Patent Abstract:
An axle boring assembly includes a portable power head or drive unit, a bearing pack to which the drive unit is attached, an adjusting base to which the bearing pack is adjustably secured and a mounting assembly which fits over a motor vehicle axle and to which the adjusting base is secured. The mounting assembly comprises a first section having axially spaced apart front and rear clamps and a substantially identical second section with matching spaced apart front and rear clamps. Threaded fasteners extend between the front and rear clamps and may be rotated to secure the mounting assembly about the end of the axle. Each clamp includes jaws which contact the axle and which may be selected from sets of various sizes and configurations to ensure accurate and suitable engagement of the axle.

Full Description:
FIELD 
       [0001]    The present disclosure relates to machines and methods for boring axles and more particularly to a boring machine, mounting assembly and method suitable for repairing a damaged semi-tractor or trailer axle. 
       BACKGROUND 
       [0002]    The statements in this section merely provide background information related to the present disclosure and may or may not constitute prior art. 
         [0003]    Commercial vehicles, particularly long haul trucks and trailers, can readily travel one hundred thousand miles a year or more. Spindle bearing journal wear accumulates constantly during such use and can be monitored, detected and corrected during routine maintenance. When such wear exceeds a certain amount, it is desirable to replace some or all of the spindles in, for example, a repair facility before they fail on the highway. Motor vehicle axle and bearing components in such commercial vehicles can fail in spite of routine preventative maintenance. Such failures typically occur when the vehicle is in service and thus miles distant from a service facility and many miles from its base of operation. Not only may the replacement of an axle consume several days during which the vehicle is out of operation, but it generally must also be towed to a service facility to undertake the repairs. Due to the expense, both of the actual repair and the lost income accompanying the down time of the vehicle, in addition to spindle and bearing replacement in a shop or maintenance facility, an industry directed to on-site repair of such failed vehicle axle components has also developed. 
         [0004]    My U.S. Pat. No. 6,024,418 illustrates a current approach to axle repair. In this method of repair, a long spindle having both inner and outer bearing surfaces and threads is utilized with a sleeve or liner. After the damaged end of the axle of either a tractor or trailer has been removed, the spindle and liner are installed in the axle and welded to the axle at locations inboard from the end of the axle, away from regions of high stress. 
         [0005]    Different axle configurations and sizes, however, necessitate different repair equipment and methods and the present invention addresses repair of a new and different axle configuration. 
       SUMMARY 
       [0006]    The present invention provides a portable boring machine, mounting assembly and methods suitable for repairing a damaged semi-tractor or trailer axle. The boring machine includes a power head or drive unit, a bearing pack which rotatably supports a boring bar and to which the drive unit is attached, an adjusting base to which the bearing pack is adjustably secured and a mounting assembly which fits securely over the axle and to which the adjusting base is secured. The mounting assembly comprises a first or upper portion having axially spaced apart front and rear clamps and a substantially identical second or lower portion with matching spaced apart front and rear clamps. Threaded fasteners extend between the front and rear clamps and may be rotated to tighten and secure the mounting assembly about the end of the axle. Each portion (upper and lower, front and rear) includes two removable and securable jaws or teeth which contact the axle and which may be selected from sets of various sizes and configurations to ensure accurate and suitable engagement of the axle when the threaded fasteners are tightened. 
         [0007]    An additional embodiment of the mounting assembly which seats on a machined outer surface of an axle is also disclosed. 
         [0008]    The axle repair method comprehends the steps of: removing, preferably by sawing, the damaged end of the axle including the bearing and oil seal surfaces, securing the mounting assembly about the end of the axle, attaching the adjusting base to the mounting assembly, attaching the bearing pack to the adjusting base, installing a shaft in the bearing pack and placing a dial indicator on the shaft into the open end of the axle, adjusting the horizontal and vertical position of the bearing pack (and shaft) to minimize runout, removing the shaft and installing a boring bar and the drive unit on the bearing pack and boring the axle to a size which will accept a spindle, a seal ring and a liner. All of the equipment is then removed from the axle, the spindle, seal ring and liner installed and welds and one or more plug welds are emplaced between the spindle components and the axle according to one of three repair procedures. 
