Internal Chamfering Device and Method

• US 20090279970A1
• Filed: 05/09/2008
• Published: 11/12/2009
• Est. Priority Date: 05/09/2008
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Gray, Everette D.
• Granted Patent: US 8,388,277 B2
• Time in Patent Office: Days
• US Class Current: 408/194
• CPC Class Codes: B23B 2222/88 Titanium
• CPC Class Codes: B23B 2226/275 Carbon fibre reinforced carbon composites
• CPC Class Codes: B23B 2228/36 Multi-layered
• CPC Class Codes: B23B 2260/128 Sensors
• CPC Class Codes: B23B 51/101 Deburring tools B23B51/103 takes precedence
• CPC Class Codes: Y10T 408/03 Processes
• CPC Class Codes: Y10T 408/8588 Axially slidable moving-means
• CPC Class Codes: Y10T 408/8734 including central Tool axially movable relative to support
• CPC Class Codes: Y10T 408/8738 including inverse cutting edge
• CPC Class Codes: Y10T 82/12 Radially moving rotating tool inside bore

Abstract

A method of forming an opening in a layered structure includes providing a layered structure including a first layer and a second layer and a near-zero gap interface defined between the first layer and the second layer; providing an opening through the layered structure such that the opening extends through the first layer and the second layer; and working simultaneously the opening in the fay surface of the first layer and the opening in the fay surface of the second layer without separating the first layer and the second layer. An internal chamfering device is also disclosed.

Claims

1. A method of forming an opening in a layered structure, comprising:

providing a layered structure including a first layer and and a second layer, a near-zero gap interface defined between said first layer and said second layer and a first fay surface on said first layer at said interface and a second fay surface on said second layer at said interface;

providing an opening through said layered structure such that said opening extends through said first layer and said second layer; and

working simultaneously said opening in said fay surface of said first layer and said opening in said fay surface of said second layer without separating said first layer and said second layer.

2. The method of claim 1 wherein said working comprises deburring said opening in said first layer and said second layer.

3. The method of claim 1 wherein said working comprises chamfering said opening in said first layer and said second layer.

4. The method of claim 1 wherein said layered structure further includes an intermediate layer disposed at said interface such that said layered structure defines a sandwich-type structure with said first layer and said second layer defining first and second outer layers, respectively, such that said fay surface of said first layer and said fay surface of said second layer abut said intermediate layer;

said providing an opening further comprises drilling an opening through said layered structure such that said opening extends through each of said first and second outer layers and said intermediate layer; and

said working further comprises working simultaneously said opening in said fay surface of said first outer layer, said opening in said fay surface of said second outer layer and said opening in said intermediate layer without separating said first outer layer, said second outer layer and said intermediate layer.

5. The method of claim 4 wherein said first and second outer layers each includes a material selected from the group consisting of metals and composites.

6. The method of claim 5 wherein said intermediate layer includes a material selected from a group comprising composites, adhesives and sealants.

7. The method of claim 1 wherein said layered structure is a sandwich-type structure and said first and second layers include titanium and further comprising an intermediate composite layer between said first and second layers, a zero-gap interface defined between each of said first and second layers and said intermediate layer such that each of said first and second layers and said intermediate layer has a corresponding fay surface at an interface;

wherein the working further comprises working simultaneously said opening in said fay surface of a first one of said first and second layers and said opening in said fay surface of said intermediate layer without separating said first layer, said second layer and said intermediate layer.

8. The method of claim 7 further comprising working simultaneously said opening in said fay surface of a second one of said first and second layers and said opening in said fay surface of said intermediate layer without separating said first layer, said intermediate layer and said second layer.

21. The method of claim 1 wherein said working step comprises deburring said opening in said first layer and said second layer by providing a deburring tool comprising a tool housing, a cutting blade attachment shaft extending from said tool housing and a cutting blade carried by said cutting blade attachment shaft, inserting said cutting blade attachment shaft in said opening and deburring said opening using said cutting blade.

