Methods and systems for forming aligned holes

Patent metadata

Field	Value
Publication number	US-9573209-B2
Application number	US-201414497278-A
Country	US
Kind code	B2
Filing date	Sep 25, 2014
Priority date	Sep 25, 2014
Publication date	Feb 21, 2017
Grant date	Feb 21, 2017

Abstract

In one embodiment, a method for forming a pair of aligned holes is provided. The method comprises determining a diameter of a cleanup hole associated with a plurality of misaligned holes, in which the cleanup hole diameter may also correspond to a fastener diameter. Additionally, a tapered reamer is at least partially inserted into a gap defined by the plurality of misaligned holes. The tapered reamer has a longitudinal axis and may be configured such that the longitudinal axis aligns with a center of the cleanup hole when the tapered reamer is inserted into the gap defined by the plurality of misaligned holes. The plurality of misaligned holes may then be reamed with the tapered reamer to form the cleanup hole defined by the plurality of aligned holes having a same center and a same diameter.

First claim

What is claimed is:

1. A method for forming a plurality of aligned holes, the method comprising:
determining a diameter of a cleanup hole associated with a plurality of misaligned holes, the cleanup hole diameter corresponding to a fastener diameter;
at least partially inserting a tapered reamer into a gap defined by the plurality of misaligned holes, the tapered reamer having a longitudinal axis and configured such that the longitudinal axis aligns with a center of the cleanup hole when the tapered reamer is inserted into the gap defined by the plurality of misaligned holes;
reaming the plurality of misaligned holes with the tapered reamer to form the cleanup hole defined by the plurality of aligned holes having a same center and a same diameter.

2. The method of claim 1 , wherein the step of determining a diameter of a cleanup hole further includes the steps of:
inserting a step gage into the gap defined by the plurality of misaligned holes, the step gage including at least a first section having a first diameter and a second section having a second diameter smaller than the first diameter, the first diameter corresponding to a first cleanup hole diameter and the second diameter corresponding to a second cleanup hole diameter larger than the first cleanup hole diameter; and
determining the diameter of the cleanup hole based on whether one or more of the first and second sections fit within the gap.

3. The method of claim 2 , wherein the step of reaming the plurality of misaligned holes further comprises reaming the plurality of misaligned holes to form the cleanup hole having a first cleanup hole diameter, wherein the first cleanup hole diameter allows a first standard fastener to be inserted through the cleanup hole.

4. The method of claim 2 , wherein the step of reaming the plurality of misaligned holes further comprises reaming the plurality of misaligned holes to form the cleanup hole having a second cleanup hole diameter, wherein the second cleanup hole diameter allows a first oversized fastener to be inserted through the cleanup hole.

5. A method for forming aligned holes, the method comprising:
inserting a step gage into a gap defined by misaligned holes, the step gage including at least a first section having a first diameter and a second section having a second diameter smaller than the first diameter, the first diameter corresponding to a first cleanup hole diameter and the second diameter corresponding to a second cleanup hole diameter larger than the first cleanup hole diameter;
when the first section fits through the gap, determining that a virtual hole diameter of the misaligned holes corresponds to a first standard fastener diameter, wherein a first standard fastener has the first standard fastener diameter; and
when the first section does not fit through the gap and the second section does fit through the gap:
determining that the virtual hole diameter of the gap is smaller than the first standard fastener diameter; and
using a tapered reamer to form a second cleanup hole centered on a virtual hole associated with the virtual hole diameter, wherein the diameter of the second cleanup hole allows a first oversized fastener to be inserted through the second cleanup hole.

6. The method of claim 5 , wherein the step gage further includes a third section having a third diameter smaller than the second diameter and a fourth section having a fourth diameter smaller than the third diameter, the third diameter corresponding to a third cleanup hole diameter larger than the second cleanup hole diameter and the fourth diameter corresponding to a fourth cleanup hole diameter larger than the third cleanup hole diameter, the method further comprising:
when the third section fits through the gap and the first and second sections do not fit through the gap:
determining that the virtual hole diameter of the gap defined by the misaligned holes corresponds to a third cleanup hole diameter;
using the tapered reamer to form an initial cleanup hole having the diameter of the second cleanup hole centered on the virtual hole associated with the virtual hole diameter; and
using a first standard reamer to form a third cleanup hole having the third cleanup hole diameter centered on the geometric center of the initial cleanup hole, wherein the third cleanup hole diameter allows a second oversized fastener to be inserted through the third cleanup hole; and
when the fourth section fits through the gap and the first, second, and third sections do not fit through the gap:
determining that the virtual hole diameter of the gap corresponds to a fourth cleanup hole diameter;
determining that a fourth cleanup hole having the fourth cleanup hole diameter centered on the virtual hole associated with the virtual hole diameter is appropriate, wherein the fourth cleanup hole diameter allows a second standard fastener to be inserted through the fourth cleanup hole.

7. The method of claim 6 , wherein upon determining that the fourth section fits within the gap and that the first, second, and third sections do not:
forming the fourth cleanup hole centered on the virtual hole associated with the virtual hole diameter.

8. The method of claim 7 , wherein the step of forming the fourth cleanup hole further comprises the steps of:
using the tapered reamer to form an initial cleanup hole having the diameter of the second cleanup hole centered on the virtual hole associated with the virtual hole diameter;
using the first standard reamer to form the third cleanup hole having the third cleanup hole diameter centered on the geometric center of the initial cleanup hole
using a second standard reamer to form the fourth cleanup hole having the fourth cleanup hole diameter centered on the geometric center of the third cleanup hole.

9. The method of claim 7 , wherein the step of forming the fourth cleanup hole further comprises the step of:
using a second standard reamer and a jig to form the fourth cleanup hole having the fourth cleanup hole diameter centered on the virtual hole associated with the virtual hole diameter.

10. The method of claim 5 , wherein the step of using a tapered reamer further comprises the step of centering the reamer on the misaligned holes without the use of a jig.

11. A system for forming aligned holes, the system comprising:
a step gage configured to be inserted through a gap defined by misaligned holes to determine a diameter of a cleanup hole, said step gage comprising:
a first section having a first diameter corresponding to a first cleanup hole diameter; and
a second section having a second diameter corresponding to a second cleanup hole diameter larger than the first cleanup hole diameter, the first and second sections being connected and extend in series along a longitudinal axis of the step gage; and

a tapered reamer having a longitudinal axis and configured such that the longitudinal axis aligns with a center of the cleanup hole when the tapered reamer is at least partially inserted into the gap defined by the misaligned holes.

12. The system of claim 11 , wherein the step gage further comprises at least a third section and a fourth section which correspond to a third cleanup hole diameter and a fourth cleanup hole diameter, respectively.

13. The system of claim 11 , wherein said tapered reamer comprises a tapered diameter section having a beginning diameter which is smaller than a final diameter, the tapered diameter section tapering from the final diameter to the beginning diameter at an angle of between about 0.5 degrees and about 1.0 degrees per side.

14. A system for connecting at least two objects together, com

Assignees

• Boeing Co

Inventors

• Scheibel John P
• Scherer James L

Classifications

• G01B5/24

  for measuring angles or tapers; for testing the alignment of axes · CPC title

• B23P19/10

  Aligning parts to be fitted together · CPC title

• G01B5/08

  for measuring diameters {(G01B5/0035 takes precedence; measuring radius of curvature G01B5/213)} · CPC title

• F16B5/04

  by means of riveting (rivets F16B19/04) · CPC title

• B23D77/12 Primary

  Reamers with cutting edges arranged in tapered form · CPC title