Rotary tool guide, orientation structure for orienting rotary tool, method for machining manhole in workpiece, workpiece and aircraft

Abstract

The invention relates to a rotary tool guide, an orientation structure for orienting a rotary tool, a method for machining a manhole in a workpiece, a workpiece and an aircraft. A rotary tool guide (15), which may be a drilling guide and / or a countersink guide, has a top side (22), a bottom side (16), and a set of rigid guide members (30). The rotary tool guide (15) also has a set of guide holes (34), each of the guide holes (34) extending through one of the guide members (30). The guide hole (34) is arranged to guide a rotary tool, such as a drill or countersink drill, through the guide hole (34). The guide members (30) are spaced apart by a flexible portion (38) that can be deformed to allow the bottom side (16) to change shape to conform to the surface of the workpiece (17).

Description

Technical Field

[0001] The present disclosure relates to the field of guiding rotary tools, such as drills and countersinks. In particular, but not exclusively, the present disclosure relates to rotary tool guides, orientation structures for rotary tools, methods of machining workpieces, workpieces and aircraft. Background Art

[0002] In fields such as aircraft manufacturing, it is often desirable to have a set of holes drilled in a workpiece with a high degree of precision, that is, the holes extend at desired angles and at desired locations (relative to each other and / or relative to features of the workpiece). As an example, an aircraft wing often has one or more access holes for allowing personnel to partially climb into the wing for inspection and maintenance purposes. Such an access hole is often oval in shape with an array of holes around its perimeter for attaching a manhole cover.

[0003] In the case of aircraft access holes and similar structures, it can be particularly difficult to drill the holes freehand with the necessary level of accuracy. For this reason, drilling jigs are often used. These jigs are rigid structures that can be attached to a workpiece (e.g., a wing skin in which an access hole has been or is to be formed) and have guide holes through which the drill can be inserted before drilling the workpiece. The guide holes determine the angle and position of the hole, so if the jig is correctly positioned on the workpiece, a high degree of accuracy can be achieved.

[0004] One problem with this approach is that workpieces may differ from one another due to manufacturing variations. For example, in the case of wing access holes, the skins of two wings that are supposed to be identical may have slightly different shapes. Conventional fixtures are designed to fit one specific workpiece geometry, so variations in the workpiece geometry may cause the fixture to not seat correctly. This in turn may mean that the holes produced using the fixture are out of tolerance in terms of angle and / or location.

[0005] Another problem with existing fixtures is that they are designed to fit one specific workpiece geometry, even though a workpiece with a slightly different geometry may require a separate fixture. For example, an aircraft wing typically has several access holes distributed along the length of the wing, and because the geometry of the wing changes slightly along the span of the wing, each access hole typically requires a separate fixture customized to that specific geometry. This makes the manufacturing process longer and therefore expensive, and means that tooling costs are relatively high.

[0006] Another approach is to use a flexible template, such as a polycarbonate sheet, with guide holes disposed therein. By being flexible, such a template is able to conform to slight differences in workpiece geometry. However, the guide holes disposed in a flexible material means that the guide holes provide less support for a drill passing therethrough, and the accuracy of hole placement may be reduced. Furthermore, the guide holes extending only through the sheet (and the flexible sheet at that sheet) means that such a template is generally not able to guide the angle of the drill. As a result, it is difficult to drill holes at the desired angle, particularly where the holes are to be drilled in a manner that is not perpendicular to the surface of the workpiece.

[0007] Similar problems exist with other machining operations using rotary tools, such as countersinking, reaming, counterboring and tapping.

[0008] The present invention seeks to alleviate one or more of the above problems.Alternatively or additionally, the present invention seeks to provide an improved or alternative rotary tool guide, an orienting structure for a rotary tool, a method of machining a workpiece, a workpiece or a vehicle. Summary of the invention

[0009] According to a first aspect of the present invention, there is provided a rotating tool guide, the rotating tool guide comprising:

[0010] a bottom side portion and a top side portion, the bottom side portion being configured for abutting against a workpiece and the top side portion facing away from the bottom side portion;

[0011] a plurality of rigid guide members; and

[0012] A plurality of guide holes, each of which is arranged to guide a rotating tool, wherein:

[0013] Each guide hole extends along the longitudinal axis and passes through the top side, the guide member, and the bottom side; and

[0014] The guide members are distributed in an elongated array, wherein flexible portions are located between the guide members, the flexible portions allowing the elongated array to bend so as to change the shape of the bottom side.

[0015] In case the bottom side can change shape, the rotating tool guide can adapt to different workpiece geometries. Thus, the rotating tool guide can provide the necessary degree of accuracy in the face of variations in workpiece geometry due to manufacturing tolerances etc. Alternatively or additionally, the rotating tool guide can be used for workpieces of intentionally different geometries (e.g. access holes located at different locations in a wing, where the curvature of the wing may be different).

[0016] In addition, in the case where the guide hole extends through a rigid guide member, sufficient support can be provided to the rotating tool passing through the guide hole. Therefore, the rotating tool guide can provide improved accuracy of hole placement and angle and can enable drilling of non-vertical holes.

[0017] For the avoidance of doubt, references herein to "drilling" are intended to be illustrative in nature. It should be understood that the rotary tool guide may be configured to support any suitable rotary tool for any suitable machining operation, such as a drill or milling cutter for drilling or countersinking, a countersink for countersinking, a tap for threading, and / or a reamer for reaming.

[0018] Where further clarification is required although understood by the skilled person, a rotary tool may be construed as any tool arranged to cut a workpiece whilst the tool is rotated about its longitudinal axis.

[0019] It should be understood that references to flexible portions herein should be interpreted in the context of precision tools. Thus, it is not intended to imply that the flexible portion must bend under its own weight or in the hand of a user without mechanical advantage. In some embodiments, the flexible portion may appear rigid to the user until the rotating tool guide is put into use.

[0020] For the avoidance of doubt, a guide member may be considered rigid if it does not deform to any significant extent during normal use. In some embodiments, the guide member is capable of withstanding bending loads sufficient to damage the flexible portion without significant deformation.

[0021] The elongated array may be substantially annular.

[0022] Annular arrays typically extend over a larger workpiece area than straight or arcuate arrays. Therefore, potential problems caused by changes in workpiece surface shape may be particularly prevalent. Therefore, one or more of the advantages discussed above may be particularly effective in these situations.

[0023] For example, where the elongated array is substantially annular, the elongated array may be substantially circular, elliptical or oval. For example, as an alternative to annular, the elongated array may follow a substantially straight line or a curved line.

[0024] The elongated array may extend along a length direction and have a width direction and a depth direction, and the flexible portion allows the elongated array to bend at least in the depth direction.

[0025] In other words, the array can be configured to bend forward / backward, rather than necessarily left / right. Accordingly, the rotary tool guide can be configured to conform to a convex / concave workpiece surface. This can be particularly beneficial for use in the manufacture of aircraft, where the workpiece surface is more likely to have variations in convexity / concavity.

[0026] The width direction can be generally parallel to the bottom side portion and / or the top side portion of the rotary tool guide. Alternatively or additionally, the width direction can be substantially perpendicular to the longitudinal axis of the guide hole.

