Abstract:
In a valve disposed between a fluid supply and a socket of a chuck and configured to regulate the flow of the fluid to the socket. There is a seal screw for modulating a preload tension. This seal screw has a first sealing surface. The valve further includes a second sealing surface in opposing relation to the first sealing surface and an elastomer seal ring disposed between the first sealing surface and the second sealing surface. The valve is configured to form a seal between the first sealing surface, the second sealing surface, and the elastomer seal in response to a force less than or equal to the preload tension being exerted in line with the seal screw. In this manner, the valve is configured to allow the flow of the fluid between the first sealing surface and the second sealing surface in response to a force exceeding the preload tension being exerted in line with the seal screw.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention generally relates to chuck or socket devices and methods. More particularly, the present invention pertains to a fluid-conduit, tool holding, socket type chuck device and method.  
       BACKGROUND OF THE INVENTION  
       [0002]     When machining a variety of materials such as metals and composites, lubricating fluid and/or air is generally utilized to facilitate heat transfer and/or chip removal. In the case of relatively small items that may be placed within a milling machine, for example, a stream of fluid or coolant may be delivered to the milling site via a fluid line separately arranged from the cutting tool. However, when forming relatively deep holes and/or when machining relatively large items, for example, with portable milling devices, it may be advantageous to deliver fluid more directly to the tip of the cutter. So called fluid chucks are generally utilized to both hold these cutting tools and provide for fluid delivery. These fluid chucks typically include a fluid coupling and a conduit to deliver coolant to the cutting tool.  
         [0003]     A disadvantage associated with some conventional fluid chucks is that the flow of fluid is not regulated in connection with the cutting action and thus, fluid may flow out of the cutting tool while no milling action is being performed. In an attempt to overcome this disadvantage, automatic shutoff valves have been incorporated into fluid chucks. However, these known fluid chucks with automatic shutoff valves have not fully overcome these disadvantages and, by way of example, are sometimes susceptible to leaking. Also, these conventional automatic shutoff valves occasionally “stick” and fail to shut off the flow of fluid at the completion of a cutting operation. Problems associated with stuck valves include fluid waste and “back side contamination.” The phrase “back side contamination” refers to fluid discharged by the cutting tool after penetration of the material. That is, as the milling tool or drill bit exits through the back of the material, fluid continues to flow and splashes the back side of the material. This problem may be particularly troublesome in the aerospace industry. For example, when machining airframes, back side contamination may foul the interior of the airframe necessitating additional cleaning operations and involving time and money. In addition, there are health concerns associated with cooling fluids. Therefore, back side contamination may have a negative impact on the health of machine operators in the vicinity.  
         [0004]     Another disadvantage associated with known fluid chucks having automatic shutoff is that the preload and travel are factory set. The term “preload” refers to an amount of resistance the automatic shutoff mechanism requires to open it for flow, and thus relates to the force required to open the shutoff valve and start the flow of fluid. The term “travel” refers to the degree of movement of the automatic shutoff mechanism required to open the shutoff valve and start the flow of fluid. Optimal preload and travel depend upon a variety of factors such as type and thickness of material machined, diameter of cutting tool, feed rates, and the like. Consequently, the factory settings are usually only optimal for a relatively narrow range of cutting operations.  
         [0005]     Accordingly, it is desirable to provide a fluid chuck method and apparatus capable of overcoming the disadvantages described herein at least to some extent.  
       SUMMARY  
       [0006]     The foregoing needs are met, to a great extent, by the present invention, wherein in one respect a fluid chuck device and method is provided that in some embodiments automatically regulates fluid delivery.  
         [0007]     An embodiment of the present invention pertains to a valve disposed between a fluid supply and a socket of a chuck. This valve is configured to regulate the flow of the fluid to the socket. The valve includes a seal screw for modulating a preload tension. This seal screw has a first sealing surface. The valve further includes a second sealing surface in opposing relation to the first sealing surface and an elastomer seal ring disposed between the first sealing surface and the second sealing surface. The valve is configured to form a seal between the first sealing surface, the second sealing surface, and the elastomer seal in response to a force less than or equal to the preload tension being exerted in line with the seal screw. In this manner, the valve is configured to allow the flow of the fluid between the first sealing surface and the second sealing surface in response to a force exceeding the preload tension being exerted in line with the seal screw.  
         [0008]     Another embodiment of the present invention relates to an apparatus for automatically regulating flow of a coolant to a socket of a chuck. This apparatus includes a means for adjusting a preload tension of a valve within the chuck and a means for forming a seal in response to the preload tension. This seal is formed by an elastomer seal disposed between a first sealing surface and a second sealing surface. The apparatus further includes a means for opening the seal in response to a force greater than the preload tension being applied to the chuck. This force is applied in a direction in line with an axis of the chuck.  
