DRILL GUIDE AND METHOD

A drill guide for drilling a bore into a workpiece having a curved surface. The drill guide comprises a drill block body having a first side portion and a second side portion opposed to the first side portion. The drill block body defines a throughbore between the first side portion and the second side portion. The throughbore extends along a throughbore axis. A first leg protrudes from the first side portion of the drill block body. A second leg protrudes from the second side portion of the drill block body. A first wing is hingedly connected to the first leg.

FIELD

This application relates to tools for positioning a drill bit relative to a surface and, more particularly, to drill guides for orienting a drill bit substantially perpendicular relative to a curved surface.

BACKGROUND

Manufacturing operations in which two or more components are to be joined by mechanical fasteners, such as in a portion of an airframe assembly, typically require precise and repeatable holes or bores be drilled through the components through which fasteners may extend. Because of the relatively complex shapes of components in an airframe assembly it is often difficult to provide quality precise and repeatable holes or bores. This is especially challenging to manually drill a hole perpendicular to a contoured or curved surface of components of the airframe assembly.

Manual drilling of complex airframe assemblies and components is labor intensive and time consuming. Such drilling often is done by experienced technical workers and typically requires specialized tools and guide jigs. It is desirable to reduce the cost, quality issues, and time that is typically associated with such manual drilling.

An airframe assembly may have multiple layers of structural components of materials in varying size, hardness, quality, and thickness. Some components may be contoured and have irregular shapes and/or complex curvatures. For example, the first component in a multi-layered assembly may be a composite component to be joined to another composite components. Any suitable material, such as titanium or aluminum may also be used to form adjoining components in an airframe assembly.

Components of airframe assemblies are generally provided with pre-drilled target or pilot holes. A technical worker may be required to enlarge the target hole to accommodate mechanical fasteners, such as rivets, to in order to join components. The technical worker may be required to drill the hole or bore substantially perpendicular to the surface of the assembly at the location of the target or pilot hole. There are often very tight or small tolerances that the holes or bores must meet, such as size and angle relative to the surface to be drilled.

Conventional manual hand drilling systems employ a number of techniques and tools to drill a hole or bore perpendicular to a contoured or curved surface. These conventional manual hand drilling systems typically lack the necessary structure required to repeatedly and reliably guide a drill bit perpendicular to a surface over a multitude of complex topographies. For example, tools such as custom drill blocks may be used as a drill guide for manual drilling applications where the surface to be drilled includes multiple contours, curvatures and/or obstructions. Such custom drill blocks may be extremely complex and costly to design, manufacture and deploy. Multiple custom drill blocks may be required to accommodate numerous and varied specific surface contours and assembly locations. Another tool may be an eggcup tool which may be used as a hand-held drill guide to guide a drill bit substantially perpendicular to a work surface. Eggcup tools typically rely on the work surface to be substantially flat to achieve a drilled hole perpendicular to the work surface. These previously known conventional manual hand drilling tools typically do not have provisions to attach and secure the tools to the workpiece. This is an important feature when very tight or small tolerances for the holes or bores must be met.

These previously known approaches and tools fail to provide for a reliable, adaptable, repeatable, efficient and economical manual hand drill system. There is a need to provide a reliable and adaptable apparatus and efficient and repeatable method to economically and accurately drill a hole substantially perpendicular to a complex surface of an airframe assembly or component. Previously known approaches and tools which manually drill a hole perpendicular to the complex surface of a component that may be used in an airframe assembly can be improved upon.

SUMMARY

Disclosed are drill guides for drilling a bore into a workpiece having a curved surface.

In one example, the disclosed drill guide includes a drill block body including a first side portion and a second side portion opposed from the first side portion, the drill block body defining a throughbore between the first side portion and the second side portion, the throughbore extending along a throughbore axis; a first leg protruding from the first side portion of the drill block body; a second leg protruding from the second side portion of the drill block body; and a first wing hingedly connected to the first leg.

