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  Methods and apparatus for machining a couplingUSPTO Application #: 20080051013Title: Methods and apparatus for machining a coupling Abstract: A method facilitates fabricating a coupling including a first annular coupling member and a second annular coupling member. The method comprises coupling the first coupling member to a machine assembly that includes a plurality of grinding wheels coupled to a tool storage member, machining a plurality of troughs in the first coupling member using at least one of the plurality of grinding wheels, such that at least one projection is defined between adjacent troughs, coupling the second coupling member to the machine assembly, and machining a plurality of troughs in the second coupling member using at least one of the plurality of grinding wheels, such that the second coupling member is configured to rotatably couple to the first coupling member. (end of abstract) Agent: John S. Beulick Armstrong Teasdale LLP - St. Louis, MO, US Inventor: Greg M. Burgess USPTO Applicaton #: 20080051013 - Class: 451051000 (USPTO) Related Patent Categories: Abrading, Abrading Process, Ring, Tube, Bushing, Sleeve, Or Cylinder Abrading The Patent Description & Claims data below is from USPTO Patent Application 20080051013. Brief Patent Description - Full Patent Description - Patent Application Claims
BACKGROUND OF THE INVENTION [0001] This invention relates generally to couplings, and more specifically to methods and apparatus for machining a coupling. [0002] Components manufactured for turbine engines may have tight tolerances and/or rigid specifications that must be satisfied for the components to function properly with other turbine engine systems. For example, rotating components within the engine may be coupled with multi-piece couplings that are rotatably mated together. Because the components are mated together, manufacturing the components within the rigid tolerances may be essential to the performance of the component. [0003] As such, manufacturing such components may be a time-consuming and laborious task. To facilitate streamlining the manufacturing process of such components, at least some known processes used a single-purpose machine that facilitates processing each component in a single-piece flow. However, such processes require frequent process setup changes to accommodate different component configurations based on the demand for each product. Specifically, known single-purpose machines include one fixture and one grinding wheel that must be manually removed and replaced each time a different component configuration is required. In addition, to facilitate reducing process variation, each time grinding wheel and/or fixture is interchanged, manual machine adjustments must typically be made prior to commencing production. BRIEF DESCRIPTION OF THE INVENTION [0004] In one aspect a method for fabricating a coupling including a first annular coupling member and a second annular coupling member is provided. The method comprises coupling the first coupling member to a machine assembly that includes a plurality of grinding wheels coupled to a tool storage member, machining a plurality of troughs in the first coupling member using at least one of the plurality of grinding wheels, such that at least one projection is defined between adjacent troughs, coupling the second coupling member to the machine assembly, and machining a plurality of troughs in the second coupling member using at least one of the plurality of grinding wheels, such that the second coupling member is configured to rotatably couple to the first coupling member. [0005] In another aspect of the invention, a machine assembly for use in machining a coupling is provided. The machine tool comprises a machine tool, at least two grinding wheels, and a tool storage member that is coupled to the machine tool. The at least two grinding wheels are removably coupled to the tool storage member. The machine tool is configured to use at least one of the two grinding wheels to machine a plurality of troughs in at least one generally annular coupling member, wherein at least one projection is defined between adjacent troughs, and such that the coupling member is configured to be rotationally coupled to another coupling member using the projections and troughs. [0006] In a further aspect, a grinding wheel is provided. The grinding wheel includes a body, at least one grinding surface extending outwardly from the body, and a cooling system extending through at least one of the body and the at least one grinding surface for supplying coolant to the at least one grinding surface. BRIEF DESCRIPTION OF THE DRAWINGS [0007] FIG. 1 is a perspective view of an exemplary coupling; [0008] FIG. 2 