High-precision sizing, cutting and welding tool system for specialty aerospace alloys

The present invention solves the problems encountered by conventional machine tool devices when specialty metals such as titanium, Inconel.TM. and stainless steel are sized, cut or welded. The Sizing Tool is capable of precisely and permanently changing the shape of a tubular workpiece because, unlike conventional static spreaders, it repeatedly bends the workpiece back and forth many times to achieve the desired deformation. The Sizing Tool includes a set of revolving rollers (14) supported by bearings (13) and a mounting plate (12). The roller (14) is capable of engaging either the inside or outside surface of a hollow metal tube (10). The rollers (14) exert force on the end of the tube (10) having a circular cross-section in a configuration that resembles a polygon inscribed in a circle. As the rollers (14) are moved toward the workpiece (10), the workpiece is gradually deformed as it moves farther into the inclined surface presented by each roller (14). The dynamic flexure flaring method provided by the present invention enables a technician to work harden and produce precisely formed surfaces within a tolerance of one-thousandth of an inch which can be relied upon to maintain their shape over long periods of time. The Cutting Tool is controlled by an innovative tool advance assembly that converts translational motion to precise radial motion which governs the action of the cutting bit as it severs a tubular workpiece (10). The Cutting Tool is not only capable of cutting a tubular workpiece (10) from the inside out, but can also be configured to cut a tube (10) from the outside.

BACKGROUND OF THE INVENTION 
The present invention includes methods and apparatus for sizing, cutting 
and welding a variety of metal workpieces fabricated from specialty 
alloys, such as titanium, Inconel.TM., or hybrid stainless steels. More 
particularly, the High-Precision Sizing, Cutting and Welding Tool System 
for Specialty Aerospace Alloys is a versatile and highly effective machine 
tool that is capable of forming meticulously accurate flared surfaces, and 
is also capable of precisely severing and welding these alloy tubes. 
The aerospace industry in the United States is rapidly being confronted 
with obsolete fabrication technology and equipment that cannot keep pace 
with the technological requirements of today's and tomorrow's aircraft 
requirements. Each year the machine tool industry encounters new demands 
of engineers who specify increasingly complex machining processes for the 
manufacture of metal parts. One of greatest challenges confronting 
designers in the precision welding industry is finding more precise and 
dependable techniques to join metal parts that may have exceedingly small 
dimensional tolerances or that may be fabricated from exotic alloys, such 
as titanium, Inconel.TM., or hybrid stainless steels. The aircraft and 
aerospace industries are constantly confronted by difficulties that arise 
when hollow cylindrical metal conduits are welded together. These tubes 
reside within the fuselage or wings of an aircraft and are used to convey 
fluids or to protect environmental control systems within the vehicle. 
Although the existence of titanium was first observed in 1790, a feasible 
process of producing titanium was not discovered until 1938. Titanium 
sponge was first developed by W. J. Kroll and was produced using the 
magnesium reduction of titanium tetrachloride. Shortly thereafter, the 
United States armed services became interested in titanium because of its 
high melting point. The first commercial titanium became available around 
1950, and the production and use of titanium alloys has increased steadily 
since that time. 
Titanium and its alloys have material properties that make it especially 
desirable for special applications, particularly within the aerospace 
industry. First, titanium has a high strength-to-weight ratio, which makes 
it comparable to many steels and stainless steels, while being only about 
56 percent as heavy. While titanium alloys are about 40 percent heavier 
than aluminum, their greater strength allows much less material to be used 
for many applications. Titanium alloys also possess good corrosion 
resistance, and high heat performance which makes them even more desirable 
for aerospace applications. 
Despite the desirable properties that titanium alloys possess, the high 
cost of the material and difficulties with production and fabrication with 
titanium alloys have limited their widespread use. Titanium alloys tend to 
be very unforgiving when standard fabrication methods are employed. They 
are at least as difficult to work with as hybrid stainless steel alloys. 
Titanium alloys are also easily contaminated at high temperatures, which 
can seriously impact the quality of a weld joint in a titanium structure. 
New techniques would be needed to prepare and weld titanium alloy 
structures that avoid such contamination and minimize the requirement of 
additional weld metal. 
