A method and apparatus has been disclosed for grinding contour punch parts. The apparatus is capable of movement on six axes. The main features of the invention include stopping rotation of the part when a flat surface is desired to be ground on the part and moving it directly vertically upwardly with respect to the grinding wheel, thus forming a smooth flat surface on the part. The part is moved on three axes, laterally, horizontally and vertically with respect to the grinding wheel. In addition, a dressing apparatus, movable on two axes, is disposed behind the grinding wheel and maintains a desired surface upon the grinding wheel. The dressing surface may form a ramp surface on the grinding wheel that will create a ramp surface on the finished part.

BACKGROUND OF THE INVENTION 
This invention in general relates to grinding machines. In particular, the 
invention relates to an improved contour punch grinder for use in grinding 
metal punches. 
Metal punches are utilized to punch apertures into sheet metal. The prior 
art machines for grinding a metal punch would pivot a metal blank into and 
away from the grinding wheel in order to shape the proper surface on the 
blank. A prior art grinding apparatus is shown in FIGS. 1 and 2. Prior art 
grinding apparatus 20 includes a cam 24 and a cam surface 26. Cam 24 was 
mounted upon a shaft 28 that rotated integrally with part holder 32. A 
motor rotates shaft 28, cam 24 and part holder 32. Shaft 28 and part 
holder 32 were mounted within main body 30, and part holder 32 had a part 
34 to be ground mounted therein. As shown in FIG. 1, main body 30 is 
mounted to fixed base 36. Grinding wheel 38 and grinding wheel cover 40 
are shown horizontally aligned with part 34. 
As shown in FIG. 2, cam 24 will rotate against cam surface 26 which is 
fixed to stationary surface 42. Main body part 30 is pivotally mounted to 
base 36 as shown by pin 44. Main body 30 is weight-biased to pivot into 
the wheel and thus cam 24 is biased into surface 26. However, the cam 
shape will cause the cam 24 and main body 30 to pivot against this bias 
whenever a relatively large diameter portion of the cam is in contact with 
the cam surface. Cam 24 would rotate along cam surface 26 and cause main 
body 30 to pivot clockwise and counterclockwise about pin 44. Part holder 
32 and part 34 would be moved therewith into and away from grinding wheel 
38. Thus, by properly shaping cam 24, a desired surface can be formed upon 
contour punch part 22. 
This type of prior art device was unsatisfactory since a cam needed to be 
manufactured for any run of contour punches that was to be manufactured. 
This is not particularly expensive if a large number, say thousands or 
hundreds of thousands, of the contour punches were to be manufactured; 
however, if only a small number of punches were to be manufactured it 
would be unduly expensive to create a cam such as shown at 24. 
One prior art device attempted to solve this problem by computerizing a 
motor to pivot main body part 30 into and away from grinding wheel 38. 
This was also unsatisfactory since the computer program was extremely 
complicated and required the introduction of several variables. 
A contour punch as is commonly found in industry is shown in FIG. 3. This 
punch consists of a main body portion 46 that may sometimes have a ramp 
portion 48 extending between main body portion 46 and a flat planar 
surface 50. A lock nut indentation 52 is formed near one end 54, the 
planar surface 50 being formed at the other end 56. In contour punch 22, 
surfaces 48 and 50 have been formed by a grinding wheel while main portion 
46 is relatively unground and retains its original shape. When utilizing a 
prior art grinder that pivoted, a flat planar surface, such as shown at 
50, will have wavy surfaces. The prior art grinding wheels were not 
capable of grinding a completely flat surface by merely pivoting into and 
away from the grinding wheel. 
It is therefore an object of the present invention to create a grinding 
apparatus that will allow the use of either a cam or a computer control to 
control the movement of the contour punch part holder into and away from 
the grinding wheel. 
It is further an object of the present invention to create a contour punch 
grinder apparatus that will grind a perfectly flat surface when one is 
desired upon a particular contour punch. 
Moreover, it is an object of the present invention to achieve these goals 
with an apparatus that is relatively simple and economical. 
