Abstract:
A material removal having a plurality of cartridges mounted on an active portion where a plurality of seating members mounted in each of the plurality of cartridges pivots about an axis between a retracted position and an extended position is disclosed. Alternative embodiments have a single pivotable seating member. The pivotable extending seating members operate to extend and retract in a scissors-like motion and enable compact and efficient machining operation, particularly for crank shaft bearing supports.

Description:
RELATED APPLICATION DATA 
     This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/092,877, filed Aug. 29, 2008, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to a material removal tool, such as a line bar tool, with cartridges pivotably housing a pair of cutting inserts, which pivot to a cutting position under a biasing force applied to the cartridge, for example by forces applied directly or indirectly by an actuation fluid. 
     BACKGROUND 
     In the discussion of the background that follows, reference is made to certain structures and/or methods. However, the following references should not be construed as an admission that these structures and/or methods constitute prior art. Applicant expressly reserves the right to demonstrate that such structures and/or methods do not qualify as prior art. 
     Conventional flexing cartridges housing cutting inserts are used to adjust (extend and retract) the radial positions of cutting inserts on material removal tools. These cartridges are typically anchored at one end of an elongate body to allow flexing at a non-anchored end. A cutting insert is mounted to the non-anchored end and thus could be repositioned radially by biasing the cartridge to flex/unflex. The anchor position and the length of the cartridge contribute to the amount of flexing and the radial displacement of the cutting inserts. To achieve larger radial displacement, greater flexing is generally used. 
     SUMMARY 
     An exemplary material removal tool comprises a housing body including a mounting portion and an active portion, a plurality of cartridges mounted on the active portion of the material removal tool, and a plurality of seating members mounted in each of the plurality of cartridges to pivot about an axis between a retracted position and an extended position, the plurality of seating members including a pocket with a seating surface for a cutting insert. 
     An exemplary method for removing material from a workpiece with a rotating material removal tool comprises inserting an active portion of the material removal tool into a bore of the workpiece, positioning a surface of the workpiece to be machined radially proximate a pivot axis of a plurality of seating members mounted in a cartridge mounted on the active portion of the material removal tool, actuating the plurality of seating members to pivot the plurality of seating members to an extended position, translating the rotating material removal tool in a first axial direction to contact the surface with a first cutting insert mounted in a pocket of a first of the plurality of seating members, and translating the rotating material removal tool in a second axial direction to contact the surface with a second cutting insert mounted in a pocket of a second of the plurality of seating members. 
     The disclosed material removal tool can increase the density of cutting inserts (number of cutting inserts per cartridge or number of cutting inserts per axial length of tool) and therefore can cut multiple bores simultaneously by utilizing multiple inserts per a bore. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
       The following detailed description can be read in connection with the accompanying drawings in which like numerals designate like elements and in which: 
         FIG. 1  is a schematic drawing of an exemplary embodiment of a material removal tool. 
         FIG. 2  is a schematic drawing of the exemplary embodiment of a material removal tool of  FIG. 1  showing the arrangement of some of the internal components. 
         FIG. 3  is a magnified view of the arrangement of some of the internal components. 
         FIG. 4  is a top, plan view of a cartridge with pivotable seating members. 
         FIG. 5  is a disassembled, perspective view of a cartridge with pivotable seating members. 
         FIGS. 6A and 6B  are side plan views of a cartridge with pivotable seating members showing the seating members (and associated cutting inserts) in a retracted position ( FIG. 6A ) and in an extended position ( FIG. 6B ). 
         FIGS. 7A to 7C  illustrate different operating positions for the pivotable seating members (and associated cutting inserts) while machining a workpiece. 
