U.S. patent application number 11/926944 was filed with the patent office on 2008-02-28 for methods and apparatus for machining a coupling.
Invention is credited to Greg M. Burgess.
Application Number | 20080051013 11/926944 |
Document ID | / |
Family ID | 39197251 |
Filed Date | 2008-02-28 |
United States Patent
Application |
20080051013 |
Kind Code |
A1 |
Burgess; Greg M. |
February 28, 2008 |
METHODS AND APPARATUS FOR MACHINING A COUPLING
Abstract
A method facilitates fabricating a coupling including a first
annular coupling member and a second annular coupling member. The
method comprises coupling the first coupling member to a machine
assembly that includes a plurality of grinding wheels coupled to a
tool storage member, machining a plurality of troughs in the first
coupling member using at least one of the plurality of grinding
wheels, such that at least one projection is defined between
adjacent troughs, coupling the second coupling member to the
machine assembly, and machining a plurality of troughs in the
second coupling member using at least one of the plurality of
grinding wheels, such that the second coupling member is configured
to rotatably couple to the first coupling member.
Inventors: |
Burgess; Greg M.;
(Maineville, OH) |
Correspondence
Address: |
John S. Beulick;Armstrong Teasdale LLP
Suite 2600
One Metropolitan Square
St. Louis
MO
63102-2740
US
|
Family ID: |
39197251 |
Appl. No.: |
11/926944 |
Filed: |
October 29, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11397999 |
Apr 5, 2006 |
|
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11926944 |
Oct 29, 2007 |
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Current U.S.
Class: |
451/51 ; 451/278;
483/33 |
Current CPC
Class: |
B24B 53/062 20130101;
Y10T 483/174 20150115; B24D 7/10 20130101; B24B 41/06 20130101;
B23F 15/06 20130101; B24B 27/0061 20130101 |
Class at
Publication: |
451/051 ;
451/278 |
International
Class: |
B24B 7/00 20060101
B24B007/00 |
Claims
1. A method for fabricating a coupling including a first annular
coupling member and a second annular coupling member, said method
comprising: coupling the first coupling member to a machine
assembly that includes a plurality of grinding wheels coupled to a
tool storage member; machining a plurality of troughs in the first
coupling member using at least one of the plurality of grinding
wheels, such that at least one projection is defined between
adjacent troughs; coupling the second coupling member to the
machine assembly; and machining a plurality of troughs in the
second coupling member using at least one of the plurality of
grinding wheels, such that the second coupling member is configured
to rotatably couple to the first coupling member.
2. A method in accordance with claim 1 wherein machining a
plurality of troughs in the first coupling member further comprises
supplying coolant to the grinding wheel through a coolant
passageway defined in the grinding wheel.
3. A method in accordance with claim 1 wherein machining a
plurality of troughs in the first coupling member further
comprises: machining a plurality of troughs in the first coupling
member using an abrasive grinding surface extending from at least
one of the grinding wheels; and supplying coolant to the abrasive
grinding surface through a coolant passageway defined in the
grinding wheel
4. A method in accordance with claim 1 wherein machining a
plurality of troughs in the first coupling member further
comprises: machining a plurality of troughs in the first coupling
member using an abrasive grinding surface extending from at least
one of the grinding wheels; and supplying coolant to the abrasive
grinding surface through a plurality of openings formed in the
grinding wheel.
5. A method in accordance with claim 1 further comprising dressing
at least one of said plurality of grinding wheels using a dressing
assembly coupled to the machine assembly.
6-20. (canceled)
21. A method for fabricating a coupling, said method comprising:
providing a machine assembly that includes a machine base, a
machine tool, and a pallet assembly; coupling a first coupling
member to the pallet assembly; forming a plurality of troughs in
the first coupling member using at least one of a plurality of
grinding wheels, such that at least one projection is defined
between each pair of adjacent troughs; coupling a second coupling
member to the pallet assembly; and forming a plurality of troughs
in the second coupling member using at least one of the plurality
of grinding wheels, such that the second coupling member is
configured to rotatably couple to the first coupling member.
22. A method in accordance with claim 21 wherein coupling a first
coupling member to the pallet assembly comprises removably coupling
the first coupling member to one of a plurality of fixtures coupled
to the pallet assembly.
23. A method in accordance with claim 21 wherein forming a
plurality of troughs in the first coupling member comprises:
forming a plurality of troughs in the first coupling member using
an abrasive grinding surface that extends from at least one of the
plurality of grinding wheels; and supplying coolant to the abrasive
grinding surface through a coolant chamber defined in the grinding
wheel.
