Align boring machine

An align boring machine for boring bearing housings of an automotive engine block wherein a boring bar is rotatably suspended by and rotatably driven between two columns positioned upon machine ways, and the engine block is mounted for aligned movement along said ways.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
This invention relates to the field of remachining automotive engines, and 
particularly to a machine for align boring main and cam bearing housings. 
2. General Description of the Prior Art 
There are several machines being marketed for the align boring of bearing 
housings of automotive engines. Commonly, they are constructed to provide 
a stationary, but adjustable, mount for an engine block and to axially 
move a rotating boring bar into the engine. In practice, this has required 
complex and costly structures. Because of their structure, set-up time is 
often considerable, and there are certain boring operations on certain 
engines which cannot be performed by them. Still further, and perhaps most 
significantly, existing machines do not embody means for finally 
determining the accuracy of a boring operation since they lack an 
alignment reference. 
Accordingly, it is the object of this invention to provide a simpler and 
less costly boring assembly, one which does not require elaborate fixtures 
for positioning a boring bar, and one which may be readily checked for 
accuracy. 
SUMMARY OF THE INVENTION 
In accordance with this invention, first and second columns are mounted at 
spaced positions on a machine table having vertical and horizontal machine 
ways, the columns being vertically aligned with the ways. A boring bar is 
supported for rotation on and between the columns and rotably driven at 
one end. The supports are axially aligned with the machine ways as is a 
table which is movable along the machine ways between columns. A 
vertically and laterally adjustable holding fixture supports an automotive 
engine block on the table, whereby align boring of bearing housings of a 
block is effected by the combination of rotation of the boring bar and 
movement of the table along the machine ways.

DETAILED DESCRIPTION OF THE DRAWINGS 
Referring to FIG. 1, machine 10 includes base 12 which is a rectangular 
box-like structure generally open at the top. Base 12 incorporates a pair 
of spaced longitudinally extending L-shaped guide surfaces 14 and 16 
individually formed of horizontal and vertical flatways 18 and 20, 
respectively. Carriage or table 22 is slidably supported by and between 
guide surfaces 14 and 16 and is thereby adapted to be moved along the 
guide surfaces. Longitudinally extending rack gears 24 are affixed to the 
underside of each horizontal flatway 18, and drive assembly 30 is attached 
to the underside of table 22 to effect controlled longitudinal movement of 
the table through driven pinion gears 28 in engagement with rack gears 24. 
Drive assembly 30 includes conventional gear reduction unit 34 which 
drives pinion gears 28, and is in turn driven by handle 36. Thus, when 
handle 36 is rotated in either direction, table 22 moves in a like 
direction. Additionally, drive assembly 30 would typically include a motor 
(not shown) which, through the just described linkage, would drive table 
22. 
An engine block to be bored is supported on table 22 by means of two 
identical support assemblies 40 and 42, each of which includes lateral 
adjustment assembly 44 and vertical adjustment assembly 46. 
FIG. 2 illustrates in detail one of the support assemblies. Rectangular 
plate 48, with its longest dimension extending laterally, provides a base 
for the support assembly, and it is initially positioned on table 22, as 
desired, as a coarse or rough adjustment, and when tightened to the table, 
it provides a firm base for lateral adjustment assembly 44. A smaller 
rectangular plate 50 provides a movable base for lateral adjustment 
assembly 44, and it is slidably mounted for transverse movement on plate 
48, being secured and limited for such movement on side 52 by pin 54 
extending into opening 55. Pin 54 is rigidly positioned by attachment 
block 56, which is in turn rigidly secured to plate 48. Plate 50 is 
further limited to transverse movement by shaft 58 which is axially 
secured by collar 60, which is in turn secured to plate 48 on the opposite 
side of plate 50. Additionally, shaft 58 includes a threaded portion 61 
which engages threads in opening 62 of plate 50, and thus by hand rotation 
of shaft 58, plate 48 is transversely movable on plate 48. 