         [0009]     Yet another embodiment of the present invention pertains to a method of automatically regulating flow of a coolant to a socket of a chuck. In this method, a preload tension of a valve within the chuck is adjusted and a seal is formed in response to the preload tension. This seal is formed by an elastomer seal disposed between first sealing surface and a second sealing surface. The method further includes opening the seal in response to a force greater than the preload tension being applied to the chuck. This force is applied in a direction in line with an axis of the chuck.  
         [0010]     There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.  
         [0011]     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.  
         [0012]     As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a perspective view of a chuck device according to an embodiment of the invention.  
         [0014]      FIG. 2  is an exploded view of the chuck device shown in  FIG. 1 .  
         [0015]      FIG. 3  is a cut away view of the chuck device shown in  FIG. 1  in a valve closed position.  
         [0016]      FIG. 4  is a cut away view of a chuck device shown in  FIG. 1  in a valve open position.  
         [0017]      FIG. 5  is a flow diagram according to an embodiment of the invention. 
     
    
     DETAILED DESCRIPTION  
       [0018]     The present invention provides a chuck device and method for the chuck device. In some embodiments, the invention provides for a chuck operable to hold a cutting tool and be driven by a suitable device such as for example a drill, operable to turn the chuck about its axis. The cutting tool may include any suitable end mill, drill bit and the like. Specific example of suitable drill devices include those manufactured by Quackenbush Company, Inc of Crystal Lake Ill., USA. Examples of suitable cutting tools include those configured to convey coolant to or near the cutting tip. The chuck is further operable to be connected to a coolant supply. The coolant may include any suitable liquid and/or gas. More specific examples of suitable coolants include, air, water, oil, a mist of air and oil, and the like.  
         [0019]     In other embodiments, the invention provides a method of automatically regulating flow of a coolant to the chuck. In this method, a preload tension of a valve within the chuck is adjusted and a seal is formed in response to the preload tension. This seal essentially prevents coolant from flowing to the socket and thereby to the cutting tool when the tool is not engaged in a cutting operation. The seal is formed by an elastomer seal disposed between first sealing surface and a second sealing surface. The method further includes opening the seal in response to a force greater than the preload tension being applied to the chuck. For example, this force is applied in a direction in line with an axis of the chuck and is utilized during a boring operation to press the cutting tool against a material to be bored.  
         [0020]     Advantages of various embodiments of the invention may include, for example: (1) adjustable preload; (2) adjustable travel; (3) reduced envelope size; and/or (4) improved reliability of automatic valve action.  
         [0021]     Preferred embodiments of the invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. As shown in  FIG. 1 a  chuck  10  includes a spindle driver  12 , a spindle  14 , and a housing  16 . The spindle driver  12  includes a threaded shank  18  operable for attachment to a drill motor. Suitable drill motors include any suitable devices configured to rotate a chuck about an axis. Specific examples of suitable drill motors include at least models S150, S275, S400, and C2AA manufactured by Quackenbush Company, Inc of Crystal Lake Ill., USA. In an embodiment of the invention, the threaded shank  18  is configured to mate with a drive of a suitable drill motor via a 0.357″ deep by {fraction (9/16)}″-18 straight thread pitch. While a threaded shank is illustrated, in various embodiments of the invention, the threaded shank  18  maybe replaced with a threaded bore, a tapered fitting, or the like.  
         [0022]     The spindle  14  includes a threaded bore  20 . This threaded bore  20  is operable for attachment to any suitable drill bit, end mill, or the like. More particularly, suitable drill bits may include those configured to deliver coolant and/or lubricant to or near a cutting tip of the bit. These drill bits may be broadly classified as, “oil hole drill bits” and specific examples of suitable oil hole drill bits include at least those manufactured by Cooper Industries of Huston Tex., USA. In an embodiment of the invention, the threaded bore  20  is configured to mate with a shank of a suitable oil hole drill bit via a {fraction (9/16)}″-18 straight thread pitch. While a treaded bore is illustrated, in various embodiments of the invention, the threaded bore  20  may be replaced with a socket-type fitting, a tapered fitting, or the like.  
         [0023]     The housing  16  includes a fitting  22  operable for connection to a coolant supply. For example, a supply line from the coolant supply may be attached to the fitting  22  and, in this manner, supply coolant to the chuck  10 . Suitable coolants for use with the chuck  10  include at least oil, water, air, oil/air mist, and the like. In operation, the housing  16  is configured to remain essentially stationary while the remainder of the components of the chuck  10  are rotated by the drill motor.  
