Monolithic precursor test coupons for testing material properties of metal-injection-molded components and methods and apparatuses for making such coupons

Patent metadata

Field	Value
Publication number	US-12233469-B2
Application number	US-202117457201-A
Country	US
Kind code	B2
Filing date	Dec 1, 2021
Priority date	May 29, 2019
Publication date	Feb 25, 2025
Grant date	Feb 25, 2025

Abstract

A method of removing flash from a gauge portion of a monolithic precursor test coupon using a flash-removal tool is provided. The flash-removal tool comprises a tool body, extending along a longitudinal tool axis, a tooth, and an engagement surface, spaced apart from the tooth along the longitudinal tool axis. The tooth projects from the tool body in a first direction and comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction. The method comprises steps of coupling the engagement surface of the flash-removal tool against a first precursor-coupon end of the monolithic precursor test coupon, orienting the longitudinal tool axis parallel to a longitudinal symmetry axis of the monolithic precursor test coupon, wherein the shearing surface registers longitudinally with the flash, and shearing, using the shearing surface, the flash from the gauge portion.

First claim

The invention claimed is:

1. A method of removing flash from a gauge portion of a monolithic precursor test coupon using a flash-removal tool, the flash-removal tool comprising a tool body, extending along a longitudinal tool axis, a tooth, and an engagement surface, spaced apart from the tooth along the longitudinal tool axis, wherein the tooth projects from the tool body in a first direction and comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction, and wherein the first direction and the second direction are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis, the method comprising steps of:
coupling the engagement surface of the flash-removal tool against a first precursor-coupon end of the monolithic precursor test coupon;
orienting the longitudinal tool axis parallel to a longitudinal symmetry axis of the monolithic precursor test coupon, wherein the shearing surface aligns with the flash; and
shearing, using the shearing surface, the flash from the gauge portion,
wherein the flash-removal tool further comprises a second tooth, and wherein the longitudinal tool axis is located between the tooth and the second tooth,
wherein the step of shearing the flash from the gauge portion comprises shearing a first one of the portions of the flash with the tooth and a second one of the portions of the flash with the second tooth,
wherein the monolithic precursor test coupon further comprises a first grip portion, a second grip portion, an intermediate portion, interconnecting the first grip portion and the second grip portion, and runners, directly interconnecting the first grip portion and the second grip portion and not directly connected to the intermediate portion; and
wherein the intermediate portion comprises the gauge portion.

2. The method according to claim 1 , wherein:
the step of orienting the longitudinal tool axis parallel to the longitudinal symmetry axis of the monolithic precursor test coupon comprises positioning the shearing surface at a radial distance from the longitudinal symmetry axis; and
the flash projects radially from a surface of the gauge portion beyond the radial distance.

3. The method according to claim 1 , further comprising inserting the tool body between two of the runners.

4. The method according to claim 1 , wherein:
the step of orienting the longitudinal tool axis parallel to the longitudinal symmetry axis of the monolithic precursor test coupon comprises circumferentially spacing the shearing surface away from the flash; and
the step of shearing the flash comprises rotating the tool body about the longitudinal symmetry axis such that the shearing surface moves circumferentially toward, and contacts, the flash.

5. The method according to claim 4 , wherein:
the flash has portions each radially aligned with a respective one of the runners, and
the step of rotating the tool body comprises shearing one of the portions of the flash before the tool body contacts the respective one of the runners.

6. The method according to claim 1 , wherein the flash has portions each radially aligned with a respective one of the runners.

7. A method of removing flash from a gauge portion of a monolithic precursor test coupon using a flash-removal tool, the flash-removal tool comprising a tool body, extending along a longitudinal tool axis, a tooth, and an engagement surface, spaced apart from the tooth along the longitudinal tool axis, wherein the tooth projects from the tool body in a first direction and comprises a shearing surface, facing in the first direction and located an offset distance away from the longitudinal tool axis in a second direction, and wherein the first direction and the second direction are orthogonal to each other and define a plane, perpendicular to the longitudinal tool axis, the method comprising steps of:
coupling the engagement surface of the flash-removal tool against a first precursor-coupon end of the monolithic precursor test coupon;
orienting the longitudinal tool axis parallel to a longitudinal symmetry axis of the monolithic precursor test coupon, wherein the shearing surface aligns with the flash; and
shearing, using the shearing surface, the flash from the gauge portion,
wherein the flash-removal tool further comprises a positioning groove defined in the tool body, the positioning groove extending longitudinally between the engagement surface and the tooth; and
wherein the step of orienting the longitudinal tool axis parallel to the longitudinal symmetry axis of the monolithic precursor test coupon comprises a step of receiving a portion of the monolithic precursor test coupon in the positioning groove.

8. The method according to claim 7 , wherein the step of coupling the engagement surface of the flash-removal tool against the first precursor-coupon end comprises coupling a longitudinal end-wall of the positioning groove against the first precursor-coupon end of the monolithic precursor test coupon.

9. The method according to claim 7 , wherein:
the monolithic precursor test coupon further comprises a first grip portion, a second grip portion, and an intermediate portion interconnecting the first grip portion and the second grip portion;
the intermediate portion comprises the gauge portion;
the positioning groove comprises a cylindrically contoured portion, extending parallel to the longitudinal tool axis; and
the step of receiving the portion of the monolithic precursor test coupon in the positioning groove comprises coupling the cylindrically contoured portion of the positioning groove against the first grip portion.

10. The method according to claim 9 , wherein:
the positioning groove further comprises a tapered portion extending between the cylindrically contoured portion and the tooth; and
the step of receiving the portion of the monolithic precursor test coupon in the positioning groove further comprises coupling the tapered portion of the positioning groove against the intermediate portion.

11. The method according to claim 7 , wherein:
the flash-removal tool further comprises a secondary groove, defined in the tool body;
the tooth divides the tool body longitudinally into two sides;
the positioning groove extends longitudinally on one of the two sides;
the secondary groove extends longitudinally on another of the two sides and faces in the first direction; and
the step of orienting the longitudinal tool axis parallel to the longitudinal symmetry axis of the monolithic precursor test coupon further comprises receiving an additional portion of the monolithic precursor test coupon in the secondary groove.

12. The method according to claim 11 , wherein:
the monolithic precursor test coupon further comprises a first grip portion, a second grip portion, and an intermediate portion interconnecting the first grip portion and the second grip portion;
the secondary groove comprises a cylindrically contoured secondary portion, extending parallel to the longitudinal tool axis; and
the step of receiving the additional portion of the monolithic precursor test coupon in the secondary groove comprises coupling the cylindrically contoured secondary portion of the secondary groove against the second grip portion.

13. The method according to claim 12 , wherein:
the secondary groove further comprises a tapered secondary portion extending between the cylindrically contoured secondary portion and the tooth; and
the step of receiving the additional portion of the monolithic precursor test coupon in the secondary groove further comprises coupling the ta

Assignees

• Boeing Co

Inventors

• Pecina Joseph A
• Backhaus Gary M

Classifications

• B23D79/021 Primary

  for removing welding, brazing or soldering burrs, e.g. flash, on pipes or rods · CPC title

• B23D79/023 Primary

  internally · CPC title