DESC:FIELD
The present disclosure relates to an apparatus used for finishing fluted components.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Conventional apparatus for finishing fluted components utilize steel wire brush along with polishing compound or polishing paste. However, the conventional apparatus fails to provide an accurate and a precise control over the dimensions of the finished components, as there are no defined cutting edges in steel wire brush. Hence , fillet radius generated at each of the flutes of the fluted components is not uniform and varies tremendously for each flute.Thus the product to be manufactured using the fluted compoents does not give desired consistent quality output. For example, in the yarn making process, it is desired that the fillet radius of each flute has a variation within a desired tolerance limit. Additionally, the use of polishing compound or paste poses hazards to the personnel engaged in the finishing operation. Often, the bristles of steel wire brushes are prone to breakage during operation and having a tendency to fly off and cause injuries to the personnel. Moreover, this leads to increased maintenance of the apparatus which increases costs involved therein.
There is, therefore, felt an apparatus for finishing fluted components, that alleviates the above-mentioned drawbacks.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
An object of the present disclosure is to provide an apparatus for finishing fluted components that provides control over the dimensions of the finished components.
Another object of the present disclosure is to provide an apparatus for finishing fluted components that facilitates consistently producing yarn having a desired quality.
Another object of the present disclosure is to provide an apparatus for finishing fluted components that eliminates use of hazardous wire brush and pastes.
Still another object of the present disclosure is to provide an apparatus for finishing fluted components that efficiently performs the finishing, radiusing and descaling operations.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure discloses an apparatus for finishing fluted components, the apparatus having a bed mounted on the floor, the bed having a first end and a second end. The apparatus comprises a plurality of pallets configured to be disposed along the bed; a plurality of components secured in each of the pallets; a finishing station configured on the bed; and a brush stack configured to be rotatably attached to the finishing station, wherein, in an operative configuration the brush stack contacts the surfaces of the components to be machined as each of the components rotate about an operative axis A. The brush stack rotates about an axis in one direction during travel of the pallet from the first end to the second end, followed by reversal of direction of rotation of the brush stack about the axis as the pallet travels from the second end to the first end.
In a preferred embodiment, the adjacently positioned components in the pallet are configured to rotate in a direction opposite to each other.
In a preferred embodiment, the brush stack includes a plurality of brushes housed in the brush stack.
In a preferred embodiment, the brush stack is in the form of a cylinder and each of the brushes is in the form of a disc having edges.
In a preferred embodiment, the brushes have abrasive bristles configured thereon for performing machining operation of the components the abrasive bristles having abrasive particles impregnated therein.
In a preferred embodiment, the size of the abrasive particles of the abrasive bristles is adjustable, to minimize variability in the size of a fillet machined on the components.
In a preferred embodiment, the density of the abrasive particles per unit area of the abrasive bristles is adjustable, to achieve a desired quality of surface finish of the fluted components.
In a preferred embodiment, the brush stack is configured to be displaced linearly in an operative transverse direction of the apparatus with respect to the finishing station.
In a preferred embodiment, the first end and the second end of the bed are both configured to receive the plurality of pallets having the components, and transfer the components to the finishing station for carrying out machining operation.
In a preferred embodiment, the finishing station is located at an operative central location along the length of the bed of the apparatus.
In a preferred embodiment, the finishing station has a canopy to prevent possibility of injury to the workperson by the burr released during machining operation of the components.
