Abstract:
An adjustable boring bar wherein the adjustment of the cutting end is provided by a prestressed internal bar bearing against the cutting end to selectively distort the boring bar in the direction of the cutting bit to compensate for wear. The adjustment is by means of rotation of the prestressed internal bar to direct the pressure of the internal bar against the boring bar and cutting bit in the desired direction.

Description:
Continuation of Ser. No. 814,941 filed Dec. 30, 1985, now abandoned. 
    
    
     CROSS-REFERENCE TO RELATED APPLICATIONS 
     Patent applications: Ser. No. 814,939, now abandoned, entitled &#34;Adjustable Boring Bar&#34; Ser. No. 814,940, now abandoned, entitled &#34;Fixed Beam Adjustable Boring Bar&#34; and Ser. No. 814,468, now abandoned, entitled &#34;Excentric Beam Mounting&#34; each in the name of Robert F. Cusack are filed concurrently herewith on related subject matter and assigned to the same assignee as the present invention. 
     FIELD OF THE INVENTION 
     This invention generally relates to machine tools and more particularly to a new and improved adjustable boring bar for use during a machining operation. 
     BACKGROUND OF THE INVENTION 
     Within the field of machining and more specifically precision boring of holes there is a need for a reliable, rigid, simple, and micro adjustable boring bar. There are numerous examples of attempts to provide precision adjustment but most are complex and inherently weaken the fundamental rigidity of the tool to accommodate their means of adjustment, such as gears and complex bearings. There are also examples of units that provide an adjustable bore size but lack the fine adjustment required to compensate for tool wear. This fine adjustment capability is increasingly important in today&#39;s ultra precise machining requirements. 
     SUMMARY OF THE INVENTION 
     This invention addresses these requirements in a most efficient manner. It basically includes the usual provision for attachment to a machine appropriately bored out, forming a thick walled, closed end tube. This tube maybe either machined as one piece with the adapter or be attached to a separate adapter. The closed end of the tube includes a provision for attaching a suitable cutting device (i.e. indexible tungsten carbide insert). This provision may consist of utilizing existing sizing heads such as are commercially available. When used, these tools would have the appropriate standard means of attachment to the nose of the boring bar. Adjustment of the closed end of the boring bar including the cutting tool is provided by the combination of a prestressed bar within the bore of the closed end tube and an arrangement for rotating the bar to direct the force of the stressed bar in the proper direction to advance to the nose of the bar. 
     The lateral force is preferably provided in discrete or measurable increments by only incrementally rotating the bar. The flexible bar is supported at each end within the tube. The supports are to position the bar in the axial center of the bar. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The object and features of this invention and the manner of obtaining them will become more apparent, and the invention itself will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings in which: 
     FIG. 1 shows a sectional perspective view of a first embodiment of the invention. 
     FIG. 2 shows a sectional perspective view of the prestressed bar; 
     FIG. 3 is a perspective view of the exterior of the embodiment of FIG. 1. of the invention. 
     FIG. 4 shows the path taken by the cutting bit as the prestressed bar is rotated; 
     FIG. 5 shows a sectional perspective view of an alternate arrangement for the adjustment of the prestressed bar. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIG. 1 there is shown a toolholder of generally cylindrical form having a shank or adapter portion 10 which is adapted to be mounted in the shank receiving socket of a powered conventional spindle. The shank of the adapter is tapered and includes a threaded bore 11 therein for receiving a mator driven screw (not shown). The adapter further includes a flange portion 12 with an annular ring for engaging drive keys (not shown). Extending from the neck 13 is the tool bit 15 holding bar 14. The cutting bit 15 is adapted to be seated in a pocket in the tool end and retained therein by conventional means. 
     The bore 16 extends beyond the threaded portion 11 through the shank portion 10 into the tool bit holding bar 14. Within this bore 16 is located a steel bar 17 of a diameter smaller than the diameter of the bore 16. This bender bar 17 is bowed during manufacture to exert the desired reactive force at its terminal ends upon attempts to return it to a straight form. A set of bearings 18, 19 and 20 located at the bit end of the bar, the adapter end and the approximate center of the bar respectively. The bearings 18, 19 and 20 serve to locate the axis of the bar 17 along the axis of the toolholder bar. 