Vertical adjustment assembly 46 includes wedge blocks 63 and 64 which 
slidably rest upon and extend vertically upward from plate 50. The upper 
portions of wedges 63 and 64 form separated but facing inclined planes 65. 
Vertical adjustment shaft 66 extends transversely through wedges 60 and 62 
and includes left-hand threads 68 extending in one direction from its 
center and right-hand threads 70 extending in the other direction. Threads 
68 and 70 engage mating female threads (not shown) in wedges 60 and 62. 
Vertical end plate 72 axially holds shaft 66 on end 74 for rotation, and 
vertical end plate 76 rotably holds shaft 66 on end 78. End 74 of shaft 66 
extends through plate 72 and has wrench flat 80 by which shaft 66 may be 
rotated and thus draw together or extend apart wedges 63 and 64. Engine 
support 82 extends vertically upward from and in the plane of wedges 60 
and 62. It is basically triangular, with its upper edge 84 (the contact 
surface) horizontal and the remaining two edges forming inclined planes 86 
which rest upon and correspond to planes 65 of wedges 63 and 64. 
As wedges 63 and 64 are moved apart or toward each other, they cause engine 
support 82 to either be raised or lowered by virtue of inclined planes 86 
and 64. Guide blocks 88 and 90 are sandwiched between engine support 82 
and vertical side members 92, which are rigidly affixed to and extend the 
length of plate 48, thus limiting movement of engine support 82 to a 
vertical plane. Guide blocks 90 are fastened to engine support 82 by pins 
96 which extend through openings 98 of guides 90 to restrict transverse 
movement by support 82. Rectangular passage 100 and circular passage 102, 
in conjunction with three tubular horizontal bars 104, 106, and 108 (FIG. 
1), are used to secure supports 40 and 44 to table 22, and in turn, engine 
block 29 to supports 40 and 42. Bar 104, passing through rectangular 
passage 100 of both supports 40 and 42, has each extended end secured to 
table 22 by L-shaped clamp assembly 102. Bar 106 extends from circular 
passage 102 in a like manner, and bar 108 extends parallel to bar 106 from 
cam shaft opening 110 in engine block 29. Hence, when the extended ends of 
bars 106 and 108 are drawn together by clamp assemblies 112, block 29 is 
held securely to supports 40 and 42. 
Referring again to FIG. 1, and forming a drive end support assembly 114, 
bar drive assembly 116 is mounted on vertical tubular member 118, which is 
slidably mounted within tubular member 120, which is in turn mounted on 
flat plate 122. The underside of flat plate 122 rests upon flatways 
124a-124d lying in a common plane and parallel to flatways 16 and 18. 
Plate 122 is longitudinally aligned by dowel pins 126 which contact 
vertical alignment wall 128 or 128a of T-slot 130, alignment walls 128 and 
128a being parallel with vertical flatways 20. Alternately, dowel pins 126 
may be positioned on the opposite end of plate 122 and insure longitudinal 
alignment by contact with alignment wall 132 or 132a of identical and 
parallel T-slot 134. Once plate 122 is so aligned, clamp bolt assemblies 
136 and 138, by engagement in T-slots 130 and 134, respectively, rigidly 
secure plate 122 to flatways 124a-124d. To preserve horizontal alignment 
between an alignment wall of a T-slot and bar drive assembly 116, vertical 
key ways 140 and 142 are cut in tubular members 118 and 120, respectively, 
and the tubular members are angularly locked together by means of key 144. 
Precise height adjustment of drive assembly 116 is effected by screw 
assembly 146 consisting of threaded rod 148, which is axially locked in 
port block 150 of bar drive assembly 116 and threaded block 152 mounted on 
tubular member 120. Handle 154, attached to a top end of rod 148, provides 
convenient means of rotation of rod 148 for raising and lowering drive 
assembly 116. 