         [0009]    It is thus an aspect of the present invention to provide a mounting assembly for securing an adjusting base, a bearing pack and a drive unit to an axle for boring the axle. 
         [0010]    It is a further aspect of the present invention to provide a mounting assembly for portable axle repair equipment having a first portion including axially spaced apart front and rear clamps and a second portion including matching spaced apart front and rear clamps. 
         [0011]    It is a still further aspect of the present invention to provide a mounting assembly for portable axle boring equipment having a first or upper portion including axially spaced apart front and rear clamps and a substantially identical second or lower portion including matching spaced apart front and rear clamps. 
         [0012]    It is a still further aspect of the present invention to provide a method of repairing a tractor or trailer axle utilizing a mounting assembly having a first portion including front and rear clamps and a second portion including front and rear clamps. 
         [0013]    It is a still further aspect of the present invention to provide a method of repairing a tractor or trailer axle utilizing a mounting assembly having a first portion including front and rear clamps and a second portion including front and rear clamps, an adjusting base, a bearing pack and a drive unit which supports and rotates a boring bar. 
         [0014]    It is a still further aspect of the present invention to provide three repair methods which utilize various combinations of a spindle, seal ring and liner with interference fits and circumferential welds and one or more plug welds to secure a replacement spindle in a motor vehicle axle. 
         [0015]    Further aspects, advantages and areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     
       DRAWINGS 
         [0016]    The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. 
           [0017]      FIG. 1  is a perspective view of a trailer axle and certain components of the brake and suspension systems with the damaged terminal portion of the axle removed; 
           [0018]      FIG. 2  is a perspective view of the axle of  FIG. 1  with a boring machine mounting assembly according to the present invention secured thereto; 
           [0019]      FIG. 3A  is a front view of the boring machine mounting assembly according to the present invention; 
           [0020]      FIG. 3B  is an enlarged, fragmentary view of a portion of a boring machine mounting assembly according to the present invention adapted for use with square axles; 
           [0021]      FIG. 4  is a perspective view of the boring machine mounting assembly and adjusting base according to the present invention secured to the trailer axle of  FIG. 1 ; 
           [0022]      FIG. 5  is a perspective view of the boring machine mounting assembly, adjusting base and bearing pack according to the present invention secured to the trailer axle of  FIG. 1 ; 
           [0023]      FIG. 6  is a perspective view of a step of the repair method in which a dial indicator is attached to a shaft disposed in the bearing pack and the bearing pack is moved to center the shaft in the axle opening; 
           [0024]      FIG. 7  is a perspective view of the boring machine mounting assembly, adjusting base, bearing pack and drive unit according to the present invention secured to the trailer axle of  FIG. 1 ; 
           [0025]      FIG. 8  is a fragmentary, perspective view of the axle, the adjusting base and boring bar according to the present invention; 
           [0026]      FIG. 9  is a perspective view of another trailer axle with the damaged portion removed and an alternate boring machine split ring mounting assembly according to the present invention secured thereto; 
           [0027]      FIG. 10  is an enlarged, fragmentary view of a portion of the alternate boring machine split ring mounting assembly showing one of the internal, curved projections; 
           [0028]      FIG. 11  is a perspective view of the trailer axle of  FIG. 9  with the alternate boring machine split ring mounting assembly and an adapter plate according to the present invention secured thereto; 
           [0029]      FIG. 12  is a full, sectional view of a first axle repair method according to the present invention utilizing the mounting assembly and boring machine described herein and a spindle and seal ring with at least one plug weld outboard of a spider plate; 
           [0030]      FIG. 13  is a full, sectional view of a second axle repair method according to the present invention utilizing the mounting assembly and boring machine described herein and a spindle, seal ring and liner with at least one plug weld inboard of a spider plate, and 
           [0031]      FIG. 14  is a full, sectional view of a third axle repair method according to the present invention utilizing the mounting assembly and boring machine described herein and a spindle and seal ring without plug welds. 
