Apparatus and method for intricate cuts

• US 8,408,972 B2
• Filed: 01/25/2010
• Issued: 04/02/2013
• Est. Priority Date: 01/25/2010
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Kenney, Kevin M.
• Primary Examiner(s): NGUYEN, GEORGE BINH MINH
• Application Number:
  US12/692,837
• Publication Number:
  US 20110183580A1
• Time in Patent Office: 1,163 Days
• Field of Search: 451/58, 451/57, 451/69, 451/70, 451/37, 451/51, 451/61, 451/164, 451/165, 451/162, 409/244, 409/259, 295/57
• US Class Current: 451/54
• CPC Class Codes: B24B 1/04 subjecting the grinding or polishing tools, the abrading or polishing medium or work to vibration, e.g. grinding with ultrasonic frequency polishing or abrading surfaces on work by means of tumbling apparatus B24B31/00, involving oscillating or vibrating containers B24B31/06; superfinishing surfaces on work, e.g. by means of abrading blocks reciprocating with high frequency, B24B35/00
• CPC Class Codes: B24B 19/009 for grinding profiled workpieces using a profiled grinding tool
• CPC Class Codes: B24B 9/20 of plastics
• CPC Class Codes: Y10T 409/303752 Process

Abstract

Certain embodiments disclosed herein relate to apparatuses and methods for intricate cuts. In particular, in one embodiment, a cutting apparatus is provided. The cutting apparatus includes a base member and an elongate member extending from the base member. The elongate member includes a tapered region having an abrasive surface. The tapered region defines at least one vertex defining an angle of a desired cutout shape. Additionally, the tapered region is toothless.

Claims

1. A method of machining intricate cuts in a work piece comprising:

cutting a work piece to form an aperture approximating a desired shape having at least one acute angle, wherein each acute angle of the desired shape is approximated by a cut having a corner radius;

inserting a tapered elongate member of a first cutting apparatus into the aperture;

pushing the tapered elongate member through the aperture to remove material from the work piece;

inserting a tapered elongate member of at least one additional cutting apparatus into the aperture; and

pushing the tapered elongate member through the aperture to remove material from work piece, thereby forming the desired shape having at least one acute angle.

2. The method of claim 1 further comprising:

mounting the first cutting apparatus to a reciprocating member; and

operating the reciprocating member while pushing the tapered elongate member through the aperture.

3. The method of claim 1 further comprising:

sequentially inserting the additional tapered elongate member of the at least one additional cutting member in order of increasingly finer abrasive surfaces to achieve the desired shape;

wherein

the tapered elongate member of the at least one additional cutting apparatus has a finer abrasive surface than the first cutting apparatus.

4. The method of claim 1 further comprising:

sequentially inserting the one or more additional elongate members having increasingly less taper to achieve the desired shape;

wherein

the additional tapered elongate member of the at least one additional cutting apparatus tapers less than the first cutting apparatus.

5. The method of claim 1 further comprising:

inserting increasingly shorter cutting apparatuses to achieve the desired shape;

wherein

the additional tapered elongate member of the at least one additional cutting apparatus has a shorter length than the first cutting apparatus.

6. The method of claim 1 further comprising:

mounting the work piece on an ultrasonic device;

placing the work piece at least partially in an abrasive slurry; and

agitating at least one of the work piece and the abrasive slurry with the ultrasonic device.

7. The method of claim 1 further comprising:

mounting the first cutting apparatus on an ultrasonic device;

placing the first cutting apparatus at least partially in an abrasive slurry; and

agitating at least one of the first cutting apparatus and the abrasive slurry with the ultrasonic device.

8. The method of claim 1 wherein cutting a work piece to form an aperture comprises using a computer numerical controlled mill.

9. An apparatus for machining intricate cuts in a work piece comprising:

a first member configured to cut a work piece to form an aperture approximating a desired shape having at least one acute angle, wherein each acute angle of the desired shape is approximated by a cut having a corner radius;

a tapered elongate member extending from the first member and configured to be inserted into the aperture, the tapered elongate member having a taper that extends along a length of the tapered elongate member towards a distal end of the tapered elongate member;

wherein

the tapered elongate is configured to remove material from the work piece, thereby forming the desired shape having at least one acute angle.

10. The apparatus of claim 9, wherein the tapered elongate member comprises a radial shape defining at least one sharp feature.

11. The apparatus of claim 9, wherein:

the tapered elongate member defines a base proximate the first member and an terminal portion spaced apart from the first member by an intermediate section; and

at least a portion of the intermediate section of the tapered elongate member tapers at a first angle from the base to the terminal portion.

12. The apparatus of claim 11, further comprising a non-tapered region defined on at least a part of the intermediate section;

wherein a cross-section of the non-tapered region corresponds in size with a largest cross-section of the tapered region.

13. The apparatus of claim 11, wherein the terminal portion of the elongate member tapers at a second angle, the second angle steeper than the first angle.

14. The apparatus of claim 11, wherein the terminal portion defines an end having a radial shape comprising at least one vertex.

15. A method of machining intricate cuts in a work piece comprising:

cutting a work piece to form an aperture approximating a desired shape having at least one acute angle, wherein each acute angle of the desired shape is approximated by a cut having a corner radius;

inserting a tapered elongate member of a first cutting apparatus into the aperture, the tapered elongate member having a taper that extends along a length of the tapered elongate member towards a distal end of the tapered elongate member; and

pushing the tapered elongate member through the aperture to remove material from the work piece, thereby forming the desired shape having at least one acute angle.

16. The method of claim 15 further comprising:

mounting the first cutting apparatus to a reciprocating member; and

operating the reciprocating member while pushing the tapered elongate member through the aperture.

17. The method of claim 15 further comprising:

inserting a tapered elongate member of at least one additional cutting apparatus into the aperture, the tapered elongate member of at least one additional cutting apparatus having a taper that extends along a length of the tapered elongate member towards a distal end of the tapered elongate member; and

pushing the tapered elongate member through the aperture to remove material from work piece.

18. The method of claim 15 further comprising:

sequentially inserting the additional tapered elongate member of the at least one additional cutting member in order of increasingly finer abrasive surfaces to achieve the desired shape;

wherein

the tapered elongate member of the at least one additional cutting apparatus has a finer abrasive surface than the first cutting apparatus.

19. The method of claim 15 further comprising:

sequentially inserting the one or more additional elongate members having increasingly less taper to achieve the desired shape;

wherein

the additional tapered elongate member of the at least one additional cutting apparatus tapers less than the first cutting apparatus.

20. The method of claim 15 further comprising:

inserting increasingly shorter cutting apparatuses to achieve the desired shape;

wherein

the additional tapered elongate member of the at least one additional cutting apparatus has a shorter length than the first cutting apparatus.

21. The method of claim 15 further comprising:

mounting the work piece on an ultrasonic device;

placing the work piece at least partially in an abrasive slurry; and

agitating at least one of the work piece and the abrasive slurry with the ultrasonic device.

22. The method of claim 15 further comprising:

mounting the first cutting apparatus on an ultrasonic device;

placing the first cutting apparatus at least partially in an abrasive slurry; and

agitating at least one of the first cutting apparatus and the abrasive slurry with the ultrasonic device.

23. The method of claim 15 wherein rough machining comprises using a computer numerical controlled mill.