DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of invention:
A MODULAR TOOLING/FIXTURE FOR BE1000 TRACK LINKS KEYWAY MACHINING AND METHOD THEREOF

Applicant:
BEML Limited
A company Incorporated in India under the Companies Act, 1956
Having Address As:
BEML Soudha, 23/1, 4th Main,
Sampangirama Nagar, Bengaluru - 560 027,
Karnataka, India

The following specification particularly describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present invention claims priority from Indian patent application numbered IN 202241060342 filed on 21st October, 2022.

FIELD OF INVENTION
[002] The present subject matter described herein, in general, relates to development of tooling/fixture for key machining and more specifically relates to development of tooling/fixture for BE1000 track links keyway machining.

BACKGROUND OF THE INVENTION
[003] At present Keyway is generated in BE1000 Track Links on conventional milling machine and Chamfering by hand grinding, which needs multiple setup and operation including bench work. More processing time leads to less productivity. The cycle time for production of one keyway is 13 minutes.
[004] Thus, as an alternative solution, a tooling/fixture is to be developed Broaching (machining) of BE1000 Track Links in HMT Broaching Machine for Key-Way generation in place of Key-way Milling & Chamfering to overcome the above constraint.

OBJECTS OF THE INVENTION
[005] Main object of the present invention is to develop a tooling/fixture for keyway machining.
[006] Another object of the present invention is Development of Modular Type Fixture to Process LH & RH Track Links in single Fixture by interchanging the Locaters on HMT Horizontal Broaching machine.
[007] Yet another object of the present invention is Development of Key-Way Broach (KBR-049) to generate the Key-way in single pass to eliminate multiple operations viz; Key-way milling and Chamfering.

SUMMARY OF THE INVENTION
[008] Before the present system is described, it is to be understood that this application is not limited to the particular machine or an apparatus, and methodologies described, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosures. It is also to be understood that the terminology used in the description is for the purpose of describing the particular versions or embodiments only, and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to the development of tooling/fixture for BE1000 track links keyway machining, and the aspects are further elaborated below in the detailed description. This summary is not intended to identify essential features of the proposed subject matter nor is it intended for use in determining or limiting the scope of the proposed subject matter.
[009] The present subject matter described herein, in general, relates to development of tooling/fixture for BE1000 track links keyway machining. This broaching method generates keyway using a single operation.

BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing summary, as well as the following detailed description of embodiments, is better understood when read in conjunction with the appended drawing. For the purpose of illustrating the disclosure, there is shown in the present document example constructions of the disclosure, however, the disclosure is not limited to the specific methods and apparatus disclosed in the document and the drawing:
[0011] The detailed description is described with reference to the accompanying figure. In the figure, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawing to refer like features and components.
[0012] Figure 1 illustrates a front view of the BE1000 track link with keyway.
[0013] Figure 2 illustrates a schematic view of the BE1000 track link with keyway.
[0014] Figure 3 illustrates a schematic view of the developed fixture with broaching machine.
[0015] Figure 4 illustrates the top view and front view of the face plate located on the fixture.
[0016] Figure 5 illustrates the schematic view of the face plate located on the fixture.
[0017] Figure 6 illustrates a puller head mounted on the fixture.
[0018] Figure 7-8illustrates a locator fixed to the fixture face plate.
[0019] Figure 9-11 illustrates a vertical bracket and horizontal bracket of the fixture.
[0020] Figures 12 illustrates a broach guide mounted on the fixture
[0021] Figures 13 and 14 illustrates the locating plate mounted on the fixture.
[0022] Figure 15 and 16 illustrates a supporting block provided for rigidity of track links.
[0023] Figure17 illustrates locators used to hold the track link during idle pass.
[0024] Figure 18 illustrates diamond pin locators used to hold the track link during cutting pass.
[0025] Figure 19illustrates the keyway broach.
[0026] Figure 20 illustrates a flow chart of the method of making a desired keyway.
[0027] The figure depicts various embodiments of the present disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF THE INVENTION
[0028] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words "comprising", “having”, and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, systems and methods are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0029] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated, but is to be accorded the widest scope consistent with the principles and features described herein.
[0030] The present subject matter is development of tooling/fixture for BE1000 track links keyway machining in place of Key-way Milling & Chamfering. This eliminates multiple machining operations on different work centers using broaching (machining) method. The keyway generation and chamfering in one setup by means of Broaching which enhances productivity and reduction in cycle time from 13 mins to 3 mins.
[0031] Referring to figure 3, a fixture assembly (2) is developed of a predefined profile for mounting the BE 1000 track link (3) on the fixture (2). The broach (4) is developed based on the profile of the keyway (1) to be grooved on the BE 1000 track link (3). The stroke length of the broach (4) is calculated based on the length of the keyway (1). Similarly, the broach loadand the cutting edges of the broach are calculated based on the keyway (1) and the material of the BE1000 track link (3).
[0032] The features of the fixture are shown in detail from figures 4-19. Figure 4 and 5 illustrates the top view and front view of the face plate (5) located on the fixture (2). The face plate (5) is mounted on horizontal broaching machine face plate (12) for alignment of fixture (2) w.r.t. key way broach. Figure 6 illustrates a puller head mounted on the fixture (2) configured for holding and pulling the key way broach (4). Figure 7 and 8 illustrates alocator (14) fixed to the fixture face plate (5) to ensure the concentricity of fixture face plate (5) with machine face plate. Figure 9-11illustrates a vertical bracket (6) provided for mounting a pin bore and bush bore locators (8) for idle pass of broach (4) (non-cutting pass). A bottom/horizontal bracket (7) is provided to mount the vertical bracket (6) with locators and also for mounting hydraulic cylinder for positive clamping of Track Links (3). Figure 12 illustrates a broach guide (13)i.e a guide way for the broach w.r.t. broach puller head ram. Figure 13 and 14 illustrates locating plates (10) (LH & RH) provided between fixture face plate (5) and diamond pin locators (9) of bush and pin bores of the track links to ensure modularity fixture concept to accommodate LH and RH Track Links (3). Figure 15 and 16 illustrates a supporting block (11) provided for rigidity of track links (3) against hydraulic clamps while machining key way. Figure 17 illustrates locators (8) used to hold the track link (3) during idle pass (Non cutting pass) to keep the link ready for broaching to reduce the idle time of the machine for better productivity. Figure 18 illustrates diamond pin locators (9) used to hold the track link (3) during cutting pass. Figure 19 illustrates the key way broach (4) for machining the keyway (1).
[0033] Referring to figure 20, the method of existing method of keyway machining is studied. The dimensional requirements and Geometrical accuracies of BE1000 Track links are studied. The schematic layout of Broaching machine, stroke length of the Broach, Broaching load and cutting edges etc are developed. Modular Type fixture to accommodate LH and RH BE1000 Links are developed. The technical specifications of Keyway broach are freezed. Manufacturing drawings released and procured the fixtures and Broach. On-job trial performance is carried out and the dimensional aspects as per the drawing is achieved. Further, similar concepts are planned and proposed for Dome Nut Seating area Broaching.
[0034] In this development multiple setups for Milling and chamfering operation is integrated into one single Broaching operation leading to significant reduction of cycle time. It is easier to clamp the components into the fixture. It reduces the operator fatigue. It provides improved surface finish.
[0035] Figures 1-20 are now described using the reference numbers stated in the below table.
Reference Numeral Description
1 Keyway
2 Fixture
3 BE 1000 Track Link
4 Key way Broach
5 Face plate of fixture
6 Vertical plate
7 Horizontal plate
8 Pin bore and bush bore locators
9 Diamond pin locator
10 Locating plate
11 Supporting plate
12 Broaching machine face plate
13 Broach guide way
14 Locator