The basic method of mating metal tubes end-to-end is commonly referred to 
as "butt welding," and is well known to persons ordinarily skilled in the 
welding art. The tubes are usually placed in a jig or fixture, aligned, 
and then welded together using a conventional weldhead. If the dimensions 
of the two tubes are not precisely matched, conventional "spreader" 
fixtures, such as that shown in FIG. 1, may be used to try to correct any 
dimensional mismatch and minimize the differences between the dimensions 
of the two mating components. This spreader fixture known as a "pie-die", 
labeled "A" in FIG. 1, includes four sections B, C, D, and E which operate 
simultaneously and are arranged in a circular pattern about a central 
point F. All of the sections, which resemble the slices of a pie cut into 
quarters, move radially away from center point F. The entire device A is 
placed inside a hollow tube which requires shaping, and then one or more 
sections B, C, D, or E is forced outward against the workpiece. In FIG. 1, 
the primed reference numerals B', C', D', and E' indicate the displaced 
positions of each of the shaping sections. This technique, however, is 
very limited because the workpiece nearly always has a tendency to spring 
back to its original position after it is stretched by the "pie-die" 
spreader. Overcoming this elastic memory or "springback" effect is 
difficult to accomplish using a non-rotating sectioned spreading device. 
This conventional method is usually imprecise and may lead to faulty welds 
that can ultimately crack and break apart. 
Previous mechanical devices have employed roller mechanisms to work thin 
gauge tin, copper, or steel sheet metal to quickly deform these common 
metals for simple fabricated objects, such as cans, drums, or tube sheets. 
In U.S. Pat. No. 1,732,861, issued on Oct. 22, 1929, Rosenbloom discloses 
a simple tool that uses rollers to form flanges out of holes in sheet 
metal plates, such as tank or drum tops. This device was designed to be 
operated with a simple drill press. In U.S. Pat. No. 1,543,583, issued on 
Jun. 23, 1925, Mason discloses a tool that uses a roller mechanism to bell 
tubes in boilers during the manufacturing process. In U.S. Pat. No. 
2,388,643, issued on Nov. 6, 1945, Rode et al. used an apparatus employing 
swaging dies to taper or swage the outer surface of common seamless 
tubing. In U.S. Pat. No. 3,811,306, issued on May 21, 1974, Yoshimura 
discloses a method and apparatus for forming and deburring a cylindrical 
can fabricated from aluminum or tin plate, which employed rollers to the 
outside surface of the workpiece. 
In U.S. Pat. No. 3,498,245, issued on Mar. 3, 1970, Hansson discloses a 
roller sizing tool for forming can bodies by working the relatively 
brittle sheet metal beyond its elastic limit. The Hansson reference 
discloses rollers (53) that protrude from shanks (54) which pass through 
bores (56) in a body (46) which contains a complex ball bearing retainer 
(60, 61, 62, 63 and 64) for each roller (53). A reduced threaded end 
portion (55) extends from each shank (54) past a washer (58), and is 
fastened on the opposite side of the body (46) with a nut (57). The 
rollers (53) are "journalled in the disk-like body 46". (See Hansson, Col. 
7, Line 35.) In Hansson's arrangement, the rollers (53), shanks (54) and 
nuts (57) spin together on an inner ball bearing race (61). Because of the 
action of the internal ball bearing (60), Hansson's rollers (54) may shift 
their positions relative to an axis that extends perpendicular to the body 
(46) when they encounter mechanical resistance presented by the workpiece. 
This slippage is perfectly acceptable for the process of manufacturing 
ordinary metal cans, but Hansson' s machine is not capable of performing 
the precise sizing of specialty aerospace alloys which possess high 
strength-to-weight ratios, good performance at elevated temperatures, and 
high corrosion resistance. 
Hansson's invention was purposely developed for spin flanging of can body 
edges. (See Hansson, Col. 1, Lines 2-3.) This operation is rough and crude 
compared to the precise tolerances involved in the processing of specialty 
alloys in for the aerospace industry. Hansson clearly states that the 
object of his invention is to increase the transverse ductility of the 
edges of a high-strength brittle metal can. (See Hansson, Col. 1, Lines 
16-17.) Hansson, however, relied on the malleability of his materials 
which do not experience hardening as they are formed. He was primarily 
concerned with reducing the stability of his workpiece. The Hansson 
reference does not provide for easy repair or replacement of the rollers 
(14). 
While past inventors provided mechanisms for the simple, non-critical 
fabrication of thin gauge common metals, they designed their devices with 
the intent to utilize the moderate ductility and malleability of the 
metals they were working with at that time. They never had to consider the 
difficulties of dealing with the high ductility that is exhibited by many 
modern high-strength aerospace alloys that are being prepared for 
precision welding techniques. Aerospace applications often require the 
precise weldments of titanium tubing of many diameters and gauge sizes, 
such as 1" diameter tube with a 0.020" wall thickness, or a 6" diameter 
with a wall thickness of 0.030" to 0.040". 