Drive assembly 116 consists basically of drive center 156 mounted in 
bearings (not shown) in support block 158 and a motor drive assembly 160 
which rotably drives center 156. Motor drive assembly 160 typically would 
include suitable speed reduction and speed control means to effect a 
desired rotational speed for center 156, depending upon the desired 
peripheral speed to be imparted to boring bar 162, as will be further 
explained. Motor drive assembly 160 is supported on mounting bracket 164 
attached to support block 158. Rotational drive by center 156 to bar 162 
is imparted by a diametrically positioned pin 166 through a shaft 
extension 168 of center 156 which mates with a correspondingly shaped slot 
in an otherwise conical slot in end 170 of boring bar 162. 
An opposite end support assembly 172 is positioned on an opposite end 
region 174 of base 12 and is similar to end support assembly 114 which is 
identical in instances of components bearing identical numbers, but with a 
suffix "a". Block 176 is similar to block 158 of end assembly 114, but it 
supports only screw assembly 146a and live center assembly 178, a 
conventional device wherein center 178a is rotably supported in block 
176a. 
Boring bar 162 is pivotally mounted at end 180 by concave center 182 which 
mates with center 178a. Additionally, concave center 182 and center 172a 
could be drawn together by a threaded rod (not shown) extending through 
the axis of center 178a which would engage mating threads in boring bar 
162. Boring bar 162 is held between center 178 and drive center 156 
precisely parallel with vertical alignment walls 128 or 128a of T-slot 130 
of 132, respectively, by virtue of the structure thus far described. It is 
held parallel with parallel flatways 124a-124d of base 12 by adjustment of 
screw assemblies 146 and 146a, as will be further described in connection 
with the description of the operation of the machine. 
Tool assemblies 184, one or more, are positioned along bar 162 to effect 
the single or dual cutting of bearing housings 186 of block 29, as 
desired. Saddle bore 188, formed integrally of block 29, comprises 
one-half of bearing housings 186, and removable cap 190 comprises the 
other half. A single tool assembly would include collar 192 affixed to bar 
162 by one or more set screws 194 and cutting tool 196 mounted in an 
opening in collar 192 and attached by a set screw (not shown). 
Alternately, cutting tools would be mounted at selected locations along 
bar 162 by tool stations drilled in bar 162 and essentially locked in 
place by locking screws. 
A steady rest assembly 198 is adapted to attach to an engine block and 
provide, where needed, a stabilizing or steadying effect near the actual 
point of cutting. It employs a split type bushing 200 which is openable 
along lines 202, and thus readily positionable around bar 162 with the bar 
in place. Upper and lower split portions 204 are then attached together by 
a conventional locking connection 206. Mounting arms 208 and 209 mount 
bushing 200 on vertical rod 210 which is slidably positionable in cross 
bar 212 and lockable in position by locking clamp 214 by means of locking 
screws 216. Cross bar 212 is attached to block 29 by means of adjustably 
positionable clamps 218 which extend over cross bar 212 and by means of 
bolts 220 which thread into engine block 29. 
To examine the operation of the machine, and with end support assemblies 
114 and 172 in place and longitudinally aligned as described, work holding 
fixtures 40 and 42 are positioned at spaced locations on table 22 and 
vertical adjustment shaft 66 and lateral adjustment shaft 58 adjusted so 
that the adjustments are at mid points. As will be appreciated from FIG. 
2, increased height is achieved by operating shaft 66 so that wedges 63 
and 64 are drawn together, and decreased height is achieved by operation 
of shaft 66 in the opposite direction so that wedges 63 and 74 are moved 
apart. Rotation of shaft 58 causes lateral adjustment assembly 44 to be 
moved generally away from front side 222 of machine 10, and when operated 
in the opposite direction, lateral adjustment assembly 44 is moved toward 
front side 222. By examination, end supports 114 and 172 are adjusted 
equally vertically so that boring bar 162, when in position, would 
generally center within the bearing housings in order that desired cuts 
may be achieved. Next, ends 170 and 180 of boring bar 162 would be snugly 
positioned on centers 156 and 178. 