       
    
    
     DETAILED DESCRIPTION 
       [0032]    The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. 
         [0033]    With reference to  FIG. 1 , a currently popular, hollow, cylindrical axle undergoing repair is illustrated and generally designated by the reference number  10 . The hollow, cylindrical axle  10  typically and routinely includes a pair of spider plates  12  (one of which is illustrated) which are associated with and to which brake components (not illustrated) are secured. The axle  10  also includes pneumatic brake operators  14  and clamps  16  which secure suspension components such a springs (not illustrated) to the axle  10 . In  FIG. 1 , the damaged terminal portion (not illustrated) of the axle  10  has been removed, preferably by sawing, so that a relatively smooth, uniform and undamaged cylindrical open end  18  of the axle  10  outboard of the spider plate  12  remains. 
         [0034]    With reference now to  FIGS. 2 and 3A , a mounting assembly  20  according to the present invention is shown in position on the axle  10 . The mounting assembly  20  includes a first or upper section or portion  22  and a second or lower section or portion  52 . Because the first section  22  and the second section  52  are substantially identical, only the first section  22  will be fully described, as will the differences between the first section  22  and the second section  52 . 
         [0035]    The first or upper section or portion  22  includes a front, flat, generally rectangular body or clamp  24  which is preferably fabricated of aluminum to save weight and may include a plurality of weight saving openings  26 , as and if desired. The front body or clamp  24  includes a large, generally centrally disposed radiused opening  28  along its lower edge. At two locations about the inner circumference of the radiused opening  28  are disposed one of a pair of jaws  30  having an inner curved (radiused) surface which contacts the axle  10 . The jaws  30  are preferably disposed at locations 60° from the vertical, that is, 30° above the horizontal. While these locations have been found to be preferable, they may be adjusted to suit other applications and operational considerations, as desired or necessary. 
         [0036]    The jaws  30  are secured to the front body  24  by threaded fasteners  32  such as cap screws or similar fasteners which are received within through threaded openings  34  in the front body  24 . As such, the positions of the jaws  30  are non-adjustable. However, it will be appreciated that since the threaded openings  34  pass entirely through the front body  24 , the jaws  30  may, if desired, be mounted on the opposite (inside) face of the front body  24 . The incorporation of the jaws  30  which contact the outside surface of the axle  10  at defined locations has been found to improve centering of the mounting assembly  20  on the axle  10 . However, and as indicated by the phantom lines in  FIG. 3A , in order to accommodate axles  10  of different outside diameters, the radial size or thickness of the jaws  30  and the radius of the inner curved surface may be varied. Accordingly, it should be understood that the invention contemplates the use of sets of jaws  30  of different radial sizes or thicknesses. Moreover, and as illustrated in  FIG. 3B , the jaws  30 ′ may define right angle notches  31  which securely engage certain axles  10 ′ which are square. 
         [0037]    A second plurality of through openings  36  arranged in a bolt circle receive fasteners which attach the adjusting base  70  as will be described subsequently. As utilized herein, the term “bolt circle” refers to an arrangement of features such as openings or apertures at generally equal circumferentially spaced intervals and at the same distance (radius) from a fixed center. At each end of the front body or clamp  24  are disposed a respective one of a pair of through apertures  38  which receive threaded fasteners  40  which extend into the second or lower section  52  and secure it to the first or upper section  22  as will be described subsequently. 
         [0038]    Directly behind and axially aligned with the front body or clamp  24  of the first or upper section  22  is a rear body or clamp  44 . The rear body or clamp  44  is essentially identical to the front body or clamp  24  and includes the weight saving openings  26 , the radiused opening  28 , the jaws  30 , the threaded fasteners  32 , the through threaded openings  34 , the pair of through apertures  38  and the pair of threaded fasteners  40 . Since the rear body or clamp  44  is not attached to the adjusting base  70 , it need not include the second plurality of through openings  36  although in view of manufacturing considerations and weight, they may be included. The front body or clamp  24  is rigidly secured to the rear body or clamp  44  by a pair of stanchions or spacers  46  and a plurality of suitable recessed threaded fasteners  48  such as cap screws which extend through aligned openings in the front and rear bodies  24  and  44 . 