The problem of providing a high-precision sizing, cutting, and welding tool 
for use with specialty alloys, such as titanium, Inconel.TM., or hybrid 
stainless steels, has presented a major challenge to engineers and 
technicians in the metalworking field. The development of an accurate and 
versatile system that overcomes the difficulties encountered when 
conventional welding and metal shaping techniques are employed to 
fabricate welded titanium, Inconel.TM., or hybrid stainless steel alloy 
parts would constitute a major technological advance in the metal 
fabrication business. The enhanced performance that could be achieved 
using such an innovative device would satisfy a long felt need within the 
industry and would enable machine tool equipment manufacturers and users 
to save substantial expenditures of time and money. 
SUMMARY OF THE INVENTION 
The High-Precision Sizing, Cutting and Welding Tool System for Specialty 
Aerospace Alloys disclosed and claimed in this patent application solves 
the problems encountered by conventional machine tool devices. The 
spinning Sizing Tool is capable of precisely and permanently changing the 
shape of a tubular titanium, Inconel.TM., or hybrid stainless steel 
workpiece because, unlike conventional static spreaders, it repeatedly 
bends the workpiece back and forth many times to achieve the desired work 
hardening and deformation. This technique, which the inventor calls 
progressive "multiple forward and reverse bending", imposes a permanent 
flare or other shape on a tube which will overcome the tube's high 
ductility. 
THE SIZING TOOL 
The sizing or flaring tool includes a set of revolving rollers supported by 
bearings and a mounting plate. Although the preferred embodiment of the 
roller has a tapered work surface, any number of useful configurations may 
be employed. The roller is capable of engaging either the inside or 
outside surface of a hollow titanium, Inconel.TM., or hybrid stainless 
steel tube. The rollers exert force on the end of a workpiece having a 
circular cross-section in a configuration that resembles a polygon 
inscribed in a circle. As the rollers are moved toward the workpiece, the 
workpiece is gradually deformed as it moves farther into the inclined 
surface presented by each roller. Each time the rollers make one 
revolution while in contact with the workpiece, each roller bends every 
spot on the end of the tube radially outward and then radially inward. The 
total deflection or deformation of the tube exceeds the elastic modulus of 
the workpiece so that "springback" is prevented. The dynamic flexure 
flaring method provided by the present invention enables a technician to 
produce precisely formed surfaces within a tolerance of one-thousandth of 
an inch which can be relied upon to maintain their shape over long periods 
of time. While the preferred embodiment utilizes eight rollers, any number 
of rollers may be utilized with varied configurations to match the needs 
presented by a particular workpiece. While the typical workpiece is a 
hollow metal tube, any number of structural shapes, including those having 
elliptical and oval cross-sections, may be sized using the present 
invention. The workpiece can be composed of any titanium, Inconel.TM., or 
hybrid stainless steel material which is susceptible to deformation under 
a gradual and repeated alternating radial force. In an alternative 
configuration, the workpiece rotates and the Sizing Tool remains 
stationary. 
THE CUTTING TOOL 
The Cutting Tool is controlled by an innovative tool advance assembly that 
converts translational motion to precise radial motion which governs the 
action of the cutting bit as it severs a tubular titanium, Inconel.TM., or 
hybrid stainless steel workpiece. A shaft bearing a revolving cam roller 
is received by a slot in a tool bit holder that is constrained to move up 
and down in a radial direction. When the cam roller moves in its circular 
pathway, the tool bit holder is constrained to move perpendicular to the 
longitudinal axis of the cam shaft and engages the workpiece that 
surrounds it. The rotational motion of the cam shaft is, in turn, 
controlled by the twisting of spiral guidance channels formed in a cup 
which resides at the opposite end of the cam shaft. These spiral channels 
are designed to receive a cam pin, which is held in place by a cam housing 
that surrounds the cam shaft. A second separate guide cup surrounds both 
the cam housing and the cam shaft located inside the cam housing. When the 
cam housing moves forward toward the workpiece, the upper portion of the 
cam pin which it bears is constrained to move only in a straight line 
parallel to the long axis of the cam shaft by slots formed along the 
separate guide cup which surrounds the cam housing. The lower portion of 
the same cam pin extends through the cam housing and engages a spiral 
channel on the cam shaft. When the cam pin moves, the spiral channels 
cause the cam shaft to rotate, which forces the cam roller to move in a 
circular path. The circular motion of the cam roller moves the tool bit up 
and down along a radial direction. The Cutting Tool is not only capable of 
cutting a tubular workpiece from the inside out, but can also be 
configured to cut a tube from the outside. 