24. A method in accordance with claim 24 wherein supplying coolant
to the abrasive grinding surface comprises channeling coolant
across an upstream surface of a coolant plate that includes a
plurality of openings that channel the coolant towards the abrasive
grinding surface.
25. A method in accordance with claim 21 wherein coupling a first
coupling member to the pallet assembly comprises coupling a first
coupling member to a dressing roll, wherein the dressing roll is
coupled to one of a plurality of fixtures coupled to the pallet
assembly.
26. A method in accordance with claim 25 further comprising
simultaneously positioning at least one of the plurality of
grinding wheels with respect to the first coupling member, and
dressing the grinding wheel using the dressing roll.
27. A method in accordance with claim 21 wherein forming a
plurality of troughs in the first coupling member comprises:
locating a desired grinding wheel from the plurality of grinding
wheels; and coupling the desired grinding wheel to a chuck.
28. A method in accordance with claim 25 further comprising
locating a selected pallet that contains an predetermined dressing
roll for dressing a selected grinding wheel of the plurality of
grinding wheels.
29. An apparatus for machining a coupling, said apparatus
comprising a machine base, a machine tool, and a pallet assembly,
said apparatus configured to: receive a first coupling member onto
a selected fixture of a plurality of fixtures, wherein said fixture
is coupled to a fixture tower of said pallet assembly; machine a
plurality of troughs in the first coupling member using at least
one of a plurality of grinding wheels, such that at least one
projection is defined between each pair of adjacent troughs;
receive a second coupling member onto a selected fixture of said
plurality of fixtures; and machine a plurality of troughs in the
second coupling member using at least one of said plurality of
grinding wheels, such that the second coupling member is formed to
rotatably couple to the first coupling member.
30. An apparatus in accordance with claim 29 further comprising an
automatic tool changer, wherein said apparatus is further
configured to: use said automatic tool changer to locate a desired
grinding wheel from said plurality of grinding wheels; and couple
said desired grinding wheel to a chuck.
31. An apparatus in accordance with claim 29 further comprising an
automatic pallet changer, wherein said apparatus is further
configured to: use said automatic pallet changer to locate a first
desired pallet comprising a dressing roll that corresponds to a
desired grinding wheel of said plurality of grinding wheels; align
said dressing roll with said desired grinding wheel; and dress said
desired grinding wheel using said dressing roll.
32. An apparatus in accordance with claim 31 wherein said apparatus
is further configured to: use said automatic pallet changer to
locate a second desired pallet comprising the first coupling
member; and align the first coupling member with said desired
grinding wheel.
33. An apparatus in accordance with claim 31 wherein said apparatus
is further configured to: use said automatic pallet changer to
locate a third desired pallet comprising the second coupling
member; and align the second coupling member with said desired
grinding wheel.
34. An apparatus in accordance with claim 29 wherein each grinding
wheel of said plurality of grinding wheels comprises an abrasive
surface, a coolant passageway, and a coolant chamber, wherein said
apparatus is further configured to supply coolant to said abrasive
grinding surface through said coolant chamber.
35. A method in accordance with claim 34 wherein said apparatus is
further configured to supply coolant to said abrasive grinding
surface by channeling coolant across an upstream surface of a
coolant plate that comprises a plurality of openings that channel
the coolant towards said abrasive grinding surface.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates generally to couplings, and more
specifically to methods and apparatus for machining a coupling.
[0002] Components manufactured for turbine engines may have tight
tolerances and/or rigid specifications that must be satisfied for
the components to function properly with other turbine engine
systems. For example, rotating components within the engine may be
coupled with multi-piece couplings that are rotatably mated
together. Because the components are mated together, manufacturing
the components within the rigid tolerances may be essential to the
performance of the component.
[0003] As such, manufacturing such components may be a
time-consuming and laborious task. To facilitate streamlining the
manufacturing process of such components, at least some known
processes used a single-purpose machine that facilitates processing
each component in a single-piece flow. However, such processes
require frequent process setup changes to accommodate different
component configurations based on the demand for each product.
Specifically, known single-purpose machines include one fixture and
one grinding wheel that must be manually removed and replaced each
time a different component configuration is required. In addition,
to facilitate reducing process variation, each time grinding wheel
and/or fixture is interchanged, manual machine adjustments must
typically be made prior to commencing production.
BRIEF DESCRIPTION OF THE INVENTION
[0004] In one aspect a method for fabricating a coupling including
a first annular coupling member and a second annular coupling
member is provided. The method comprises coupling the first
coupling member to a machine assembly that includes a plurality of
grinding wheels coupled to a tool storage member, machining a
plurality of troughs in the first coupling member using at least
one of the plurality of grinding wheels, such that at least one
projection is defined between adjacent troughs, coupling the second
coupling member to the machine assembly, and machining a plurality
of troughs in the second coupling member using at least one of the
plurality of grinding wheels, such that the second coupling member
is configured to rotatably couple to the first coupling member.
