Sensing tip reamer

A system for preventing the performance of an out-of-sequence reaming operation during the machining of holes in a lamination of fiber-reinforced plastic material. The system automatically stops or inhibits a reaming operation if a sensing tip of the reamer encounters an incompletely drilled pre-hole or blank material (i.e., no pre-hole) instead of a fully drilled pre-hole. The system does not require any human intervention to inhibit the reaming operation. In one embodiment, the human or operator cannot re-start the reaming process until the machine tool or reaming equipment is reset. In some cases the reset may require manual intervention.

BACKGROUND

The present disclosure relates generally to the machining of composite material. In particular, this disclosure relates to machining of holes in composite material.

Composite components are being utilized in a wide variety of articles of manufacture due to their high strength and light weight. This is particularly true in the field of aircraft manufacturing. Typical materials used in the manufacture of composite components include glass or graphite fibers that are embedded in resins, such as phenolic, epoxy, and bismaleimide resins. A composite lamination can be built up by laying successive plies of fiber tows (e.g., carbon fiber tows preimpregnated with a thermoset epoxy resin) around a mandrel and then curing. As more advanced materials and a wider variety of material forms have become available, aerospace usage of composites has increased.

Certain machining applications require drilling and/or reaming a hybrid stack-up of materials. A hybrid stack-up of materials may be defined as layers of discontinuous materials such as a carbon fiber-reinforced plastic (CFRP) composite material and titanium, aluminum or steel. For example, certain aircraft require a wing made from a composite material, such as CFRP, be joined to a titanium section of an aircraft body with fasteners that pass through holes made through the mating sections. When using fasteners to attach composite skins to metal substrates, coaxial holes must be drilled in both the skin and an underlying metal substrate. High-quality holes must be produced in such materials with dimensions within narrow tolerances. The wing-to-body join task typically requires a three-step conventional drilling process comprising a pilot drill, followed by a step drill, followed by a finish diameter reamer.

Reamers are cutting tools that are typically used to perform the final cutting operation on holes, particularly holes with small tolerances. Specifically, reamers perform secondary cutting operations after a hole has been drilled close to a desired final size. Reamers therefore typically have an external diameter that is slightly larger than that of the drilled hole, and are designed to finish the hole to within a small tolerance of the desired size and to provide a relatively smooth inner wall.

Standard reamers typically include a shank, a body portion at one end of the shank, and a plurality of teeth, such as 4-8 teeth, that are spaced around the body portion and extend outwardly therefrom to form the cutting surfaces of the reamer. Each tooth includes a rake face and a cutting edge that actually engages the workpiece in the course of reaming a hole. In some cases, the teeth are uniformly spaced around the body portion. In other cases, the teeth have non-uniform or irregular spacing.

During the machining of holes in composite material, severe delamination can occur if a reaming operation is performed prior to a hole being drilled or after a hole has been only partially drilled. The repairs for this kind of damage are very expensive and production flow must be halted until the problem is resolved.

Mechanics use visual inspection and tooling pins to assure that the pre-hole is complete before they move on to the reaming operation. Visual inspection of these holes is difficult in some areas due to limited access and time consuming.

Thus there is a need for a system to inhibit or terminate (without human intervention) the performance of a reaming operation if the pre-hole is missing or other dimensional characteristics do not meet the pre-hole requirements such as depth, diameter, orientation, and location.

SUMMARY

A system is disclosed for preventing the performance of an out-of-sequence reaming operation during the machining of holes in a lamination of fiber-reinforced plastic material. The system automatically stops or inhibits a reaming operation if a sensing tip of the reamer encounters an incompletely drilled pre-hole or blank material (i.e., no pre-hole) instead of a fully drilled pre-hole. The system does not require any human intervention to inhibit the reaming operation. In one embodiment, the human or operator cannot re-start the reaming process until the machine tool or reaming equipment is reset. In some cases the reset may require manual intervention.