         FIG. 8  is a schematic drawing of an exemplary embodiment of a material removal tool with an alternative exemplary embodiment of a cartridge with a single pivotable seating member. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a schematic drawing of an exemplary embodiment of a material removal tool  10 . The material removal tool  10  comprises a housing body  12  and includes a plurality of cartridges  14  located in enclosed pockets  16  along the axial length. In a preferred embodiment, the cartridges  14  at substantially the same axial position are radially opposing each other, an arrangement that helps to balance cutting forces in the material removal tool during operation. The plurality of cartridges  14  includes a plurality of pivotable seating members  18 . The pivotable seating members  18  include a pocket  20  with a seating surface  22  for a cutting insert  24 . Suitable cutting inserts can be of any type, e.g., milling, turning, boring. One exemplary embodiment of suitable cutting inserts is the side locking insert disclosed in U.S. Application Publication No. 2007/0245535, the entire contents of which are incorporated herein by reference. The cutting inserts  24  mounted in the pocket  20  of each of the plurality of seating members  18  in any one cartridge can be the same type or can be of at least two different types. Further, the cutting inserts  24  mounted in the pocket  20  of each of the plurality of seating members  18  in any one cartridge can perform different cutting operations, i.e., semi-finish and finish cutting operations. 
     Other features of the material removal tool  10  visible in  FIG. 1  include a delimiting structure, such as an adjustment assembly  26 , at a first end  28  and a connector  30  at a second end  32 . When mounted on a machine tool, the first end  28  is a distal end relative to the machine tool and the second end  32  is a mating end for attachment to the machine tool. A slot  34  in the housing body  12  is positioned near the first end  28 . The slot  34  mates with a rotary bushing (not shown) for support. During operation, the bushing rotates in conjunction with material removal tool  10  and there is no relative motion between the material removal tool  10  and the bushing. Other features include various openings, connectors and manipulators for assembly and operation of the material removal tool  10 . 
     The connector  30  at the second end  32  of the material removal tool  10  attaches to a machine tool, such as a HAAS VF6 milling machine, for operation. The connector  30  can take any suitable form that allows attachment to a desired machine tool, e.g., attachment to a spindle of the machine tool. In an exemplary embodiment, the connector  30  has a tapered surface  36 , for example, tapered rearward or toward the second end  32 . A transition piece  38  can optionally be included with the connector  30 . An example of a transition piece  38  includes at least one feature for mating to an operating machine or to a storage system. For example, the transition piece  38  can include a circumferential groove  40 . The circumferential groove  40 , or similar structure, can provide an attachment point for mating the material removal tool  10  to a carousel storage system used in machining operations to store multiple material removal tools. In another example, the transition piece  38  can include a key slot  42 . The key slot  42 , or similar structure, can provide an orientation or a mating with a corresponding feature on the machine tool when the material removal tool is mounted for use. 
     The material removal tool can be generally described as having an active portion and a mounting portion. Referring again to the exemplary embodiment of  FIG. 1 , the active portion I is separated from the mounting portion II at a transition line  44 . The transition line  44  can be coincident with the transition piece  38  or, as shown, can be at a different location of the material removal tool  10 . The plurality of cartridges  14  are mounted on the active portion I of the material removal tool. During operation, the active portion I is placed near or, for example during boring, inserted into the volume of the workpiece. The mounting portion II generally does not get operatively positioned within the volume of the workpiece. Thus, only locations and features on the active portion I are available for material removal operations. 
     In the exemplary embodiment of  FIG. 1 , the active portion I has a generally regular shape, e.g., cylindrical, and has a different diameter than that of the mounting portion II. For an active portion I that has a regular shape, such as a cylinder, the diameter at any point of the active portion I is substantially constant along its axial length and an active volume of the material removal tool  10  can be defined as the volume occupied by the rotating material removal tool based on that diameter of the active portion I. For irregularly shaped active portions, an active volume can be defined as the volume occupied by the rotating material removal tool based on the largest diameter at any point of the active portion. When the active portion of the material removal tool has cutting inserts and is the radially outermost surface along the active portion, then the diameter at the outermost surface of the cutting inserts is used to determine the active volume. 
       FIG. 2  is a schematic drawing of the exemplary embodiment of a material removal tool of  FIG. 1  showing the arrangement of some of the internal components. In  FIG. 2 , the exterior of the material removal tool  10  is not shown to allow viewing of interior features. The material removal tool  10  includes an actuating body  100  in which a piston head  102  is internally positioned in an actuating chamber (not shown). A translating bar  104  includes a first end operably connected to the piston head  102  to axially translate (T) along a first axis  106  between a first position and a second position when the piston head  102  translates. The translating bar  104  can be connected to the piston head  102  by any suitable means. The piston head  102  translates by an actuating fluid. Actuating fluid is supplied above the piston head  102  and vented from below the piston head (and vice versa) via internal passages, which are supplied and vented through spindle. The actuating fluid can be a liquid or a gas. In an exemplary embodiment, the actuating fluid is a liquid and can, in some embodiments, be a liquid that is also used as a coolant by the material removal tool  10 . 