THE WELDING TOOL 
The present invention is a high performance Sizing, Cutting, and Welding 
Tool System that addresses the troublesome fabrication difficulties posed 
by conventional metal-working and welding methods. These innovative 
methods and apparatus provide an effective and efficient means that will 
enable manufacturers of aviation equipment to create high quality products 
that will enhance the safety and reliability of a wide variety of aircraft 
tubular components fabricated from titanium, Inconel.TM., or hybrid 
stainless steel. 
An appreciation of other aims and objectives of the present invention and a 
more complete and comprehensive understanding of this invention may be 
achieved by studying the following description of a preferred embodiment 
and by referring to the accompanying drawings.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
THE SIZING TOOL 
FIG. 1 depicts a conventional "pie-die" spreader which is described above 
in the background section. FIG. 2A presents a schematic illustration of a 
hollow cylindrical titanium, Inconel.TM., or hybrid stainless steel metal 
tube 10 and the Sizing Tool. The tube 10 has an axis of revolution 10a 
that extends through its central aperture 10b. The present invention is 
capable of forming either a flared or reduced surface 11 at the end of 
tube 10. In this specification, the term "flared" generally refers to a 
surface which opens out or is larger than some reference surface, such as 
the surface 11 shown in FIG. 2A at the end of tube 10. In contrast, the 
term "reduced" is generally employed to connote a constricted or 
diminished dimension. 
The titanium used for many aerospace applications, such as specified by 
Boeing Inc. of Seattle Wash., for use with the tube 10 in the present 
invention, is typically a Grade II titanium alloy, which starts as 
sheet/strip stock in accordance with AMS and U.S. military specification 
standards MIL-T-9046, AB-1, (Ti-6Al-4V). The tensile properties of this 
titanium alloy for which the present invention is designed are presented 
below: 
TABLE ONE 
______________________________________ 
Constituent Grade II (Ti--6Al--4V) Titanium 
______________________________________ 
Yield Strength (PSI) 
40,000 to 60,000 
Ultimate Strength (PSI) 
50,000 minimum 
Elongation Percent 
20 minimum 
______________________________________ 
The acceptable chemical analysis of this titanium alloy by Boeing Inc. is 
shown below: 
TABLE TWO 
______________________________________ 
Constituent Grade II 
______________________________________ 
Titanium 99.2 percent minimum 
Hydrogen 0.006 percent (60 ppm) maximum 
Oxygen 0.14 percent (1400) maximum 
Iron 0.20 percent maximum 
______________________________________ 
One distinct feature of titanium alloys, such as that specified for 
applications by Boeing Inc., is their high degree of ductility, which 
proves to be challenging for fabricated tubing assemblies. The present 
invention is designed to extensively and precisely work harden these 
ductile alloys into a precise and permanent geometry which can then be 
welded into a larger aerospace structure. 
FIG. 2A also depicts a mounting plate 12 connected to bearings 13 that each 
support a roller 14. Plate 12 has an axis of revolution 12a that extends 
through its center. Axis 12a is colinear with axis 10a that extends 
through the center of the workpiece 10. The mounting plate 12 and rollers 
14 are held by a tool mount assembly 15, which may be viewed in greater 
detail in FIGS. 4 and 6. The tool mount assembly 15 may include either the 
Sizer Tool, or the Cutter Tool, which is described below. In the preferred 
embodiment of the invention, the workpiece 10 is stationary and the plate 
12 and rollers revolve around axes 10a and 12a. In an alternative 
configuration, the workpiece rotates and the Sizing Tool remains 
stationary. While the preferred embodiment utilizes eight rollers 14, any 
number of rollers 14 may be utilized to match the needs presented by a 
particular workpiece 10. While the typical workpiece 10 is a hollow tube 
of exotic aircraft metal such as titanium or stainless steel that 
resembles a right circular cylinder, any number of structural end shapes, 
including those having elliptical and oval cross-sections, may be formed 
using the present invention. The workpiece can be composed of any material 
which is susceptible to deformation under a gradual and repeated radial 
force. 
As best shown in FIG. 2B, each roller 14 includes a front surface 4a, a 
bevel 14b, a work surface 14c, a side flat surface 14d, and a back surface 
14e. The work surface 14c of each roller 14 may be formed in a wide 
variety of profiles. In many of the multiple embodiments of the invention, 
the work surface 14c is a simple linear taper that is inclined ten to 
fifteen degrees to axes 10a and 12a. The work surface may also be curved 
to produce different flared or reduced surfaces on the workpiece 10. In 
the most preferred embodiment, the roller taper is ten degrees. A screw 
14f runs through the center of each roller 14 to secure it to its 
respective bearing 13. A disc-shaped front plate (not shown) may be 
secured to one or more of the front faces 14a of the rollers 14 to provide 
added strength to the Sizing Tool. The preferred embodiment utilizes 
rollers having a diameter which insures that the edges between the beveled 
surfaces 14b and the work surfaces 14c almost touch. This configuration 
insures that the workpiece will experience the most gradual and gentle 
level of multiple reverse bending. 