         [0039]    The second or lower section or portion  52  likewise includes a front body or clamp  54  and a rear body or clamp  64 . Both of the front and rear clamps  54  and  64  preferably include the weight saving openings  26 , the radiused opening  28 , the jaws  30 , the threaded fasteners  32  and the through threaded openings  34 . Once again, the front body or clamp  54  includes the second plurality of through openings  36  while the rear body or clamp  64 , since it is not connected to the adjusting base  70 , need not. Furthermore, the front body or clamp  54  is rigidly secured to the rear body or clamp  64  by a pair of stanchions or spacers  46  and suitable recessed threaded fasteners  48  such as cap screws which extend through openings in the front and rear bodies  54  and  64 . Finally, and distinct from the front body or clamp  24  and the rear body or clamp  44  of the first or upper section  22 , the front body or clamp  54  and a rear body or clamp  64  include threaded openings  56  and  66  at their ends which receive the threaded fasteners  40  extending from the clamps  24  and  44  of the first or upper section  22 . The threaded fasteners  40  are utilized to attach the first or upper section  22  of the mounting assembly  20  to the second or lower section  52  and to tightly secure the mounting assembly  20  to the axle  10  as illustrated in  FIG. 2 . 
         [0040]    Turning now to  FIG. 4 , the adjusting base  70  will be described. The adjusting base  70  is illustrated in position on the outer flat faces of the mounting assembly  20 . The adjusting base  70  includes an annular baseplate  72  having a size (diameter) approximately equal to the size (outer curved edges) of the mounting assembly  20 . The annular baseplate  72  includes a plurality of through openings  74  which align with three of the second plurality of through openings  36  of the first or upper section  22  and three of the second plurality of through openings  36  of the second or lower section  52 . Extending through these aligned openings  36  and  74  are preferably six threaded fasteners  76  which receive nuts  78  which may be tightened to secure the adjusting base  70  to the mounting assembly  20 . 
         [0041]    Axially spaced from and secured to the annular baseplate  72  by two oblique trapezoidal braces  80  is a rectangular panel member that defines a left and right pair of rectangular plates  82 A and  82 B having flat, co-planar surfaces  84  which are also parallel to the annular baseplate  72 . The braces  80  are preferably secured to the annular baseplate  72  and the rectangular plates  82 A and  82 B by welding and for additional rigidity, pairs of upper and lower oblique struts  86 , also preferably secured by welding, may be disposed between the baseplate  72  and each of the trapezoidal braces  80 . 
         [0042]    Arranged in cooperating pairs adjacent the pair of rectangular plates  82 A and  82 B are three pairs of adjustment assemblies. A first pair of adjustment assemblies  90  each includes a mounting plate  92  supported by stanchions or standoffs which receives a threaded adjustment screw  94  having a thumbwheel  96  at one end and a bumper  98  at the opposite end. One of the first pair of adjustment assemblies  90  is secured to the left side of the left rectangular plate  82 A and the other of the first pair of adjustment assemblies  90  is secured to the right side of the right rectangular plate  82 B, preferably in axial alignment with the adjustment assembly  90  on the left rectangular plate  82 A. The first pair of adjustment assemblies  90  cooperate with a bearing pack  130 , illustrated in  FIG. 5 , to positively translate it horizontally, i.e., left and right, relative to the adjusting base  70 . As such, the threaded adjustment screws  94  are utilized and function in opposition. That is, to translate the bearing pack to the left, the thumbwheel  96  and adjustment screw  94  on the left is rotated counterclockwise while the thumbwheel  96  and the adjustment screw  94  on the right is rotated clockwise. To effect translation of the bearing pack  130  to the right, opposite actions are undertaken. 