     At pressure, the actuating fluid above the piston head  102  overcomes the biasing force of biasing elements. In exemplary embodiments, the biasing element is preloaded to exert a force to bias the piston head toward the second end  32  of the material removal tool  10 , although the opposite arrangement can also be constructed. Examples of biasing elements include mechanical systems, such as springs, dashpots, pistons and bellows, elastic materials, and non-mechanical systems, such as compressible fluids and compressible gases. Biasing can be accomplished by any desired technique. For example, a mechanical biasing element, such as a spring, can be used. 
     The translating bar  104  includes an actuating surface  108  at a second end or a plurality of actuating surfaces  108  spaced axially along the translating bar  104 . In exemplary embodiments, the actuating surface  108  has an outer surface having the shape of a cone or frustum. The actuating surface  108  is formed of a hard, wear resistant material, such as cemented carbide. In exemplary embodiments, the actuating surface  108  onto the translating bar, although any suitable attachment means can be used. The actuating surface can be polished to a desired smoothness. A suitable smoothness for the actuating surface is about (i.e., ±10%) 4 RMS. 
     Also shown in  FIG. 2  is the plurality of cartridges  14 . The plurality of cartridges  14  is secured in the housing body (not shown) by any suitable mounting mechanism  110 , such as fastener, a cap screw, a bolt or a screw. The cartridge  14  itself is securely mounted relative to the housing body  12 . However, the seating members  18  are pivotable about an axis  112 . The pivoting of the seating members  18  is actuated by translation of the translating bar  104  operating through actuating surface  108  contacting push pin  114 . Although the term pin is used, the push pin can take any geometric shape, such as, for example, curved geometric shapes, and regular and irregular polygonal shapes. The actuating surface  108  has a variable radius along a set axial distance. As the actuating surface  108  moves relative to the push pin  114 , the radial position of the end of the push pin  114  along a second axis changes in correlation to the variable radius of the actuating surface  108 . This change in radial position of the end of the push pin  114  then directly or indirectly changes the position of or creates a force operating on the pivotable seating member  18 . Therefore, as the translating bar axially translates between a first position and a second position when the piston head translates, the plurality of seating members move from a first position, i.e., a retracted position, to a second position, i.e., an extended position. In  FIG. 2 , the cutting inserts  24  are shown in stand-off relationship to the seating members  18  to show the pockets  20 . 
     Turning to  FIG. 3 , which is a magnified view of the arrangement of some of the internal components, the relative positions of the cartridge  14 , the seating members  18 , axis  112 , translating bar  104 , actuating surface  108  and push pin  114  can be observed more clearly. For example, each of the seating members  18  has a separate push pin  114 . An adjustment screw  116  in the seating member  18  protrudes inward from the seating member and has an end that contacts the end of the push pin  114 . As such, the adjustment screw  116  can be used for fine adjustment of the radial position of the seating member  18 . Multiple locating pins  120  are shown distributed circumferentially about the translating bar  104 . These locating pins  120  can be used to support and center the translating bar  104 . 
     Turning to the cartridge  14 , such as exemplary illustrated in top plan view in  FIG. 4 , the cartridge  14  comprises a body  200  with a cavity  202  in which the pivotable seating members  18  are removably mounted. The cavity  202  is open on two sides of the cartridge  14  to facilitate manufacture and assembly, but other embodiments can have a cavity open to one side, three sides, or more, depending on design. As seen in  FIG. 4 , the pivotable seating members  18  share a common pivot axis  204 . However, the pivotable seating members  18  can alternatively have different pivot axes. Here, the pivotable seating members  18  share a common pivot axis  204  by each of the pivotable seating members cooperating with only a portion of the axis  204  to pivot. As seen in  FIG. 4 , the pivotable seating member  18  is only half-width in the area of the axis  204  so that the pivotable seating members  18  stack next to each other along the axis  204 . In the  FIG. 4  embodiment, a closure plate  206  is attached to the body  200  and assists in positioning the pivotable seating members  18  and the associated pivot axis  204 . Further, the closure plate  206  has openings  208  to allow mounting, indexing and exchanging of cutting inserts in the pocket  20 . In one exemplary embodiment and as seen in the side plan view of  FIGS. 6A and 6B . the openings  208  are similar to crenellations, but any suitable geometry of the openings  208  can be used that allows access to the pocket  20 . 