SUMMARY OF THE INVENTION 
The present invention discloses a contour punch grinder that utilizes 
movement upon six different axes to ensure that the final contour punch 
will have a desire surface. 
The contour punch grinder of the present invention achieves these goals by 
having a main body portion that is guided for movement along all three 
dimensions. That is, the main body may be moved directly vertically, 
horizontally, and laterally. In addition, a contour punch part holder is 
rotatably mounted within the main body and is driven by a rotating motor. 
Thus, when it is desired to grind a particular surface on a contour punch, 
the main body is brought horizontally into alignment with a grinding wheel 
and then moved laterally into contact with the grinding wheel. The part is 
held in contact with the grinding wheel, and it is rotated to create any 
curved surfaces that may be desired on the contour punch. The movement of 
the main body and the contour punch part holder may be controlled by a 
cam, or it may be computer controlled. If a cam is used, some computer 
control is envisioned for driving the various motors. 
When it is desired to create a flat surface upon a particular contour punch 
the part holder is first prevented from rotating and maintained in a 
static position. The part is then brought into contact with the grinding 
wheel, and the vertical movement motor of the main body of the contour 
punch grinder apparatus is activated to move the entire body of the 
contour punch grinder vertically upwardly or downwardly. This will bring 
the associated contour punch part holder and contour punch along 
therewith. The contour punch is thus caused to move vertically along the 
grinding wheel while not rotating. Due to this movement, an entirely flat 
surface will be created on the contour punch. Although vertical movement 
is preferably used to create the flat surface, horizontal movement may 
also be acceptable. 
The main body of the contour punch grinder apparatus has a first motor for 
lateral movement with respect to the grinding wheel, a second motor for 
horizontal movement with respect to the grinding wheel, and a third motor 
for vertical movement with respect to the grinding wheel. 
An additional feature of the invention consists of having a high-pressure 
gas jet applied against the main body to bias it into contact with a 
laterally furthermost position in the direction of the grinding wheel. In 
the event that the part or grinding wheel seizes and an overly large force 
is applied to the body, the body will move away from the wheel and against 
the force of the high-pressure jet and relieve the seizure of the part or 
wheel. 
A further aspect of the present invention is a dresser apparatus for 
accurately maintaining the desired surface on the grinding wheel. The 
dresser apparatus of the present invention consists of a diamond-tipped 
dresser member that is brought into and out of contact with a rear portion 
of the grinding wheel. The dresser member is moved into contact with the 
wheel in order to grind off a surface of the wheel. A second motor moves 
the dresser apparatus laterally along the wheel. By entering the desired 
surface of the grinding wheel into the computer control, the control will 
then position the diamond-tipped dresser member against the grinding wheel 
to form any ramps or the like that may be desired upon the grinding wheel 
and the final contour punch. 
The method of the present invention consists of horizontally and laterally 
aligning the part with the grinding wheel and controlling the movement of 
the various motors on the main body part to grind down the contour punch 
part to a rough approximation of its final shape. The part is then moved 
away from the grinding wheel, and the dresser assembly is brought into 
contact with the wheel in order to accurately shape a desired surface face 
upon the grinder wheel. Once the dresser assembly has accurately formed 
the desired face upon the grinder wheel, the part is then brought back 
into contact with the grinding wheel, and a finished grind is performed. 
It is to be understood that several increments of this dressing and finish 
grinding may be performed in order to more accurately shape the finished 
contour punch to the desired dimensions. Whenever a flat surface is 
desired upon the contour punch, the rotary motor driving the part holder 
is stopped, and the part is moved vertically with respect to the grinding 
wheel. This causes the part to have a finished flat surface that is 
smooth. 
Further objects and features of the present invention can be best 
understood from the following specification and drawings, of which the 
following is a brief description thereof.

DETAILED DESCRIPTION OF A DISCLOSED EMBODIMENT 
This invention discloses an improved contour punch grinder 60 for use in 
forming contour punches such as shown at 22 in FIG. 3. 