FIG. 2C provides a front view of the present invention which illustrates 
the novel multiple forward and reverse bending method. Each time each 
roller 14 makes one revolution around the inside of the workpiece 10, each 
spot on the workpiece undergoes a differential radial deflection that 
results from the combined outward and inward flexing caused by the rollers 
14. Each roller 14 pushes out the tube 10 and creates an arc centered at 
the point which coincides within the longest extent of radial deflection. 
This repeated dynamic flexing is graphically delineated in FIG. 2C by the 
reference label ".delta.r". 
FIGS. 2D through 2K are side views of rollers that exhibit illustrative 
examples of the various work surfaces that may be utilized with the 
present invention. 
FIG. 2L is a schematic diagram of one moving roller 14 impinging upon a 
workpiece 10. The illustration provided by FIG. 2L is based on a portion 
of the drawing supplied by FIG. 2C. As the roller 14 rotates in a 
clockwise direction, all the points along the inner circumference of the 
hollow cylinder 10 experience alternating forward (+) and reverse (-) 
bending. The rollers 14 alternately cause the tube wall 10 that is in 
contact with each roller to flex in opposite directions, while gently 
traversing the roller curvature. 
FIG. 2M presents a side view of a sized titanium, Inconel.TM., or hybrid 
stainless steel cylinder 10. During the sizing operation, each roller 14 
engages the tube 10 and imparts a gentle progressive flexuring of the tube 
end. These repeated forces cause the small crystals or fibers of metal at 
the end of the tube to pass their yield point. The repeated flexure forces 
enhance the ability of the metal fibers to resist the elastic forces that 
would naturally tend to force the tube back to its original shape. Once 
enough mechanical strength and stability is achieved through repeated 
flexure, the tube retains its new shape and is less likely to tear or 
crack along the area of the bend. Reference numerals 11a and 11c indicate 
the points of minimum and maximum deflection caused by the dynamic flexure 
action of the rollers 14. The point on the flared tube wall that 
experienced the minimum deflection, 11a, is the most mechanically stable 
area of the entire sized surface. This mechanical stability reduces the 
natural tendency of the tube to spring back to its original position. The 
very end of the flared portion of the tube, 11c, which experienced the 
most bending forces, is less stable and is more susceptible to the elastic 
"springback" forces inherent in the metal. Each crystal or fiber of metal 
along the flare from 11a to 11c is included within the region labeled 11b. 
Each small section of metal in this area 11b is progressively more stable 
than the one that preceded it. Each point on the flared end supports its 
neighbor toward the end of the flare, and preserves the mechanical 
stability of the entire shape. 
FIG. 3 provides a front view of a roller plate 12 bearing eight cam rollers 
14. This assembly is held together by a set of alternating screws and 
dowels 17. 
FIG. 4 is a cross-sectional view of the tool mount assembly 15 that 
includes the plate 12 and rollers 14. A housing 18 encloses a retainer 
plate 20 and a rotor 22 that, in turn, extends into a drive shaft 24. The 
tool mount assembly 15 typically rotates the plate 12 and rollers 14 at 
fifty to two hundred revolutions per minute. The operational angular 
velocity of the plate 12 and rollers 14 is determined by the toughness or 
thickness of the workpiece. Each material may be machined using a 
preselected, appropriate speed. This advantage is not available when 
conventional static spreaders are employed. 
FIGS. 5a, 5b, 5c, and 5d exhibit detailed views of the rollers 14 and 
roller plate 12. A stud 14g supports anti-friction bearings (not shown) 
that, in turn, support the tapered roller 14. A retainer 14h and a screw 
14f hold the roller 14 on plate 12. 
FIG. 6 is a cross-sectional rendering of the motor assembly 16 which drives 
the tool mount assembly 15. A drive motor 26 turns a spur gear 28, which, 
in turn, drives a ring gear 30. A mounting flange 32 is enclosed within 
gear box housing 34 and side stiffening plate 36. Two ball shafts 38 on 
either side of the motor assembly 16 slide within ball bushings 40 that 
are supported by ball bushing mounts 42 and ball shaft mounts 44. The ball 
shafts 38 are enclosed by extensions 46. Ball shaft mounts 44 are attached 
to a base plate 48. Either the Sizer Fool or the Cutter Tool can be 
mounted on a motor mount side plate 50. FIG. 6 shows the roller plate 12 
in its full thrust position for the sizing operation, which is delineated 
by reference numeral 52. The full thrust position for the cutter tool 
operation is marked by reference numeral 54. A tail stock 56 is mounted on 
the ball shaft 38. The ball shall 38 maintains concentricity with the tool 
spindle center-line (axis of revolution) 12a. The tail stock 56 holds the 
tube 10. Inserts 58 having various diameters (best seen in FIG. 7) can 
accommodate many different sizes of tubes 10. 