         [0043]    A second pair of adjustment assemblies  100  are secured to the left rectangular plate  82 A and are oriented along an axis perpendicular to the axis extending between the first pair of adjustment assemblies  90 . Once again, each of the second pair of adjustment assemblies  100  includes a mounting plate  102  supported by stanchions or standoffs which receives a threaded adjustment screw  104  having a thumbwheel  106  at one end and a bumper  108  at the opposite end. The second pair of adjustment assemblies  100 , as described above, are typically utilized in opposition to adjust the vertical position of the left side or portion of the bearing pack  130  along a second, vertical axis perpendicular, or generally perpendicular, to the first, horizontal axis. 
         [0044]    In a similar fashion, and disposed on the right rectangular plate  82 B are a third pair of adjustment assemblies  110 . The third pair of adjustment assemblies  110  are oriented along an axis parallel to, and spaced from, the axis of the second pair of adjustment assemblies  100  (and perpendicular to the axis of the first pair of adjustment assemblies  90 ). Each of the third pair of adjustment assemblies  110  includes a mounting plate  112  supported by stanchions or standoffs which receives a threaded adjustment screw  114  having a thumbwheel  116  at one end and a bumper  118  at the opposite end. The third pair of adjustment assemblies  110 , as described above, are also typically utilized in opposition to adjust the vertical position of the right side or portion of the bearing pack  130  along a second, vertical axis perpendicular, or generally perpendicular, to the first, horizontal axis. 
         [0045]    Each of the pair of rectangular plates  82 A and  82 B include a plurality of threaded apertures  122 . Threaded into the threaded apertures  122  (preferably those near the respective centers of the rectangular plates  82 A and  82 B) are a pair of threaded studs  124 . Alternatively, the apertures  122  may be unthreaded and conventional machine bolts (not illustrated) may extend therethrough. The threaded studs  124  and cooperating nuts  142  are utilized to secure the bearing pack  130 , illustrated in  FIG. 5 , to the adjusting base  70 . 
         [0046]    Referring now to  FIG. 5 , the bearing pack  130  includes a generally rectangular flat plate  132  preferably having significant thickness, on the order of 0.5 inches to 0.75 inches (12.7 mm to 19.1 mm) which thus defines a wide edge surface  134 . The rectangular plate  132  has a length and width approximately equal to the horizontal and vertical separations between the pairs of bumpers  98  and  108  and  118  when the respective pairs of threaded shafts  94  and  104  and  114  are approximately at their mid-positions in the brackets  92  and  102  and  112 . As illustrated in  FIG. 5 , the bumpers  98 ,  108  and  118  engage the edge surface  134  of the flat plate  132  and, by rotation of the adjustment assemblies  90 ,  100  and  110  described above, facilitate horizontal and vertical, repositioning of the bearing pack  130  relative to the mounting assembly  20 . 
         [0047]    The rectangular flat plate  132  includes a plurality of relatively large through apertures  136  which may receive a respective one of the studs  124  (or machine bolts), one of which extends from each of the rectangular plates  82 A and  82 B. The through apertures  136  are sufficiently large, relative to the studs  124  or bolts, such that horizontal and vertical translation and repositioning of the rectangular flat plate  132  on the surfaces  84  of the rectangular plates  82 A and  82 B may be readily accommodated. Pairs of conventional washers  138  and nuts  142  are utilized to secure the bearing pack  130  to the adjusting base  70  after it has been positioned in an appropriate position, as described below, by the adjustment assemblies  90 ,  100  and  110 . 
         [0048]    The bearing pack  130  includes an elongate cylindrical housing  144  which receives and supports a pair of axially spaced-apart ball bearing assemblies  146 . The cylindrical housing  144  may be secured to the rectangular flat plate  132  by welding and welded gussets  148  may be utilized to reinforce the bearing pack  130 . The cylindrical housing  144  terminates in a square plate  152  having a flat face  154  which is parallel to the end face of the rectangular flat plate  132 . The square plate  152  is preferably secured to the cylindrical housing  144  by welding and includes a plurality of through openings  156  which receive a like plurality of machine bolts  158  which selectively attach a boring bar drive assembly  170 , illustrated in  FIG. 7 , to the bearing pack  130 . 