Bars 106 and 108 and clamp assembly 112 are now used as previously 
explained to secure block 29 to engine support assemblies 40 and 42. Bar 
104 and L-shaped clamp assembly 109 are positioned to secure engine 
support assemblied 40 and 42 to table 22, as previously explained, but are 
not tightened at this time. 
Next, a dial indicator would be positioned generally on a top region of 
block 29 and oriented so that its sensing arm senses the bottom of bar 162 
and table 122 moved back and forth by rotation of handle 36. Thus, in this 
fashion, it is determined what, if any, adjustments need to be made in the 
vertical positioning of either of engine support assemblies 40 and 42 to 
maintain bar 162 in a parallel horizontal plane to that of guide surfaces 
18. With this adjustment made, and thus with bar 162 aligned with surfaces 
14 and 16, the next step is to position engine block 29 in alignment with 
bar 162 so that one may bore along the original axial center of bearing 
housings. To do this, the dial indicator is attached to boring bar 162 so 
that its sensing container enters and touches the face of one of saddle 
bores 188. The bore is aligned with the bar when the indicator reads the 
same at three points in the block bore; and to effect this alignment, 
vertical adjustment shaft 66 of engine support assemblies 40 and 42 and 
lateral adjustment screws 58 of engine support assemblies 40 and 42 are 
adjusted. It is significant that one is only concerned with the block half 
of the bore, and the three points to be concerned with are each side of 
the bore right below the parting face of cap 190 and the point at the 
center distance between these two points which is normally in line with an 
oil hole in block 29. In each case, the saddle bores nearest the bar ends 
are the ones to be centered. 
After the foregoing adjustments have been made, it is desired to vertically 
move both ends of the block up approximately 0.001 inch, as this will 
enable cutting tool 196 to be set at a proper size to clean up the block 
portion of the bore. However, it is critical that not much be removed from 
the saddle bore half of the housing as this will result in gear and chain 
problems with assembled engines. After this last adjustment has been made, 
holding bar 104 is finally locked in place by firm connection of clamp 
assemblies 109 and to each end of table 22. 
Now, with all adjustments made and cutting tool 196 set in collar 192 to 
take a desired cut in boring housing 186, motor 160 is turned on and 
steady rest 198 mounted and secured to block 29 without a cut being taken. 
In this fashion, the bar is steadied to run in an aligned position, and 
thus cutting may be commenced. To accomplish this, handle 36 is rotated 
and through drive assembly 26 moves table 22, to in turn move a bearing 
housing into rotating cutter 196 and to effect the reboring of the bearing 
housing. After reboring one housing, the block may be continued in 
advancement, thereby allowing a second in-line bearing housing 186 (cap 
not shown) to be bored without moving collar 192. The procedure may be 
continued to additional bearing housings, provided there is still 
sufficient travel left on the ways of the machine. When this is not the 
case, collar 192 would be tightened on bar 162 in a different location, 
whereby the bearing housings not bored may be bored. Thus, by the machine 
of this invention and the following procedure outlined, the boring 
housings may be align bored precisely and simply. By virtue of the fact 
that there are basic references, guide surfaces 16 and 18, which are 
vertical and horizontal references, the boring bar can be readily held to 
alignment and then the work piece moved along the same references. The 
result is the operator knows when his adjustments are right and can 
proceed with confidence in accuracy over long periods of usage of the 
machine. In the event that there should occur some misalignment by virtue 
of bearing or other component wear, the problem will be readily apparent 
and correction can be taken before use of the machine in the cutting 
operation. In this fashion, there would be no excuse for taking an 
incorrect cut or otherwise damaging an engine block. 
FIGS. 3-5 illustrate an alternate form of the invention wherein, in 
particular, means are provided to enable the support columns or other 
boring bar support means to be moved to the end of, behind, or otherwise 
to the side of the machine ways to enable machine 10 to be employed for 
other purposes, such as, as a broach wherein a cutting mechanism, located 
below ways 18 and 20, would be raised into an operating position for 
performing a broaching operation on an engine block. 