FIG. 7 is a front cross-sectional view of the apparatus shown in FIG. 6. 
FIG. 8 provides front and side views of a workpiece frame. The motor mount 
sliding plate 50 moves back and forth on ball bushing 40 and ball shaft 
38. This motion permits the tool mount assembly 15 which includes the 
rollers 14 to move in and out of the workpiece 10. This motion is limited 
by adjustable stops, guides, and gauge blocks (not shown) which set the 
thrust positions for each tool and which provide precise positioning for 
sizing and cutting. 
FIG. 9 includes several views of a tool advance mechanism. FIG. 9(a) 
portrays a thrust pivot frame 70 that supports a thrust mechanism 72 which 
includes a pivot hook 74 and a handle 76. The various handle positions are 
marked by reference numerals 76a through 76e which indicate the 
corresponding operational condition of the thrust mechanism for each 
position: 
TABLE THREE 
______________________________________ 
Handle Position 
Thrust Mechanism Operation 
______________________________________ 
76a Idle 
76b Initial contact 
76c Initial thrust 
76d Half thrust 
76e Full thrust 
______________________________________ 
ADVANTAGES OF THE SIZING TOOL 
The novel dynamic bending method utilized by the present invention produces 
results which are superior those achieved by conventional static spreader 
devices. The Sizing Tool is not only much faster than the older pie-die 
spreader, but does not require lubrication or cooling of any kind. By 
avoiding the lubricants that are generally used in conventional devices 
that form into a die or mold, the present invention eliminates the need to 
perform expensive and nettlesome clean-up operations of exotic metals. The 
invention claimed below may also be used to form an inward flare or can be 
used with an induction heating device to assist in the deformation of the 
hollow tube. Unlike the older static spreader devices, the Sizing Tool 
places a flared edge exactly where it is required. Older machines can only 
attempt to form a permanent flare, and unusable excess areas must then be 
trimmed from the tube. The present invention also affords an additional 
engineering advantage by allowing a technician to fabricate a flare on a 
relatively short workpiece. Previous machines require so much force to 
impose a deformation on a hollow tube that a short workpiece would be 
unable to withstand the very large forces required to create the flare. 
Since the Sizing Tool applies the deflection energy via the dynamic sizing 
method described above, much lower forces are needed and shorter 
workpieces are readily sized. Centering the workpiece is also much easier 
to accomplish using the present invention, as compared to the pie-die 
spreader. 
THE CUTTING TOOL 
FIG. 17 reveals an exploded perspective view of a Cutting Tool Bit Drive 
Assembly 100. A tool bit holder subassembly 101 includes a body 101A and a 
bit holder 101B which translates inside a slot 101C and holds a bit 101D. 
The bit holder 101B has a rear cam roller slot 101E formed in its rear 
face 101F. The entire tool bit holder subassembly 101 is held in place by 
a pair of tool bit holder clamp guides 102. The guides 102 are held by 
machine screws against a tool bit guide clamp mount 104A and a machine 
head mounting plate 104B, which is mechanically coupled to a cam bearing 
103. The mounting plate 104B is coupled to a rotor 105, which includes a 
forward portion 105A, a step portion 105B, and a rear portion 105C. The 
elements described above between and including the tool bit holder 101 
back through and including the mounting plate 104B are specific to either 
the Sizing or the Cutting Tool. All the elements behind the mounting plate 
104B starting with rotor 105 are common to both the Sizing and the Cutting 
Tools. The rotor 105 is attached to the center of a rotor ring gear 106 
that is driven by a smaller pinion gear (not shown in FIG. 17). The pinion 
gear, in turn, is powered by a main motor which provides rotary energy to 
the Cutting Tool Bit Advance Assembly 100. In an alternative embodiment, 
the ring gear 106 may be replaced by a belt or some other suitable 
traveling or rotating energy transfer device. 