         [0049]    Referring now to  FIGS. 5 and 6 , in order to ensure that the subsequent boring procedure uniformly removes material from the cylindrical axle  10  and achieves uniform wall thickness, it is necessary that the axis of the bearing pack  130  be positioned co-axially, or as substantially co-axially as can reasonably be achieved, to the open end  18  of the hollow cylindrical axle  10 . Hence, a shaft  160 , which may be a boring bar, is inserted into the ball bearing assemblies  146  of the bearing pack  130  and a dial indicator  162  is attached to the end of the shaft  160  proximate the open end  18  of the hollow axle  10 . The sensing probe  164  and the dial indicator  162  are then adjusted, that is, positioned with the sensing probe  164  inside that axle  10 , so that the dial indicator  162  indicates run-out. The shaft  160  and the dial indicator  162  are then rotated and the adjustment assemblies  90 ,  100  and  110  of the adjusting base  70  are adjusted to horizontally and vertically translate the bearing pack  130  to minimize run-out. The nuts  142  on the studs  124  are then tightened to maintain this aligned position of the bearing pack  130  with the inside diameter of the axle  10 . 
         [0050]    Referring now to  FIG. 7 , the portable drive or power unit  170  is illustrated in position on the bearing pack  130 . The drive or power unit  170  includes two electric motors, speed reduction assemblies and control devices that provide rotation and bi-directional axial translation of a boring bar  172 . A first bi-directional and variable speed electric motor  174  rotates a pair of captive threaded nuts (not illustrated) in a housing  176  which advances and retracts along a pair of stationary lead screws  178  which, in turn, advances and retracts the boring bar  172 . A second electric motor  180  rotates the boring bar  172  at a constant speed through a speed reduction assembly  182 . A controller  184  includes a first, three position switch  186  and a variable speed control  188  which selects the direction and speed of the first (feed) motor  174  and a second, on-off switch  192  which controls the second (boring bar) motor  180  and an ammeter which  194  indicates the current draw thereof. Further details of the portable drive or power unit  170  appear in my U.S. Pat. No. 7,066,690 which is hereby incorporated herein by reference in its entirety. 
         [0051]    Referring briefly to  FIGS. 7 and 8 , a boring bar  172  having a cutter  196  is installed in the bearing pack  130  and connected to the drive or power unit  170 . The cutter  196  is adjusted to a first radial position to achieve a first, rough cut within the axle  10 . The first switch  186  is activated to the “IN” position and the boring bar  172  is advanced to the open end  18  of the axle  10 . The second switch  192  is then activated and a first rough boring pass into the axle  10  is undertaken. The first switch  192  is then moved to the “OUT” position and the boring bar  172  retracts from the axle  10 . The cutter  196  may then be advanced radially outwardly a small distance and the boring process repeated one or more additional times. Preferably, the radial position of the cutter  196  will be adjusted such that each pass of multiple passes will remove less material so that the finish of the inside of the axle  10  will improve with each pass. It should be appreciated that a boring machine having manual feed, rather than the automatic feed here disclosed, is both suitable and within the purview of this invention. 
         [0052]    Referring now to  FIGS. 9 and 10 , an alternate mounting assembly  200  is illustrated. The alternate mounting assembly  200  is preferably utilized with certain axles  210  that are fabricated with a machined outer surface  212  outboard of the spider plate  214 . Once again, the damaged outer portion of the spindle (not illustrated) has been removed, preferably by sawing, so that a relatively smooth, uniform and undamaged cylindrical open end  218  of the axle  210  adjacent the machined outer surface  212  remains. The alternate mounting assembly  200  mounts on the machined outer surface  212 . 
         [0053]    The alternate mounting assembly  200  is essentially a ring split along a diameter and includes a first, semi-circular section  220  and a substantially identical second, semi-circular section  240 . Because the first section  220  and the second section  240  are substantially identical, only the first section  220  will be fully described, as will the differences between the first section  220  and the second section  240 . As illustrated in  FIG. 10 , the first section  220  defines a center, semi-circular opening  222  having a curved inner wall  224  which includes a pair of spaced apart, curved, inwardly extending lugs or projections  226 . The pair of lugs or projections  226  are preferably disposed at angles of 30° from the split and facilitate secure mounting on an axle  210  that may be slightly out of round. Spaced in a bolt circle about the center opening  222  are a plurality of threaded openings  232 . Inboard of the ends of the first section  220 , adjacent the split, are tangentially oriented threaded openings  234 . 