Thus, as shown in FIG. 3, a base plate 200 of an end support assembly 198 
would have a round opening 202 which is dimensioned to accept a 
cylindrical support 206 having an internal threaded region 208 adapted to 
be threaded on a threaded region 209 of L-shaped support 210 attached to 
base 12 by means not shown. Base plate 200, when in an operating position 
with base plate 200 resting on ways 18, would be alignable as illustrated 
in FIG. 1 with vertical ways 20 by pins 126a and 126b. It would be secured 
to horizontal flat ways 18 by clamp bolt assemblies identical, or similar, 
to clamp bolt assemblies 136a and 138a shown in FIG. 1. One of these 
assemblies would attach through each of slots 212 and thereby with the 
clamping assemblies tightened, base plate 212 would be rigidly attached to 
horizontal flat ways 18. 
Vertical guide post 214 is supported by post support 216, in turn rigidly 
attached to base plate 200 (by means not shown). Bearing support 218 has 
an opening 220 which enables the bearing support to fit around and 
slidably move vertically on guide post 214. Vertical movement is precisely 
controlled and adjusted by means of lead screw 224 which is axially 
restrained by plate 224 (by means not shown) and rigidly attached to the 
top of guide post 214, lead screw 224 threadably engaging an internal 
thread 226 in bearing support 218. Lead screw 222 is rotably operated by a 
crank assembly 256 attached to the upper end of lead screw 222. Boring bar 
162 is rotably supported in a split bushing assembly 228 of bearing 
support 218, and wherein a bushing tightening adjustment is provided by 
bolts 230 and thread into one side region 232 of split bushing assembly 
228 and have ends 234 which butt against the face of opposite side region 
236. The bushing is tightened or locked in the adjusted position (to 
assure essentially a zero clearance fit) by bolts 238 which thread into 
side region 236 of the bushing assembly. 
The end support assembly shown in FIGS. 3 and 4 is the drive end assembly, 
and boring bar 162 has a pulley 240 mounted on its end 242 which is driven 
by a belt 244 by pulley 246 on motor 248. Motor 248 is mounted on a base 
250, in turn attached to lever arm 252 rotably supported on base plate 200 
by means of pivot pin 254. By this arrangement, an essentially constant 
belt tension is maintained as bearing support 218 is adjusted vertically 
by operation of crank assembly 256. 
The opposite end of boring bar 162 is supported by an end support assembly 
260 which is identical to that of end support assembly 198 except that the 
rotary drive mechanism is omitted and that lead screw 222 is on the 
opposite side as shown in FIG. 5. Accordingly, like components of end 
support assembly 260 of these assemblies are identically numbered in FIG. 
5. 
For normal operation, the base plates would be aligned by guide pins 126a 
and 126b for each of base plates 200 and locking assemblies, like those 
illustrated for locking assemblies 136a and 138a, would be attached to 
each of slots 212 and the base plates rigidly attached on horizontal ways 
18 in an aligned position with vertical ways 20. Thereafter, with an 
engine block mounted to an engine support, such as engine support 82, or 
simply a flat base plate rigidly attached to table 22 or, in fact, 
directly to table 22, an adjustable alignment effected between the motor 
block and boring bar 162 by adjustable positioning of the motor block (by 
support 82 shown in FIG. 2 or by hand positioning and shims on a flat 
support) and adjustment of lead screw 222 of each of support assemblies 
198 and 260. After the completion of a boring operation, and where it is 
desired to employ machine 10 for other purposes, the locking assemblies 
(e.g., 136a) would be unlocked, freeing the locking assemblies from slots 
212, and thereby enabling cylinder 206 to be rotated, raising, in each 
case, the support assemblies, and thereafter, the support assemblies would 
be rotated on cylindrical support 206 to an out-of-the-way position, 
typically to the outside of one side of machine 10.