[0027] The depth direction can be generally perpendicular to the bottom side portion and / or the top side portion of the rotary tool guide. Alternatively or additionally, the depth direction can be substantially parallel to the longitudinal axis of the guide hole.

[0028] It will be appreciated that in the case where the elongate array is annular or arcuate, the length direction can be the circumferential direction and the width direction can be the radial direction. Thus, it is clear that the length direction can follow a curved path and / or the width direction can change (in an absolute sense) along the length direction. However, in other cases, the length direction and / or the width direction can be straight.

[0029] As an alternative, the flexible portion can allow the array to bend only in the width direction, e.g., to accommodate variations in the desired position of a hole in the workpiece surface (e.g., an aircraft access hole has slight variations in its oval shape).

[0030] In the case where the flexible portion allows the elongate array to bend at least in the depth direction, the flexible portion can allow the elongate array to bend substantially only in the depth direction.

[0031] An elongate array that is substantially non-bendable in the width direction can improve the accuracy with which the rotary tool guide can position the guide hole at the desired location. Conversely, in an arrangement where the array can also bend in the depth direction, the rotary tool guide may inadvertently bend out of the shape required to correctly position the guide hole (e.g., slightly change the aspect ratio of the guide hole in the case of an oval or ovoid array).

[0032] Optionally:

[0033] The rotary tool guide further includes a set of one or more tool support inserts;

[0034] And

[0035] Each tool support insert has: a cylindrical portion that can be closely received in the guide hole; and a tool opening that is configured to guidingly receive a rotary tool therethrough.

[0036] The use of a tool support insert may allow the portion of the rotary tool guide that receives the rotary tool to be detachable. This may allow the tool support insert to be replaced if it becomes worn or damaged without having to replace the entire rotary tool guide. Alternatively or additionally, the portion of the rotary tool guide that receives the rotary tool may be optimized for this purpose without affecting other portions. For purposes of example, the tool support insert may be made of a hard and wear resistant material for longevity purposes, with the flexible portion being made of a more flexible material.

[0037] Each tool support insert may have a head that protrudes beyond the top side when the outer surface is received in the guide hole. The head may be configured to engage the top side of the rotating tool guide.

[0038] The cylindrical portion of the or each tool support insert may be substantially circular in cross section, such as cylindrical or frustoconical. Alternatively, the cylindrical portion may have a cross section of any other suitable shape, such as a star-shaped, square, hexagonal or octagonal cross section.

[0039] The tool support inserts may be substantially identical to one another. Alternatively, the tool support inserts may differ from one another in shape and / or material composition.

[0040] The cylindrical portion of the or each tool support insert may have a cross-sectional shape complementary to that of the guide hole in which the cylindrical portion can be snugly received (e.g. each cylindrical portion and each guide hole may be circular in cross-section). This may improve contact between the cylindrical portion and the guide hole, thereby allowing the guide hole to provide more support for the cylindrical portion.

[0041] At least one of the barrel of the tool support insert and the guide hole that can tightly receive the barrel can be circular in cross section. For example, the tool support insert can have a cylindrical barrel that can tightly receive in a guide hole that is square in cross section, or the tool support insert can have an octagonal cross section that can tightly receive in a cylindrical guide hole, or both the barrel and the guide hole can be frustoconical or cylindrical. This can allow the barrel to be rotatable within the guide hole, which can be beneficial in some cases as discussed later.

[0042] As an alternative, both the barrel and the guide bore may be non-circular in cross-section.This may prevent the barrel (and hence the tool support insert) from rotating, for example restricting the barrel to occupy one or more discrete angular positions about the longitudinal axis of the guide bore.

[0043] For the avoidance of doubt, a cylindrical portion may be considered to be snugly receivable in a guide bore if the cylindrical portion can be received in the guide bore in a manner that substantially prevents lateral or sideways movement of the cylindrical portion.

[0044] Where the rotating tool guide includes two or more tool support inserts, the tool support inserts may be substantially identical to one another, or may differ from one another in shape and / or material composition.

[0045] As an alternative to using a tool support insert, the guide bore may be configured to directly receive the rotating tool in a guided manner.

[0046] In each tool support insert, the tool aperture may define an aperture axis and the barrel may define a barrel axis, the aperture axis and the barrel axis being positioned at an angle to each other. The angle between the aperture axis and the barrel axis is preferably non-zero. The aperture axis and the barrel axis may be non-parallel. The aperture axis and the barrel axis may be non-coaxial.

[0047] This may allow the tool support insert (and therefore the entire rotary tool guide) to guide movement of the rotary tool in a direction that is angled with respect to the longitudinal axis of the guide bore that receives the rotary tool.

[0048] The bore axis and the barrel axis may be positioned at an angle of at least 1 degree, such as at least 2 degrees or at least 5 degrees to each other. Alternatively or additionally, the bore axis and the barrel axis may be positioned at an angle of less than 20 degrees, such as less than 15 degrees or less than 10 degrees to each other.

[0049] As an alternative, the bore axis and the barrel axis may be co-linear, whereupon the longitudinal axis of the guide bore determines the direction in which the rotating tool will be guided. As another alternative, the bore axis and the barrel axis may be parallel, for example with a tool support insert similar to an eccentric bushing. This may allow the path in which the rotating tool will be guided to be adjusted by changing the angular position of the tool support insert about the longitudinal axis of the guide bore.

[0050] Optionally:

[0051] The rotary tool guide includes a set of one or more complementary tool support inserts;

[0052] Each supplemental tool support insert has a cylindrical portion that is closely receivable in the guide hole and a tool opening configured to guidingly receive a rotating tool therethrough; and

[0053] The supplemental tool support insert differs in shape from the tool support insert.

[0054] A rotating tool guide having both a tool support insert and a supplemental tool support insert may allow different operations to be performed (e.g., drilling holes of different diameters or drilling holes at different positions or angles) depending on whether the tool support insert or the supplemental tool support insert is used. For purposes of example, the tool support insert may have a tool opening of a different diameter than the supplemental tool support insert, and / or the tool support insert may have a tool opening at a different angle relative to the supplemental tool support insert.

[0055] As required, one or more of the guide holes may be configured to closely receive a tool support insert or a complementary tool support insert. Thus, this may allow the same guide hole to guide different operations.

[0056] Where the rotary tool guide includes two or more supplemental tool support inserts, the supplemental tool support inserts may be substantially identical to one another, or may differ from one another in shape and / or material composition.

[0057] The rotary tool guide may also include a set of one or more clamping inserts configured to clamp the rotary tool guide against the workpiece, each clamping insert having: a barrel portion that can be closely received in the guide hole; and a head portion configured to engage the top side.

[0058] Where the clamping insert has a cylindrical portion that can be closely received in the guide bore, the position of the clamping insert can be used to accurately position the rotary tool guide on the workpiece.

[0059] As an alternative, the rotary tool guide may have a clamping insert that is configured to extend through or into the corresponding guide hole without being tightly received. As another alternative, the rotary tool guide may include a clamping member that is not receivable in the guide hole. For example, such a clamping member may abut the top side of the rotary tool guide.