     The cartridge  14  can optionally include adjusting features for both axial and radial positioning. For example, the cartridge can include an axial locating device, such as a locating screw  210 , which can be adjusted to change the axial position of the cartridge  14  in the enclosed pockets  16 . The enclosed pockets  16  provide a mounting mechanism for the cartridges  14  that leaves a maximum amount of the housing body intact to provide stiffness and strength from the mass of the housing body. Non-enclosed pockets can also be used if the housing body is sufficiently large and/or of sufficient mass to obtain the desired stiffness. A similar radial locating device can also be utilized. In regard to the radial adjustment of the pivotable seating member  18 , reference is made to the adjustment screw  116 , which was previously shown and described and is shown more clearly in  FIGS. 4 and 5 . 
       FIG. 5  is a disassembled, perspective view of a cartridge  14  with pivotable seating members  18 . In addition to the features of the cartridge  14  previously shown and described,  FIG. 5  also shows the biasing element  212 , which acts on an end surface  214  of the individual seating members  18  to bias the seating member  18  in a retracted position, and the axle pin  216  about which the seating members  18  pivot and more clearly shows the adjustment screw  116  and the pocket  20  with the seating surface  22  (the pocket and seating surface on the second seating member  18  is not labeled for clarity). 
       FIGS. 6A and 6B  show the seating members  18  (and associated cutting inserts  24 ) in a retracted position ( FIG. 6A ) and in an extended position ( FIG. 6B ). In the retracted position ( 6 A), a biasing member, such as a torsional spring positioned about the axis or an axial spring positioned to perate lever-like on a surface of the seating member, biases the seating member  18  in the retracted position. In the extended position ( FIG. 6B ), the seating members  18  have been moved radially outward and pivoted inward toward each other in a scissor-like motion (M) by operation of the push pin  114  contacting the adjustment screw  116  and being moved radially outward by the change in radial position of the actuating surface  108  of the translating bar  104 . Pivoting the seating members  18  between the retracted and extended positions can be either simultaneous or sequential and can be controlled based on the design and operation of the translating equipment such as the translating bar and actuating surfaces. A typically radial difference between the retracted position and the extended position is on the order of millimeters, e.g., 1-3 millimeters or about 1.5 millimeters. Furthermore, the seating members  18  in any one cartridge  14  do not have to be at the same radial distance in either the retracted or extended positions. 
       FIGS. 7A to 7C  illustrate different operating positions for the pivotable seating members (and associated cutting inserts) while machining a workpiece. In the illustrated example, the workpiece  300  is a crank shaft bearing support and is shown in partial view; similarly, only a portion of the material removal tool  10  is shown. 
       FIG. 7A  illustrates a starting position for removing material from the workpiece. An active portion of the material removal tool  10  is inserted into a bore of the workpiece  300 . The active portion is positioned relative to the workpiece to position a surface  302  of the workpiece to be machined radially proximate a pivot axis  204  of a plurality of seating members  18  mounted in a cartridge mounted on the active portion of the material removal tool. Because the illustrated cartridges is mounted in an enclosed pocket, the cartridge is not visible in the  FIGS. 7A to 7C  views. As seen in the  FIG. 7A  view and for this material removal operation, the two cutting inserts  24  in any one cartridge are in an initial retracted position and are on opposite sides of the workpiece  300 . In the retracted position, the outermost surface of the cutting insert  24  is at a distance d 1  from the surface of the seating member  18  (see  FIG. 6A ). 
     The plurality of seating members are then actuated to pivot to an extended position and the rotating material removal tool is translated in a first axial direction T 1 . In the extended position, the outermost surface of the cutting insert  24  is at a distance d 2  from the surface of the seating member  18  (see  FIG. 6B ), where d 2  is greater than d 1 . This movement contacts the extended cutting insert  24  mounted in a pocket of a first of the plurality of seating members with the surface  302  of the workpiece to be machined and removes some of the material.  FIG. 7B  shows the material removal tool with the seating members in the extended position and after translating the tool in the first axial direction, i.e., at the completion of the first machining operation. 