         [0054]    The second, semi-circular section  240  also defines a center, semi-circular opening  222  having a curved inner wall  224  which includes a pair of spaced apart, curved, inwardly extending lugs or projections  226 . The pair of lugs or projections  226  are also preferably disposed at angles of 30° from the split and facilitate secure mounting on an axle  210  that may be slightly out of round. Spaced in a bolt circle about the center opening  222  are a plurality of threaded openings  232 . Inboard of the ends of the second section  240 , adjacent the split, are tangentially oriented openings  254  which, when the first and second sections  220  and  240  are assembled, aligns with the threaded openings  234 . A pair of cap screws  256  or similar fasteners may be inserted into the openings  254  and into the threaded openings  234  and tightened to secure the alternate mounting assembly  200  to the outer machined surface  212  of the damaged axle  210 . 
         [0055]    Referring now to  FIG. 11 , an adapter plate  260  is shown in position on the assembled and mounted alternate mounting assembly  200 . The adapter plate  260  includes a large center opening  262  which accommodates the boring bar  172  and an array of arcuate slots  264  disposed about the center opening  262 . The arcuate slots  264  generally align with the threaded openings  232  in the first, semi-circular section  220  and the second, semi-circular section  240  when it is clamped on an axle  210  as illustrated and allow limited rotation relative to the alternate mounting assembly  200 . A plurality of machine bolts  266  extending through the arcuate slots  264  and into the threaded openings  232  may be utilized to secure the adapter plate  260  to the alternate mounting assembly  200 . The adapter plate  260  also includes a bolt circle of through openings  268  which may receive threaded fasteners  76  (illustrated in  FIG. 4 ) such as machine bolts which, with nuts  78  (also illustrated in  FIG. 4 ), secure the adapter plate  260  to the adjusting base  70  (also illustrated in  FIG. 4 ). 
         [0056]    Referring now to  FIG. 12 , a first embodiment of an axle repair method is illustrated. The axle  10  which has had a damaged portion (not illustrated) removed includes the spider plate  12  and an undamaged cylindrical open end  18  which has been bored out to a desired diameter with the apparatus and according to the method described above. A replacement spindle  280  having an inner bearing surface  282 , an outer bearing surface  284  and a threaded terminal portion  286  includes an elongate cylindrical portion  288 , preferably having the same outside diameter as the inner bearing surface  282 . Disposed about this cylindrical portion  288  is a seal ring  290  which is retained thereon by an interference fit subsequent to heating to approximately 350° F. to 400° F. (177° to 204° C.) and placement on the cylindrical portion  288  of the spindle  280 . This and the other interference fits described below are standard practice interference fits and, given the sizes of the components generally utilized, will be in the approximate range of 0.003 inches to 0.008 inches. It should be appreciated that as an alternative to the separate spindle  280  and seal ring  290 , these components may be fabricated as a single component, so that the spindle  280  includes the seal ring  290 , by, for example, forging. 
         [0057]    The seal ring  290  includes an oil seal surface  292  and extends approximately from the inboard end of the spindle  280  to proximate the inner edge of the inner bearing surface  282 . The outside diameter of the seal ring  290  is several thousandths of an inch greater than the bored, inside diameter of the axle  10 . The spindle  280  and the seal ring  290  are secured to the axle  10  by, first of all, an interference fit which is achieved by heating the axle to approximately 350° to 400° F. and placement of the spindle  280  and the seal ring  290  into the open end  18  of the axle as shown in  FIG. 12 . Next, a circumferential weld bead  294  is placed about the seal ring  290  at the corner formed by the oil seal surface  292  and the end  18  of the axle  10 . Finally, a single opening  296  at the top of the axle  10  or a pair of openings  297  in both sides of the axle  10  outboard of the spider plate  12  at approximately the 10 o&#39;clock and 2 o&#39;clock positions, i.e., approximately 60° off the vertical, are ground or cut into the axle  10  and on or a pair of plug welds  298  are installed which extend between and secure the seal ring  290  to the axle  10 . 