[0060] As required, one or more of the guide holes can be configured to closely receive a clamping insert or a tool support insert and / or a supplementary tool support insert. As required, this can allow the same guide hole to be used in a clamping rotary tool guide or in a machining operation.

[0061] Each clamping insert may have a shank extending from the barrel in a direction generally away from the head, the shank being narrower than the barrel.

[0062] Such a shank may allow the clamping insert to extend into the workpiece without requiring a hole in the workpiece having a diameter at least as large as the barrel.

[0063] The shank may be threaded, for example for engagement with a threaded hole supported in or on a workpiece.

[0064] The rotational tool guide may also include a set of one or more alignment protrusions, each alignment protrusion having an active configuration in which the alignment protrusion extends from the guide member and protrudes beyond the top side.

[0065] The or each alignment protrusion may be arranged as a reference point for determining the angular position of the tool support insert and / or the supplementary tool support insert. For example, the tool support insert may have a surface that is spaced apart from the alignment protrusion by a specific amount when the tool support insert is in a desired angular position.

[0066] Alternatively or additionally, the or each alignment protrusion may be configured to provide a stop side portion against which a surface of the tool support insert and / or the supplementary tool support insert may rest when the tool support insert and / or the supplementary tool support insert is in the desired angular position.

[0067] This functionality may be particularly beneficial when the tool support insert and / or the supplementary tool support insert has an opening axis which is not colinear with the axis of the cylindrical portion (whereby the position of the opening axis relative to the longitudinal axis of the associated guide hole depends on the angular position of the tool support insert and / or the supplementary tool support insert).

[0068] In the active configuration, the alignment protrusion may extend from a guide member whose guide hole receives the tool support insert. Alternatively, in the active configuration, the alignment protrusion may extend from a guide member adjacent to the guide member.

[0069] Each alignment protrusion may also have a passive configuration in which the alignment protrusion does not extend from the guide member.

[0070] This may allow the alignment protrusion to be moved out of the way when not needed.

[0071] Each alignment protrusion may have a passive configuration in which the alignment protrusion is separated from the associated guide member. For example, each alignment protrusion may take the form of a screw that is engageable with a threaded hole in the guide block, the alignment protrusion being in an active configuration when screwed into the threaded hole and being in a passive configuration when screwed out of the hole.

[0072] Alternatively or additionally, each alignment protrusion may have a passive configuration in which the alignment protrusion is flush with or recessed below the associated guide member. For example, each alignment protrusion may take the form of a set screw engageable with a threaded hole in the guide block, the alignment protrusion being in an active configuration when partially screwed out of the threaded hole and being in a passive configuration when fully screwed into the threaded hole.

[0073] As an alternative to each alignment protrusion having a passive configuration, each alignment protrusion may be permanently attached to an associated guide member in an active configuration.

[0074] The longitudinal axes of the guide holes may each intersect the bottom side at an acute angle.

[0075] Thus, the rotating tool guide may be used to drill holes (etc.) that are not perpendicular to the workpiece surface, which is particularly difficult using conventional techniques.

[0076] The acute angle may be at least 1 degree, such as at least 2 degrees or at least 5 degrees. Alternatively or additionally, the acute angle may be no greater than 20 degrees, such as no greater than 15 degrees or no greater than 5 degrees.

[0077] As an alternative, the guide holes may each intersect the bottom side at a right angle.

[0078] The longitudinal axes of the guide holes may each intersect the top side at approximately 90 degrees.

[0079] This can provide a particularly strong and stable contact between the head of the tool support insert, the head of the complementary tool support insert or the head of the clamping insert.

[0080] The guide member and the flexible portion may be formed integrally with one another, the flexible portion taking the form of a narrow section of material.

[0081] Beneficially, this may allow the rotary tool guide to be stronger, easier to manufacture and / or have components that are less prone to becoming loose or detached from one another over time.

[0082] The guide member and the flexible portion may be integrally formed from aluminum or any other suitable material, such as another metal, a composite material such as carbon fiber, or a polymer such as nylon or aromatic.

[0083] The flexible portion and the guide member may comprise different materials.

[0084] This can allow the materials of making the guide member and the flexible portion to be more targeted to the specific requirements of the guide member and the flexible portion. For example, the flexible portion can be made of a material that is more flexible than the material of making the guide member.

[0085] The flexible portion may be formed from a continuous length of flexible material providing the bottom side, the guide members being spaced apart along the continuous length of flexible material.

[0086] The flexible portion may comprise or be formed from spring steel.Alternatively or additionally, the guide member may comprise or be formed from aluminium.

[0087] According to a second aspect of the present invention, there is provided an orientation structure for orienting a rotating tool, the orientation structure having:

[0088] a base portion and a top side portion, wherein the base portion is used to engage the workpiece, and the top side portion is located on a face of the directional structure opposite to the base portion;

[0089] two or more non-flexible directional members;

[0090] Two or more directional apertures, each directional aperture being positioned to receive a rotating tool therethrough, wherein:

[0091] Each orientation aperture extends along the centerline and extends through the orientation structure, through the top side, one of the orientation members, and the base;

[0092] The orienting members are positioned in a longitudinal arrangement and are spaced apart from one another by the flexible regions; and

[0093] The longitudinal arrangement and thus the base can be bent by deformation of the flexible region.

[0094] Such a directional structure may provide one or more of the advantages discussed above.

[0095] According to a third aspect of the present invention, there is provided a method for machining a workpiece using the rotary tool guide of the first aspect of the present invention, the method comprising:

[0096] placing a bottom side of the rotating tool guide in abutment with a surface of the workpiece;

[0097] fixing the bottom side of the rotating tool guide in close contact with the workpiece surface by deforming one or more of the flexible portions so that the shape of the bottom side conforms to the shape of the workpiece surface; and

[0098] A rotating tool is inserted through a guide hole of one of the guide members, which guides movement of the rotating tool into the workpiece, and is inserted into a workpiece to process the workpiece.

[0099] Because the method uses a rotating tool guide according to the first aspect of the invention, the method may allow machining operations to be performed with increased accuracy for the reasons discussed above. Alternatively or additionally, this may allow the method to be performed on workpieces that differ from one another with little or no tool or program modification.

[0100] Placing the bottom side in abutment with the workpiece surface and securing the bottom side in close contact with the workpiece surface may be performed at different stages of the same operation. For example, the rotating tool guide may be aligned with the workpiece surface and then clamped in place, with tightening of the clamping structure first bringing the bottom side into abutment with the workpiece surface before continuing to tighten to ensure close contact of the bottom side.

[0101] A rotational tool (the same rotational tool or two or more different rotational tools) may be inserted through more than one of the guide holes (eg, all or substantially all of the guide holes).

[0102] Optionally:

[0103] The method further includes inserting a cylindrical portion of a tool support insert into the guide bore prior to inserting the rotary tool; and

[0104] The guide bore guides the movement of the rotating tool via the tool support insert, the guide bore determines the position of the tool support insert, and the tool opening of the tool support insert guides the movement of the rotating tool into the workpiece.