     With the prestressed bar 17 thus positioned within the bore 16 of the boring bar, the tool bit holding end 14 carving the bit 15 is twisted or bent in the direction the force of the bend of the bar 17. The track of the obtainable positions of the end of the boring bar and its bit 15 is illustrated in FIG. 4. To facilitate rotation of the bar 17 a key hole 21 may be used. Thus a hex key (not shown) may be inserted from the adapter end in through the base 11 into the key way to rotate the bar to obtain the desired bit position. 
     An alternate arrangement for facilitating the rotation of the bar 17 is shown in FIG. 5. In this figure is shown a passage 23 drilled into the tool bit holding end of the boring bar 14. The end of the prestressed bar 17 is then accessible through this drilled passage. This accessible end of the bar 17 is then provided with a key hole 22 similar to that shown in FIG. 2 whereby the bar may be rotated. Index marks may be provided as shown to facilitate repeatable positioning. 
     The basic principle of operation is as follows: The bender bar 17 as it is rotated axially translates approximately 50% of the available force to each of its end points, if the bearing 20 is centrally positioned on the bender bar. Other ratios may be used as may be required for appropriate applications. Example: a short or an extra long bar. Since the adapter 10 side is essentially rigid with respect to the boring bar 14 it provides a stable reference with respect to the machine tool. As the bender bar 17 is turned, the portion of its force at the end is applied to its point of contact via the bearing 18 within the boring bar 14. This force urges the boring bar in the direction of the force according to the standard principle, of beam loading and bending such as referenced in Marks Standard Handbook to Mechanical Engineers &amp; Machineries Handbook. 
     The available force of the central bender bar being fixed results in a fixed distance the boring bar 14 is displaced from its true axial position. However, since the bar 17 may be rotated, the direction of bending of the entire boring bar assembly can be controlled. As shown on FIG. 4 this rotation can be translated into the desired distance of displacement of the tool tip. This rotation provides the means for the ultra fine resolution of adjustment of this system while providing a remarkable range of displacement. 
     As an example a bar has been constructed as per FIG. 1. The essential dimensions are as follows: This boring bar is essentially 8 inches long with the section including the neck 13 back being of approximately a 2 inch diameter by 4 inches long with section 14 being of 1 inch diameter and 4 inches long. The entire bar is bored to a 0.625 in diameter about its entire length. It is assumed for simplicity that the 2 inch diameter section is relatively inflexible with respect to the 1 inch diameter section. 
     The boring bar is pretensioned to the maximum deflection for the boring bar with a safe stress limit of 120,000 psi. 
     The maximum deflection (F) for the boring bar with a safe stress (S) limit of 120,000 psi is: ##EQU1## F=Deflection in inches W=Force in pounds 
     S=Stress in pounds/square inch 
     L=Length 
     h=Height 
     E=Youngs modules (30,000,000 P.S.I. for steel) 
     I=Moment of inertia 
     D=Outside diameter 
     d=Inside diameter 
     The moment of inertia of a one inch outside diameter 0.625 inside diameter bar equals: 
     
         I=0.049 (DR4-dR4) 
    
     
         I=0.049 (1.sup.4-0.6254) 
    
     
         I=0.04152 
    
     Keeping the stress to a very conservative 10% maximum the force required to deflect the bar 0.009&#34; is ##EQU2## 
     The central 1/2 inch diameter bar in this example can safely produce a 536 lb. force at each end with a displacement at its center of 0.122 inches. This means that for each 0.001 inch of displacement on the center of the bender bar the tool tip is urged ##EQU3## 
     Thus the central displacement required to produce a 0.000010 inch tool tip displacement is 10/74×0.001=0.000135 inches. This corresponds to an approx. 1.36 degree increment on a 1/4-28 pitch adjusting screw. That is for each 1.36 degress of rotation on the adjusting screw the tool tip will advance 10 micro inches. 
     It can be appreciated by those trained in the art that the specific cross sections and internal geometry&#39;s must be dictated by the design requirements of each type of bar. 
     It should be understood that the foregoing description contains a specific example of various features of this invention which may be used individually if desired but when combined cooperate to provide an extremely easy and precisely adjustable boring bar construction. Various modifications of the specifically illustrated examples will become apparent those skilled in the art upon a study of the specification, drawings and the following claims.