Systems and methods for forming an opening in a stack

Patent metadata

Field	Value
Publication number	US-9643260-B2
Application number	US-201414160982-A
Country	US
Kind code	B2
Filing date	Jan 22, 2014
Priority date	Jan 22, 2014
Publication date	May 9, 2017
Grant date	May 9, 2017

Abstract

One aspect of the disclosure relates to a cutting tool for forming a final opening in a stack that includes at least two layers and a pilot opening having a pilot-opening dimension and extending through at least one of the at least two layers. The cutting tool includes a shank. The cutting tool also includes a first portion including at least one of a first coating or the first coating and a second coating, wherein the first coating at least partially covers the first portion. The cutting tool also includes a second portion between the shank and the first portion, wherein the second portion includes the second coating, and wherein the second coating at least partially covers the second portion.

First claim

What is claimed is:

1. A cutting tool for forming a final opening in a stack that includes at least two layers and a pilot opening having a pilot-opening dimension and extending through at least one of the at least two layers, the cutting tool comprising:
a shank;
a first portion including at least one of a first coating or a second coating, wherein the first coating at least partially covers the first portion, the first portion having a first side-surface diameter that is constant, the first portion including a first end surface, the first end surface being a flat disk, the first end surface covered with the first coating; and
a second portion interposed between the shank and the first portion along a longitudinal symmetry axis of the cutting tool, wherein the first portion and the second portion do not overlap along the longitudinal symmetry axis, wherein the second portion is contiguous with the first portion and the shank, wherein the second portion includes the second coating, and wherein the second coating at least partially covers the second portion, wherein all of the second portion has a second side-surface diameter that is constant and that is different from the first side-surface diameter.

2. The cutting tool of claim 1 , wherein:
the first portion further includes a first side surface, the first side surface having a maximum first side-surface diameter that is smaller than the pilot-opening dimension;
the second portion includes a second end surface and a second side surface, the second side surface having at least one second side-surface diameter that is greater than the maximum first side-surface diameter; and
the second coating includes a different material than the first coating, the second coating covering at least a portion of the second end surface.

3. The cutting tool of claim 2 , wherein the second portion is adjacent to the first portion, and wherein the second end surface is a substantially annular ring.

4. The cutting tool of claim 3 , wherein the first end surface includes a first end-surface cutting edge and the second end surface includes a second end-surface cutting edge.

5. The cutting tool of claim 1 , wherein the first coating has a higher wear resistance than the second coating.

6. The cutting tool of claim 1 , wherein the first coating comprises a diamond material.

7. The cutting tool of claim 6 , wherein the second coating comprises an AlCrN material.

8. The cutting tool of claim 1 , wherein the second portion is substantially devoid of the first coating.

9. The cutting tool of claim 1 , wherein the first coating and the second coating at least partially overlap along the first portion.

10. The cutting tool of claim 1 , wherein at least one of the first portion and the second portion includes a tapered surface.

11. The cutting tool of claim 10 , wherein the second coating substantially completely covers the first portion.

12. The cutting tool of claim 11 , wherein the second coating covers the first coating.

13. The cutting tool of claim 1 , wherein the first portion is substantially devoid of the second coating and the second portion is substantially devoid of the first coating.

14. A method of processing a stack that includes at least two layers, the method comprising:
providing a cutting tool comprising:
a shank;
a first portion including at least one of a first coating or a second coating, wherein the first coating at least partially covers the first portion, the first portion having first side-surface diameter that is constant, the first portion including a first end surface, the first end surface being a flat disk, the first end surface covered with the first coating; and
a second portion interposed between the shank and the first portion along a longitudinal symmetry axis of the cutting tool, wherein the first portion and the second portion do not overlap along the longitudinal symmetry axis, wherein the second portion is contiguous with the first portion and the shank wherein the second portion includes the second coating, and wherein the second coating at least partially covers the second portion, wherein all of the second portion has a second side-surface diameter that is constant and that is different from the first side-surface diameter; and

rotating the cutting tool about the longitudinal symmetry axis and urging the cutting tool through the stack parallel to or perpendicular to the longitudinal symmetry axis to form a final opening having a final-opening diameter and extending through the at least two layers, wherein the first portion is smaller than a pilot opening having a pilot-opening dimension and extending through at least one of the at least two layers, the final-opening diameter is substantially equal to or larger than the pilot-opening dimension, and the final opening is substantially coaxial with the pilot opening.

15. The method of claim 14 , wherein the at least two layers of the stack comprise a first layer and a second layer, and wherein the first layer comprises a different material than the second layer, wherein the first portion is used to cut the first layer and the second portion is used to cut the second layer.

16. The method of claim 14 , wherein the at least two layers of the stack include a composite layer comprising a composite material and a ferrous layer comprising a ferrous material, wherein the pilot opening extends through at least the ferrous layer, and wherein the first coating does not contact the ferrous material of the ferrous layer when the cutting tool is urged through the stack.

17. The method of claim 16 , wherein the pilot opening extends through the ferrous layer and does not extend through the composite layer.

18. The method of claim 14 , further comprising providing the pilot opening before the at least two layers are assembled to form the stack.

19. The method of claim 14 , further comprising forming the pilot opening after the at least two layers are assembled to form the stack.

20. The method of claim 14 , further comprising orbiting the cutting tool about a working axis as the cutting tool is rotated and urged through the stack.

Assignees

• Boeing Co

Inventors

• Lipczynski Gary
• Holleman Wesley E
• Whinnem Eric
• Zanteson William P

Classifications

• B23C3/02 Primary

  Milling surfaces of revolution (B23C3/06, B23C3/08 take precedence) · CPC title

• B23B2226/31

  Diamond · CPC title

• B23B2224/08

  Aluminium nitride · CPC title

• B23B2226/275

  Carbon fibre reinforced carbon composites · CPC title

• Y10T408/81

  Tool having crystalline cutting edge · CPC title