[0105] The tool support insert may be inserted before, during or after the bottom side is placed in abutment with the workpiece surface. In the case where the tool support insert is inserted after the bottom side is placed in abutment with the workpiece surface, the tool support insert may be inserted before, during or after the bottom side is fixed in close contact with the workpiece surface.

[0106] The tool support insert may be inserted into the guide hole until a head of the tool support insert contacts a top side of the rotating tool guide.

[0107] Optionally, the method further comprises:

[0108] inserting the cylindrical portion of the supplementary tool support insert into the guide hole of one of the guide members; and then

[0109] inserting a rotary tool through the guide hole and into the workpiece to perform processing on the rotary tool,

[0110] Therein, the guide bore guides the movement of the rotating tool via the supplementary tool support insert, the guide bore determines the position of the supplementary tool support insert, and the tool opening of the supplementary tool support insert guides the movement of the rotating tool into the workpiece.

[0111] The supplemental tool support insert may be inserted before, during or after the insertion of the tool support insert.

[0112] The rotary tool guided by the tool support insert may be the same as the rotary tool guided by the supplemental tool support insert (ie, the tool support insert and the supplemental tool support insert may support substantially the same rotary tool, or may support the exact same tool but at different points in time).

[0113] As an alternative, the tool support insert and the complementary tool support insert may guide different tools. For example, the tool support insert may guide a drill bit for performing a drilling operation, and the complementary tool support insert may guide a countersink drill for performing, for example, a countersinking operation.

[0114] The supplemental tool support insert may guide the associated rotating tool before, during or after the tool support insert guides the associated rotating tool.

[0115] The same guide bore can guide the movement of the rotating tool via the tool support insert and, at a different time, guide the movement of the rotating tool via a supplementary tool support insert.

[0116] In other words, the same guide hole can be used to guide the cutting tool twice - once via the tool support insert and once via the complementary tool support insert. Thus, two machining operations can be performed at the same location.

[0117] Alternatively, one guide hole may receive a tool support insert and another guide hole (such as an adjacent guide hole, for example a guide hole of an adjacent guide member) may receive a complementary tool support insert.

[0118] The step of inserting the cylindrical portion of the tool support insert into the guide bore may include securing the tool support insert in a desired angular position about the longitudinal axis of the guide bore using the alignment projections in the active configuration.

[0119] The tool support insert can be inserted into the guide hole, rotated to the desired angular position and then secured by the alignment protrusions. Alternatively, the tool support insert can be positioned in the correct angular position before being inserted into the guide hole (then the tool support insert can be secured by the alignment protrusions during or after insertion).

[0120] The step of securing the tool support insert in the desired angular position may include rotating the tool support insert in the guide hole to the desired angular position with the alignment protrusion in the passive configuration and then moving the alignment protrusion to the active configuration to secure the tool support insert.

[0121] The alignment protrusion may be moved to the active configuration before, during, or after the tool support insert is inserted into the guide hole and / or before, during, or after the tool support insert is positioned in a desired angular position.

[0122] The method may also include repeating some or all of the above steps at different locations on the workpiece.

[0123] The step of securing the bottom side of the rotating tool guide in close contact with the workpiece surface may include:

[0124] inserting the cylindrical portions of two or more clamping inserts into the corresponding guide holes;

[0125] engaging each clamping insert with a complementary structure supported by the workpiece to form a clamping mechanism; and

[0126] The clamp insert and its complementary structure are tightened to tighten the clamping mechanism, thereby clamping the bottom side of the rotating tool guide against the workpiece surface and deforming one or more of the flexible portions.

[0127] For example, the complementary structure may be a threaded hole in the workpiece or a threaded hole in a nut supported in or in the workpiece.

[0128] The complementary structure may engage a shank of a corresponding clamping insert.

[0129] As an alternative, the complementary structure may take the form of a bolt which is engageable with a threaded opening in the clamping insert.

[0130] According to a fourth aspect of the present invention, there is provided a workpiece machined using the apparatus according to the first aspect or the second aspect of the present invention and / or the method according to the third aspect of the present invention.

[0131] As discussed above, the workpiece may be machined with advantageous precision.

[0132] The workpiece may comprise a wing skin having an access hole provided therein. The access hole may comprise a circumferential array of holes machined using the apparatus according to the first aspect of the invention or using the method according to the third aspect of the invention.

[0133] According to a fifth aspect of the present invention, there is provided an aircraft comprising a workpiece according to the fourth aspect of the present invention.

[0134] Due to the improved workpiece machining accuracy, the entire aircraft can be produced with favorable accuracy.Alternatively or additionally, since the same rotating tool guide can be used in two or more positions instead of separate fixtures, the aircraft can be produced faster (and therefore at a lower cost) and / or with reduced tooling costs.

[0135] Of course, it will be understood that the features described about one aspect of the present invention can be incorporated into other aspects of the present invention. For example, the method according to the present invention can be combined with any of the features described with reference to the device of the present invention and vice versa. Similarly, the device of the present invention may include features configured to perform one or more steps or operations described about the method of the present invention. In addition, it is noted that the methods described herein are not intended to be limited to the steps of these methods being performed in the order in which these steps are narrated. It will be apparent to the technician that the steps can be performed in different orders or cannot be performed in different orders. BRIEF DESCRIPTION OF THE DRAWINGS

[0136] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying schematic drawings, in which:

[0137] Figure 1 shows a perspective view of an aircraft according to a first embodiment of the invention;

[0138] Figure 2 yes Figure 1 A three-dimensional view of an aircraft manhole;

[0139] Figure 3 A plan view showing a main body of a rotary tool guide according to a first embodiment;

[0140] Figure 4 shows the alignment with the workpiece Figure 2 A side view of the subject;

[0141] Figure 5 Shows Figure 3 and Figure 4 A cross-sectional view of the body of

[0142] Figure 6 A perspective view showing a clamping insert of a rotating tool guide of a first embodiment;

[0143] Figure 7 A perspective view showing an alignment projection of a rotary tool guide of a first embodiment;

[0144] Figure 8 It shows that Figure 6 The clamping insert shown in Figure 7 The alignment protrusion assembly shown in Figures 2 to 4 A stereogram of the subject;

[0145] Fig. 9 A perspective view showing a tool support insert of a rotating tool guide of the present embodiment;

[0146] Fig.10 A top perspective view showing a second embodiment of a supplemental tool support insert of the present invention positioned in a guide hole;

[0147] Fig.11 The guide hole is shown Fig.10 A cross-section of a supplementary tool support insert;

[0148] Fig.12 Shown with Fig.10 and Fig.11 A perspective view of a body of a second embodiment of a combination of a supplemental tool support insert, a tool support insert, a set of clamping inserts and a set of alignment protrusions;

[0149] Fig.13 A flow chart showing a method according to a second embodiment of the present invention is shown. DETAILED DESCRIPTION

[0150] Figure 1 An aircraft 2 according to an embodiment of the invention is shown. The aircraft 2 has a body 4, a tail 6 and two wings 8. Each wing 8 extends from the body 4 in the span direction, terminates in an upwardly turned wing tip 10 and supports an engine 12. Each wing has on its underside a set of access holes (not visible) distributed along the span of the wing 8.