Contour punch grinder 60 consists of a motor 62 for moving a main body 63 
vertically upwardly and downwardly with respect to a grinder wheel. Main 
body 63 is mounted for movement on fixed base 68. Table 69 moves main body 
63 horizontally, as shown in FIG. 4, with respect to base 68. Table 69 is 
driven by a motor, not shown. A cam 72, similar to the prior art cams, may 
be utilized with the improved grinder 60. However, a cam is not necessary. 
Cam 72 is mounted upon shaft 70 which is in turn mounted to part holder 
76. Part holder 76 holds contour punch part 22. 
Grinder wheel 78 and grinder wheel cover 80 are mounted on a first axis in 
the vicinity of part 76. For the purpose of the description included in 
this disclosure, the direction "laterally with respect to the grinder 
wheel" refers to movement into and out of the paper as shown in FIG. 4. 
The use of the words "vertically" and "horizontally" refers to movement 
with respect to the grinding wheel as illustrated in FIG. 4. 
A computer control is illustrated at 82 and acts to control the various 
motors and members of the grinder apparatus 60. The details of this 
control are not part of this invention. A worker in the art could assemble 
an adequate control. 
A grinder wheel dresser apparatus 84 is mounted laterally behind grinder 
wheel cover 80. 
A source of pneumatic pressure 86 is associated with contour punch grinder 
apparatus 60. 
An abutment 88 serves to move main body 63 laterally, or into an out of the 
paper as shown in FIG. 4. As can be seen, abutment 88 is vertically larger 
than cam 72. 
FIG. 5 is a view similar to that shown in FIG. 2, but illustrating the 
movement of the contour punch grinder 60 of the present invention. As can 
be seen in FIG. 5, a cam 72 may ride along abutment 88 which is connected 
to motor 92. Main body 63 can be seen to be capable of movement in both 
the lateral and vertical directions. Thus, in the improved contour punch 
grinder 60 of the present invention, the main body does not pivot; 
however, it is guided both laterally and vertically. As is also seen from 
FIG. 5, cam 72 and shaft 70 are rotatably driven within main body 63. 
A first embodiment is shown largely schematically in FIG. 6, main body 63 
can be moved laterally, vertically, and also horizontally. Main body 63 
consists of inner body 64 and outer body 66. A first motor 92 causes the 
main body 63 to be moved laterally with respect to the grinding wheel, 
"laterally" being defined as shown in FIG. 4. 
A first motor 92 consists of a rotary motor 94 with a shaft 96 having the 
screw thread 98 guided in abutment 88. Abutment 88 is prevented from 
rotating and the resulting connection is a rotary to reciprocating 
connection. The exact motor structure forms no part of the invention and 
is well known in the art. Thus, when control 82 causes motor 94 to rotate 
screw thread 98 rotates within abutment 88 and causes abutment 88 to 
reciprocate laterally. Since abutment 88 is in contact with cam 72 which 
is in turn mounted within main body 63, the entire main body is moved 
laterally by abutment 88. However, there is no positive mechanical 
connection between abutment 88 and cam 72. Thus, abutment 88 only causes 
cam 72 to move main body 63 away from the grinding wheel. An air cylinder 
180 is connected to a pressure air source 86. Pressure air source 86 sends 
high-pressure air against a piston 182 which is mounted within chamber 
180. Piston 182 is connected to outer body 66 and thus causes the entire 
main body 63 to be brought towards the grinding wheel. 
When laterally positioning main body 63, motor 92 causes abutment 88 to 
abut cam 72 and move body 63 in a direction away from the grinding wheel. 
Alternatively, when it is desired to move main body 63 towards the 
grinding wheel, cylinder 180 is sued and piston 182 is biased towards the 
grinding wheel and brings body 63 along. It is to be understood that when 
it is desired to move body 63 towards the grinding wheel, abutment 88 is 
moved laterally towards the grinding wheel also. Thus, cam 72 can move 
along with main body 63 in the direction of the grinding wheel and will 
not abut abutment 88. Should a seizure occur between the wheel and the 
part, body 63 will be forced against the biased on piston 180 and move 
away from the grinding wheel. 