[0005] In another aspect of the invention, a machine assembly for
use in machining a coupling is provided. The machine tool comprises
a machine tool, at least two grinding wheels, and a tool storage
member that is coupled to the machine tool. The at least two
grinding wheels are removably coupled to the tool storage member.
The machine tool is configured to use at least one of the two
grinding wheels to machine a plurality of troughs in at least one
generally annular coupling member, wherein at least one projection
is defined between adjacent troughs, and such that the coupling
member is configured to be rotationally coupled to another coupling
member using the projections and troughs.
[0006] In a further aspect, a grinding wheel is provided. The
grinding wheel includes a body, at least one grinding surface
extending outwardly from the body, and a cooling system extending
through at least one of the body and the at least one grinding
surface for supplying coolant to the at least one grinding
surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of an exemplary coupling;
[0008] FIG. 2 is a perspective view of a portion of the coupling
shown in FIG. 1;
[0009] FIG. 3 is a perspective view of an exemplary machining
assembly for fabricating a coupling, such as the coupling shown in
FIG. 1;
[0010] FIG. 4 is a perspective partial cutaway view of a portion of
an exemplary grinding wheel for use with a machining assembly, such
as the machining assembly shown in FIG. 3;
[0011] FIG. 5 is a cross-sectional view of a portion of the
grinding wheel shown in FIG. 4;
[0012] FIG. 6 is a perspective view of an exemplary scrubber
assembly for a grinding wheel, such as the grinding wheel shown in
FIG. 4, and in an operational;
[0013] FIG. 7 is a perspective view of the scrubber assembly shown
in FIG. 6 illustrating the scrubber assembly in a retracted
position;
[0014] FIG. 8 is a cross-sectional view of a portion of the
scrubber assembly shown in FIG. 6 and taken along line 8-8; and
[0015] FIG. 9 is a perspective view of an exemplary dressing roll
for use with a pallet assembly of a machining assembly, such as the
machining assembly shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 1 is a perspective view of an exemplary coupling 10.
FIG. 2 is a perspective view of a portion of coupling 10. Coupling
10 includes a first coupling member 12 and a second coupling member
14. Coupling members 12 and 14 each include a substantially
cylindrically shaped body 16 and 18, respectively. Bodies 16 and 18
are each annular and extend between a respective first end 20 or 22
and a respective second end 24 or 26. A central axis 27
respectively, extends through bodies 16 and 18. A bore 28 and 30
extends through each respective body 16 and 18 between each
respective first end 20 or 22 and each respective second end 24 and
26. More specifically, bores 28 and 30 are substantially concentric
with respect to bodies 16 and 18, respectively.
[0017] A plurality of teeth 32 extend outwardly from each
respective body second end 28 and 30. More specifically, each tooth
32 extends outwardly from a respective root 36 to a respective tip
38. More specifically, each tip 38 is truncated and forms a mating
surfaces 40. A plurality of respective troughs 44 and 46 are
defined between adjacent teeth 32.
[0018] In the exemplary embodiment, members 12 and 14 are rotatably
coupled together. More specifically, when coupled together, members
12 and 14 are aligned such that teeth 32 extending from body 16 are
aligned with, and received within troughs 46, and such that teeth
32 extending from body 18 are aligned with, and received within
troughs 44 such that rotational movement of body 16 or 18 with
respect to the other body 18 or 16, respectively, is prevented.
[0019] FIG. 3 is a perspective view of an exemplary machining
assembly 100 for machining a coupling, such as coupling 10 (shown
in FIGS. 1 and 2). Assembly 100 includes a machine base 102, a
machine tool 104, and a pallet assembly 106. Machine tool 104 is
coupled to base 102 and includes a tool storage carousel 108
moveably coupled thereto in any suitable manner. In one embodiment,
machine tool 104 is a computer numeric control (CNC) machining
center. Carousel 108 includes a plurality of grinding wheels 110
that are removably coupled thereto in any suitable manner, and may
also include any number of other machining tools 112 and/or
inspection tools 114 that are also removably coupled thereto in any
suitable manner. Machine tool 104 also includes an automatic tool
changer 116 coupled thereto in any suitable manner, a scrubber
assembly 118 movably coupled thereto in any suitable manner, and a
chuck 120. Chuck 120 includes a tool, and more specifically in the
exemplary embodiment, grinding wheel 110, coupled thereto. Tool
changer 116 removes a tool from chuck 116 and replaces the removed
tool with another tool selected from carousel 108. Chuck 120 is
configured to rotate about an axis of rotation 122. Scrubber
assembly 118 is also rotatable about axis of rotation 122 and
provides coolant to a tool.