[0151] Figure 2 One such access hole 19 is shown surrounded by a section of a workpiece 17 prior to assembly of the wing 8, which when assembled will form part of the lower skin of the wing 8. The outer surface 21 of the workpiece 17 has a chamfer 23 extending circumferentially around the access hole 19 and positioned at 7 degrees from parallel (i.e., a tapered angle of 83 degrees). The chamfer 23 also has an elliptical array of holes 25. Each hole 25 supports a captive nut for engagement by a bolt (not shown) that extends through the access hole cover (not shown) to secure the cover to the access hole 19.

[0152] In order for the bolt (not visible) to fit correctly in the hole 25, the hole 25 must be set at the correct position and positioned at the correct angle. To ensure that the hole 25 is correctly set and positioned, the hole 25 is machined using a rotary tool in the form of a drill and a rotary tool guide according to the present embodiment.

[0153] Figure 3 , Figure 4 and Figure 5 The body 14 of the rotating tool guide 15 is shown from the top, from the side and in cross section respectively. Figure 4 The body 14 is shown aligned with the access hole 19 of the workpiece 17, with the body 14 having structural support members (not visible) therebelow.

[0154] Now combine Figure 1 and Figure 2 Reference Figures 3 to 5 , the body 14 of the rotating tool guide 15 has a bottom side 16 configured to abut against an outer surface 21 of a workpiece, more specifically a chamfer 23. The bottom side 16 of the body 14 consists of an abutment surface 18 and a pair of chamfered surfaces 20 of varying width. In use, the abutment surface 18 presses against a corresponding surface of the skin of the wing 8, more specifically against the chamfer 23, as discussed in more detail later. Therefore, the abutment surface 18 also has a tapered angle of 83 degrees.

[0155] The body 14 also has a top side 22 facing away from the bottom side 16. In this embodiment, the top side 22 has a sawtooth shape, having raised portions 24 and lowered portions 26.

[0156] In this embodiment, the body 14 is a single piece of aluminum. The volume of aluminum below each of the raised portions 24 forms a rigid guide member 30. The rigid guide members 30 are distributed in an elongated array 32 extending along the length direction. In this embodiment, the length direction is the circumferential direction (from Figure 4 ). Thus, array 32 is not only elongated in shape, but also annular, more specifically elliptical.

[0157] The array 32 also has a width direction and a depth direction, the width direction being the radial direction (from Figure 4 The depth direction is the direction extending between the bottom side portion 16 and the top side portion 22 (from Figure 4 The length direction, width direction and depth direction are all perpendicular to each other. In this embodiment, the width of the array is the same as the width of the guide member 30, but in other embodiments, two or more guide members can be positioned side by side in the array.

[0158] The body 14 has a set of guide holes 34, each of which is arranged to guide a rotating tool, such as a drill discussed in more detail later. Each guide hole 34 extends along a longitudinal axis 36 and passes through the top side 22 (more specifically, through one of the raised portions 24), through one of the guide members 30, and through the bottom side 16 (more specifically, the abutment surface 18). Most of the guide members 30 have a single guide hole 34, but one of the guide members 30 (from the bottom side 16) has a single guide hole 34. Figure 3 The guide member (the rightmost guide member from the perspective of FIG. 1 ) has two guide holes 34. Each guide hole 34 is provided with an adjacent threaded blind hole 35, the purpose of which will be discussed later.

[0159] In the present embodiment, the longitudinal axes 36 of the guide holes 34 intersect the top side 22 at 90 degrees. Since the abutment surface 18 has a tapered portion, the longitudinal axis 36 of the guide hole intersects the abutment surface 18 (and therefore the bottom side 16 as a whole) at an acute angle. In the case where the tapered angle of the abutment surface 18 is 83 degrees, the longitudinal axis intersects the abutment surface 18 at 83 degrees.

[0160] Whereas the guide members 30 have a sufficient volume of aluminum to remain rigid during use, the material portions 38 have a sufficiently small volume to remain flexible beneath each of the lowered portions 26 of the top side 22. These flexible portions 38 positioned between adjacent guide members 30 are configured to allow the array 32 to bend so as to change the shape of the bottom side 16. More specifically, in this embodiment, the flexible portions are wide enough to substantially prevent bending in the width direction, but are thin enough so that the array 32 (and therefore the body 14 as a whole) can bend in the depth direction.

[0161] In order for the rotating tool guide 15 to guide the drilling of the hole 25 at the correct position on the workpiece 17, the body 14 must be fixed to the workpiece at the correct position itself. The rotating tool guide 15 has a set of clamping inserts for this purpose, one of which is in the Figure 6 Now we will combine Figures 1 to 5 Reference Figure 6 .

[0162] Each clamping insert 40 is configured to clamp the rotating tool guide 15 (particularly the body 14) against the workpiece 17 and is substantially identical in structure and function. Each clamping insert 40 has a head 42, a cylindrical barrel 44 and a shank 46. The head 42 is configured to engage the top side 22 (more particularly the raised portion 24 of the top side 22) and has a pair of flats 43. The barrel 44 is capable of being tightly received in the guide hole 34. In the present embodiment, the guide holes 34 are substantially identical to each other, so the barrel 44 of any clamping insert 40 can be tightly received in any guide hole 34. The shank 46 is narrower than the barrel 44, extends from the barrel 44 in a direction away from the head 42 and has a threaded tip 48 for engaging with a threaded hole provided by a nut (not visible) supported by the workpiece 17 behind the skin.

[0163] The body 14 may be secured against the workpiece in a desired position by inserting the clamp insert 40 into the appropriately located guide hole 34, inserting the shank 46 of the clamp insert 40 into the corresponding nut and tightening the clamp insert 40 into the nut, as described in more detail later.

[0164] The rotary tool guide 15 of this embodiment also has a set of alignment projections in the form of thumb screws. Figure 7 One of the alignment protrusions 50 is shown, and each of the alignment protrusions 50 is aligned with Figure 7 35 . Each alignment protrusion 50 has a slotted head 52, a shoulder 54, and a threaded shank 56. The shank 56 of the alignment protrusion 50 can be screwed into the threaded blind hole 35 until the shoulder 54 abuts the top side 22 to place the alignment protrusion 50 in the active configuration. With the alignment protrusion 50 in the active configuration, the alignment protrusion 50 extends from the guide member 30 (a guide member having the blind hole 35 into which the alignment protrusion has been screwed) and protrudes beyond the top side 22. Likewise, when the alignment protrusion 50 is not needed, the alignment protrusions 50 can be screwed out of their respective blind holes 35 to place the alignment protrusions 50 in the passive configuration in which the alignment protrusions 50 do not extend from the guide member 30.

[0165] The distance between each guide hole 34 and its associated blind hole 35 is selected so that, with the clamp insert 40 located in the guide hole 34, the alignment protrusion 50 can only be screwed into the blind hole 35 (i.e., moved to the active configuration) when one of the flats 43 of the head 42 of the clamp insert 40 directly faces the blind hole 35. By tightening the clamp insert 40 to the point where one of the flats is so positioned, the alignment protrusion 50 can be screwed into the blind hole 35 to fix the clamp insert 40 in this angular position, thereby preventing the clamp insert 40 from rotating and loosening, for example due to vibration or accidental collision.