         [0024]      FIG. 2  is an exploded view of the chuck  10  according to  FIG. 1 . As shown in  FIG. 2 , the chuck  10  further includes a pair of retainers  24 A and  24 B, an adjustment screw  26 , a seal ring  28 , a spring system  30 , and a set screw  32 . As described in greater detail herein, the adjustment screw  26  is configured to facilitate a variety of tasks including securing the spindle  14  to the spindle driver  12 , adjusting a preload tension, and adjusting an amount of travel. Also as described in greater detail herein, the seal ring  28  is configured to elastically conform to various sealing surfaces. In this regard, the seal ring  28  may include elastomers such as rubber, urethane, and/or any other suitably elastic material. The spring system  30  is preferably composed of one or more Belleville spring washers. Examples of suitable Belleville spring washers include those manufactured by Belleville Springs Ltd. of Lakeside United Kingdom. As is generally known, these Belleville springs may be arranged in a variety of manners and thereby modify the force required to deflect the spring system  30  and/or modify the deflect capacity of the spring system  30 . Although Belleville-type spring washers are preferred, any suitable spring or spring system may be substituted in place of, or used in combination with, the one or more Belleville springs described.  
         [0025]     The spindle  14  includes a channel  34  disposed about the circumference of the spindle  14 . This channel  34  is configured to provide a path or conduit through which coolant may flow as the spindle  14  revolves within the housing  16 . The spindle  14  also includes at least one orifice  36 . The orifice  36  is configured to provide a conduit for the coolant to flow from the channel  34  into the spindle  14 .  
         [0026]      FIG. 3  is a cutaway view of the chuck  10  according to  FIG. 1 . As shown in  FIG. 3 , the adjustment screw  26  includes a head  38  having a sealing surface  40 . In addition, the spindle  14  includes a partition  42  having a sealing surface  44 . The chuck  10  includes a valve  46  formed via the interaction of the seal ring  28  disposed between the sealing surface  40  and the sealing surface  44 . Furthermore, the partition  42  includes a thrust surface  48  and the spindle driver  12  includes a thrust surface  50 . The valve  46  is closed as a result of a preload tension, supplied by the spring system  30 , acting upon the thrust surface  48  and thrust surface  50 . As shown, the valve  46  is in a closed position. It is an advantage of this arrangement that coolant is essentially prevented from leaking through the valve  46  when in a closed position. For example, minor imperfections of the sealing surfaces  40  and  44 , particulate matter within the coolant, and the like may be accommodated by the elastic nature of the seal ring  28 .  
         [0027]     To facilitate proper alignment and/or action of the spring system  30  within the chuck  10 , the spring system  30  is disposed within a spring bore  52 . The spring guide  52  and the spring system  30  are preferably configured to conform sufficiently so as to facilitate a relatively smooth and repeatable action of the valve  46 . For example, the inside diameter of the spring bore  52  may be formed to a tolerance of about 1 to 10 micrometers greater than the outside diameter of the spring system  30 .  
         [0028]     The spindle driver  12  includes an axial bore  54 , which is sized and includes threads configured to mate with both the adjustment screw  26  and the set screw  32 . Prior to boring or drilling operation, the chuck  10  may be assembled by arranging the various components as described herein and threading the adjustment screw  26  into the axial bore  54 . The preload tension may further be adjusted via the modulation of the adjustment screw  26  and/or modification of the spring system  30 . For example, given a particular number and/or arrangement of Belleville springs, threading the adjustment screw  26  further into the spindle driver  12  may tend to increase the preload tension. In another example, relatively larger adjustments to the preload tension may be produced via the rearrangement and/or addition or subtraction of Belleville springs. In order to set or lock the particular adjustment to the chuck  10 , the set screw  32  may be threaded into the axial bore  54  in a manner opposing the adjustment screw  26  until the set screw  32  and adjustment screw  26  meet with sufficient force so as to substantially prevent movement of these two screws within the axial bore  54 . Thus, it is an advantage of various embodiments of the invention that the preload tension may be adjusted. It is an additional advantage that this adjusted preload tension may be locked by the action of the set screw  32 . It is a further advantage of various embodiments that, as a result of the locking action of the set screw  32 , the assembled chuck  10  may be substantially prevented from inadvertent disassembly.  