A critical transmission means which controls the motion of the Cutting Tool 
is a tool bit advance cam shaft 107. This shaft 107 has a central portion 
107A, an eccentric cam roller 107B mounted on a forward-facing flange 
107C, and terminates at the end opposite flange 107C in a spiral channel 
cup 107D. This cup 107D includes at least one spiral guidance channel 
107E. In the preferred embodiment of the invention, the spiral channels 
107E are formed at an angle of approximately thirty degrees from the 
central axis of shaft 107. The shaft 107 is received by another critical 
transmission means in the Cutting Tool, a cam pin housing longitudinal 
guide cup 108. This cup has a cylindrical body portion 108, a front face 
108B that is oriented toward shaft 107, and a hole 108C that leads to a 
central chamber 108D. The end of the cup 108 which lies at the opposite 
end from the front face 108B includes at least one straight longitudinal 
guidance slot 108E. The slots 108E are formed at the rear end of the cup 
108 which defines a rear opening 108F that receives a cam actuating 
housing 109. This housing 109 includes a body portion 109A, a front face 
109B, a central chamber 109C, a rear flange 109D, and a cam pin hole 109E. 
A cam pin 110 is seated in cam pin hole 109E. The cam pin 110 has an upper 
portion 110A, a middle portion 110B that extends through housing 109, and 
a lower portion 110C that extends into the central chamber 109C enveloped 
by the housing 109. A rear fitting 110D fits over the flange portion 109D 
of housing 109. A lead screw bearing 111 is coupled to a lead screw nut 
112 and a traveling thrust bearing 113, that, in turn, are received by a 
control rod base 114 which includes a front flange 114A and a hole 114B. A 
lead screw shaft 115 fits through the rod base 114 and includes a rear 
portion 115A that has a slotted end 115B. The shaft 115 also includes a 
threaded portion 115C and a forward reduced portion 115D. A pair of 
longitudinal position control rods 116 are located parallel to shaft 115 
and are received by holes in a ring bearing retainer 118 that is attached 
to a shaft bearing retainer 117. A bearing lock ring 119 is coupled to a 
fixed thrust bearing 120 by a lock ring pin 121. A motor mount 122 having 
a front face 122A and a flange portion 122B surrounds an advance mechanism 
drive motor shaft 123 that includes a shaft body 123A, a front flange 
123B, a forward projection 123C, and a pin 123D. The shaft 123 is coupled 
to an adjustable optical sensor 124 which provides longitudinal distance 
control. The motion of the shaft 123 is governed by an optical speed 
control 125 which includes an adjustable mount 126, an actuator 127, and 
an encoder board 128. 
The Cutting Tool is rotated by the action of the pinion gear, which engages 
ring gear 106. The advance cam shaft 107 provides the radial motion which 
provides precise control of the cutting action of the tool bit 101D. The 
cam roller 107A passes through the center of the ring gear 106, rotor 105, 
mounting plate 104B, clamp mount 104A, and bearing 103 and is engaged by 
slot 101E. The circular movement of cam roller 107A at the end of shaft 
107 forces the bit holder 101B to ride up and down in slot 101C. After the 
Cutting Tool has been moved inside a tubular workpiece, the up and down 
radial motion of the holder 101B in slot 101C forces the bit 101D into the 
interior surface of the metal tube which is to be cut. The shaft 107, 
which moves the bit holder 101B, is rotated by the twisting motion of the 
spiral channel cup 107D. The spiral guidance channels 107E are designed to 
receive the lower portion 110C of cam pin 110, which is held by cam 
actuating housing 109. When housing 109 is moved toward the workpiece, it 
slides forward but does not rotate, since cam pin 110 is constrained to 
move along a straight line of travel by longitudinal slot 108E in guide 
cup 108. Since the cam pin 110 can not rotate, the lower portion of the 
cam pin 110C that extends into spiral channel 107E forces shaft 107 to 
rotate. The spiral channels 107E act as a transmission which converts the 
back-and-forth translation motion of the housing 109 and the cam pin 110 
that it holds into precise rotational motion that governs the radial 
action of the cutting bit against the tubular workpiece. 
FIG. 27 is a chart which illustrates the design allowable stress of various 
specialty alloys used in high temperature applications. 
FIG. 28 is a diagram which illustrates the history of the commercial 
introduction of heat resistant titanium alloys in the United States. 
FIG. 29 depicts the various effects of annealing temperatures of an 
aerospace grade titanium alloy. 
FIG. 30 is a chart that reveals the structural classes of titanium base 
alloys. 
FIG. 31 is a diagram that provides typical heat treatments of alpha-beta 
and beta titanium alloys. 
The High-Precision Sizing, Cutting, and Welding Tool System for Specialty 
Aerospace Alloys disclosed and claimed in this patent application 
constitutes a major step forward in the machine tool art and will provide 
a valuable tool for designers and manufacturers of aircraft and aerospace 
vehicles. 