[0166] Figure 8 The main body 14, all the clamping inserts 40 and all the alignment protrusions 50 are shown positioned together to engage the workpiece 17. The alignment protrusions 50 are all in their respective active configurations. Figures 1 to 7 Reference Figure 8 .

[0167] from Figure 8 It can be easily seen that each blind hole 35 of the body 14 has an associated alignment protrusion 50. Likewise, it is apparent that there are many more guide holes 34 than clamping inserts 40. In the present use case, those guide holes 34 that do not receive clamping inserts 40 instead receive tool support inserts. In this embodiment, the tool support inserts are identical to one another. Fig. 9 One of the tool support inserts 60 is shown.

[0168] Now combine Figures 1 to 8 Reference Fig. 9Each tool support insert 60 has a head 61, a cylindrical barrel 62 and a tool opening 64. The barrel 62 can be tightly received in the guide hole 34. The tool opening 64 is configured to guidely receive a drill bit (not shown) of a drilling machine and is sized to fit snugly with the drill bit so that the drill bit (not shown) must be aligned with the tool opening 64 during drilling.

[0169] The tool opening 64 defines an opening axis 66 along which a drill bit (not shown) is guided as it passes through the tool opening 64. Likewise, the barrel 62 defines a barrel axis 68. In this embodiment, the opening axis 66 and the barrel axis 68 are co-linear. Thus, with the tool support insert 60 received in the guide hole 34, the longitudinal axis 66 of the tool opening 64 will be at the same position and at the same angle regardless of the rotational position of the tool support insert 60 about the longitudinal axis 36 of the guide hole.

[0170] The head 61 is generally cylindrical but has a notch 63 and a recess 65 positioned above the lip 67. The notch 63 is shaped and positioned so that with the cylindrical portion 62 of the tool support insert 60 received in the guide hole 34 of the body 14 and the notch 63 facing the corresponding threaded blind hole 35, the head 52 of the alignment protrusion 50 can move along the notch 63. This allows the tool support insert 60 to be placed into or removed from the guide hole 34 with the alignment insert 50 remaining in the associated threaded hole 35, or likewise allows the alignment insert to be screwed into or screwed out of the threaded hole 35 with the tool support insert 60 remaining in the associated guide hole.

[0171] The height of the lip 67 is slightly greater than the height of the shoulder 54 of the alignment protrusion 50. Therefore, the lip 67 cannot fit under the head 52 of the alignment protrusion 50 when the alignment protrusion 50 is fully screwed into the threaded hole 35, but can fit under the head 52 of the alignment protrusion 50 when the alignment protrusion 50 is partially screwed out. Therefore, the alignment aperture 50 can be used to fix the tool support insert 60 in a particular angular position (e.g., a position where the notch 63 faces the threaded hole 35) by fully screwing the alignment protrusion 50 in the same manner as described above, but the alignment protrusion 50 can also be used to hold the head 61 of the tool support insert 60 against the top side 22 of the body 14. In the present embodiment, the function of holding the head 61 of the tool support insert 60 against the top side 22 of the body 14 is more useful because, as described above, the position of the tool opening 64 does not depend on the rotational position of the tool support insert 60. By loosening the alignment tab 50 slightly, the space between the bottom side of the head 52 and the top side 22 of the body 14 can be increased until the space is greater than the height of the lip 67. The tool support insert 60 can then be rotated to insert the lip 67 under the head 52 of the alignment tab 50, wherein a portion of the head 52 of the alignment tab 50 is received within the recess 65 in the head 61 of the tool support insert 60. The alignment tab 50 can then be tightened down onto the lip 67 to secure the tool support insert 60.

[0172] Now combine Figures 1 to 9 Reference Figures 10 to 12 The second embodiment of the rotary tool guide of the present invention is described below. The rotary tool guide of the second embodiment is very similar to the rotary tool guide of the first embodiment, so only the differences will be described here, and the rotary tool guide from Figures 1 to 9 The corresponding features of this embodiment are indicated by the figure numerals.

[0173] The main body 14 of this embodiment differs from the main body 14 of the first embodiment only in the placement of the threaded blind holes 35 on the guide member 30. In the first embodiment, the threaded blind holes 35 are positioned radially inside their corresponding guide holes 34, while in the second embodiment, the threaded blind holes 35 are positioned radially outside their corresponding guide holes 34 and offset in the length direction.

[0174] In addition to the tool support insert 60, the rotary tool guide 15 of this embodiment also has an equal number of supplementary tool support inserts 70. Similar to the tool support insert 60, each of the supplementary tool guide inserts 70 has a cylindrical barrel 72 that can be tightly received in the guide hole 34, and a tool opening 74 that is configured to guidely receive a rotary tool therethrough. In addition, similar to the barrel 62 and tool opening 64 of the tool support insert 60, the barrel 72 of each supplementary tool support insert 70 defines a barrel axis 78, and the tool opening 74 defines an opening axis 76.

[0175] Although the supplemental tool support inserts 70 share many features with the tool support inserts 60, they differ in many ways in shape. First, the head 80 of the supplemental tool support inserts 70 is larger than the head 61 of the tool support inserts 60 and lacks the primary cylindrical shape of the head 61 of the tool support inserts 60. The head 80 of each supplemental tool support insert 70 does have a recess 82 that can accommodate the head 52 of the tool support portion in a manner similar to the recess 65 of the tool support inserts 60. However, the recess 82 is a shape that is complementary to the head 52 of the alignment insert 50, while the recess 65 is not a shape that is complementary to the head 52 of the alignment insert 50, and the head 80 lacks a recess similar to the recess 63 of the tool support insert 60.

[0176] The supplementary tool support insert 70 also differs from the tool support 60 in that the bore axis 76 and the barrel axis 78 are not co-linear. Instead, the bore axis 76 and the barrel axis 78 are positioned at an angle to each other. In the present case, the bore axis 76 and the barrel axis 78 are positioned at an angle of 7 degrees, thereby enabling the tool bore 74 to be positioned to intersect the abutment surface 18 of the body 14 at 90 degrees.

[0177] With the bore axis 76 and the barrel axis 78 positioned at an angle to each other, the position and alignment of the bore axis 76 (and therefore the rotating tool guided thereby) depends on the rotational position of the supplementary tool support insert 70 about the longitudinal axis 36 of the guide hole 34 in which the supplementary tool support insert 70 is received. The position of the recess 82 in the head 80 is selected so that the tool bore 74 is in the correct position with the recess 82 pointing toward the blind hole 35 associated with the guide hole 34 in which the supplementary tool support insert 70 is received.