In another example, the disclosed drill guide includes a drill block body including a first side portion and a second side portion opposed from the first side portion, the drill block body defining a throughbore between the first side portion and the second side portion, the throughbore extending along a throughbore axis; a first leg protruding from the first side portion of the drill block body; a second leg protruding from the second side portion of the drill block bod; each of the first leg and second leg having an arcuate end surface for engagement with the curved surface; a first wing hingedly connected to the first leg, the first wing for securing the drill block body against the curved surface; a second wing hingedly connected to the second leg, the second wing for securing the drill block body against the curved surface; and a bushing receivable in the throughbore in the drill block body, the bushing defines a second throughbore extending through the bushing, the second throughbore a generally cylindrical shape and having an axis coextensive with the axis of the drill block body.

Also disclosed are methods for forming a bore through a workpiece having a curved surface.

In one example, the disclosed method includes steps of (1) placing a drill block body with a first bore and a pair of spaced apart legs on a workpiece with a curved surface, each of the pair of spaced apart legs having an arcuate end surface and located on opposite sides of the first bore; (2) engaging the arcuate end surface of each of the pair of spaced apart legs of the drill block body against the curved surface; (3) pivoting at least one wing depending from the drill block body in a direction towards the curved surface; (4) engaging an arcuate surface of the at least one wing with the curved surface; and (5) securing the at least one wing with the curved surface to position the drill block body relative to the curved surface whereby an axis of the first bore of the drill block body extends substantially perpendicular to the curved surface.

Other examples of the disclosed drill guides and methods for using a drill guide will become apparent from the following description, the accompanying drawings and the appended claims.

DETAILED DESCRIPTION

A drill guide and method for using a drill guide, according to at least one aspect, overcome the shortfalls and disadvantages of previously known tools, techniques and methods. The drill guide provides a reliable, efficient and adaptable tool and method to attach and secure the drill guide to a workpiece, and repeatedly and accurately drill a hole or bore substantially perpendicular to a contoured or curved surface of an airframe assembly or component.

In one aspect, a drill guide is provided for drilling a hole or bore into a workpiece, such as an airframe assembly or component having a contoured or curved surface as may be present in an aircraft. At least a portion of the airframe assembly may be fabricated using the drill guide. The drill guide includes a drill block body having a first side portion and a spaced second side portion opposed to the first side portion. The drill block body has a throughbore located between the first side portion and the second side portion. The throughbore extends along a throughbore axis. A first leg protrudes from the first side portion of the drill block body. A second leg protrudes from the second side portion of the drill block body. An arcuate end on each of the legs is for engagement with the curved surface of the component. The legs may be integrally formed as one piece with the drill block body. A first wing is hingedly connected to the first leg. The first wing is for attaching and securing the drill block body in a desired location relative to the curved surface of the component.

The drill guide also may include a second wing hingedly connected to the second leg. The first wing and the second wing are each connected at a respective first end portion for pivotal movement relative to the drill block body. The second wing is also for attaching and securing the drill block body in a desired location relative to the curved surface of the component. Each of the first wing and second wing have an arcuate surface at a respective second end portion spaced from the first end portion. Each of the arcuate surfaces is for engagement with the curved surface to position and secure the drill block body relative to the curved surface. The first wing and the second wing each have an opening therein. Each opening is sized and shaped to receive a mechanical fastener that secures the drill block body to the component.

The drill guide also may include a bushing removably received in the throughbore in the drill block body. The bushing has a bushing throughbore extending through the bushing. The bushing throughbore is of a generally cylindrical shape and has an axis coextensive with the throughbore axis of the drill block body. The drill guide may include a sleeve received in the throughbore of the drill block body. The sleeve is located between the drill block body and the bushing.

The bushing has a cylindrical inner surface to closely fit a drill bit. The bushing is one of a plurality of bushings. Each bushing of the plurality of bushings defines a second throughbore having a unique inner diameter. A locking mechanism may be provided to inhibit rotation of the bushing relative to the drill block body.

When the drill guide is positioned on the curved surface, a distance between a first location of contact of the first leg and a second location of contact of the second leg is less than a radius of the curved surface. The throughbore axis is substantially perpendicular to the curved surface.

