Tool and method for forming aligned holes from approximately full-size holes

Abstract

The present invention relates to a tool and method for forming aligned holes from approximately full-size holes. The tool includes a cutting member having a first diameter and a guide member connected to the cutting member and coaxial with the cutting member. A first section of the guide member includes a centering member and is positioned between the cutting member and a second section having a second diameter. The centering member may include a cutting surface. The second diameter corresponds to a positional tolerance for misalignment of a plurality of approximately full-size holes having the same diameter and full-size hole diameter. The centering member may have a third diameter between the first diameter and the second diameter. The centering member may be tapered. The guide member may be inserted into a plurality of approximately full-size holes, and the cutting member may cut through the holes to form a plurality of aligned full-size holes.

Description

Technical Field

[0001] Examples described herein relate to tools and methods for producing multiple aligned holes from multiple near full-sized holes. Embodiments disclosed herein can reduce perceived looseness of a tool while forming a full-sized hole through two or more components. Background Art

[0002] Two or more parts may be connected together during the process of forming an assembly. For example, multiple parts may be connected together to form an aircraft. Fasteners may be inserted through holes in two or more parts to connect the parts together. Holes are formed in each part so that the holes are intended to be aligned when the parts are brought together, thereby connecting the parts together. Misalignment of corresponding holes in the parts may occur for a variety of reasons, including variations in the manufacturing process and acceptable tolerances.

[0003] In some cases, the holes formed in each component may be initially formed to approximate full-size holes. In other words, the holes formed in the components are formed to have a smaller diameter than the diameter required to insert the desired fastener through the corresponding hole. It is challenging to form corresponding full-size holes through the components, which are also aligned to allow the desired fastener to be inserted through each corresponding full-size hole.

[0004] A cutter having a guide member attached to the cutter can be used to form a full-size hole in two or more parts. The diameter of the guide member is selected to allow the guide member to pass through an initial pair of misaligned holes that are aligned or misaligned to a specified maximum misalignment. The specified maximum misalignment corresponds to the highest degree of misalignment between the pair of holes for which the cutter will be able to cut an aligned full-size hole through the corresponding parts. In this way, when the tool is inserted into two or more holes, the degree of misalignment of the holes is less than the maximum misalignment. The perceived looseness potentially increases with a decrease in the degree of misalignment.

[0005] U.S. Patent No. 9,573,209 describes a method for forming a pair of aligned holes. The method includes determining a diameter of a clean-up hole associated with a plurality of misaligned holes, wherein the clean-up hole diameter may also correspond to a fastener diameter. Additionally, a conical reamer is at least partially inserted into a gap defined by the plurality of misaligned holes. The conical reamer has a longitudinal axis and may be configured such that when the conical reamer is inserted into the gap defined by the plurality of misaligned holes, the longitudinal axis is aligned with the center of the clean-up hole. The plurality of misaligned holes may then be reamed with the conical reamer to form a clean-up hole defined by a plurality of aligned holes having the same center and the same diameter.

[0006] U.S. Patent No. 10,213,855 describes a method for forming a plurality of aligned holes, the method comprising aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole is at least partially aligned with the second hole to form a gap. A virtual hole diameter is measured, wherein the virtual hole diameter is the diameter of a virtual hole passing through the gap, and the virtual hole diameter is the smallest bisector of the gap. In response to the virtual hole diameter having the first virtual hole diameter, a first cleaning hole having a first cleaning hole diameter is formed through the gap, wherein the first cleaning hole is concentrically aligned with the virtual hole. A first fastener having a first size is inserted into the first cleaning hole, and the first surface is attached to the second surface using the first fastener. Summary of the invention

[0007] The present disclosure relates to tools and methods for producing a plurality of aligned holes from a plurality of approximately full-size holes.

[0008] An example of the present disclosure is a tool for producing a plurality of aligned full-size holes from a plurality of approximate full-size holes. The tool includes a cutting member having a first diameter and a guide member connected to the cutting member. The guide member is coaxial with the cutting member and includes a first section having a centering member and a second section having a second diameter. The first section is located between the cutting member and the second section.

[0009] The centering member may include a cutting surface. The first diameter is greater than the second diameter. The centering member may be configured to center the guide member within a first hole of the plurality of approximately full-size holes. The centering member may be configured to reduce looseness of the guide member within the first hole of the plurality of approximately full-size holes.