A rotary cutting tool is also disclosed that comprises the following elements: (a) a body comprising an internal cavity that extends from one end of the body along an axis, the internal cavity comprising a first portion having a first cross-sectional area and a second portion having a second cross-sectional area less than the first cross-sectional area; (b) a plurality of teeth extending outwardly to form cutting surfaces near another end of the body; (c) a shaft disposed in the internal cavity along the axis, the shaft being movable axially relative to the body; and (d) a sensing tip coupled to or integrally formed with one end of the shaft and disposed outside the internal cavity. A spring, fluid piston or other suitable biasing member may be arranged to resist movement of the shaft from a first position toward a second position. The shaft and the internal cavity are configured so that another end of the shaft is disposed in the first portion of the internal cavity when the shaft is in the first position and is disposed in the second portion of the internal cavity when the shaft reaches the second position.

In addition, a method for using a rotary cutting tool having a leading tip axially movable relative to a plurality of cutting edges is disclosed. The method comprises the following steps: (a) mechanically resisting relative movement of the cutting edges and the leading tip toward each other; (b) actuating a drill motor that rotates the cutting edges; (c) advancing the rotating cutting edges forward along an axis of a pre-hole; (d) monitoring a parameter to determine when the value of that parameter reaches a specified threshold corresponding to the cutting edges advancing a specified distance relative to the leading tip after the latter has stopped advancing; and (e) stopping the rotation and advancement of the cutting edges when the value of the parameter reaches the specified threshold. The leading tip is carried by a shaft that is axially movable inside a body that carries the cutting edges. In a particular embodiment, the monitored parameter may be associated with a fluid that is ported or supplied to the body at an opening proximate to one end thereof. The fluid parameter monitored may correspond to a rate of flow of fluid through the body or a pressure in the line supplying fluid to the body. Step (e) is performed when the shaft position causes the fluid parameter to reach a threshold value.

Another aspect of the disclosed subject matter is a system comprising: a source of fluid; a rotary cutting tool comprising a plurality of cutting edges, a forward tip axially movable relative to the cutting edges, an inlet, an internal cavity in fluid communication with the inlet, and means for biasing the tip and cutting edges toward moving apart, wherein the forward tip is movable between a first position where the forward tip does not reduce the flow of fluid through the internal cavity and a second position where the forward tip reduces the flow of fluid through the internal cavity; a motor coupled to the rotary cutting tool for driving rotation of the cutting edges; a shutoff device for shutting off the motor; a subsystem for guiding the flow of fluid from the fluid source to the inlet of the rotary cutting tool, the subsystem comprising a sensor capable of producing a signal when a value of a parameter of the fluid reaches a specified threshold; and a controller coupled to the sensor for receipt of the signal from the sensor, the controller being programmed to output a shutoff signal to the shutoff device in response to receipt of the signal from the sensor. For example, the sensor can be a flow sensor or a fluid pressure sensor.

A further aspect is a system comprising: a reamer comprising an axial internal cavity having first and second openings at first and second ends of the reamer and a plurality of teeth extending outwardly to form cutting surfaces near the first end of the reamer, the internal cavity comprising a first portion having a first cross-sectional area and a second portion having a second cross-sectional area less than the first cross-sectional area; a sensor capable of producing a signal when a value of a parameter reaches a specified threshold; a flow path connecting the sensor to the second opening of the reamer; a shaft disposed in the internal cavity, the shaft being movable axially relative to the reamer from a first position toward a second position; and a tip coupled to or integrally formed with another end of the shaft and disposed outside the internal cavity. The shaft and the internal cavity are configured so that another end of the shaft is disposed in the first portion of the internal cavity when the shaft is in the first position and is disposed in the second portion of the internal cavity when the shaft reaches the second position, a flow through the internal cavity being reduced when the shaft moves from the first position to the second position.

Other aspects of the invention are disclosed and claimed below.

