Floating insert removal tool

A removal tool comprising:

• a shaft having a first end, a second end, and an axis extending through the shaft in which the second end of the shaft is configured to be attached to a drill;
• a cutter associated with the shaft and having a first channel configured to receive the first end of the shaft and a portion of the shaft in which the cutter comprises a cylinder;
• a plurality of blades;
• and slots between the plurality of blades in which the slots are configured to have a length greater than a depth of a plastic insert having a movable metal nut within an opening in the plastic insert and the slots have a shape configured to remove debris generated by the cutter cutting the plastic insert and in which the cutter is removably attached to the shaft;
• a sleeve configured to move along the axis within the first channel of the cutter and having a second channel configured to receive the first end of the shaft and the portion of the shaft and configured to be biased away from the second end of the shaft, wherein the first end of the shaft has a flange configured to retain the first end of the shaft within the second channel of the sleeve;
• and
• a biasing system configured to apply a force on the sleeve in a direction along the axis away from the second end of the shaft, wherein the biasing system comprises a spring having a first end and a second end in which the first end of the spring contacts the base portion of the shaft and the second end of the spring contacts a second end of the sleeve in which the base portion of the shaft has a first engagement feature and the cutter has a second engagement feature at a first end of the cutter and the plurality of blades at a second end of the cutter, and the first engagement feature and the second engagement feature engage each other to retain the cutter on the shaft.

A method for removing an insert, the method comprising:

• positioning a removal tool relative to the insert;
• and
• rotating the removal tool to cut the insert,
• wherein the removal tool comprises:
• a shaft having a first end, a second end, a base portion, and an axis extending through the shaft;
• a cutter associated with the shaft and having a first channel configured to receive the first end of the shaft and a portion of the shaft;
• a sleeve configured to move along the axis within the first channel of the cutter and having a second channel configured to receive the first end of the shaft and the portion of the shaft and configured to be biased away from the second end of the shaft;
• and
• a biasing system configured to apply a force on the sleeve in a direction along the axis away from the second end of the shaft such that a first end the sleeve engages a plastic insert while the cutter moves in the direction along the axis, wherein the biasing system comprises a spring having a first end and a second end in which the first end of the spring contacts the base portion of the shaft and the second end of the spring contacts a second end of the sleeve,
• wherein the first end of the shaft has a flange configured to retain the first end of the shaft within the second channel of the sleeve, and
• wherein a base portion of the shaft has a first engagement feature, the cutter has a second engagement feature at a first end of the cutter and a plurality of blades at a second end of the cutter, and the first engagement feature and the second engagement feature engage each other to retain the cutter on the shaft.

A method for removing a plastic insert with a movable metal nut from a composite panel, the method comprising:

• positioning a removal tool relative to the plastic insert in which the removal tool comprises a shaft having a first end, a second end, and an axis extending through the shaft in which the second end of the shaft is configured to be attached to a drill;
• a cutter associated with the shaft and having a first channel configured to receive the first end of the shaft and a portion of the shaft in which the cutter comprises a cylinder, a plurality of blades, and slots between the plurality of blades in which the slots are configured to have a length greater than a depth of the plastic insert with the movable metal nut and the slots have a shape configured to remove debris generated by the cutter cutting the plastic insert and in which the cutter is removably attached to the shaft;
• a sleeve configured to move along the axis within the first channel of the cutter and having a second channel configured to receive the first end of the shaft and the portion of the shaft and configured to be biased away from the second end of the shaft in which the first end of the sleeve is configured to engage the plastic insert while the cutter rotates against the plastic insert and in which the first end of the shaft has a flange configured to retain the first end of the shaft within the second channel of the sleeve;
• and a biasing system configured to apply a force on the sleeve in a direction along the axis away from the second end of the shaft such that a first end the sleeve engages a plastic insert while the cutter moves in the direction along the axis, wherein the biasing system comprises a spring having a first end and a second end in which the first end of the spring contacts the base portion of the shaft and the second end of the spring contacts a second end of the sleeve;
• rotating the removal tool to cut the plastic insert;
• and
• stopping rotation of the removal tool after the plastic insert becomes separated from the composite panel.