In a preferred embodiment, the components are fluted components with the flutes inclined to the axis of the component.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
The apparatus for finishing fluted components, of the present disclosure will now be described with the help of the accompanying drawing, in which:
Figure 1 shows a view of a conventional wire brush that has no defined cutting edges and no abrasive particles impregnated therein;
Figure 2 shows a view of the wire brush of the present disclosure that shows defined cutting edges i.e. bristles having impregnated abrasives thereon, in accordance with an embodiment of the present disclosure;
Figure 3 shows an isometric view of the apparatus that uses the method for finishing fluted components, in accordance with an embodiment of the present disclosure;
Figure 4 shows a top view of the apparatus of Figure 3;
Figure 5 shows another isometric view of the apparatus of Figure 3;
Figure 6 shows a top view of the components loaded in apparatus of Figure 3;
Figure 7 shows an isometric view of a knurled component to be machined;
Figure 8 shows an isometric view of a component having flutes oriented at an angle to the component axis;
Figure 9 shows a side view of the component having flutes being finished by a brush, during the first pass of the machining method;
Figure 10 shows a side view of the component having flutes being finished by a brush, during the second pass of the machining method;
Figure 11 shows a view of the component having flutes;
Figure 12 shows an enlarged view of a flute of the component; and
Figure 13 shows an enlarged view of Figure 10 with an edge radius machined on the flute.
LIST OF REFERENCE NUMERALS USED IN DETAILED DESCRIPTION AND DRAWING
10 – brush stack
10a, 10b, 10c – brush
50 – component
50a – first component
50b – second component
50c – third component
52 – flute top
54 – radius
56 – first end
58 – second end
60 – pallet
100 – finishing station
101 – bed
102 – first end
104 – second end of bed
105 – canopy
1000 – apparatus
L – operative longitudinal direction
T – operative transverse direction
A – axis of the component
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on", “engaged to”,“connected to”, or “coupled to” another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third, etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Fluted components are typically used in yarn making process i.e. spinning. A fluted component is a shaft configured with a plurality of flutes. Flutes are grooves having peculiar shape that span the length of the shaft. The flutes facilitate guiding of threads during production of a yarn. The Conventional methods for finishing fluted components utilize steel wire brush with polishing compound or polishing paste. However, the conventional methods fail to provide accurate and precise control over the dimensions of the finished components. This is due to absence of defined cutting edges in the steel wire brush. Moreover, there is no control on the dimensions of the cutting edges 12a’, 12b’, 12c’ of the steel wire brush, as shown in the flgure 1 of the existing steel wire brush. As a consequence, a fillet radius generated on each of the flutes is not uniform and there is significant variation in the radius generated at the fillet radius of each of the flutes of the fluted component. Additionally, the use of a polishing compound or a paste poses hazards to the personnel engaged in the finishing operation. Often, the bristles of the steel wire brushes are prone to breakage during machining operation and have a tendency to fly off and cause injuries to the personnel. Moreover, this leads to increased maintenance of the apparatus of the conventional method, which increases costs involved therein. The present disclosure aims to address these shortcomings of the conventional methods.
In an embodiment of the present disclosure, referring to the figures 1-13, an apparatus 1000 for descaling, finishing and edge radiusing operation of the fluted components will now be described. The apparatus 1000 has a bed 101 mounted on the floor and spans in an operative longitudinal direction L. The apparatus 1000 comprises a finishing station 100 located centrally with respect to the bed 101 of the apparatus 1000. The apparatus has a first end 102 of the bed 101 and a second end 104 of the bed. The first end 102 and the second end 104 of the bed 101 are configured to receive a plurality of pallets 60. The pallets 60 secure a plurality of components 50 that are required to be machined by the apparatus 1000. The components 50 are held in the pallets 60 and the pallets 60 are conveyed to the finishing station 100 for descaling, finishing and edge radiusing operation. At a time, a single pallet 60 having components 50 mounted thereon can be conveyed to the finishing station 100 for carrying out machining operation. A brush stack 10 is provided on the finishing station 100. The brush stack 10 is configured to be rotated in the finishing station 100 about an axis 12. In a preferred embodiment, the axis 12 is oriented in an operative horizontal direction. The direction of rotation of the brush stack 10 is configured to be reversed. The brush stack 10 is configured to be linearly displaced