         [0029]     In operation, torque applied to the threaded shank  18  results in rotation about an axis “A” of the spindle driver  12  and the spindle  14 . In this regard, torque is applied to the spindle  14  by the spindle driver  12  at an interface  56 . This interface  56  is configured to facilitate axial movement of the spindle  14  relative to the spindle driver  12  while substantially preventing rotational movement of the spindle  14  relative to the spindle driver  12 . In various embodiments of the invention, the interface  56  may have a variety of different forms. For example, one or more axially oriented ridges or lands and groves may be formed on the mating surfaces of the interface  56 . In another example, a keyed channel or other such configuration may be utilized.  
         [0030]      FIG. 4  is a cut away view of the chuck  10  according to  FIG. 1  in which the valve  46  is in an open position. The valve  46  may be opened in response to an axially applied, compressive force upon the chuck  10 . For example, in response to a compressive force sufficient to overcome the preload tension as well as any frictional resistance presented by the interface between the spindle driver  12  and spindle  14 , the spindle  14  may collapse toward the spindle driver  12  and the valve  46  may open. In operation, this compressive force is generally achieved via the action of a drill motor attached to the threaded shank  18  pressing a drill bit or other tool attached to the threaded bore  20  into a material to be drilled. However, other ways of applying sufficient compressive force in an axial manner to the chuck  10  may be implemented result in modulation of the valve  46 .  
         [0031]     In order to deliver coolant to or near the cutting tip of a drill bit or other tool secured within the threaded bore  20 , various embodiments of the invention provide a conduit  58  through which the coolant may flow from the fitting  22  to the threaded bore  20 . It is an advantage of embodiments of the invention that the valve  46  is provided to regulate the flow of coolant through the conduit  58 . As a result of the valve  46  being in the open position and as illustrated by flow lines  60  and  62 , coolant may flow to the threaded bore from the fitting  22  via the channel  34 , the orifice  36 , and the valve  46 .  
         [0032]     In order to substantially prevent a shank of a drill bit inserted in the threaded bore  20  from impeding the action of the valve  46 , a stop  64  is provided for in at least some embodiments. For example, the stop  64  may be formed as a result of tapering or chamfering a portion of the threaded bore  20  and thereby, having a remaining portion of the threaded bore  20  retain a relatively smaller diameter. This stop  64  may be formed at a point in the threaded bore  20  sufficiently prior to the head  38  so as to substantially prevent a shank of a drill bit inserted in the threaded bore  20  from impeding the action of the valve  46 .  
         [0033]     The chuck  10  may further include a plurality of seals configured to substantially prevent coolant from leaking out of the conduit  58 . For example an interface between the housing  16  and the spindle  14  may be configured to substantially prevent leakage of coolant. In addition, an interface between the retainers  24 A and  24 B, the housing  16 , and/or the spindle  14  may be configured to substantially prevent leakage of coolant. Furthermore, the interface  56  may be configured to substantially prevent leakage of coolant.  
         [0034]      FIG. 5  is a flow diagram of a method  70  according to an embodiment of the invention. In the method  70 , a drilling or other machining system may be assembled and utilized to bore one or more holes or otherwise machine a surface. As shown in  FIG. 5 , the method  70  may be initiated at step  72  by determining whether the preload tension is acceptable. This determination may be performed in a variety of manners. For example, the chuck  10  may be compressed with a plurality of different forces, at least one of which does not collapse the spindle  14  towards the spindle driver  12 , and at least one of which does collapse the spindle  14  towards the spindle driver  12 . In this manner an approximate preload tension may be determined and preload tension may be adjusted based upon this determination. If it is determined that the preload tension is acceptable or within an acceptable range, step  74  may be performed in preparation to drill a hole or otherwise machine a surface. If it is determined that the preload tension is not acceptable, step  76  may be performed in preparation to adjust the preload tension.  
         [0035]     At step  76 , it may be determined whether the valve  46  is locked. For example, a tool configured to mate with the set screw  32  may be utilized to modulate the set screw  32 . If it is determined that the set screw  32  is not locked against the adjustment screw  26 , adjustment of the preload tension may be performed at step  80 . If it is determined that the set screw  32  is locked against the adjustment screw  26 , the valve  46  may be unlocked at step  78 . For example, a tool configured to mate with the set screw  32  may be utilized to loosen the set screw  32  at step  78 .  
         [0036]     At step  80 , the preload tension of the valve  46  may be adjusted. This preload tension may be adjusted with a tool such as for example a screw driver or Allen wrench configured to mate with the head  38 . For example, the preload tension may be increased by turning the head  38  in a clockwise manner. In addition, relatively larger adjustments to the preload tension may be performed by disassembling the chuck  10  and modifying the spring system  30 . For example, the number and conformation of Belleville springs may be altered. In another example, a helical spring may be replaced with another spring having different tension properties. Furthermore, travel of the chuck  10  may be modulated in a similar manner. For example, turning the head  38  in a clockwise manner may tend to reduce the travel. Following the step  80 , the adjustment may be locked at step  82 . For example, the set screw  32  may be screwed into the axial bore  54  until the set screw  32  is pressing tightly against the adjustment screw  26 . In this manner, the preload tension adjusted at step  80  may be retained until it is desirable to re-adjust the preload tension.  