In another aspect, a method is used to form a hole or bore through a workpiece of an aircraft or component having a curved surface. The method is suitable for assembling a portion of an aircraft. The method includes placing a drill block body with a first throughbore and a pair of spaced apart legs on a workpiece with a curved surface. Each of the legs has an arcuate end surface. The legs are located on opposite sides of the first throughbore. The arcuate end surfaces of the spaced apart legs of the drill block body engage the curved surface. At least one wing depending from the drill block body is pivoted in a direction towards the curved surface. An arcuate surface of the wing engages the curved surface. The wing is attached and secured to the curved surface of the component to position the drill block body relative to the curved surface. An axis of the first bore of the drill block body extends substantially perpendicular to the curved surface. A drill bit is rotated and advanced through the drill block body to form a bore in the curved surface of the component.

The method may also include inserting a bushing with a cylindrical second bore into the first bore of the drill block body. A drill bit of a size closely fitting the cylindrical second bore of the bushing is placed into the cylindrical second bore of the bushing. Various removable and replaceable bushings with different inside diameters of the cylindrical second board accommodate drill bits of various sizes.

Referring toFIG.1, a drill guide20, according to at least one aspect, is described. The drill guide20overcomes the shortfalls and disadvantages of previously known tools and methods. The drill guide20provides a reliable, efficient and adaptable tool and method for attaching and securing the drill guide to repeatedly and accurately drill a hole or bore substantially perpendicular to a contoured or curved surface of a component22. Such a component22with the curved surface may be encountered, for example, in the construction of at least a portion of an aircraft or portion of an airframe assembly24. The drill guide20assures that the hole or bore is drilled through the component22within a very tight tolerance from perpendicular.

By way of example, the curved surface of the component22of the airframe assembly24illustrated inFIG.1is a slightly concave surface. The drill guide20may be employed with equal and satisfactory results on a component22that has a convex surface. The drill guide20may be employed on surfaces of varying sizes and varying complex curvatures. This eliminates or minimizes the need for multiple previously known custom drill blocks and associated cost and complexity of manufacturing and using the custom drill blocks.

The drill guide20is illustrated as being temporarily attached to the component22of the airframe assembly24by clamps40. The drill guide20also may be temporarily attached to the airframe assembly24by any various and suitable mechanical means, such as threaded fasteners44as illustrated inFIGS.7-8. Temporarily attaching the drill guide20to the curved surface of the component22allows a drill bit42to be adjusted and/or aligned with a target or pilot hole44(FIG.7) in the component of the airframe assembly24.

The drill guide20locates and positions the drill bit42for drilling a hole or bore46(FIG.8) into a workpiece, such as the airframe assembly24or component22having a contoured or curved surface. The drill guide20assures that such hole or bore46is substantially perpendicular to the curved surface of the component22and repeatable within a very tight or small tolerance.

The drill guide20includes a drill block body60. The drill block body60has a first side portion62and a second side portion64. The second side portion64is located on an opposite side of the drill block body60from the first side portion62. The drill block body60has a cylindrical throughbore66. The cylindrical throughbore66is located between the first side portion62and the second side portion64. The throughbore66has a central longitudinally extending throughbore axis68. The drill block body60may be made of any suitable material, such as plastic or metal and by any suitable manufacturing process.

A first leg82protrudes from the first side portion62of the drill block body60. A second leg84protrudes from the second side portion64of the drill block body60. The first leg82has an end with an arcuate surface86facing in a direction away from the drill block body60for engaging a surface of the component22. The second leg84has an end with an arcuate surface88facing in a direction away from the drill block body60for engaging a surface of the component22. The first leg82and second leg84may be integrally formed as one piece with the drill block body60. The throughbore66and the throughbore axis68are adapted to extend substantially perpendicular to the curved surface of the component22.

A first wing102is operably connected to the first leg82of the drill block body60by a hinge pin106(FIGS.4-5) for pivotal movement relative to the drill block body. The hinge pin106extends through openings in spaced apart first end portions122of the first wing102and through an opening in the first leg82. The drill guide20also may include a second wing104operably connected to the second leg84of the drill block body60by a hinge pin108for pivotal movement relative to the drill block body. The hinge pin108extends through openings in spaced apart first end portions124of the second wing104and through an opening in the second leg84of the drill block body60. The first wing102and second wing104may be made from any suitable material and by any suitable process.