DETAILED DESCRIPTION

The system disclosed herein is designed to prevent the running of a reaming operation prior to drilling the necessary pre-hole in CFRP material. A reaming technology is provided that will not harm the CFRP structure if a reamer were used out of sequence. A reamer having a sensing tip is installed in a powered drill motor that may be powered electrically, by pressurized air or other known means. The system shuts off the drill motor if the tip of the reamer encounters blank material. The system employs a control that shuts off the drill motor when a fluid parameter associated with a coolant or lubricant flowing through the reamer is restricted due to depression (relative to the reamer cutting edges) of the sensing tip, which is axially movable relative to the cutting edges of the reamer. The coolant or lubricant may comprise a liquid, gas, or mixture of liquid and gas such as a mist coolant or lubricant. Suitable gases may include air, inert gas or refrigerant. Depression of the sensing tip occurs when the tip meets blank material or an obstacle inside an incompletely drilled pre-hole while the cutting portion of the reamer continues to advance. If the tip is depressed by an amount sufficient to cause the magnitude of the monitored fluid parameter to reach a specified threshold, the control causes a shutoff valve to close in the case of an air-powered drive or opens a switch in the case of an electric drive, thereby stopping rotation and advancement, or advancement, of the reamer. The control may also shut down the metering pumps that provide air/coolant to the reamer. The system inhibits a reaming operation when blank or partially drilled material is encountered.

FIG. 1shows an isometric view of a rotary cutting tool in accordance with one embodiment. The tool comprises reamer10and an integrally formed sensing tip/shaft comprising a sensing tip16and a shutoff shaft. The shutoff shaft is not visible inFIG. 1because it is inside the reamer10. The reamer10comprises a hollow body12having an internal cavity (not shown inFIG. 1) that extends from a forward end to a rearward end along a central axis. The reamer10further comprises a plurality of teeth14extending outwardly to form cutting surfaces near the forward end of hollow body12. The cutting edges define an outer diameter of the reamer10.

FIG. 2shows (on a magnified scale) the sensing tip16in its most forward position relative to reamer10. The sensing tip16comprises three contact arms18disposed radially outward at angles of 120 degrees. If any portion of the sensing tip16encounters an obstacle during reaming of a pre-hole, the sensing tip as seen inFIG. 2will move to the right relative to the cutting teeth14. In one specific implementation, the diameter of a hypothetical circle around the contact arms18may be in the range of 0.005 to 0.100 inch smaller than the reamer outer diameter. The tip16is relieved to minimize any impact to chip flow. In that same implementation, the tip is made of stainless steel.

FIG. 2also shows that each flute between cutting teeth14is provided with one or more vent holes4. As will be described in more detail below with reference toFIG. 5, a jet spray of droplets of coolant suspended in air will flow through an internal cavity of the reamer and exit the reamer via the vent holes4, thereby cooling the cutting teeth14during the reaming operation.

The integrally formed sensing tip/shaft is shown removed from the reamer inFIG. 3. The contact arms18of sensing tip16are machined with a tri-lobed contact surface20, each lobe disposed at a 135-degree angle. The integrally formed sensing tip/shaft further comprises a shutoff shaft22. The shutoff shaft22comprises a guide body24, a plurality of circumferentially distributed, radially projecting guide features26and a retention slot28.FIG. 4shows an end view as seen from a vantage forward of the sensing tip16. The guide body24has an annular groove that receives a seal such as an O-ring30. The guide body24has an outer diameter greater than the outer diameter of the main portion of the shutoff shaft22.

FIG. 5is a sectional view showing a sensing tip reamer (of the type depicted inFIG. 1) during reaming a completed hole40in a stack-up consisting of metal42and composite material44. In the example depicted inFIG. 5, during advancement of the reamer10, the sensing tip16did not make contact with any obstacle inside completed pre-hole40, so the reaming operation did not need to be aborted. In other words, the entire pre-hole40was reamed completely.