in an operative transverse direction T so as to engage or disengage the brush stack 10 from the components 50 to be machined. The brush stack 10 includes a plurality of brushes 10a, 10b, 10c having bristles 12a, 12b, 12c made of an abrasive material. More [articularly, the bristles 12a, 12b, 12c are impregnated with abrasive particles. The grain size or grit size as well as the density of the abrasive particles per unit volume of the bristles 12a, 12b, 12c is adjustable. Further, the diameter and the length of the bristles 12a, 12b, 12c is adjustable. This imparts increased control in machining a fillet radius of each of the flutes of the fluted components. In a preferred embodiment, each of the brushes 10a, 10b, 10c is in the form of a disc, and the brush stack 10 is also in the form of a cylinder. The brushes 10a, 10b, 10c are positioned adjacent to each other to impart cylindrical shape to the brush stack 10. The brush stack 10 with the brushes 10a, 10b, 10c imparts a well-defined construction profile thereto, which facilitates accurate machining of the components 50. More specifically, the well-defined cutting edges of the brushes 10a, 10b, 10c. Each component 50 is configured to be rotated in the finishing station 100 about an axis A of the component 50. The direction of rotation of each component 50 is configured to be reversed about the axis A when the components 50 travel in the direction from the second end 104 to the first end 102 of the bed. The finishing station 100 has a canopy 105 to prevent possibility of injury to the workperson by the burr released during machining operation of the components 50.
In an embodiment, the pallets 60 facilitate positioning of a plurality of components 50 having flutes. The grit size controlled abrasive particles are impregnated on the bristles of the brushes 10a, 10b, 10c to machine the flutes of the components 50. The density of grinding particles can be controlled per unit volume of the bristles. The parameters of the bristles such as diameter and length can be controlled as desired to obtain the desired processing on the components 50. During processing of the component 50, a flute top 52 is polished to an Ra value within the range of 0.2 to 0.4 microns, as well as the edge of the flutes are provided with a radius 54. The radius 54 is obtained between 25 to 50 microns. The areas other than the flute top 52 are descaled including the area between the adjacent flutes and roots of the flutes. Adjacent components 50 positioned on each of the pallets 60 are configured to be rotated in opposite direction.
In another embodiment, a single fluted component 50 may be finished using the method and the apparatus 1000 of the present disclosure.
In another embodiment, a single pallet 60 having the fluted compnents 50 desired to be finished may be conveyed with the method and the apparatus 1000 of the present disclosure.
In yet another embodiment, a conveyor may be provided to transport the fluted components 50 that are desired to be finished.
The working of the apparatus 1000 will now be explained. One of the loaded pallets 60 moves inside the finishing station 100. Each of the components 50 is held between revolving centres of the finishing station 100. Each of the components 50 rotate about an axis A. The direction of rotation of each of the component 50 is configured to be reversed. The adjacently positioned components 50 always rotate in opposite direction to each other. In an embodiment, when viewed from one end of the apparatus 1000, if a first component 50a rotates in clockwise direction, a second component 50b placed adajacently to the first component 50a rotates in counterclockwise direction. A third component 50c placed adjacent to the second component 50b rotates in clockwise direction and so on, as shown in the figure 4. In a further step of the machining operation, the brush stack 10 is configured to be linearly displaced in an operative transverse direction T of the apparatus 1000 with respect to the finishing station 100. The linear displacement of the brush stack 10 in the operative transverse direction T is done to contact the bristles of the brushes (10a, 10b, 10c) of the brush stack 10 with each of the components 50. The component 50 moves along a longitudinal axis A from the first end 102 to the second end 104 of the bed 101 to ensure that the entire the length of the components 50 is machined. As the components 50 reach the second end 104 of the bed 101, a first pass of the machining is completed. As shown in the figure 9, during first pass, the brush stack 10 is rotated in an anticlockwise direction as seen from a front side of the apparatus 1000. This is indicated by the arrows in the figure 9. In a second pass of the machining operation, the pallet 60 with the components 50 is linearly displaced in the longitudinal direction L along the bed 101 of the apparatus 1000 from the second end 104 towards the first end 102. During the second pass, the brush 10 stack rotation is reversed as well as the direction of rotation of the components 50 about the axis A is reversed. As shown in the figure 10, during second pass, the brush stack 10 is rotated in a clockwise direction as seen from the front side of the apparatus 1000.
