanks of circular cross-section.
9. The method according to claim 1 wherein step A comprises
face-machining opposite sides of each of a plurality of ring-shaped
metal blanks of non-circular cross-section.
10. The method according to claim 1 wherein the blanks used in step
A are identical, and the components formed in step C are
identical.
11. The method according to claim 1 wherein the machining tools
further include a hole-forming drill.
12. An apparatus for machining metal components, comprising: an
arbor defining an axis, the arbor having a stop surface at one
axial end thereof and a clamp at an opposite axial end thereof; a
set of ring-shaped metal blanks clamped on the arbor between the
stop surface and the clamp so as to be immovable relative to one
another; and a plurality of machining tools for performing a
plurality of different chip-removing machining operations on each
blank for reshaping the blanks, one of the machining tools arranged
for making axial cuts through the blanks in a direction parallel to
the axis for separating each blank into a number of components
distributed around the axis.
13. The apparatus according to claim 12 wherein the arbor includes
a cylindrical envelop surface having circumferentially spaced,
axially extending grooves for receiving peripheral portions of the
one machining tool which makes axial cuts.
14. The apparatus according to claim 13 wherein the clamp comprises
a cage axially movable along the arbor, and a nut threadedly
mounted on the arbor for pushing the cage toward the stop
surface.
15. The apparatus according to claim 14 wherein the stop surface is
formed on a stop member, the stop member and the cage including
recesses axially aligned with respective ones of the grooves.
Description
BACKGROUND OF THE INVENTION
[0001] The invention pertains to methods and apparatus for the
manufacture of metal components requiring chip removal
machining.
[0002] Tools for chip removing machining, such as milling tools,
drilling tools, turning tools and the like commonly include
miscellaneous components which are of a limited size in relation to
the tool in its entirety and which must be machined to high
accuracy. Examples of such components are cassettes and wedges for
milling tools, shims for drilling and turning tools, clamps and
chip breakers for milling tools, etc. Critical surfaces on such
components often require tolerances within the range of 0.005-0.02
mm. The same fine tolerances are also required for holes in the
components and for serrations, thereon. Such components are usually
made of steel, which requires hardening.
[0003] Manufacturing methods, known hitherto, require individual
handling of metal blanks, which are slightly larger than the
components will be after all machining has been completed. Usually,
the blanks are cast in steel, and then the individual blanks are
machined in a series of different operations. In the case of, for
instance, cassettes for milling tools, seats are milled for cutting
inserts at a certain machining station, while grinding of external
surfaces takes place at another station. At additional stations,
serrations may be produced by the milling of an external surface,
and holes may be drilled and possibly screw-threaded.
[0004] Between these stations, the individual blanks have to be
handled separately since they have to be released from the fixture
in question after a first machining operation and then re-mounted
in another fixture for the next machining operation. In case one
and the same blank is to be submitted to many machining operations,
the handling as a whole will be time-consuming and expensive.
Furthermore, the individual handling at and between different
machining stations has the aggravating disadvantage that the
dimensional accuracy may suffer. Thus, if all blanks are not
positioned and fixed in the same way, there is a risk that
individual components get unacceptable tolerance deviations. It
should also be mentioned that the requisite hardening of the
blanks/components has to be carried out individually.
OBJECTS AND FEATURES OF THE INVENTION
[0005] The present invention aims at obviating the above-mentioned
disadvantages of the previously applied manufacturing method and,
in a first aspect, at providing an improved method for the
manufacture of components which require chip removing machining. A
primary object of the invention is to provide a manufacturing
method which permits an accurate machining of the requisite metal
blanks without the need to move, between different machining
stations and fixtures, respectively, a plurality of components
which in all essentials could instead be machined to completion at
one machining station. An object is also to provide a manufacturing
method, which permits an efficient and thereby inexpensive
production.
[0006] According to the invention, at least the primary object is
obtained by a method of manufacturing metal components, comprising
the step of:
[0007] A) face-machining opposite sides of each of a plurality of
ring-shaped metal blanks;
[0008] B) securing the face-machined blanks in axially adjacent
relationship along an axis, whereby the blanks are immovable
relative to one another; and
[0009] C) performing a plurality of different chip-removing
machining operations on each blank for reshaping the blanks, one of
the machining operations comprising making axial cuts through the
blanks in a direction parallel to the axis to separate each blank
into a number of components distributed around the axis.