[0010] The second diameter may correspond to a positional tolerance for misalignment of the plurality of approximately full-size holes and a full-size hole diameter. The plurality of approximately full-size holes may include a first hole and a second hole, and wherein at least a portion of a boundary of the first hole and at least a portion of a boundary of the second hole may define a gap, the positional tolerance including a width dimension of the gap.

[0011] The centering member may have a third diameter, wherein the third diameter and the second diameter are smaller than each diameter of the plurality of approximately full-size holes. The size of the third diameter may be half the difference between the size of the first diameter and the size of the second diameter. The first diameter may be larger than the diameter of any of the plurality of approximately full-size holes.

[0012] The centering member may include a taper. The taper may have a lower end and an upper end. The lower end may have a lower diameter substantially equal to the second diameter. The upper end may have an upper diameter substantially equal to the first diameter. The taper may be substantially 10 degrees.

[0013] One example of the present disclosure is a method for producing a plurality of aligned holes from a plurality of holes. The method includes inserting a guide member into the plurality of holes, the guide member including a first section and a second section. The first section has a centering member. The first section is connected to a cutting member having a first diameter. The second section has a second diameter that is smaller than the first diameter. The first section is positioned between the cutting member and the second section. The second diameter corresponds to a positional tolerance of the plurality of holes and a full-size hole diameter. The method includes cutting through the plurality of holes with the cutting member.

[0014] Cutting through the plurality of holes with the cutting member may include forming a plurality of full-size holes, wherein the plurality of holes are approximately full-size holes. Inserting the guide member into the plurality of holes may include inserting a second section having a second diameter into a first hole in the plurality of holes, wherein the second diameter is less than a diameter of each of the plurality of holes. The method may include inserting a first section having a centering member into the first hole in the plurality of holes after inserting the second section into the first hole in the plurality of holes to reduce perceived looseness of the guide member, wherein the centering member has a third diameter greater than the second diameter of the second section of the guide member, thereby reducing a gap between the guide member and a sidewall of the first hole in the plurality of holes to reduce perceived looseness of the guide member.

[0015] The method may include inserting the first segment having a centering member into the first of the plurality of holes after inserting the second segment into the first of the plurality of holes to center the guide member within the first of the plurality of holes, the centering member having a constant diameter greater than the second diameter and less than the first diameter, the constant diameter of the centering member reducing a gap between the guide member and a sidewall of the first of the plurality of holes to center the guide member within the first of the plurality of holes. The method may include inserting the first segment having a centering member into the first of the plurality of holes after inserting the second segment into the first of the plurality of holes to center the guide member within the first of the plurality of holes, the centering member having a tapered surface reducing a gap between the guide member and a sidewall of the first of the plurality of holes to center the guide member within the first of the plurality of holes. The method may include cutting through the plurality of holes by contacting a sidewall of at least one of the plurality of holes with a cutting surface on the tapered surface of the centering member. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 An example of a tool that can be used to form a plurality of aligned full-size holes from a plurality of holes is shown.

[0017] Figure 2 An example of a tool that can be used to form a plurality of aligned full-size holes from a plurality of holes is shown.

[0018] Figure 3 is a schematic diagram of two components, each having an approximately full-size hole, wherein the approximately full-size holes are aligned.

[0019] Figure 4 is a schematic diagram of two approximately full-size holes showing misalignment.

[0020] FIG. 5A to FIG. 5C is a schematic side view showing a tool for forming aligned full-size holes in two components having misaligned holes.

[0021] FIG. 6A to FIG. 6C is a schematic side view showing a tool for forming aligned full-size holes in two components having misaligned approximately full-size holes.

[0022] Figure 7 is a close-up view showing the tool positioned within a misaligned, approximately full-size hole.

[0023] Figure 8 is a close-up view showing the tool positioned within a misaligned, approximately full-size hole.

[0024] Fig. 9 is a flow chart of an example of a method for producing a plurality of aligned holes from a plurality of holes.

[0025] Although the present disclosure is susceptible to various modifications and alternative forms, specific embodiments have been illustrated by examples in the accompanying drawings and will be described in detail herein. However, it should be understood that the present disclosure is not intended to be limited to the specific forms disclosed. On the contrary, the present invention covers all modifications, equivalents and substitutes falling within the scope of the present disclosure defined by the appended claims. DETAILED DESCRIPTION

[0026] Embodiments described herein can be used to form a plurality of aligned full-size holes from a plurality of holes, which may be approximate full-size holes. As used herein, an approximate full-size hole is a hole in a part or component that is undersized relative to a specified full-size or finished hole, and is a hole for inserting a fastener to connect the part or component to one or more additional parts or components. In other words, the diameter of the approximate full-size hole is smaller than the specified diameter of the full-size hole to receive the necessary or expected fastener. The specified diameter of the full-size hole will be slightly larger than the diameter of the fastener to be inserted into the full-size hole. Typically, the full-size or finished hole will be specified within an engineering specification detailing the assembly of two or more components.

