Novel composite tool holders and boring tools
OwnerGregory J. Kay, Richard Theriault +1inventors
InventorsGregory J. Kay, Richard Theriault, Lawrence Schoenleber
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Abstract
Tool bars that are manufactured as a composite, that is, layered devices. The tool bars can have a solid core, covered with a wrapped composite material, and then optionally covered with a metal sleeve. The tool bars are provided with high strength, improved stiffness over prior art tool bars, high density, low coefficient of thermal expansion, high damping capacity, improved rigidity, improved damping, less chatter and vibration, improved work piece tolerance, improved surface finish, increased speed/fee rates, and low production cost.
Claims52
A mandrel stem useful in boring tools, said mandrel stem being manufactured from the group consisting of:
- a. metal,
- b. ceramic, and
- c. plastic,
- wherein the mandrel stem is covered with a wrapped composite material.
A composite tool holder comprising:
- a solid steel rod having a predetermined outside diameter, said solid steel rod having a center segment, a first end segment, and a second end segment, the first end segment being capable of being converted to a tool head, the second end segment being capable of being converted to a tool tail, said center segment having a lesser diameter than the first end segment and the second end segment and said center segment being covered with a cured wrapped composite material.
A mandrel stem comprising a solid steel rod, said steel rod having a first end and a second end, wherein the first end is capable of being affixed to a solid steel head and the second end is capable of being affixed to a solid steel tail, wherein the solid steel rod is covered with a cured wrapped composite material.
The composite tool holder as claimed in claim 67 wherein there is a portion of the first end segment that is tapered down from the predetermined outside diameter to the diameter of the center segment of the solid steel rod and a portion of the second end segment is not tapered down from the predetermined outside diameter of the solid steel rod to the diameter of the center segment of the solid steel rod and the center segment of the solid steel rod and the tapered down portion of the first end segment are covered with a cured wrapped composite material.
The composite tool holder comprising:
- a solid steel rod having a predetermined outside diameter, said solid steel rod having a center segment, a first end segment, and a second end segment, the first end segment having a butt end, which butt end is smaller in diameter than the outside diameter of the first end segment, the second end segment having a front end, which front end is smaller in diameter than the outside diameter of the second end segment,
- the first end segment being capable of being converted to a tool head, the second end segment being capable of being converted to a tool tail, said center segment having a lesser diameter than the butt end of the first end segment and the front end of the second end segment and said center segment, the center segment, the butt end of the first end segment and the front end of the second end segment being covered with a cured wrapped composite material.
A method of manufacturing a boring bar, said method comprising
- A. providing a solid steel bar having a predetermined thickness and a predetermined length;
- B. removing metal from the solid metal bar to provide a metal mandrel stem having a predetermined thickness while leaving a portion of the solid metal bar to provide a boring head;
- C. milling the boring head to provide desired features into the boring head;
- D. wrapping the metal mandrel stem with an uncured composite material precursor in a predetermined thickness and thereafter curing the uncured composite material.
A method for manufacturing a composite tool holder, said method comprising:
- A. providing a first solid steel rod having a predetermined thickness and a predetermined length as a basis for a boring head, said solid steel rod having a back end;
- B. providing a centered opening in the back end of the first solid steel rod at a predetermined depth;
- C. providing a second rod having a predetermined length and a thickness less than the thickness of the first solid steel rod to provide a mandrel stem;
- D. inserting one end of the second steel rod into the centered opening in the back of the first solid steel rod and coupling the first solid steel rod and second solid steel rod together,
- E. milling the first solid steel rod to provide a boring head having desired features, said coupling of the steel boring head and the mandrel stem being achieved by a method selected from the group consisting of:
- (a) heat shrinking one end of the mandrel stem into a centered opening in the back end of the boring head;
- (b) heat pressing one end of the mandrel stem into a centered opening in the back end of the steel boring head;
- (c) threading one end of the mandrel stem into a centered opening in the back end of the steel boring head wherein the boring head centered opening has the inner diameter threaded and the outer diameter of one end of the mandrel stem is threaded to accommodate the inner diameter threads;
- (d) chemical adhesive bonding, and
- (e) vacuum assisted chemical adhesive bonding;
- (f) wrapping the second solid steel rod with a composite material.
A tool bar including:
- (A) a steel adaptor constructed to be coupled to a driving device;
- (B) a central body, and
- (C) a steel head;
- the metal adaptor, central body and metal head being coupled together in a linear axis;
- the central body being manufactured from a mandrel stem at the center, surmounted by a wrapped composite material.
Dependencies are inferred from the claim text.