[0020] Pallet assembly 106 includes a pallet base 124, an automatic
pallet changer 126, and a plurality of pallets 128. Pallets 128 are
each removably coupled to base 102 and each includes a fixture base
130 and a fixture tower 132 that extends outwardly from fixture
base 130. Each fixture tower 130 includes a plurality of
quick-change fixtures 134 coupled thereto in any suitable manner.
Fixtures 134 are each removably coupled to at least one of coupling
members 12 and 14, and a dressing roll (not shown in FIG. 3).
Accordingly, each fixture tower 130 can include a plurality of
fixtures 134, wherein each fixture is configured to couple with a
different configuration of a coupling member 12 and 14, or a
dressing roll.
[0021] Each pallet 128 is removably coupled to pallet base 124.
Pallet changer 126 couples and uncouples each pallet 128 to pallet
base 124. Pallet base 124 is positionable along axis 122, and each
pallet 128 is rotatable with respect to pallet base 124 along an
axis of rotation 136 when a pallet 128 is coupled to pallet base
124.
[0022] FIG. 4 is a perspective partial cut-away view of a portion
of an exemplary grinding wheel 110 for use with machining assembly
100 (shown in FIG. 3). FIG. 5 is a cross-sectional view of a
portion of grinding wheel 110 and taken along line 5-5. In one
embodiment, grinding wheel 110 is fabricated from aluminum oxide.
In an alternative embodiment, wheel 110 is fabricated from cubic
boron nitride (CBN). Grinding wheel 110 includes an arbor portion
200, a grinding wheel body 202, and a working projection 204. Arbor
portion 200 is removably coupled to machine tool chuck 120 (shown
in FIG. 3) in any suitable manner.
[0023] Grinding wheel working projection 204 extends outwardly from
body 202 along an axis of rotation 206 and between a base 208 and a
tip 210. Projection 204 is substantially annular and includes an
abrasive working surface 212 adjacent tip 210. Surface 212 is
configured to machine teeth troughs 44 and 46, such that teeth 32
are defined between adjacent troughs 44 or 46. In one embodiment,
surface 212 is a vitrified abrasive surface.
[0024] A coolant passage 214 extends completely through arbor
portion 200 and body 202 to a coolant chamber 216 defined within
body 202 between a coolant plate 218 and a downstream end 220 of
passage 214. In one embodiment, coolant passage 214 is
substantially cylindrical and is concentrically aligned with
respect to axis 206 and projection 204. Coolant passage 214 is
coupled in flow communication with a source of coolant (not shown),
and delivers cooling fluid to chamber 216. Coolant plate 218 is
coupled to a radially inner surface 222 of projection 204 and a
radially inner surface 224 of body 202. Coolant plate 218 includes
a plurality of openings 226 for channeling coolant to projection
204, and more specifically towards abrasive surface 212. Coolant
openings 226 each include a central axis 228 that extends obliquely
towards surface 212 with respect to axis of rotation 206. More
specifically, during operation, coolant 230 is channeled from the
coolant source through passage 214 to chamber 216. Within chamber
216, coolant 230 is channeled across an upstream surface 232 of
plate 218 and through openings 226, wherein the cooling fluid is
then channeled towards abrasive surface 212.
[0025] Although grinding wheel projection 204 is herein described
and illustrated in the exemplary manner, it should be understood
that the particular geometry and cross-sectional shape of
projection 204, and more specifically abrasive surface 212, will
vary depending on the particular configuration and geometrical
shape of coupling 10. The embodiment illustrated is intended as
exemplary, and is not intended to limit the geometry and
cross-sectional shape of projection 204 including abrasive surface
212.
[0026] FIG. 6 is a perspective view of an exemplary scrubber
assembly 300 for use with grinding wheel 110 (shown in FIG. 4), and
in an operational position. FIG. 7 is a perspective view of
scrubber assembly 300 scrubber assembly 300 in a retracted
position. FIG. 8 is a cross-sectional view of a portion of scrubber
assembly 300 taken along line 8-8. Assembly 300, as described
below, supplies cleaning fluid, and includes a base 302 that is
coupled to machine tool 104 (shown in FIG. 3) in any suitable
manner. Base 302 is rotatable with respect to machine tool 104,
with respect to machine tool chuck 120 (shown in FIG. 3), and about
axis 122 (shown in FIG. 3).