[0027] Figure 1An example of a tool 100A is shown, which can be used to form a plurality of aligned full-size holes from a plurality of holes, which may be approximate full-size holes. The tool 100A includes a cutting member 130 and a guide member 105B. The cutting member 130 has a first diameter 131. The guide member 105A is connected to the cutting member 130. The guide member 105A is coaxial with the cutting member 130. For example, by aligning the centerline 135 of the cutting member 130 with the centerline 115A of the guide member 105A, the guide member 105A is coaxial with the cutting member 130. The guide member 105A includes a first section 107A having a centering member 120A and a second section 110 having a second diameter 111. The first section 107A is positioned between the cutting member 130 and the second section 110.

[0028] The first diameter 131 of the cutting member 130 is configured to cut a full-size hole through two or more components. The cutting member 130 includes a cutting surface 133 to enable the cutting member 130 to cut a full-size hole through two or more components. The first diameter 131 can be configured to be slightly larger than the diameter of a standard-sized fastener, or slightly larger than the diameter of a designated fastener used to connect two or more components together to form an assembly. The first diameter 131 can be the same diameter as the diameter of a standard-sized fastener, or the same diameter as the designated fastener used to connect two or more components together to form an assembly. The first diameter 131 is larger than the diameter of any one of the plurality of approximately full-size holes.

[0029] If an interference fit fastener is used, the first diameter 131 can be smaller than the diameter of a standard size fastener, or smaller than the diameter of a specified fastener used to connect two or more components together to form an assembly. The first diameter 131 that determines the full-size hole diameter is a function of the fastener size and the level of assembly, i.e., clearance, transition, or interference. The cutting member 130 has a first length 132 that is configured to cut through two or more components to form an aligned full-size hole. The first diameter 131 of the cutting member 130 is greater than the second diameter 111 of the second section 110 of the guide member 105A.

[0030] The second diameter 111 is configured to be smaller than the diameter of the approximately full-size hole into which the guide member 105A will be inserted. The second diameter 111 of the second section 110 of the guide member 105A may correspond to the positional tolerance of the misalignment of multiple approximately full-size holes and the expected full-size hole diameter. In other words, the second diameter 111 may be configured to correspond to the maximum misalignment between two or more approximately full-size holes, which will ensure that the expected full-size hole diameter corresponding to the first diameter 131 of the cutting member 130 will cut through the full-size hole of the component that completely surrounds the two or more approximately full-size holes, as discussed herein. The second section 110 of the guide member 105A has a second length 112. The second length 112 of the second section is configured to enable the second section 110 to pass through the holes in the two or more components as needed. The positional tolerance of the misalignment may include the width dimension W2 of the gap C2 of the approximately full-size hole.

[0031] The first section 107A of the guide member 105A includes a centering member 120A. The centering member 120A includes a cutting surface 123A. The centering member 120A has a third length 122A and a third diameter 121A. The centering member 120A can be configured to reduce the looseness of the guide member 105A in the first hole 211 of the approximately full-size holes 211, 221. For example, the third diameter 121A can be configured to reduce the perceived looseness of the tool 100A when inserted into two or more approximately full-size holes in a plurality of components. The third diameter 121A is less than the first diameter 131 of the cutting member 130 and greater than the second diameter 111 of the second section 110 of the guide member 105A. The size of the third diameter 121A can be half of the difference between the size of the first diameter 131 and the size of the second diameter 111. The centering member 120A is configured to center the guide member 105A in the first hole 211 of the plurality of approximately full-size holes 211, 221. For example, the third diameter 121A can be configured to center the guide member 105A within the plurality of holes. The third diameter 121A of the guide member 105A can be smaller than the diameter of the plurality of approximately full-size holes in the plurality of components to enable the guide member 105A to be inserted into the plurality of approximately full-size holes. The third diameter 121A and the second diameter 111 are smaller than each diameter D1 of the plurality of approximately full-size holes 211, 221.

[0032] The centering member 120A of the first section 107A of the guide member 105A may include a cutting surface 123A to enable the centering member 120A to cut through a portion of one or more components through which the full-size hole will be cut. For example, when the guide member 105A is inserted into a pair of misaligned holes, the centering member 120A may be configured to align the tool 100A along the centerline of the first hole, but when the cutting member 130 begins to cut the full-size hole in the proximal component, the centering member 120A may engage a portion of the distal component due to the misalignment of the pair of holes. The cutting surface 123A of the centering member 120A may enable the centering member 120A to cut through the distal component.