     Subsequently, the material removal tool is axially translated in a second axial direction T 2 . This movement contacts the extended cutting insert  24  mounted in a pocket of a second of the plurality of seating members with the surface  302  of the workpiece to be machined and removes some of the material.  FIG. 7C  shows the material removal tool with the seating members in the extended position and after translating the tool in the second axial direction, i.e., at the completion of the second machining operation. 
     Because the radial position of the cutting insert mounted in a pocket of a second of the plurality of seating members are greater than the radial position of the cutting insert mounted in a pocket of a first of the plurality of seating members, the first cutting operation removes some material and the second cutting operation removes more material. In addition, the different cutting operations allow use of different cutting insert types. For example, the cutting insert mounted in a pocket of a first of the plurality of seating members can be a semi-finish cutting insert and the cutting insert mounted in a pocket of a second of the plurality of seating members can be a finish cutting insert. The above method forms a finished surface of the bore in one stroke of the material removal tool, i.e., a forestroke and a backstroke. 
     The above first and second cutting operations have been described with the plurality of seating members extending once and retracting once. In such an operation, the first cutting insert  24  potentially contacts the surface  302  of the workpiece to be machined during both translation in the first axial direction and translation in the second axial direction. This can cause undesirable cutting defects during the backstroke. As an alternative, the seating members can be actuated more times. For example, after translating the rotating material removal tool in the first axial direction and before contacting the surface with the second cutting insert, preferably before translation in the second axial direction begins, the plurality of seating members are actuated to pivot the plurality of seating members to a retracted position. This disengages the first cutting insert from the surface of the workpiece or from potentially contacting the surface of the workpiece. The rotating material removal tool is then partially translated in the second axial direction to move the first cutting insert past the workpiece, and the plurality of seating members are reactuated to pivot the plurality of seating members to the extended position. Translation in the second axial direction is then completed with the cutting insert  24  mounted in a pocket of a second of the plurality of seating members contacting the surface  302  of the workpiece to be machined and removing some of the material. 
     After completion of cutting operations, the plurality of seating members are actuated to pivot the plurality of seating members to a retracted position and the active portion of the material removal tool can be withdrawn from the bore of the workpiece. 
     To further ensure against unwanted contact between the cutting inserts and the workpiece during operation, in the retracted position, the plurality of seating members are each inward of an outermost surface of the active portion, and wherein in the extended position, the plurality of seating members are each outward of the outermost surface of the active portion. 
     Although only one cutting position is shown in  FIGS. 7A to 7C , the same cutting operations can be accomplished at multiple cutting positions of the material removal tool to cut multiple bores simultaneously utilizing multiple inserts per bore. 
     Benefits of the disclosed material removal tool includes balanced cutting forces (as compared to single point cutting) and longer tool life between insert changes. In addition, because the forward and back stroke is minimized by the closer positioning of the two cutting inserts relative to each other, non-cutting time is reduced and cutting operations are more efficient. 
     In an optional embodiment, the cartridge can include only one pivotable seating member, with suitable features as shown and described herein with respect to cartridges with a plurality of pivotable seating members.  FIG. 8  is a schematic drawing of an exemplary embodiment of a material removal tool with an alternative exemplary embodiment of a cartridge with a single pivotable seating member. In the  FIG. 8  view, a material removal tool  400  has a plurality of cartridges  402  with a single pivotable seating member  404 . One of the cartridges  402  is shown in disassembled, perspective view and the individual components thereof can be viewed. Cutting operations using the material removal tool  400  with a cartridge  402  with only one pivotable seating member  404  can be completed in a single axial translation of the material removal tool, with suitable other operations, actuations, extensions and retractions as shown and described herein with respect to cutting operations with material removal tools with cartridges with a plurality of pivotable seating members. The alternative embodiment of the cartridge  402  including only one pivotable seating member  404  can be used, for example, on material removal tools with active portions defined by short axial lengths that may only accommodate such cartridges, which can occupy a shorter axial length of the active portion due to having only a single pivotable seating member. 
     Although described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without department from the spirit and scope of the invention as defined in the appended claims.