FIG. 5shows the internal structure of the reamer10and how shutoff shaft22is disposed inside the reamer internal cavity. The internal cavity comprises four circular cylindrical bores32athrough32dwhich increase in diameter from right to left (as seen inFIG. 5). A jet spray of air and suspended droplets of liquid coolant enters section32aof the internal cavity via an opening50at the rear end of the hollow body12of reamer10. The air/coolant jet flows through sections32a,32band32c, exiting the hollow body12through the aforementioned vent holes (not shown) between the cutting teeth14. As seen inFIG. 5, the guide features26hold the shutoff shaft22in a central position inside section32cof the internal cavity of reamer10. The outer diameter of the guide features26is greater than the outer diameter of shutoff shaft22, creating an annular space between the outer surface of shutoff shaft22and the inner surface of section32c. The air/coolant flows through this annular space on its way to the vent holes (see items 4 inFIG. 2) located between the cutting teeth14.

To assemble the sensing tip reamer, the shutoff shaft22is inserted into the internal cavity of hollow body12and then a set screw36is passed through the retention slot28in shutoff shaft22, the ends of the set screw being threadably coupled in diametrally opposed threaded holes (one such hole6can be seen inFIG. 1) formed in the wall of the hollow body12. The set screw36retains the shutoff shaft22inside the hollow body12but, in cooperation with elongated axial slot28formed in shutoff shaft22, allows the shutoff shaft22to move axially between first and second limit positions relative to the hollow body.FIG. 5depicts shutoff shaft22in the first limit position, further axial movement rearward being stopped by impingement of the rearward end of slot28against set screw36. The sensing tip/shaft16is urged into the relative position seen inFIG. 5by a compression spring38which is placed between respective annular surfaces on the guide body24and on the hollow body12. In the absence of a force depressing the sensing tip, the sensing tip/shaft will remain in the relative position shown inFIG. 5. In this relative axial position, the rear end22aof shutoff shaft22does not enter section32bof the reamer internal cavity as seen in area8.

In accordance with alternative embodiments, the compression spring38can be omitted and the shutoff shaft22can be pressure biased in the forward direction by the coolant flowing into the internal cavity of the reamer. The forces on the shutoff shaft22are unbalanced and bias the shaft to the extended position when coolant pressure is present.

In contrast,FIG. 6shows a sectional view of the same sensing tip reamer depicted inFIG. 5, except that the sensing tip reamer has been inserted in a partially drilled pre-hole46(closed at the bottom) in the metal/composite stack-up42/44. When tip16impinges against the blank bottom of incomplete pre-hole46, the sensing tip/shaft ceases to advance while the reamer10continues its advance. The result is that the sensing tip/shaft moves rearward relative to reamer10. In particular, the end22aof shutoff shaft22moves axially past position8and into section32bof the reamer internal cavity. The end portion near end22awhich enters section32bhas an annular groove in which an O-ring34is seated. Because the diameter of section32bis less than the diameter of section32c, where shutoff end22apreviously resided, the cross-sectional area of the annular space between the shaft end22aand the internal cavity is reduced. In addition, the O-ring34further reduces the amount of air/coolant that can flow axially from section32binto section32c. The result of the rearward movement of the shaft into section32bof the reamer internal cavity is a reduction in the rate of air/coolant flow through the reamer (accompanied by a pressure increase in the line feeding air/coolant to the reamer). In other embodiments the O-ring34and the annular groove that it sits in can be omitted and a clearance fit between the rear end22aof shutoff shaft22and section32bcan be provide which is capable of causing a suitable reduction in the rate of air/coolant flow through the reamer when rear end22ais engaged with section32b. As will be explained in more detail later, this reduction in the fluid flow rate (or increase in pressure) is detected by the system. In response to the fluid flow rate falling below a specified threshold (or the pressure increasing above a specified threshold), the supply of pressurized air to the drill motor is shut off and the reaming operation is automatically aborted.FIG. 6shows the shutoff shaft22in a third position relative to the hollow body12, which third position is between the first and second limit positions.