[0033] Figure 2 An example of a tool 100B is shown, which can be used to form a plurality of aligned full-size holes from a plurality of holes, which may be approximate full-size holes. Tool 100B includes a cutting member 130 and a guide member 105B. Cutting member 130 has a first diameter 131. Guide member 105B is connected to cutting member 130. Guide member 105B is coaxial with cutting member 130. For example, by aligning centerline 135 of cutting member 130 with centerline 115B of guide member 105B, guide member 105A is coaxial with cutting member 130. Guide member 105B includes a first section 107B having a centering member 120B and a second section 110 having a second diameter 111. First section 107B is positioned between cutting member 130 and second section 110.

[0034] The first diameter 131 of the cutting member 130 is configured to cut a full-size hole through two or more components. The cutting member 130 includes a cutting surface 133 so that the cutting member 130 can cut a full-size hole through two or more components. The first diameter 131 can be configured to be slightly larger than the diameter of a standard-sized fastener, or slightly larger than the diameter of a designated fastener used to connect two or more components together to form an assembly. The first diameter 131 can be the same diameter as the diameter of a standard-sized fastener, or the same diameter as the designated fastener used to connect two or more components together to form an assembly. If an interference fit fastener is used, the first diameter 131 can be smaller than the diameter of a standard-sized fastener, or smaller than the diameter of a designated fastener used to connect two or more components together to form an assembly. The first diameter 131 that determines the full-size hole diameter is a function of the fastener size and the assembly level, i.e., clearance, transition, or interference. The cutting member 130 has a first length 132 that is configured to cut through two or more components to form an aligned full-size hole. The first diameter 131 of the cutting member 130 is greater than the second diameter 111 of the second section 110 of the guide member 105B. The first diameter 131 is greater than the diameter of any of the plurality of approximately full-sized holes.

[0035] The second diameter 111 is configured to be smaller than the diameter of the approximately full-size hole into which the guide member 105B will be inserted. The second diameter 111 of the second section 110 of the guide member 105B can correspond to the positional tolerance of the misalignment of multiple approximately full-size holes and the expected full-size hole diameter. In other words, the second diameter 111 can be configured to correspond to the maximum misalignment between two or more approximately full-size holes, which will ensure that the expected full-size hole diameter corresponding to the first diameter 131 of the cutting member 130 will cut the full-size hole through the component that completely surrounds the two or more approximately full-size holes, as discussed herein. The second section 110 of the guide member 105B has a second length 112. The second length 112 of the second section is configured to enable the second section 110 to pass through the holes in the two or more components as needed.

[0036] The first section 107B of the guide member 105B includes a centering member 120B. The centering member 120B includes a cutting surface 124B. The centering member 120B has a third length 123B. The centering member 120B includes a taper. The centering member 120B tapers from a lower end to an upper end. At the lower end, the centering member 120B has a lower diameter 121B, which can be substantially equal to the second diameter 111 of the second section 110 of the guide member 105B. At the upper end, the centering member 120B has an upper diameter 122B, which can be substantially equal to the first diameter 131 of the cutting member 130. The centering member 120B is configured to reduce the looseness of the guide member 105B in the first hole 211 of the approximately full-size holes 211, 221. For example, the taper of the centering member 120B can be configured to reduce the perceived looseness of the tool when inserted into two or more approximately full-size holes in a plurality of components. The taper may be substantially 10 degrees. The lower diameter 121B is smaller than the upper diameter 122B. The centering member 120B is configured to center the guide member 105B within the first hole 211 of the plurality of approximately full-size holes 211, 221. For example, the taper of the centering member 120B may be configured to center the guide member 105B within the plurality of holes.

[0037] The centering member 120B of the first section 107B of the guide member 105B may include a cutting surface 124B to enable the centering member 120B to cut through a portion of one or more components through which a full-size hole will be cut. For example, when the guide member 105B is inserted into a proximal hole in two or more components, a portion of the tapered portion of the centering member 120B will engage the component before the guide member 105B is fully inserted through the hole of the component to be connected. The cutting surface 124B of the centering member 120B enables the tool 100A to begin cutting through the proximal component until the cutting surface 133 of the cutting member 130 engages the proximal component. The tapered portion of the centering member 120B is configured to align the tool 100B along the centerline of the proximal hole of two or more approximately full-size holes through which the full-size hole is formed.