[0010] Another aspect of the invention involves an apparatus for
machining metal components. The apparatus includes an arbor which
defines an axis. The arbor has a stop surface at one axial end
thereof and a clamp at an opposite axial end thereof. A set of
ring-shaped metal blanks is clamped on the arbor between the stop
surface and the clamp so as to be immovable relative to one
another. A plurality of machining tools is provided for performing
a plurality of different chip-removing machining operations on each
blank for reshaping the blanks. One of the machining tools is
arranged for making axial cuts through the blanks in a direction
parallel to the axis for separating each blank into a number of
components distributed around the axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings:
[0012] FIG. 1 is a schematic, exploded view showing a number of
tangentially spaced, finish-machined components, as well as a
number of components arranged axially one after the other,
[0013] FIG. 1A is a side elevational view of an arbor according to
the present invention;
[0014] FIG. 2 is a partial cross-sectional side view showing a
number of ring blanks fixed on the arbor,
[0015] FIG. 3 is a side view of a single ring blank,
[0016] FIG. 4 is a cross-section through the ring blank according
to FIG. 3,
[0017] FIG. 5 is an enlarged cross-section through the arbor
according to FIG. 2 with a number of components positioned
peripherally on the arbor, and
[0018] FIG. 6 is an enlarged, partial cross-section through an
arbor and a number of other components illustrating other feasible
machining operations than those shown in FIG. 5.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
[0019] In FIG. 1a number of metal components 1 are shown, of which
some are tangentially spaced and located in a ring-shaped
configuration, while others are arranged side by side in an axial
extension of one of the components in the ring formation. In the
shown example, these components consist of wedges having the
purpose of clamping a cutting insert in a cassette included in a
milling tool (wherein the wedges would be arranged in the shown
ring shape). In addition to a number of planar surfaces, this type
of wedge is delimited by a concavely arched surface 2.
[0020] Reference is now made to FIGS. 1A-6, which illustrate
schematically a method according to the invention for making the
wedges, together with a device for carrying out the method.
[0021] In FIGS. 3 and 4 a metal blank 3 in the shape of a ring is
shown (in a small scale). In this case, the ring is cylinder-shaped
in that the same is delimited by a cylindrical inner surface 4 and
a likewise cylindrical outer surface 5, the two opposite side
surfaces 6 being planar and mutually substantially parallel.
Alternatively, the ring and arbor could be non-cylindrically
shaped, e.g., polygonally shaped in cross-section.
[0022] In FIGS. 1A, 2, 5 and 6, reference numeral 7 designates an
arbor which at one end has a stop member 8 and at the opposite end
an axially movable clamping mechanism generally designated 9. In
the preferred embodiment, this clamping mechanism includes a cage
10 axially movable along the arbor, as well as a nut 11, which is
fastened with screws on a threaded end portion 12 of the arbor. In
the example, the stop member 8 consists of a thickened portion of
the arbor. This thickened portion as well as the cage 10 have
planar shoulder surfaces 13 and 14, respectively, which extend
perpendicularly to the geometrical, longitudinal axis of the
arbor.
[0023] Two cutting tools, shown schematically, are in the form of
so-called slitting cutters 15. Slits or cuts may be milled in the
ring blanks 3 by means of these cutters, which blanks are mounted
in axially adjacent relationship on the arbor and fixed thereon by
means of the clamping mechanism. A number of circumferentially
spaced grooves 16 extending axially along the arbor are provided in
order to be able to receive peripheral edges of the cutters whilst
they cut completely through the set of rings. Partially circular
recesses 17 serving as extensions of the grooves 16 are formed in
the portion 8, which serves as a stop member. Analogous recesses
17' are formed in the cage 10.
[0024] An important feature of the method according to the
invention consists of using, as manufacturing blanks, rings 3 which
individually have a volume large enough to form a plurality of
finished components 1. In the example according to FIG. 1, each
individual ring blank 3 is assumed to be large enough to permit the
manufacture of ten components.
[0025] In a first manufacturing step, the individual ring blank is
face-machined on the two opposite sides 6 thereof. This machining,
which, in practice, can consist of face milling or face grinding,
can be carried out in a conventional way, to an accuracy within the
range of 0.005-0.02 mm. In a second step, two or more face machined
ring blanks are put together one after the other along a common
geometrical axis, and fixed in relation to each other while forming
a stable set of rings. In the example according to FIG. 2, twelve
ring blanks are shown in such a set. In practice, the rings are
axially inserted onto the arbor 7, and then the cage 10 is applied
and tightened by means of the nut 11. Thanks to the fact that all
the ring blanks have face-machined, parallel side surfaces 6, and
that the pressing surfaces 13, 14 extend perpendicularly to the
longitudinal axis of the arbor, an immovable clamping of the rings
in the set is achieved.