The first wing102has a second end portion142spaced from the first end portion122. The second wing104has a second end portion144spaced from the first end portion124. The second end portion142of the first wing102has an arcuate surface146for engagement with the curved surface of the component22to position and retain the drill block body60relative to the curved surface of the component22. The second end portion144of the second wing104has an arcuate surface148for engagement with the curved surface of the component22to position and retain the drill block body60relative to the curved surface of the component22. The first arcuate surface146and the second arcuate surface148engage the curved surfaces of the component22span the target or pilot hole44.

The radius of the arcuate surface86of the first leg82is larger than the radius of the arcuate surface146of the first wing102. The radius of the arcuate surface88of the second leg84is larger than the radius of the arcuate surface148of the second wing104. This assures that just the arcuate surface86of the first leg82and the arcuate surface88of second leg84engage the curved surface of the component22.

The first wing102has an opening162extending through the first wing. The second wing104has an opening164extending through the second wing. Each of the openings162,164is sized and shaped to receiving a mechanical fastener180(FIGS.7-8). Each of the openings162,164is elongated to allow for some lateral movement of the drill block body60relative to the curved surface of the component22. The drill bit42could be aligned and centered on the target or pilot hole44or drilled into the component22. The target or pilot hole44is used to locate the drill bit42into a desired position along the curved surface of the component22.

When the drill guide20is positioned on the curved surface of the component22, a distance D (FIG.6) between a first location of contact202of the arcuate surface86of the first leg82and a second location of contact204of the arcuate surface88of the second leg84is less than a radius R of the curved surface of the component22. The arcuate surfaces86,88are for engagement with the curved surface of the component22. The arcuate surface86and the arcuate surface88engage the curved surfaces of the component22and span the target or pilot hole44.

The first wing102and/or the second wing104may be mechanically attached to the curved surface of the component22. InFIG.1the drill guide20is illustrated as temporarily attached by clamps40which can be easily removed. The first wing102has an opening162extending through the first wing. The second wing104has an opening164extending through the second wing. InFIGS.7and8the drill guide20is illustrated as temporarily attached by mechanical fasteners180extending through the opening162in the first wing102and the opening164in the second wing104. The mechanical fasteners180can be easily removed. Any suitable devices or mechanisms may be used to attach the drill guide20to the curved surface of the component22. Thus, the first wing102and/or second wing104have features to attach and secure the drill guide20to the workpiece. This is an important feature when very tight or small tolerances for the holes or bores46must be met.

The drill guide20may also include a bushing220removably receivable within the throughbore66in the drill block body60. The bushing220defines a cylindrically shaped bushing throughbore222extending through the bushing. The bushing throughbore222has a longitudinally extending axis224coextensive with the throughbore axis68of the drill block body60.

The inner surface of the bushing throughbore222of the bushing220has a unique inner diameter that closely fits the outside diameter of the drill bit42. The bushing220is chosen from a plurality of bushings depending on the diameter of the hole or bore46desired in the component22. A locking mechanism244is provided to inhibit rotation of the bushing220relative to the sleeve240and drill block body60.

The drill guide20may also include a sleeve240receivable in the throughbore66of the drill block body60. The sleeve240is located between the drill block body60and the bushing220in order to support the bushing in the drill block body. The outer diameter of the sleeve240closely fits the inner diameter of the throughbore66in the drill block body60. The sleeve240may be press fit into the drill block body60. The diameter of the inner surface242of the sleeve240closely fits the outer diameter of the bushing220. The bushing220and sleeve240may be made from any suitable material and by any suitable manufacturing process. The bushing220and sleeve240may be made from different materials.

In order to use the drill guide20on a curved surface of a component22, the drill block body60is located near the target or pilot hole44as viewed inFIG.7. The throughbore66and throughbore axis68of the drill block body60are positioned along the longitudinal central axis of the target or pilot hole44. The target or pilot hole44is intended to serve as a locating guide for the tip of the drill bit42. The first and second legs82,84of the drill block body60are brought into contact with the component22and span the target or pilot hole44.