[0038] Figure 32 is a schematic diagram of a system 200 having a first component 210 with a first approximately full-size hole 211 and a second component 220 with a second approximately full-size hole 221, which are collectively referred to as the approximately full-size holes 211, 221, wherein the approximately full-size holes 211, 221 are aligned. Both approximately full-size holes 211, 221 have a diameter D1 that is smaller than the diameter 230 of the intended full-size hole. When the two approximately full-size holes 211, 221 are aligned, the diameter D1 of each of the two approximately full-size holes 211, 221 is also the same as the gap C1 through the two approximately full-size holes 211, 221. The positional tolerance of the misalignment may include a width dimension W1 of the gap C1 through the two approximately full-size holes 211, 221. As the degree of misalignment between the two holes increases, the gap through the two or more approximately full-size holes will decrease. Although the two holes 211, 221 are aligned, the two holes 211, 221 are approximately full-size holes and will require the use of a cutting tool, such as Figure 1 Tools 100A or Figure 2 Tool 100B is used to enlarge two approximately full-size holes into two aligned full-size holes.

[0039] The guide members 105A, 105B are insertable into the two approximately full-size holes 211, 221, and the centering members 120A, 120B are configured to align the tools 100A, 100B so that the cutting member 130 can cut full-size aligned holes through the two components 210, 220. As discussed herein, the first diameter 131 of the cutting member 130 corresponds to the diameter 230 of the expected full-size holes to enable the desired fastener to be inserted through the components 210, 220, thereby coupling the components 210, 220 together. Figure 3 The number, size, location, shape and / or configuration of components 210 , 220 , full-size diameter 230 , diameter D1 , gap C1 , and holes 211 , 221 in FIG. 2 are shown for illustrative purposes and may vary depending on the application.

[0040] Figure 4 is a schematic diagram showing two approximately full-size holes 211, 221 that are not aligned. For the sake of clarity, components are not included in the schematic diagram. The two approximately full-size holes 211, 221 result in a gap C2 that is smaller than the diameter of the two approximately full-size holes 211, 221. The gap C2 results in a virtual hole diameter 240 that passes through the two misaligned approximately full-size holes 211, 221. When the two approximately full-size holes are at a predetermined maximum misalignment, the gap C2 will be the minimum possible value that still allows the second section 110 of the guide member 105A, 105B to pass through the two approximately full-size holes 211, 211 and the first diameter 131 of the cutting member 130 to completely surround the two holes 211, 221. As shown in FIG. Figure 4As shown, a portion of the boundary of the first hole 211 and a portion of the boundary of the second hole 221 define a gap C2. At the maximum misalignment between the two holes 211, 221, the position tolerance corresponding to the second diameter 111 corresponds to the width dimension of the gap C2.

[0041] FIG. 5A to FIG. 5C is a schematic side view showing a system 300A including a tool 100A for forming aligned full-size holes in two parts 210 , 220 having two nearly full-size misaligned holes 211 , 221 . Figure 5A The second section 110 of the guide member 105A is shown positioned within two non-aligned approximately full-size holes 211, 221. The guide block 250 can be positioned on top of one component 210 to guide the tool 100A to position the second section 110 within the two nearly full-size non-aligned holes 211, 221. The second diameter 111 of the second section 110 of the guide member 105A is configured to correspond to the positional tolerance to ensure that the tool 100A will be able to cut a full-size hole through the components 210, 220 that surrounds both of the non-aligned approximately full-size holes 211, 221. If the second section 110 of the guide member 105A of the tool 100A cannot pass through both of the non-aligned approximately full-size holes 211, 221, the tool 100A will not be able to form two aligned full-size holes. For illustrative purposes, the second section 110 of the guide member 105A of the tool 100A is shown positioned within the two nearly full-size non-aligned holes 211, 221. FIG. 5A to FIG. 5C Two components 210 , 220 with two approximately full-size holes 211 , 221 are shown in FIG, and may vary depending on the application.

[0042] Figure 5B The centering member 120A of the tool 100A is shown positioned within the proximal approximately full-size hole 221. The third diameter 121A can be configured to center the tool 100A within the proximal approximately full-size hole 221. The third diameter 121A can be configured to reduce any perceived looseness of the tool when the tool 100A is inserted through the two approximately full-size holes 211, 221. For example, the third diameter 121A can be half of the difference between the second diameter 111 of the second section 110 of the guide member 105A and the first diameter 131 of the cutting member 130. Alternatively, the third diameter 121A can be half of the difference between the second diameter 111 of the second section 110 of the guide member 105A and the diameter of the proximal approximately full-size hole 221. Since the centering member 120A has a cutting surface 123A, the third diameter 121A can be any diameter between the first diameter 131 and the second diameter 111. Figure 5C The cutting member 130 is shown inserted through both the proximal component 210 and the distal component 220 to cut two full-sized aligned holes in the components 210 , 220 .