22. The method of claim 21 wherein said deburring tool further comprising a nosepiece carried by said tool housing and engaging said cutting blade attachment shaft and wherein said deburring said opening in said first layer and said second layer comprises adjusting said cutting blade attachment shaft with respect to said tool housing by rotating said nosepiece.

23. The method of claim 22 wherein said deburring tool further comprising a chamfer depth control knob carried by said tool housing and engaging said cutting blade and wherein said deburring said opening in said first layer and said second layer comprises extending and retracting said cutting blade with respect to said cutting blade attachment shaft by rotation of said chamfer depth control knob.

9. The method of forming an opening in a layered structure, comprising:

providing a layered structure including a first layer and and a second layer, a near-zero gap interface defined between said first layer and said second layer and a first fay surface an said first layer at said interface and a second fay surface on said second layer at said interface;

providing an opening through said layered structure such that said opening extends through said first layer and said second layer;

providing an internal chamfering device comprising a device housing and a tool bit extendable from said device housing; and

working simultaneously said opening in said fay surface of said first layer and said opening in said fay surface of said second layer by inserting said internal chamfering device in said opening and extending said tool bit from said device housing of said internal chamfering device without separating said first layer and said second layer.

10. The method of claim 9 further comprising a tool bit opening provided in said device housing and wherein said extending said tool bit from said device housing of said internal chamfering device comprises extending said tool bit through said tool bit opening.

11. The method of claim 9 wherein said providing an internal chamfering device comprising a device housing comprises providing an internal chamfering device comprising a device housing including a tool base, a center sleeve extending from said tool base and a rear sleeve extending from said center sleeve.

12. The method of claim 9 wherein said providing an internal chamfering device comprises providing an internal chamfering device comprising a cam bar in said device housing and displaceable along a longitudinal axis of said device housing and a tool bit slot provided in said cam bar and wherein said tool bit is slidable along said tool bit slot.

13. The method of claim 12 further comprising providing a magnetoresistive tracking probe on said tool bit and a main giant magnetoresistive probe in said device housing in spaced-apart relationship with respect to said magnetoresistive tracking probe.

14. The method of claim 12 further comprising providing a slot depression in said cam bar and wherein said, tool bit slot extends along said slot depression.

15. The method of claim 14 further comprising providing a tool bit guide in engagement with said cam bar and wherein said tool bit is extendable from said tool bit guide.

16. An internal chamfering device, comprising:

a generally elongated device housing having a tool bit opening;

a cam bar provided in said device housing and displaceable along a longitudinal axis of said device housing;

a slot depression provided in said cam bar;

a tool bit slot provided in said cam bar and extending along said slot depression; and

a tool bit slidably engaging said tool bit slot and extendable through said tool bit opening.

17. The internal chamfering device of claim 16 wherein said device housing comprises a tool base, a center sleeve extending from said tool base and a rear sleeve extending from said center sleeve.

18. The internal chamfering device of claim 16 further comprising a magnetoresistive tracking probe carried by said tool bit and a main giant magnetoresistive probe provided in said device housing in spaced-apart relationship with respect to said magnetoresistive tracking probe.

19. The internal chamfering device of claim 16 further comprising a x-axis tool bit motor engaging said cam bar and adapted to slide said cam bar in said device housing.

20. The internal chamfering device of claim 16 further comprising a z-axis plunge motor engaging said device adapted to move said device housing along a z-axis and a y-axis rotation motor engaging said device and adapted to rotate said device housing about a y-axis.

24. A deburring tool, comprising:

a tool housing;

a cutting blade adjustment shaft extending from said tool housing;

a nosepiece carried by said tool housing and engaging said cutting blade adjustment shaft; and

a cutting blade carried by said cutting blade adjustment shaft.

25. The deburring tool of claim 24 further comprising a nosepiece stop carried by said tool housing.

26. The deburring tool of claim 24 further comprising a chamfer depth control knob carried by said tool housing and operably engaging said cutting blade and adapted to facilitate extension and retraction of said cutting blade with respect to said cutting blade adjustment shaft.

27. The deburring tool of claim 24 further comprising a blade pilot carried by said cutting blade adjustment shaft and wherein said cutting blade is carried by said blade pilot.