This is indicated by the arrows in the figure 9. The first component 50a now rotates in the counterclockwise direction and the second component 50b now rotates in the clockwise direction, and the third component 50c rotates in the counterclockwise direction, and so on. In a further step, the brush stack 10 is linearly displaced in the operative transverse direction T so as to cease the contact between the components 50 and the bristles of the brushes (10a, 10b, 10c) of the brush stack 10. The linear displacement of the brush stack 10 in the transverse direction T is accomplished by a pneumatic cylinder. The finishing operation is complete.
The apparatus 1000 facilitates accurate and precise finsihing of the components 50 positioned on the pallet 60. The use of wire brush and pastes is eliminated and the probability of hazards posed to the working personnel are reduced. Moreover, the apparatus 1000 eliminates the requirement of a lower limit of cutting speed of the brush stack 10. As the brush stack 10 has definite cutting edges thereon, finishing quality is improved significantly.
In an embodiment, the combination of different abrasive particles used on the bristle filament is in the range of 40 to 60 percent. The diameter of each bristle 12a, 12b, 12c can be controlled. The abrasive bristle brush 10a has abrasive particles impregnated on the bristles 12a, 12b, 12c, hence grinding particle size i.e. grain size or grit can be defined. Moreoever, the density of grinding particles can be controlled in unit area of bristles.
In another embodiment, different properties of distinct filaments can be combined to achieve descaling and radiusing at the same time. In addition, the equal edge radiusing on all the fluted area and a good descaling and good surface fininsh on the top of the flutes is obtained by the apparatus 1000 of the present disclosure.
In a preferred embodiment, the components 50 are fluted components with the flutes inclined to the axis A of the component 50.
A method for finishing fluted components will now be described. The method for finishing fluted components comprises the following steps:
• transporting the fluted components 50 to be finished into the finishing station 100 along the operative longitudinal direction L;
• rotating the fluted components 50 in one direction along an operative axis A, with the adjacent components 50a, 50b rotating in opposite direction;
• rotating the brush stack 10 with each brush having bristles impregnated with abrasive particles, the brush stack 10 being rotatable about an operative axis 12;
• displacing the brush stack 10 in an operative transverse direction T driven by a pneumatic cylinder,
• displacing the pallets 60 from the first end 102 to the second end 104 to perform finishing operation on the fluted components 50 in a first pass, as the length of the fluted components 50 is completely traversed along the operative longitudinal direction L ;
• reversing the direction of rotation of the fluted components 50a, 50b along the operative axis A, as well as reversing the direction of rotation of the brush stack 10 along the operative axis 12;
• reversing the traveling direction of the pallet 60 with the fluted components 50 along the operative longitudinal direction L from the second end 104 to the first end 102 to perform finishing operation in a second pass;
• displacing the brush stack in an operative transverse direction T, thereby disengaging the brush stack 10 from the fluted components 50 and completing the finishing operation.
The technical advancement of the present disclosure lies partly in improved brush stack construction, and partly in the method in which the sense of rotation of the brush stack relative to the sense of rotation of the fluted components, and the direction of travel of the fluted components in the longitudinal direction L. The brush bristles are impregnated with abrasive particles whose dimensions are controlled. More specifically, the size of the abrasive particles is adjustable to minimize variability in the size of the fillet machined on the components 50. The density of the abrasive particles per unit area of the abrasive bristles 12a, 12b, 12c on the brush 10a is adjustable, to achieve a desired quality of surface finish of the fluted components 50.