FIG. 7shows a sectional view of the same sensing tip reamer depicted inFIG. 5, except that the sensing tip reamer has been inserted in an incompletely drilled pre-hole46that is only a small distance (e.g., 0.050 inch) short of a completed hole. When tip16impinges against the undrilled material at the exit side of the incomplete pre-hole46, the sensing tip/shaft again ceases to advance while the reamer10continues its advance. The result is that the sensing tip/shaft will again move rearward relative to reamer10, eventually aborting the reaming operation.

FIG. 8is a block diagram showing components of a system providing the functionality described above. The reamer10is coupled to a positive feed drill52(e.g., a Quackenbush positive feed drill) having a pneumatic motor. The pneumatic motor of drill52is powered by pressurized air from a plant air source54via a solenoid-actuated main air shutoff valve56and an air valve58[DMFI]. The operational state of shutoff valve56is controlled by a microcontroller64which can activate/deactivate a solenoid to respectively open/close the shutoff valve56. The microcontroller64can be programmed using an external personal computer66. When the system is in a locked state (i.e., key switch68is open), the system can be activated only by using a key to close key switch68.

When the system is activated, the microcontroller first opens the shutoff valve56. Pressurized air flows through shutoff valve56to air valve58. Some of the air flow (indicated by a line labeled “PILOTAIR” inFIG. 8) is diverted to an air distribution system that distributes pilot air to solenoid-actuated valves70,72,74and an air pressure sensor62. The air pressure sensor62outputs a digital signal representing the pilot air pressure to the microcontroller64.

When the pilot air pressure reaches a first specified threshold, the microcontroller64is programmed to open valves70and72, thereby supplying pilot air respective air pulse generators (not shown) which are used to send pulses of air to activate pistons of respective metering pumps (also not shown) that respectively meter motor oil and coolant from respective reservoirs78and80. If the pilot air pressure reaches a second specified threshold (higher than the first specified threshold and corresponding to a pressure buildup if no air is being supplied to the drill motor), the microcontroller is programmed to open a dump valve74to equalize the system.

FIG. 8depicts the delivery of motor oil via a capillary tube (labeled “AIRMOTORLUBE” inFIG. 8) to an air line60connected to air valve58. The motor oil is metered by a metering pump (not shown inFIG. 8) coupled to an outlet of an oil reservoir78. In one implementation, the metering pump is an adjustable-stroke piston pump. As previously described, pilot air from air valve58is provided via open valve70to an air pulse generator (not shown) that sends pulses of air to activate the motor oil metering pump.

The pilot air is also received by a sensor76. In accordance with one embodiment, sensor76is a flow sensor that outputs an analog signal (0 V to 5 V) representing the rate of air flow through the sensor to the microcontroller64. (When there is no flow, the output of the sensor is 0 V.) In accordance with an alternative embodiment, sensor76is a fluid pressure sensor. The air (labeled “DRILLBITAIR” inFIG. 8) flowing out of sensor76is supplied to the drill bit, i.e., reamer10, via an air line82.FIG. 8also depicts the delivery of lubricant (e.g., Micro-cut26coolant or Boelube oil) through a capillary tube (labeled “DRILLBITLUBE” inFIG. 8) to line82, which feeds the air and lubricant to the reamer10. In one implementation, the lubricant (coolant or oil) is supplied to the reamer10via a ⅜-inch line for air with a ⅛-inch capillary for lubricant inside. In the implementation depicted inFIG. 8, the lubricant is Micro-cut26coolant. The coolant is delivered by a metering pump (not shown inFIG. 8) coupled to an outlet of a coolant reservoir80. Again the metering pump is an adjustable-stroke piston pump. The valve72(under the control of microcontroller64) opens pilot air from air valve58to an air pulse generator (not shown) that sends pulses of air to activate the coolant metering pump.