,CLAIMS:
1. A modular tooling/fixture for BE1000 track links (3) keyway machining comprising:
a fixture assembly (2) configured to adapt a BE1000 track link (3); and
a broaching assembly configured to develop a keyway (1) of a predefined profile on the BE1000 track link (3).

2. The fixture as claimed in claim 1 wherein, said fixture assembly (2) is configured from components viz., a face plate (5), a vertical plate (6), a horizontal plate (7), a locator (8), a diamond pin locator (9), a locating plate (10), a supporting plate (11) and a locator (14).

3. The fixture as claimed in claim 1 wherein, said broaching assembly is configured of a broach (4) and a guide way (13).

4.The fixture as claimed in claim 1, wherein said guide way (13) is configured to support the broach (4) and to guide the broach (4) in cutting operation.

5. The fixture as claimed in claim 1, wherein said broach (4) is configured of a predefined broach load and a predefined cutting edge based on the keyway (1) and the material of BE 1000 track link (3).

6. The fixture as claimed in claim 1, wherein said face plate (5) is configured to be mounted on a broaching machine face plate (12) for alignment of said fixture (2) selectively w.r.t. key way broach (4) to adapt left hand or right hand BE1000 Links.

7. The fixture as claimed in claim 1, wherein a puller head is mounted on the Broaching machine for holding and pulling the key way broach (4).
8.The fixture as claimed in claim 1, wherein a locator (14)is configured to be mounted on said fixture face plate (5) for aligning said fixture face plate (5) with said machine face plate.

9. The fixture as claimed in claim 1, wherein said vertical bracket (6) is configured for mounting a locator (8) for idle pass of broach (4) to hold the track link (3) during idle pass.

10. The fixture as claimed in claim 1, wherein said horizontal bracket (7) is configured to hold the vertical bracket (6) with locators and also for mounting a cylinder for positive clamping of BE1000 track links (3).

11. The fixture as claimed in claim 1, wherein said fixture (2) is configured of plurality of diamond pin locators (9) to hold the BE1000 track links (3) on the fixture assembly (2) during cutting pass.

12. The fixture as claimed in claim 1, where in said fixture (2) is configured of plurality of locating plates (10) provided between fixture face plate (5) and plurality of diamond pin locators (9) to accommodate the left hand and right hand BE1000track links (3).

13.The fixture as claimed in claim 1, wherein said supporting block (11) is configured to provide rigidity to BE100 track links (3) against the clamps while key way (1) machining.

14. The method for developing tooling/fixture for BE1000 track links (3) keyway machining comprises the steps of:
• Mounting a fixture (2) based on the profile of the BE1000 track link (3);
• Determining the profile of the keyway (1);
• Selecting the broach (4), the broach stroke, broach load, and cutting edges of the broaching machine based on the keyway profile;
• Mounting the broach (4) on the guide way (13);
• Mounting the BE1000 track link (3) on fixture (2); and
• Machining the keyway (1) on BE1000 track link (3) based on the keyway (1) to be grooved on the left hand or right hand BE1000 track link (3).