[0178] In a manner similar to holding the clamp insert 40 or the tool support insert 60 in a desired rotational position, the alignment protrusion 50 can be placed in an active configuration to secure the supplemental tool support insert 70 in place. When the alignment protrusion 50 is screwed into the blind hole 35, a portion of the head 42 of the alignment protrusion 50 is received in the recess 82, which prevents the supplemental tool support insert 70 from rotating out of this position. In fact, in this embodiment, the recess 82 is positioned above a lip (not visible) that is slightly higher than the shoulder 54 of the alignment protrusion 50. Therefore, the recess 82 can secure the supplemental tool support insert 70 in an angular position in a manner similar to the notch 63 of the tool support insert 60, and also secure the supplemental tool support insert 70 against the top side 22 of the body in a manner similar to the recess 65 of the tool support insert.

[0179] The supplemental tool support insert 70 also differs in shape from the tool support insert 60 in that the tool opening 74 of the supplemental tool support insert 70 is larger. This is because while the tool opening 64 of the tool support insert 60 is sized to fit a drill bit, the tool opening 74 of the supplemental tool support insert 70 is sized to fit a countersink.

[0180] Now combine Figures 1 to 11 Reference Fig.12 A method according to a second embodiment of the invention will now be described. The method of this embodiment is a method of machining a workpiece 17 using a rotating tool guide 15 to produce counterbores 25 around a set of access holes 19 in a wing 8 .

[0181] In a first step 102 of the method, the body 14 of the rotating tool guide 15 is introduced into the workpiece 17, wherein the alignment protrusion 50 is in a passive configuration (i.e., not screwed into the corresponding threaded blind hole 35 of the alignment protrusion 50). The clamping insert 40 is inserted into the corresponding guide hole 34, wherein the cylindrical portion 44 of the clamping insert 40 is tightly received in the guide hole 34, which causes the tip 48 of the shank 46 of the clamping insert 40 to be inserted into a corresponding complementary structure in the form of a nut (not visible) supported in the workpiece 17 behind the skin. Then, the clamping insert 40 is rotated so that the tip 48 of the shank 46 of the clamping insert 40 is threadedly engaged with the nut, thereby forming a set of clamping mechanisms. The clamping mechanism is tightened by continued rotation of the clamping insert 40 until the bottom side 16 of the body abuts the outer surface 21 of the workpiece 17 (more specifically, the abutment surface 18 of the bottom side 16 abuts the bevel 23 of the workpiece).

[0182] In step 104, the clamping mechanism formed by the clamping inserts 40 and the nuts (not shown) corresponding to the clamping inserts 40 continue to be tightened. This clamps the bottom side 16 against the workpiece 17 and fixes the bottom side 16 in close contact with the workpiece surface 21 (more particularly the bevel 23) and fixes the bottom side 16 in place. Where necessary, some of the flexible portions 38 are deformed and bent so as to bend the array 32 of the guide members 30 in the depth direction, thereby allowing the bottom side 16 to conform to the shape of the outer surface 21 of the workpiece 17 and provide close contact. Each clamping insert 40 is tightened until one of the flat portions 43 on its head 42 points to the corresponding threaded blind hole 35, whereupon an alignment protrusion is inserted into the hole 35 to fix the clamping insert 40 in the desired rotational position and prevent the clamping insert 40 from accidentally loosening.

[0183] With the bottom side 16 of the body 14 in close contact with the workpiece surface 21, the guide holes 34 are positioned at a desired position and a desired angle relative to the workpiece 17. In step 106, a rotating tool (not shown) is inserted into the workpiece 17 through some of the guide holes 34 (those guide holes that do not accommodate the clamping insert 40) to process the workpiece 17, wherein the guide holes 34 guide the rotating tool (not shown) to move into the workpiece 17.

[0184] In the present embodiment, this step is performed as two stages 108, 110. In the first stage 108, which is a drilling stage, the tool support insert 60 is inserted into all the guide holes 34 that do not accommodate the clamping insert 40, and more alignment inserts 50 are fixed. Each alignment insert 50 is screwed into one of the threaded blind holes 35, wherein the head 52 of the alignment insert 50 progressively travels along the notch 63 of the associated tool support insert 60, and then the tool support insert 60 is rotated to place its lip 67 under the alignment insert 50, and the alignment insert 50 is tightened to hold the tool support insert 60 against the top side 22 of the body 14.

[0185] A rotary tool in the form of a drill is then inserted into the tool opening 64 of each tool support insert 60 in turn, thereby drilling a hole around the access hole 19. For each hole, the associated guide hole 34 indirectly guides the movement of a drill bit (not shown) via the tool support insert 60, wherein the guide hole 34 determines the position of the tool support insert 60 and the tool support insert physically guides the movement of the drill bit using the tool opening 64. After all holes have been drilled, the tool support inserts 60 are removed from their respective guide holes 34 in preparation for the second stage 110. In this embodiment, the alignment tabs 50 securing the tool support inserts 60 are completely removed, rather than just being loosened to release the lip 67 of the tool support insert 60.

[0186] The second stage 110 is the countersinking stage. The supplementary tool support inserts 70 are inserted into all guide holes 34 that are not occupied by the clamping inserts 40 (i.e., the same guide holes 34 that previously guided the movement of the drill (not shown) via the tool support inserts 60). Each supplementary tool support insert is then secured in a desired rotational position using one of the previously removed alignment inserts 50. After each supplementary tool support insert 70 is inserted into the guide hole 34, the supplementary tool support insert 70 is rotated about the longitudinal axis 36 of the guide hole 34 until the recess 82 in the head of the supplementary tool support insert 70 is aligned with the associated threaded blind hole 35. The alignment protrusion 50 is then screwed into the hole 35, and the head 52 of the alignment protrusion 50 is received in the recess 82 to secure the supplementary tool support insert 70 in the desired rotational position (and to secure the head 80 of the supplementary tool support insert 70 against the body 14).

[0187] With the supplementary tool support inserts 70 fixed, a second rotary tool in the form of a countersink drill (not shown) is inserted sequentially through the guide holes 34 into the tool opening 74 of each supplementary tool support insert 70 and into the workpiece 17 to countersink the hole drilled in the previous stage 108. For each hole, the associated guide hole 34 indirectly guides the movement of the countersink drill (not shown) via the supplementary tool support insert 70, wherein the guide hole 34 determines the position of the supplementary tool support insert 70 and the supplementary tool support insert 70 physically guides the movement of the countersink drill using the tool opening 74.

[0188] In step 112, the rotating tool guide 15 is removed from the workpiece 17. The alignment protrusion 50 of the fixed complementary tool support insert 70 is unscrewed to move the alignment protrusion 50 to the passive configuration, and the clamping insert 40 is rotated to loosen the clamping mechanism and disengage the threaded tip 48 of the clamping insert 40 from the nut (not shown). The body 14 and the clamping member 40 can then be removed from the workpiece together or separately from each other.

[0189] In a modification of this embodiment, the clamping member 40 may then be inserted into a different guide hole 34 to reattach the body and allow drilling to be guided by the guide hole that previously contained the clamping member 40. However, in this embodiment, sufficient holes can be produced without this step.

[0190] In a final step 114, the remaining alignment protrusions 50 are removed, followed by the supplementary tool support insert 70. The rotary tool guide 15 is then ready for another access hole 19, located at a different location on the same workpiece 17 or on a different workpiece. In this embodiment, the above steps are performed three times to produce three different access holes on the wing 8, wherein the same rotary tool guide is used for each case.