         [0037]     At step  84 , the chuck  10  may be attached to a suitable drill motor or drill device. Specific example of suitable drill devices include at least models S150, S275, S400, C2AA, and the like manufactured by Quackenbush Company, Inc of Crystal Lake Ill., USA.  
         [0038]     At step  86 , a drill bit, end mill, or other suitable cutting tool maybe attached to the chuck  10 . For example, a shank of a drill bit may be screwed into the threaded bore  20 .  
         [0039]     At step  88 , a coolant supply may be attached to the chuck  10 . For example, a coolant line may be affixed to the fitting  22 .  
         [0040]     At step  90 , one or more holes may be bored or surfaces machined. For example, the drill device or other machining tool may be operated according to manufacturers instructions.  
         [0041]     At step  92 , it is determined whether more holes are to be bored and/or additional surfaces machined. If it is determined more holes are to be bored, it is then determined if the preload tension is acceptable, at step  72 . For example, it may be advantageous to alter the preload tension and/or travel of the chuck based on the anticipated drilling conditions. More particularly, it may be advantageous to alter preload tension and/or travel based upon such drilling conditions as bit wear, material hardness, material thickness, and the like. Alternatively, if it is determined that additional holes are not going to be bored, the assembled drilling apparatus may idle until additional holes are to be bored or the assembled drilling apparatus is disassembled.  
         [0042]     If, at step  72 , it is determined that preload tension and travel are acceptable then, at step  74 , it is determined whether the valve  46  is locked. For example, in a manner similar to step  76 , at step  74 , a tool configured to mate with the set screw  32  may be utilized to modulate the set screw  32 . If it is determined that the set screw  32  is not locked against the adjustment screw  26 , the valve may be locked at step  82 . If it is determined that the set screw  32  is locked against the adjustment screw  26 , it may be determined whether the chuck  10  is adequately attached to a suitable drill motor at step  94 .  
         [0043]     At step  94 , it is determined whether a suitable drill motor is adequately attached to the chuck  10 . For example, the model number of the drill motor may be verified and/or the attachment of the chuck  10  to the drill motor may be examined. If at step  94  it is determined a suitable drill is not adequately attached to the chuck  10 , the chuck  10  may be properly attached to a suitable drill motor at step  96 . If at step  94  it is determined a suitable drill is adequately attached to the chuck  10 , it may be determined if a proper bit is attached to the chuck  10  at step  98 .  
         [0044]     At step  98 , it is determined whether a proper bit is attached to the chuck  10 . In this regard, it is generally known that different sized holes are typically bored utilizing bits having a corresponding size. In addition, different drill bits may be optimized for particular materials. Therefore, depending upon these and other factors it may be determined if a proper bit is attached to the chuck  10 . If at step  98  it is determined that a proper bit is attached to the chuck  10 , it is determined if the bit is properly attached to the chuck  10  at step  100 . If at step  98  it is determined that no bit or an improper bit is attached to the chuck  10 , the improper bit, if present, may be removed at step  102  and an appropriate bit may be properly attached to the chuck  10  at step  104 .  
         [0045]     At step  100 , it is determined if the bit is properly attached to the chuck  10 . For example, the degree to which a bit has been inserted into the threaded bore  20  may be evaluated according to manufacturers specifications. If at step  100  it is determined that a bit is not properly attached to the chuck  10 , the appropriate bit maybe properly attached to the chuck  10  at step  104 . Following step  104  or in response to determining the appropriate bit is properly attached to the chuck  10  at step  100 , it is determined whether a coolant supply it attached to the chuck  10  at step  106 .  
         [0046]     At step  106 , it is determined whether a coolant supply is functionally attached to the chuck  10 . For example, it may be determined if a coolant supply line is attached to the fitting  22 . In addition, it may be determined if a coolant supply is properly pressurized and in working order. Furthermore, a compressive force may be placed upon the chuck  10  to verify the functionality of a coolant supply. If it is determined that the coolant supply is not functional, the coolant supply may be functionally attached to the chuck  10  at step  88 . If it is determined that the coolant supply is functionally attached to the chuck  10 , the drilling system may be operated at step  90  to bore at least hole.  
         [0047]     The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.