[0026] When the set of ring blanks have been fixed, the ring set is
submitted to a number of chip removing machining operations, the
nature of which depends on the type of component which is desired.
In FIGS. 5 and 6 examples are given as to how drills 23, 23', 23"
may provide a possible means of drilling holes of different types
in the ring blanks, e.g. a through-hole 18 for receiving a fastener
screw, a hole 18' which forms a spring seat, and a hole 18",
respectively, for a pin. Furthermore, serrations 19 may be formed
by means of a milling cutter along one side of the component. In
other respects, a number of face machined surfaces 20 are formed by
means of one or more face-mills which with modem milling equipment
may be given a very close dimensional accuracy. Although the
drilling operations are carried out one-by-one in different
positions, all milling operations may be carried out by relative
axial movements between the ring set and the milling tool, whereby
each surface or serration can be machined in one single pass. In
other words, the tool and/or the ring set is/are transported in one
single, unbroken motion from one end of the ring set to the
opposite one.
[0027] In a number of concluding machining operations, the ring set
is given tangentially spaced and radially oriented through-cuts,
which form individual components 1 from each blank 3. This may be
carried out with the above-mentioned slitting cutters 15, which may
cut through the rings entirely, in that the peripheral portions of
the cutters carrying the cutting inserts may be led down into the
grooves 16 and the recesses 17, 17', respectively, in the stop
member 8 and the cage 10, respectively. This slit cutting can be
carried out by axial displacement of the milling-cutter through the
ring set while forming the component-separating slits 21, whereby
the individual components, which are separated from each other,
still hang together because they are clamped between the cage 10
and the stop member 8. In other words, the finish-machined
components will be separated from the arbor 7 only when the nut 11
and the cage 10 have been separated.
[0028] In cases where the components are intended to be included in
tools for chip removing machining, they are usually manufactured in
steel. The invention offers a possibility to carry out the
requisite hardening of the steel before the above-mentioned
machining operations are started. In other words, the unmachined
ring blanks 3 while in the unmachined state may be submitted to
hardening. In that manner, the following advantages are won, the
machining accuracy is improved, and the comparatively large ring
blanks facilitate and hasten the requisite handling in connection
with hardening (the numerous, small components which are extracted
from each ring blank would require a handling which is more
time-consuming).
[0029] A significant advantage of the invention is that numerous
components may be machined and extracted at the same time without
having to be repeatedly moved between different machining stations
and fixtures. This, in turn, ensures high accuracy of the
components after all machining has been completed. In all
essentials, all components become identical.
[0030] In the embodiments exemplified, the ring blanks 3 are
cylinder-shaped and used for the manufacture of wedges which have
concavely arched surfaces 2 of the type shown in FIG. 1. Other
components may, however, require differently shaped surfaces, e.g.
planar surfaces. In case the ring blank is cylindrical, a final
face machining is required when the components have been separated
from each other.
[0031] Although after-treatment of the individual components may be
needed, the majority of machining operations may be carried out
while the ring blanks are kept together in a set which has a stable
shape. In this connection, it has been pointed out that the ring
blanks, as well as the arbor, may be of a shape other than
cylindrical. The ring blanks, for instance, as well as the arbor,
may be of a polygonal shape in cross-section (e.g. quadrangular,
pentagonal and hexagonal, respectively). In such cases, the arbor
and the ring blanks, respectively, may be formed and located in
such a way in relation to each other that gaps result between the
interior of the ring and the outside of the arbor, with the
peripheral portion of the slitting cutter being housed in these
spaces. In other words, there would be no need for providing
grooves in the arbor.
OTHER FEASIBLE MODIFICATIONS OF THE INVENTION
[0032] The invention is not limited to the embodiments illustrated
schematically in the drawings. Thus, it is feasible to dispose the
ring blanks in a set in which ring-shaped shims between adjacent
ring blanks are included. In other words, the ring blanks do not
need to be pressed in direct surface contact with each other as is
shown in FIG. 2.
[0033] Although the ring blanks, in the preferred embodiments, are
placed concentrically in relation to a mutual geometrical axis,
e.g. on an arbor common for all rings, it is also feasible to mount
the rings without any requirement regarding concentricity. Although
the above invention has been described in connection with
components intended to be included in different types of tools for
chip removing machining, the same may also apply for other
arbitrary, small components irrespective of the material
thereof.
* * * * *