[0027] Base 302 includes a first fluid duct 304 extending outwardly
therefrom generally along axis 122 and having a fluid passageway
306 defined therein. First duct 304 extends outwardly along axis
122 to a downstream end 308 of duct 304. Passageway 306 is coupled
in flow communication with a source of fluid (not shown). A second
fluid duct 310 extends outwardly from first duct 304 and is
substantially perpendicular to duct 304 and axis 122. In one
embodiment, duct 304 is formed integrally with duct 310. In an
alternative embodiment, duct 304 is an independent component
fixedly coupled to duct 310. Second duct 310 includes a passageway
312 that is defined therein, and is in flow communication with
passageway 306. Second duct 310 also includes a plurality of
nozzles 314 that extend outwardly from duct 310 along axis 122 and
towards chuck 120 and wheel 110.
[0028] Assembly 300 includes an operational position 316 (shown in
FIG. 6), wherein during operation of machine tool 104, and more
specifically grinding wheel 110, assembly 300 rotates around
grinding wheel 110 such that nozzles 314 direct a coolant 318
delivered from passageways 306 and 312 to wheel 110, and more
specifically abrasive surface 212 (shown in FIG. 4). Assembly 300
also includes a retracted position 320 (shown in FIG. 7), wherein
assembly 300 does not deliver fluid for cleaning to wheel 110. More
specifically, retracted position 320 may be used during a wheel
110, or tool 112 or 114, change, and also may be used when a
conventional tool 112 or 114 is coupled to chuck 120.
[0029] FIG. 9 is a perspective view of an exemplary dressing roll
400 for use with pallet assembly 106 (shown in FIG. 3). As
described above, dressing roll 400 is configured to removably
couple to fixtures 134 (shown in FIG. 3) in any suitable manner.
Roll 400 includes a first annular portion 402, a second annular
portion 404 extending outwardly from first portion 402, a third
annular portion 406 extending outwardly from second portion 404,
and a fourth annular portion 408 extending outwardly from third
portion 406. Second portion 404, third portion 406, and fourth
portion 408 are each configured to dress at least one configuration
of wheel 110 (shown in FIG. 4). In addition, other dressing rolls
400 may be coupled to assembly 106 to include even more
configurations of wheel 110.
[0030] Furthermore, in combination with machine tool 104, dressing
roll 400 provides a continuous-path dressing system. More
specifically, machine tool 104 is configured to generally
simultaneously position wheel 110 and dress wheel 110 using roll
400. In one embodiment, at least one of second portion 404, third
portion 406, or fourth portion 408 includes diamond plating on an
outer surface thereof for dressing wheel 110.
[0031] In operation, and referring now to FIGS. 1-9, an operator
loads at least one coupling member 12 and 14 onto fixtures 134 and
a particular coupling member configuration is chosen to be
machined. Using automatic tool changer 116, assembly 100 chooses
the appropriate grinding wheel 110 from carousel 108 and couples
the chosen wheel 110 to chuck 120. In one embodiment, using
automatic pallet changer 126, assembly 100 chooses a pallet 128
that contains an appropriate dressing roll 400 for dressing the
chosen wheel 110, the dressing roll 400 is aligned with the chosen
wheel 110, and machine tool 104 dresses the wheel 110 using roll
400. Assembly 100 then chooses a pallet 128 that contains a
coupling member 12 or 14 desired to be machined, aligns the chosen
coupling 12 or 14 with grinding wheel 110, and machines the chosen
coupling 12 or 14 using the chosen grinding wheel 110. In the
exemplary embodiment, assembly 110 is coupled to at least one
processor (not shown) that facilitates executing the
above-described method for machining a coupling 12 or 14.
[0032] The above-described machining assembly is cost-effective,
highly reliable, and highly accurate for machining a coupling. More
specifically, the assembly allows a plurality of coupling
configurations to be machined without manually changing machine
tools and machine fixtures, resulting in lower cycle times and
possibly a reduced inventory. In addition, the above-described
assembly provides improved cooling to a grinding wheel, and further
provides a continuous path dressing system. Because of the above,
the machining assembly facilitates machining a higher quality
coupling having a decreased dimensional variation in a
cost-effective and reliable manner.
[0033] Exemplary embodiments of machining assemblies are described
above in detail. The systems are not limited to the specific
embodiments described herein, but rather, components of each
assembly may be utilized independently and separately from other
components described herein. Each machining assembly component can
also be used in combination with other machining assembly
components.
[0034] While the invention has been described in terms of various
specific embodiments, those skilled in the art will recognize that
the invention can be practiced with modification within the spirit
and scope of the claims.
* * * * *