A motor 110 is mounted to the side of inner body 64 and causes part holder 
76 and cam 72 to rotate. Motor 110 consists of a rotary motor 108 that 
drives a shaft 112. A belt 114 connects shaft 112 with shaft 70. A belt 
guard 74 covers this belt connection. As can be seen, outer housing 66 is 
cut away in the vicinity of motor 110 to allow motor 110 to be mounted 
directly to inner body 64. Alternatively, motor 110 could be mounted to 
outer body 66 and the tightness of belt 114 would simply vary as part 
holder 76 is moved vertically. 
Rotary motor 62 provides movement of main body 63 in a third direction. As 
shown in FIG. 7, a rotary motor 118 is mounted upon outer body portion 66. 
A screw thread portion 120 rotates integrally along with rotary motor 118 
and is mounted within inner body portion 64. Since inner body portion 64 
is about the same lateral size as outer body portion 66 it is prevented 
from rotating. Thus, the rotation of threaded surface 120 within inner 
body portion 64 will cause it to advance vertically both upwardly and 
downwardly with respect to outer body portion 66. Basically, outer body 66 
surrounds inner body 64 on all but the horizontal sides. Alternatively, 
there could simply be an opening in outer housing 66 that allows the cam 
and the part holder to move vertically with respect to the outer housing. 
Inner body portion 64 is of a smaller vertical dimension than outer body 
portion 66. This creates a clearance 124 that allows the inner portion 64 
to move within the outer portion 66. Alternatively, any other type of 
rotary-to-reciprocating motor may be utilized rather than the one 
illustrated at 62 in FIG. 7. 
Also shown in FIG. 7 is the mounting of body 63 with respect to moving 
table 69. As shown by the arrow, table 69 can move horizontally in either 
direction and body 63 will move along therewith. A portion 125 of table 69 
has a railing 126 slidably mounted thereon. Railing 126 can move laterally 
with respect to portion 125. Point bearings 127 are mounted so as to guide 
railing 126 upon portion 125. This connection allows main body 63 to be 
moved laterally with respect to portion 125 and thus table 69. 
FIG. 8 shows a dresser assembly 84 for use in creating a desired surface 
along grinder wheel 78. Dresser assembly 84 consists of a diamond-tipped 
needle 128 mounted within a first housing 130. Rotary motor 132 having a 
spiral surface 134, similar to that disclosed above for motor 62, is 
received within part 136. Part 136 fixedly holds diamond tip 128. Guide 
shoulders 138 prevent rotation of part 136 and thus cause part 136 to 
reciprocate into and out of housing 130. The reciprocation causes diamond 
tip 128 to be brought into contact with grinder wheel 78 and may cause 
diamond tip 128 to be brought radially further into contact with grinder 
wheel 78. A second motor 140 causes the entire dresser assembly 84 to move 
along the surface of grinder wheel 78. Thus, diamond tip 128 can create a 
desired surface upon grinder wheel 78 by being moved within housing 130 
further into or away from grinder wheel 78 and by being moved horizontally 
along the surface thereof. 
As shown in FIG. 9, grinder wheel 78 has grinder wheel cover 80 and is 
rotatably mounted on axis 142. Dresser assembly 84 consists of diamond tip 
128, outer housing 130, rotary motor 132, spiral surface 134, part 136, 
guide shoulders 138, and second motor 140. The entire grinder assembly 84 
is mounted for movement upon fixed base 144. The details of the mount 
between dresser assembly 84 and fixed base 144 are not important to this 
invention and could be of any type that would allow the movement described 
above. A further feature of grinder cover 80 is notched portion 146 that 
allows access to grinder wheel 78 from diamond tip 128. An alignment notch 
148 integral with housing 130 ensures that diamond tip 128 is properly 
positioned with respect to grinder wheel 78. That is, notch 146 receives 
flange 148 to ensure the proper positioning of diamond tip 128. 