CONCLUSION 
Although the present invention has been described in detail with reference 
to a particular preferred embodiment, persons possessing ordinary skill in 
the art to which this invention pertains will appreciate that various 
modifications and enhancements may be made without departing from the 
spirit and scope, of the claims that follow. The various materials that 
have been disclosed above are intended to educate the reader about one 
preferred embodiment, and are not intended to constrain the limits of the 
invention or the scope of the claims. Although the preferred embodiments 
have been described with particular emphasis on titantium alloys, Inconel 
and stainless steel, the present invention may be beneficially implemented 
with other similar materials. The List of Reference Numerals which follows 
is intended to provide the reader with a convenient means of identifying 
elements of the invention in the specification and drawings. This list is 
not intended to delineate or narrow the scope of the claims. 
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LIST OF REFERENCE NUMERALS 
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FIG. 1 
A Conventional pie-die spreader tool 
B, C, D, E 
Spreader tool sections 
B', A', D', E' 
Positions of displaced sections 
F Center 
G Radial displacement of sections 
FIGS. 2A, 2B, & 2C 
10 Cylinder 
10a Axis of revolution of cylinder 
10b Central aperture 
11 Flared end of cylinder 
12 Plate 
12a Tool spindle center-line (Axis of revolution) 
13 Bearing 
14 Roller 
14a Front surface 
4b Bevel 
14c Work surface 
14d Side flat surface 
14e Back surface 
14f Screw 
15 Tool Mount Assembly 
16 Motor assembly 
.delta.r Radial bending 
FIGS. 3 & 4 
17 Alternate screw & dowel 
18 Housing 
20 Retainer plate 
22 Rotor 
24 Shaft 
FIG. 5 
14g Stud 
14h Retainer 
FIGS. 6 & 7 
26 Drive motor 
28 Spur gear 
30 Ring gear 
32 Mounting flange 
34 Gear box housing 
36 Side stiffening plate 
38 Ball shaft 
40 Ball bushing 
42 Ball bushing mount 
44 Ball shaft mount 
46 Extension for tail stock support 
48 Base plate 
50 Motor mount slide plate 
52 Roller full thrust position 
54 Cutter full thrust position 
FIG. 8 
56 Workpiece frame 
58 Inserts 
60 Hinge 
62 Hinge motion limiter 
64 Lever 
66 Latch 
68 Ball shaft 
FIG. 9 
70 Thrust pivot frame 
72 Thrust mechanism 
74 Thrust pivot hook 
76 Handle 
Handle Positions: 
76a Idle 
76b Initial contact 
76c Initial thrust 
76d Half thrust 
76e Full thrust 
FIG. 17 
100 Cutting Tool Drive Assembly 
101 Tool bit holder subassembly 
101A Body 
101B Bit holder 
101C Slot 
101D Bit 
101E Rear cam roller slot 
102 Tool bit holder guide clamp 
103 Cam bearing 
104A Tool bit guide clamp mount 
104B Machine head mounting plate 
105 Rotor 
105A Forward portion of rotor 
105B Step portion of rotor 
106 Rotor ring gear 
107 Cutter advance cam shaft 
107A Central portion of shaft 
107B Cutter advance eccentric cam roller 
107C Cam roller flange 
107D Spiral channel cup on advance cam shaft 
107E Spiral guidance channel 
108 Cam pin housing longitudinal guide cup 
108A Body portion of guide cup 
108B Front face 
108C Front hole 
108D Central chamber 
108E Straight longitudinal guidance slot 
108F Rear hole 
109 Cam actuating housing 
109A Body of cam actuating housing 
109B Front face 
109C Central chamber of cam actuating housing 
109D Rear flange 
109E Cam pin hole 
110 Cam pin 
110A Upper portion of cam pin 
110B Middle portion of cam pin 
110C Lower portion of cam pin 
110D Rear fitting 
111 Lead screw bearing 
112 Lead screw nut 
113 Traveling thrust bearing 
114 Control rod base 
114A Front flange of control rod base 
114B Hole in control rod base 
115 Lead screw shaft 
115A Rear portion of shaft 
115B Slotted end of shaft 
115C Threaded portion of shaft 
115D Forward reduced portion of shaft 
116 Longitudinal position control rod 
117 Shaft bearing retainer 
118 Ring bearing retainer 
119 Bearing lock ring 
120 Fixed thrust bearing 
121 Lock ring pin 
122 Motor mount 
123 Cutter advance mechanism drive motor shaft 
123A Body portion 
123B Flange 
123C Projection 
123D Pin 
124 Adjustable optical sensor for longitudinal distance 
control 
125 Optical speed control 
126 Optical sensor adjustable mount 
127 Optical sensor actuator 
128 Encoder board 
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