[0191] It will be appreciated that many modifications of the embodiments described above may also fall within the scope of the invention as defined by the appended claims. For example, in the embodiments above, the guide members and the flexible portion are formed integrally with each other from a single piece of aluminium. In one modification, the guide members are each made of aluminium but the flexible portion is provided by a continuous annular spring steel strip to which the guide members are attached.

[0192] For the avoidance of doubt, it should be understood that the terms "tool support insert" and "supplemental tool support insert" do not imply any particular order of use. In the above embodiments, the tool support insert may be equally considered a supplemental tool support insert, and the supplemental tool support insert may be considered a tool support insert.

[0193] Where reference is made to an entirety or element in the foregoing description that has a known, obvious or foreseeable equivalent, such equivalents are incorporated herein as if set forth individually. Reference should be made to the claims to determine the true scope of the invention, which should be interpreted as including any such equivalents. The reader will also understand that entireties or features of the invention described as preferred, advantageous, convenient, etc. are optional and do not limit the scope of the independent claims. In addition, it is understood that such optional entireties or features may be beneficial in some embodiments of the invention, but may not be desirable in other embodiments, and therefore may not exist.

[0194] Unless the context requires otherwise, the term "or" should be construed as "and / or".

Claims

1. A rotary tool guide, comprising: a bottom side portion and a top side portion, the bottom side portion being configured for abutment with a workpiece, the top side portion facing away from the bottom side portion; a plurality of rigid guide members; as well as A plurality of guide holes, each of which is arranged to guide a rotating tool, wherein: Each guide hole extends along the longitudinal axis and passes through the top side, the guide member and the bottom side; and The guide members are distributed in a generally annular elongated array, wherein flexible portions are located between the guide members, the flexible portions allowing the generally annular elongated array to bend so as to change the shape of the bottom side, in: The rotary tool guide also includes a set of one or more tool support inserts; and Each tool support insert has a cylindrical portion that is closely received in the guide hole and a tool opening configured to guidingly receive a rotating tool therethrough, and wherein in each of the tool support inserts, the tool aperture defines an aperture axis and the barrel defines a barrel axis, the aperture axis and the barrel axis being positioned at an angle to one another.

2. The rotary tool guide according to claim 1, wherein: The elongated array extends along a length direction and has a width direction and a depth direction, and the flexible portion allows the elongated array to bend at least in the depth direction.

3. The rotary tool guide according to claim 2, wherein: The flexible portion allows the elongated array to bend substantially only in the depth direction.

4. The rotary tool guide according to any one of claims 1 to 3, wherein: The rotary tool guide includes a set of one or more supplemental tool support inserts; Each supplemental tool support insert has a cylindrical portion closely receivable in the guide bore and a tool opening configured to guidingly receive a rotary tool therethrough; and The supplemental tool support insert is different in shape from the tool support insert.

5. A rotary tool guide according to any preceding claim, further comprising a set of one or more clamping inserts configured to clamp the rotary tool guide against a workpiece, each clamping insert having a cylindrical portion that can be tightly received in the guide hole and a head configured to engage a top surface.

6. The rotary tool guide according to claim 5, wherein: Each clamping insert has a shank extending from the barrel in a direction generally away from the head, the shank being narrower than the barrel.

7. The rotary tool guide of any preceding claim, further comprising a set of one or more alignment protrusions, each alignment protrusion having an active configuration in which the alignment protrusion extends from the guide member and protrudes beyond the top surface.

8. The rotary tool guide according to claim 7, wherein: Each alignment protrusion also has a passive configuration in which the alignment protrusion does not extend from the guide member.

9. A rotary tool guide according to any preceding claim, wherein: The longitudinal axes of the guide holes each intersect the bottom side at an acute angle.

10. A rotary tool guide according to any preceding claim, wherein: The longitudinal axes of the guide holes each intersect the top surface at approximately 90 degrees.

11. A rotary tool guide according to any preceding claim, wherein: The guide member and the flexible portion are formed integrally with each other, the flexible portion being in the form of a narrow section of material, or wherein the flexible portion and the guide member comprise different materials.

12. An orientation structure for orienting a rotating tool, the orientation structure comprising: a base portion and a top surface, the base portion being adapted to engage a workpiece, the top surface being located on a face of the orienting structure opposite the base portion; two or more non-flexible directional members; Two or more directional apertures, each positioned to receive a rotating tool therethrough, wherein: Each orientation aperture extends along a centerline and extends through the orientation structure, through the top surface, one of the orientation members, and the base; The orienting members are positioned in a longitudinal arrangement along the elliptical path to form an elliptical layout of orienting members and are spaced apart from each other by flexible regions; and The oval configuration and therefore the base can be bent by deformation of the flexible region, And among them: The orienting structure further includes a set of one or more tool support inserts; and Each tool support insert has a cylindrical portion that is closely receivable in the directional aperture and a tool opening configured to guidingly receive a rotating tool therethrough, and Wherein, in each tool support insert, the tool aperture defines an aperture axis and the barrel defines a barrel axis, the aperture axis and the barrel axis being non-parallel to one another.

13. A method of machining an access hole in a workpiece, the method using a rotary tool guide according to any one of claims 1 to 12, the method comprising: placing the bottom side of the rotating tool guide in abutment with a workpiece surface; fixing the bottom side portion of the rotary tool guide in close contact with the workpiece surface by deforming one or more of the flexible portions so that the shape of the bottom side portion conforms to the shape of the workpiece surface; as well as Inserting a rotating tool through a guide hole of one of the guide members and into the workpiece to process the workpiece, the guide hole guiding the movement of the rotating tool into the workpiece, wherein: The method further includes inserting the cylindrical portion of the tool support insert into the guide bore prior to inserting the rotary tool; and The guide hole guides the movement of the rotating tool via the tool support insert, the guide hole determines the position of the tool support insert, and the tool opening of the tool support insert guides the movement of the rotating tool into the workpiece, and Wherein, the step of inserting the cylindrical portion of the tool support insert into the guide bore includes fixing the tool support insert in a desired angular position about the longitudinal axis of the guide bore.

14. The method according to claim 13, wherein: The method further comprises: inserting the cylindrical portion of the supplemental tool support insert into a guide hole of one of the guide members; and then inserting a rotating tool through the guide hole and into the workpiece to process the workpiece, wherein the guide hole guides the movement of the rotating tool via the supplementary tool support insert, the guide hole determines the position of the supplementary tool support insert, and the tool opening of the supplementary tool support insert guides the movement of the rotating tool into the workpiece, Therein, the same guide bore guides the movement of the rotating tool via the tool support insert and at different times guides the movement of the rotating tool via the supplementary tool support insert.

15. A workpiece comprising a wing skin, wherein: An access hole is provided in the wing skin, the periphery of the access hole having an array of circumferential, substantially elliptical holes machined using the apparatus of any one of claims 1 to 12 and / or the method of any one of claims 13 or 14.

16. An aircraft comprising a workpiece according to claim 15.

Images