         [0058]    Referring now to  FIG. 13 , a second embodiment of an axle repair method is illustrated. Once again, a damaged portion (not illustrated) has been removed from the axle  10  which includes the spider plate  12  and the undamaged cylindrical open end  18  and the axle  10  have been bored out to a desired diameter with the apparatus and according to the method described above. A replacement spindle  300  having an inner bearing surface  302 , an outer bearing surface  304  and a threaded terminal portion  306  includes an elongate cylindrical portion  308 , preferably having the same outside diameter as the inner bearing surface  302 . Disposed about the cylindrical portion  308  is a seal ring  310  which is retained thereon by an interference fit subsequent to heating to approximately 350° to 400° F. and placement on the cylindrical portion  308  of the spindle  300 . 
         [0059]    The seal ring  310  includes an oil seal surface  312  and extends approximately from the inner edge of the inner bearing surface  302  to the outer edge of the spider plate  12 . An annular sleeve or liner  314  is disposed about the inner end of the spindle  300  and secured there by inner and outer circumferential welds  316 . As an alternative construction, it should be appreciated that the separate spindle  300 , the seal ring  310  and the liner  314  may be fabricated as a single component, so that the spindle  300  includes the seal ring  310  and the liner  314 , by, for example, forging. The outside diameter of the sleeve or liner  314  is slightly larger than the bored inside diameter of the axle  10 . Once again, the axle  10  is heated to approximately 350° to 400° F. and the spindle  300 , the seal ring  310  and the sleeve  314  are inserted into the open end  18  of the axle  10 . Next, a circumferential weld bead  318  is placed about the seal ring  310  at the end of the axle  10  and finally a single opening  322  is ground or cut at the top of the axle  10  or a pair of openings  323  are ground or cut into the axle  10  at the 10 o&#39;clock and 2 o&#39;clock positions in line with the annular sleeve or liner  314  and one or a pair of plug welds  324 , extending between the axle  10  and the sleeve or liner  314  are installed. 
         [0060]    Referring now to  FIG. 14 , a third embodiment of an axle repair method is illustrated. Once again, a damaged portion (not illustrated) has been removed from the axle  10  which includes the spider plate  12  and the undamaged cylindrical open end  18  and the axle  10  have been bored out to a desired larger inside diameter 328 with the apparatus and according to the method described above. Due to the nature and extent of material removal, multiple passes of the boring bar  172  are preferred such as at least a rough cut and a finish cut. A replacement spindle  330  having an inner bearing surface  332 , an outer bearing surface  334  and a threaded terminal portion  336  includes an elongate cylindrical portion  338 , preferably having the same outside diameter as the inner bearing surface  332 . Disposed about this cylindrical portion  338  is a seal ring  340  which is retained thereon by an interference fit subsequent to heating it to approximately 350° to 400° F. and placement on the cylindrical portion  338  of the spindle  330 . A circumferential weld bead  342  is placed between the inner end of the spindle  330  and the seal ring  340 . As an alternative construction, it should be appreciated that the separate spindle  330  and seal ring  340  may be fabricated as a single component, so that the spindle  330  includes the seal ring  340  by, for example, forging. 
         [0061]    The seal ring  340  includes an oil seal surface  344  and extends approximately from the inner edge of the inner bearing surface  332  to at least the inner edge of the spider plate  12 . The outside diameter of the seal ring  340  is slightly smaller than the bored inside diameter 328 of the axle  10 . Once again, the axle  10  is heated to approximately 350° to 400° F. and the spindle  330  and the seal ring  340  are inserted into the open end  18  of the axle  10 . Last of all, a circumferential weld bead  346  is placed about the seal ring  340  at the end of the axle  10 . 
         [0062]    The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. For example, it should be appreciated and understood that diverse automatic and manual boring and drilling equipment as well as cutting tools and cutting technologies may be readily used with the mounting devices and repair methods of the present invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Technology Classification (CPC): 8