is a perspective view of a portion of the coupling shown in FIG. 1; [0009] FIG. 3 is a perspective view of an exemplary machining assembly for fabricating a coupling, such as the coupling shown in FIG. 1; [0010] FIG. 4 is a perspective partial cutaway view of a portion of an exemplary grinding wheel for use with a machining assembly, such as the machining assembly shown in FIG. 3; [0011] FIG. 5 is a cross-sectional view of a portion of the grinding wheel shown in FIG. 4; [0012] FIG. 6 is a perspective view of an exemplary scrubber assembly for a grinding wheel, such as the grinding wheel shown in FIG. 4, and in an operational; [0013] FIG. 7 is a perspective view of the scrubber assembly shown in FIG. 6 illustrating the scrubber assembly in a retracted position; [0014] FIG. 8 is a cross-sectional view of a portion of the scrubber assembly shown in FIG. 6 and taken along line 8-8; and [0015] FIG. 9 is a perspective view of an exemplary dressing roll for use with a pallet assembly of a machining assembly, such as the machining assembly shown in FIG. 3. DETAILED DESCRIPTION OF THE INVENTION [0016] FIG. 1 is a perspective view of an exemplary coupling 10. FIG. 2 is a perspective view of a portion of coupling 10. Coupling 10 includes a first coupling member 12 and a second coupling member 14. Coupling members 12 and 14 each include a substantially cylindrically shaped body 16 and 18, respectively. Bodies 16 and 18 are each annular and extend between a respective first end 20 or 22 and a respective second end 24 or 26. A central axis 27 respectively, extends through bodies 16 and 18. A bore 28 and 30 extends through each respective body 16 and 18 between each respective first end 20 or 22 and each respective second end 24 and 26. More specifically, bores 28 and 30 are substantially concentric with respect to bodies 16 and 18, respectively. [0017] A plurality of teeth 32 extend outwardly from each respective body second end 28 and 30. More specifically, each tooth 32 extends outwardly from a respective root 36 to a respective tip 38. More specifically, each tip 38 is truncated and forms a mating surfaces 40. A plurality of respective troughs 44 and 46 are defined between adjacent teeth 32. [0018] In the exemplary embodiment, members 12 and 14 are rotatably coupled together. More specifically, when coupled together, members 12 and 14 are aligned such that teeth 32 extending from body 16 are aligned with, and received within troughs 46, and such that teeth 32 extending from body 18 are aligned with, and received within troughs 44 such that rotational movement of body 16 or 18 with respect to the other body 18 or 16, respectively, is prevented. [0019] FIG. 3 is a perspective view of an exemplary machining assembly 100 for machining a coupling, such as coupling 10 (shown in FIGS. 1 and 2). Assembly 100 includes a machine base 102, a machine tool 104, and a pallet assembly 106. Machine tool 104 is coupled to base 102 and includes a tool storage carousel 108 moveably coupled thereto in any suitable manner. In one embodiment, machine tool 104 is a computer numeric control (CNC) machining center. Carousel 108 includes a plurality of grinding wheels 110 that are removably coupled thereto in any suitable manner, and may also include any number of other machining tools 112 and/or inspection tools 114 that are also removably coupled thereto in any suitable manner. Machine tool 104 also includes an automatic tool changer 116 coupled thereto in any suitable manner, a scrubber assembly 118 movably coupled thereto in any suitable manner, and a chuck 120. Chuck 120 includes a tool, and more specifically in the exemplary embodiment, grinding wheel 110, coupled thereto. Tool changer 116 removes a tool from chuck 116 and replaces the removed tool with another tool selected from carousel 108. Chuck 120 is configured to rotate about an axis of rotation 122. Scrubber assembly 118 is also rotatable about axis of rotation 122 and provides coolant to a tool. [0020] Pallet assembly 106 includes a pallet base 124, an automatic pallet changer 126, and a plurality of pallets 128. Pallets 128 are each removably coupled to base 102 and each includes a fixture base 130 and a fixture tower 132 that extends outwardly from fixture base 130. Each fixture tower 130 includes a plurality of quick-change fixtures 134 coupled thereto in any suitable manner. Fixtures 134 are each removably coupled to at least one of coupling members 12 and 14, and a dressing roll (not shown in FIG. 3). Accordingly, each fixture tower 130 can include a plurality of fixtures 134, wherein each fixture is configured to couple with a different configuration of a coupling member 12 and 14, or a dressing roll. Continue reading... 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