FIG. 10 shows the part holder apparatus 76 and part lock member 77. Part 
lock member 77 firmly receives part 22. Ramp 48 and flat portion 50 can be 
seen to extend beyond part lock member 77. A central portion 149 will 
rotate along with belt 114 and includes part lock member 77. Notches 150 
receive Allen screws or the like and align with indent 52 formed in part 
22. The holes 150 and indent 52 ensure proper placement of part 22 within 
part lock 77. The part lock connection ensures that part 22 will be 
accurately positioned with respect to grinding wheel 78 while the grinding 
operation is in progress. 
The grinding operation will now be described with respect to FIGS. 3 to 10. 
When a desired contour punch is to be manufactured, the basic desired 
parameters will be entered into control 82. The details of control 82 are 
not important to this invention, and the worker in the art could 
understand how to achieve the required controls. A part blank to be ground 
is inserted in part lock 77, holes 150 and indent 52 ensuring proper 
alignment. Part lock 77 is then brought into alignment with grinding wheel 
78 along with main body 63. Initial grinding is commenced, and part lock 
77 is rotated along grinding wheel 78 to create any curved surfaces that 
may be desired. The part lock 77 and the associated part 22 are moved 
laterally and horizontally with respect to grinding wheel 78 while the 
part lock 77 is being rotated in order to form the desired surface upon 
part 22. 
If it is desired to have a flat surface, such as shown at 50 in FIG. 3, 
formed on the part 22, the rotary motor 110 is stopped. Rotary motor 62 is 
energized, inner portion 64, part lock 77, and associated part 22 are 
moved vertically along grinding wheel 78. This causes a smooth flat 
surface 50 to be formed upon punch 22. 
If a ramp, such as shown at 48, is desired, the wheel 78 is initially 
shaped to form the ramp. This shaping is described below. 
Once the rough grinding has been done, the part lock 77 and associated part 
22 are moved away from grinding wheel 78. Dresser assembly 84 is then 
brought into contact with grinding wheel 78 to accurately form a desired 
surface upon grinding wheel 78. If, for instance, a ramp, such as shown at 
48 in FIG. 3, is desired upon the final contour punch, the dresser 
assembly and the associated diamond tip 128 will be utilized to form the 
correct surface upon grinding wheel 78. 
In forming a ramp such as shown at 48, diamond tip 128 would be kept 
relatively withdrawn into housing 130 at the lefthand side of grinding 
wheel 78, as shown in FIG. 8, and moved out of housing 130 into grinding 
wheel 78 as it moves to the right along grinding wheel 78. Thus, by moving 
diamond tip 128 further into grinding wheel 78 as diamond tip 128 moves 
from left to right along grinding wheel 78, the surface of grinding wheel 
78 would have a ramp-like configuration roughly approximating the desired 
ramp 48 on contour punch 22. It is to be understood that the surface of 
grinding wheel 78 would be the mirror image of the ramp 48 desired on the 
part. That is, where the ramp 48 is at its thickest extent near main part 
46, the wheel 78 would be at its smallest diameter. At the tail end of 
ramp 48, near flat surface 50, the grinding wheel 78 will be maintained at 
a greater diameter. This ramp forming may also be performed prior to any 
rough grinding. 
The dresser assembly 84 may also be utilized simply to ensure the surface 
of grinder wheel 78 is maintained relatively level along its extent. That 
is, the rough grinding of part 22 may cause gauges or nicks in the surface 
of grinding wheel 78 that will be corrected by dresser assembly 84. 
Once dresser assembly 84 has accurately formed the desired surface on 
grinder wheel 78, part 22 is brought back into contact with grinder wheel 
78 and the finish grinding is begun. Finish grinding is performed exactly 
as has been described above with respect to the rough grinding. 
It is to be understood that three or four iterations of this dressing and 
subsequent grinding may be performed in order to achieve a final contour 
punch. 
The teachings of this invention will apply to any type of grinding, and in 
particular anytime it is desired to grind ramps and flat surfaces. 
Preferred embodiments of the present invention have been disclosed; 
however, they are not intended to limit the scope of the invention. The 
following claims should be read in order to determine the exact scope of 
the invention claimed herein.