The first wing102and second wing104may then be pivoted and mechanically attached to the component22. An arcuate surface146on the first wing102and an arcuate surface148on the second wing104engage the curved surface of the component22. Any suitable attachment may be used such as the clamps40illustrated inFIG.1or the mechanical fasteners180illustrated inFIGS.7-8. The first wing102and second wing104permit some lateral displacement of the drill block body60by the openings162,164in the wings to ensure that the throughbore axis68of the drill block body60and axis224of the bushing220are substantially coaxial with the centerline of the target or pilot hole44. The drill bit42is then aligned with the pilot hole44. The drill bit42is advanced through the bushing220and into the target or pilot hole44. The drill bit42is further advanced until it completely extends through the component22and forms the hole or bore46. The resultant hole or bore46, as illustrated inFIG.8, is substantially perpendicular to the curved surface of the component22. While the drill bit42is illustrated and described as forming a bore46through a single component22, the drill bit may form coaxial bores through adjacent or adjoining components of the airframe assembly24, as illustrated inFIG.1.

Thus, the drill guide20is a tool for manual hand drilling a hole or bore substantially perpendicular to a contoured or curved surface of the component22, such as may be part of an airframe assembly24or a portion of an aircraft. The drill guide20structure provides a system to reliably guide a drill bit42substantially perpendicular to a surface over a multitude of complex topographies that was lacking in previously known tools. Such complex topographies may be encountered in an airframe assembly24, a component22of an airframe or a portion of an aircraft having a contoured or curved surface.

In another aspect, a method for employing the drill guide20to assemble at least a portion of an aircraft with a curved surface of a component22, such as may be found in an airframe assembly24of an aircraft. The method includes forming a hole or bore46through the component22or the portion of the aircraft having a curved surface. The hole or bore46is formed substantially perpendicular to the curved surface of the component22. The method assures that the hole or bore46is drilled through the component22within a very tight tolerance from perpendicular relative to the curved surface.

The method includes placing a drill block body60with a throughbore66and a first leg82spaced from a second leg84on a workpiece component22with a curved surface, such as may be found in an aircraft, portion of an aircraft, or an airframe assembly24. Each of the first and second legs82,84have respective ends with arcuate surfaces86,88located on opposite sides of the throughbore66. The ends of the arcuate surfaces86,88of the first and second legs82,84of the drill block body60are brought into contact with the curved surface of the component22. The throughbore66of the drill block body60is preliminarily aligned over a target or pilot hole44in the component22.

At least one wing, and preferably both the first wing102and the second wing104, depending from the drill block body60are pivoted in a direction towards the curved surface of the component22. Arcuate surface146of the first wing102and arcuate surface148of the second wing104are brought into engagement with the curved surface of the component22. At least one of the first wing102and second wing104is secured to the component22to position and secure the drill block body60relative to the curved surface. It may be preferred that both of the first wing102and second wing104are secured to the component22to position and secure the drill block body60relative to the curved surface. Such securement may be made by any suitable means, such as mechanical fasteners180as illustrated inFIGS.7and8or clamps40as illustrated inFIG.1. The throughbore axis68of the throughbore66of the drill block body60extends substantially perpendicular to the curved surface of the component22. Thus, the first wing102and/or second wing104enable attachment and securement of the drill guide20to the component22, thereby ensuring the drill bit42does not move relative to the component22during drilling. This is an important feature when very tight or small tolerances for the holes or bores46must be met.

The drill bit42is aligned with the target or pilot hole44. In the event that the drill bit42is not aligned with the target or pilot hole44, the drill block body60can be moved so alignment occurs. This can be done by loosening the mechanical fasteners180or clamps40on the first wing102and second wing104and positioning the drill bit42in a desired alignment with the target or pilot hole44and then re-tightening the mechanical fasteners. The drill bit42then is rotated and advanced within the bushing220to form the bore46through the component22or multiple coaxial bores in multiple components.

The method may also include inserting the bushing220with the cylindrical bushing throughbore222into the throughbore66in the drill block body60. A drill bit42of a size closely fitting the cylindrical bushing throughbore222of the bushing220is placed into the cylindrical bore. The method may also include inserting the bushing220into a sleeve240that is placed within the throughbore66of drill block body60. The bushing220may be retained by locking mechanism244to prevent rotation relative to the sleeve240and drill block body60. The drill bit42then is rotated and advanced to form the bore46in the curved surface of the component22.

Although various aspects of the drill guide and method of using the drill guide have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.