As previously described, following the actuation of the drill motor, a pre-hole in a composite/metal stackup can be reamed by the rotating cutting teeth of the advancing reamer10. In accordance with a flow sensor embodiment, the flow sensor output to the microcontroller is monitored to determine if the flow rate of air through the reamer has been sufficiently reduced due to obstruction of the sensing tip. The microcontroller is programmed to actuate closure of shutoff valve56as well as motor oil and coolant valves70and72in response to the air flow rate falling below a specified threshold. In accordance with a pressure sensor embodiment, the pressure sensor output to the microcontroller is monitored to determine if the air pressure in the supply line has increased sufficiently due to obstruction of the sensing tip. In this case, the microcontroller is programmed to actuate closure of shutoff valve56as well as motor oil and coolant valves70and72in response to the air pressure rising above a specified threshold.

One implementation of a method of aborting a reaming operation is depicted in the logic diagram ofFIG. 9. First, the motor air supply is turned on (step84). Then the coolant valve72is opened. Pressurized air (90 psi) and coolant are then supplied to the reamer (step86). The air flow rate is measured by the flow sensor, which outputs an analog signal representing the air flow rate to the microcontroller. The microcontroller continuously monitors whether the coolant/air flow rate has fallen below 4 cfm (step88). If not, then the main air shutoff valve is not closed (step90). The 3-second loop92is the time the system takes to detect that a drop in flow has occurred. This is an adjustable setting in the system software. The setting should be selected to avoid any momentary events that may trigger a shutoff and still stop the system in time to mitigate any damage to the workpiece to be reamed. If the coolant/air flow rate has fallen below 4 cfm, then the main air shutoff valve is switched from open to closed (step94). The microcontroller then sends a message to a user screen displayed on a personal computer (step96).

Referring back toFIG. 8, the key switch68is a reset feature used after the system encounters an undersize or blank hole condition. It is preferred to keep this functionality away from the reamer operator so that he/she cannot not simply reset the system without removing the drill motor from the drill jig. The reset key resides with the drill motor set-up technician. This forces the operator to take a step back from the process to determine why the system tripped.

In the embodiment shown inFIGS. 3 and 4, the sensing tip and shutoff shaft were integrally formed. In accordance with an alternative embodiment depicted inFIG. 10, a sensing tip100is removable and rotatably coupled to one end of a shutoff shaft98. The rotating sensing tip100has two contact arms18and comprises a plug102having an annular groove. The plug102of sensing tip100is inserted into a socket104formed in a guide body106at one end of shutoff shaft98. The plug102is coupled to the socket104by inserting a slotted spring pin108into a radial opening in the socket wall. The radially inward end of slotted spring pin108sits in the annular groove102of the sensing tip100. This arrangement allows the sensing tip100to rotate relative to the shutoff shaft98while being coupled for axial movement therewith.

As in the earlier-described embodiment, the shutoff shaft98has a plurality of circumferentially distributed, radially projecting guide features26and a retention slot28. The guide body106has an annular recess that receives an O-ring30. The guide body106has an outer diameter greater than the outer diameter of the shutoff shaft98, providing an annular bearing surface for the spring38which urges the shutoff shaft and the reamer in opposite directions.

While a sensing tip reamer has been described with reference to various embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the teachings herein. In addition, many modifications may be made to adapt a particular situation to the teachings herein without departing from the essential scope thereof. Therefore it is intended that the claims set forth hereinafter not be limited to the disclosed embodiments.

In particular, a sensing tip arranged to block the flow of an air-coolant mixture to a reamer or drill when confronted by an obstruction is not limited to use with pneumatic drilling systems, but rather could also be incorporated in electrical drilling systems. In such embodiments, instead of closing a shutoff valve, thereby shutting down the drill motor, in response to rearward relative displacement of the sensing tip, the electrical drilling system would simply be shut down by changing the state of an electrical switch.

The method claims set forth hereinafter should not be construed to require that the steps recited therein be performed in alphabetical order or in the order in which they are recited. Nor should they be construed to exclude any steps being performed concurrently.