[0043] FIG. 6A to FIG. 6C is a schematic side view showing a system 300B including a tool 100B for forming aligned full-size holes in two parts 210 , 220 having two nearly full-size misaligned holes 211 , 221 . Fig. 6A The second section 110 of the guide member 105B is shown positioned within two misaligned approximately full-size holes 211, 221. The guide block 250 can be positioned on top of one component 210 to guide the tool 100B to position the second section 110 within the two nearly full-size misaligned holes 211, 221. The second diameter 111 of the second section 110 of the guide member 105B is configured to correspond to the positional tolerance to ensure that the tool 100B will be able to cut a full-size hole through the components 210, 220 that surrounds both of the misaligned approximately full-size holes 211, 221. If the second section 110 of the guide member 105B of the tool 100B cannot pass through both of the misaligned approximately full-size holes 211, 221, the tool 100B will not be able to form two aligned full-size holes. For illustrative purposes, in FIG. 6A to FIG. 6C Two components 210 , 220 with two approximately full-size holes 211 , 221 are shown in FIG, and may vary depending on the application.

[0044] Figure 6B A centering member 120B of the tool 100B is shown positioned within a portion of the proximal approximately full-size hole 221. As described herein, the centering member 120B is tapered, and the tapered portion can be configured to center the tool 100B within the proximal approximately full-size hole 221. The tapered portion of the centering member 120B can be configured to reduce any perceived looseness of the tool when the tool 100B is inserted through the two approximately full-size holes 211, 221. The centering member 120B includes a cutting surface 124B to enable the centering member 120B to cut through a portion of the components 210, 220 when the tool 100B is inserted through the holes 211, 221. Figure 6C The cutting member 130 is shown inserted through both the proximal component 210 and the distal component 220 to cut two full-sized aligned holes in the components 210 , 220 .

[0045] Figure 7 Shows Figure 5A, wherein the second section 110 of the guide member 105A is positioned within two non-aligned approximately full-size holes 211, 221. The second section 110 of the guide member 105A creates a first gap G1 between the second section 110 and the proximal hole 211. The centering member 120A is configured to create a second gap G2 between the second section 110 and the proximal hole 211 that is smaller than the first gap G1. The centering member 120A reduces the perceived looseness of the tool 100A and / or can center the tool 100A within the proximal hole 211.

[0046] Figure 8 Shows Fig. 6A , wherein the second section 110 of the guide member 105B is positioned within two non-aligned approximately full-size holes 211, 221. The second section 110 of the guide member 105B creates a first gap G1 between the second section 110 and the proximal hole 211. The centering member 120B is configured to create a second gap G2 that is smaller than the first gap G1 between the second section 110 and the proximal hole 211 when the tapered portion of the centering member 120B engages the proximal first component 210. The tapered portion of the centering member 120B is configured to reduce the perceived looseness of the tool 100B and / or to center the tool 100B within the proximal hole 211.

[0047] Fig. 9 4 is a flow chart of an example of a method 400 for producing a plurality of aligned holes from a plurality of holes. The method 400 includes inserting a guide member into the plurality of holes at 410. The guide member includes a first section and a second section, the first section having a centering member. The first section is connected to a cutting member having a first diameter, and the second section has a second diameter that is smaller than the first diameter. The first section is positioned between the cutting member and the second section, and the second diameter corresponds to a positional tolerance and a full-size hole diameter of the plurality of holes. For example, the second section 110 of the guide member 105A, 105B of the tool 100A, 100B is inserted into the plurality of holes 211, 221.

[0048] The method 400 includes inserting a second segment having a second diameter into a first hole in the plurality of holes at step 415, wherein the second diameter is smaller than a diameter of each hole in the plurality of holes. The method 400 includes cutting through the plurality of holes with a cutting member at 460. For example, the cutting member 130 of the tool 100A, 100B cuts through the plurality of holes 211, 221 in the plurality of parts 210, 220. The method 400 includes forming a plurality of full-size holes at 470. For example, cutting through the plurality of holes with the cutting member 130 also includes forming a plurality of full-size holes, wherein the plurality of holes 211, 221 are approximately full-size holes.

[0049] After inserting the second section into the first hole, the method 400 may include inserting the first section with the centering member into the first hole of the plurality of holes at 425 to reduce the perceived looseness of the guide member. For example, after inserting the second section into the first hole of the plurality of holes of the first section of the guide member, the first section may be inserted. The first section of the guide member includes a centering member having a third diameter, which is greater than the second diameter of the second section of the guide member. The larger diameter of the centering member reduces the gap between the guide member and the sidewall of the first hole of the plurality of holes to reduce the perceived looseness of the guide member. Alternatively, the method 400 may include inserting the first section with the centering member into the first hole of the plurality of holes at 435 to center the guide member in the first hole of the plurality of holes. For example, the centering member may have a constant diameter greater than the second diameter and less than the first diameter. The constant diameter of the centering member reduces the gap between the guide member and the sidewall of the first hole of the plurality of holes to center the guide member in the first hole of the plurality of holes.

[0050] The method 400 may include inserting a first segment having a centering member into a first hole of the plurality of holes to center the guide member within the first hole of the plurality of holes at 445. The centering member has a tapered surface. For example, the tapered surface may reduce clearance with the guide member within the first hole of the plurality of holes. The method 400 may include cutting through the plurality of holes at 455. For example, the tool may cut through the plurality of holes by contacting a sidewall of at least one hole of the plurality of holes with a cutting surface on the tapered surface of the centering member.

[0051] In addition, the present disclosure includes implementations according to the following examples:

[0052] Example 1. A tool for producing multiple aligned full-size holes from multiple approximate full-size holes, the tool comprising: a cutting member having a first diameter; and a guide member connected to the cutting member, the guide member being coaxial with the cutting member, the guide member comprising a first section having a centering member and a second section having a second diameter, the first section being positioned between the cutting member and the second section.

[0053] Example 2. The tool of Example 1, wherein the centering member includes a cutting surface.

[0054] Example 3. The tool of Example 1 or 2, wherein the first diameter is greater than the second diameter.

[0055] Example 4. The tool of any of Examples 1 to 3, wherein the centering member is configured to center the guide member within a first hole of the plurality of approximately full-size holes.

[0056] Example 5. The tool of any of Examples 1 to 4, wherein the centering member is configured to reduce loosening of the guide member within a first hole of the plurality of approximately full-size holes.

[0057] Example 6. The tool of any of Examples 1 to 5, wherein the second diameter corresponds to a positional tolerance for misalignment of the plurality of approximately full-size holes and a full-size hole diameter.

[0058] Example 7. The tool of Example 6, wherein the plurality of approximately full-size holes include a first hole and a second hole, and wherein at least a portion of a boundary of the first hole and at least a portion of a boundary of the second hole define a gap, and the positional tolerance for misalignment includes a width dimension of the gap.

[0059] Example 8. The tool of Example 7, wherein the centering member has a third diameter, wherein the third diameter and the second diameter are smaller than each diameter of the plurality of approximately full-size holes.

[0060] Example 9. The tool of Example 8, wherein the size of the third diameter is half the difference between the size of the first diameter and the size of the second diameter.

[0061] Example 10. The tool of Example 8 or 9, wherein the first diameter is greater than a diameter of any of the plurality of approximately full-size holes.

[0062] Example 11. The tool of any of Examples 1 to 10, wherein the centering member includes a cone.

[0063] Example 12. The tool of Example 11, wherein the cone has a lower end and an upper end, the lower end having a lower diameter substantially equal to the second diameter, and the upper end having an upper diameter substantially equal to the first diameter.

[0064] Example 13. The tool of Example 12, wherein the taper is substantially 10 degrees.

[0065] Example 14. A method for producing a plurality of aligned holes from a plurality of holes, the method comprising: inserting a guide member of a tool as described in any one of Examples 1 to 13 into the plurality of holes; and cutting through the plurality of holes with a cutting member of the tool.

[0066] Example 15. A method for producing multiple aligned holes from multiple holes, the method comprising: inserting a guide member into the multiple holes, the guide member comprising a first section and a second section, the first section having a centering member, the first section being connected to a cutting member having a first diameter, the second section having a second diameter smaller than the first diameter, wherein the first section is positioned between the cutting member and the second section, and wherein the second diameter corresponds to a positional tolerance and a full-size hole diameter of the multiple holes; and cutting through the multiple holes with the cutting member.

[0067] Example 16. The method of Example 14 or 15, wherein cutting through the plurality of holes with the cutting member further comprises forming a plurality of full-sized holes, wherein the plurality of holes are approximately full-sized holes.

[0068] Example 17. The method of any of Examples 14 to 16, wherein inserting the guide member into the plurality of holes further comprises inserting a second segment having a second diameter into a first hole in the plurality of holes, wherein the second diameter is smaller than a diameter of each hole in the plurality of holes.

[0069] Example 18. The method of Example 17, further comprising inserting the first segment having a centering member into the first hole of the plurality of holes after inserting the second segment into the first hole of the plurality of holes to reduce perceived looseness of the guide member, wherein the centering member has a third diameter greater than the second diameter of the second segment of the guide member, thereby reducing a gap between the guide member and a side wall of the first hole of the plurality of holes to reduce perceived looseness of the guide member.

[0070] Example 19. The method of Example 17 or 18, further comprising inserting the first segment having a centering member into the first hole of the plurality of holes after inserting the second segment into the first hole of the plurality of holes to center the guide member in the first hole of the plurality of holes, the centering member having a constant diameter greater than the second diameter and less than the first diameter, the constant diameter of the centering member reducing a gap between the guide member and a side wall of the first hole of the plurality of holes to center the guide member in the first hole of the plurality of holes.

[0071] Example 20. The method of any one of Examples 17 to 19, further comprising inserting a first segment having a centering member into a first hole among the plurality of holes after inserting the second segment into the first hole among the plurality of holes to center the guide member within the first hole among the plurality of holes, the centering member having a tapered surface that reduces a gap between the guide member and a side wall of the first hole among the plurality of holes to center the guide member within the first hole among the plurality of holes.

[0072] Example 21. The method of Example 20, further comprising cutting through the plurality of holes by contacting a side wall of at least one of the plurality of holes with a cutting surface on a tapered surface of the centering member.

[0073] Although the present disclosure has been described in terms of certain embodiments, other embodiments that are obvious to those skilled in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of the present disclosure. Therefore, the scope of the present disclosure is limited only by the appended claims and their equivalents.

Claims

1. A tool (100A, 100B) for producing a plurality of aligned full-size holes from a plurality of approximately full-size holes (211, 221), the tool comprising: a cutting member (130) having a first diameter (131) and a first length (132) configured to cut through two or more of the plurality of approximately full-size holes (211, 221) to form aligned full-size holes; as well as A guide member (105A, 105B) connected to the cutting member, the guide member being coaxial with the cutting member, the guide member comprising a first section (107A, 107B) having a centering member (120A, 120B) and a second section (110) having a second diameter (111) and a second length (112), the first section being positioned between the cutting member and the second section, wherein The centering member comprises a tapered cutting surface, The conical cutting surface is basically 10 degrees, The centering member is configured to reduce looseness of the guide member in the first hole (211) by creating a second gap that is smaller than a first gap between the second section and a first hole (211) of the plurality of approximately full-size holes (211, 221), The second length (112) is configured to enable the second section (110) to pass through two or more of the plurality of approximately full-size holes (211, 221), and The second diameter corresponds to a positional tolerance for misalignment of the plurality of approximately full-size holes and a full-size hole diameter (230).

2. The tool according to claim 1, wherein: The first diameter is greater than the second diameter.

3. The tool according to claim 1, wherein: The centering member is configured to center the guide member within the first hole (211) by generating the second gap.

4. The tool according to claim 1, wherein: The plurality of approximately full-size holes also include a second hole (221), and wherein at least a portion of a boundary of the first hole and at least a portion of a boundary of the second hole define a gap (C1, C2), and the misaligned position tolerance includes a width dimension (W1, W2) of the gap.

5. The tool according to claim 4, wherein: The centering member has a third diameter (121A), and wherein the third diameter and the second diameter are less than each diameter (D) of the plurality of approximately full-size holes.

6. The tool according to claim 5, wherein: The size of the third diameter is half the difference between the size of the first diameter and the size of the second diameter.

7. The tool according to claim 5 or 6, wherein: The first diameter is greater than a diameter of any of the plurality of approximately full-size holes.

8. The tool according to claim 1, wherein: The tapered cutting surface has a lower end and an upper end, the lower end having a lower diameter (121B) substantially equal to the second diameter, and the upper end having an upper diameter (122B) substantially equal to the first diameter.

9. A method (400) for producing a plurality of aligned holes from a plurality of holes, the method comprising: inserting (410) the guide member of the tool according to claim 1 into the plurality of holes; as well as Cutting through the plurality of holes with the cutting member of the tool is performed (460).

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