On the other hand, the direction of rotation of the brush stack 10, the direction of rotation of the fluted components 50, and the travel of the fluted components 50 in the longitudinal direction L between the first end 102 and the second end 104 facilitates formation of the machining burr on the same side during the first pass and the second pass.
The construction of the bristled brush stack, in particular, the construction of each of the bristles 12a, 12b, 12c, as well as the method of machining the fluted components 50 eliminates a lower limit of cutting speed.
Further, it is highly desirable to maintain a predetermined level of accuracy and precision of the dimensions of the flutes of the components 50. As the flutes of the components 50 determine the quality of the yarn produced, controlling the machining method and the construction of the bristle brush stack 10 is highly desired. Thus, quality of yarn produced is controlled by the apparatus 1000 and method of the present disclosure.
EXAMPLE
Table 1 shows a comparison between the method of the present disclosure and the conventional method for the various parameters listed below. The parameters were Ra roughness values, edge radius i.e. the fillet radius on the edge of each of the flutes. It is observed that the edge radius i.e. the fillet radius obtained on each of the flutes of the fluted components with the present disclosure has less variability as compared to the edge radius obtained on each of the flutes of the fluted components having a greater variability of 15 to 80 microns. Similar trend was observed while analysing the surface roughness values. For both the parameters of the edge radius and the surface roughness, it is seen that the desired criteria is met by the fluted components that were machined by the method and apparatus of the present disclosure. With regards to the performance in removing black scales, the apparatus of the present disclosure offered superior performance to the conventional apparatus and method without the release of any hazardous chemicals.
Parameter Criteria Conventional method of wire brush with no defined cutting edges Present disclosure method with defined cutting edges of bristle brush and with impregnated abrasive particles
Roughness Ra= 0.2 to 0.4 microns Ra < 0.2 microns Ra = 0.2 to 0.4 microns
Rsk < -0.5 microns Rsk > +0.1 microns Rsk < -0.5 microns
Edge Radius 20 to 50 microns 15 to 80 microns 20 to 50 microns
Black Scale Removal OK, with a polishing paste Polishing Paste OK without any hazardous chemical used

The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an apparatus for finishing fluted components, that:
• increases accuracy and precision of machine components;
• reduces possibility of hazard to personnel; and
• decreases cost of maintenance.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, or step, or group of elements, or steps, but not the exclusion of any other element, or step, or group of elements, or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. An apparatus [1000] for finishing fluted components, said apparatus [1000] having a bed [101] mounted on the floor, the bed [101] having a first end [102] and a second [104], said apparatus [1000] comprising:
• a plurality of pallets [60] configured to be disposed along the bed [101];
• a plurality of components [50] secured in each of said pallets [60]; configured to roatated in both drections, pl. confirm
• a finishing station [100] configured on the bed;
• a brush stack [10] configured to be rotatably attached to said finishing station [100], wherein, in an operative configuration said brush stack [10] contacts the surfaces of the components [50] to be machined as each of the components [50] rotate about an operative axis [A];
wherein, said brush stack [10] rotates about an axis [12] in one direction during travel of said pallet [60] from the first end [102] to the second end [104], followed by reversal of direction of rotation of said brush stack [10] about the axis [12] as the pallet [60] travels from the second end [104] to the first end [102].
2. The apparatus as claimed in claim 1, wherein the adjacently positioned components in said pallet [60] are configured to rotate in a direction opposite to each other.
3. The apparatus as claimed in claim 1, wherein said brush stack [10] includes a plurality of brushes (10a, 10b, 10c) housed in said brush stack [10].
4. The apparatus as claimed in claim 1, wherein the brush stack [10] is in the form of a cylinder and each of the brushes (10a, 10b, 10c) is in the form of a disc having edges.
5. The apparatus as claimed in claim 3, wherein said brushes (10a, 10b, 10c) have abrasive bristles configured thereon for performing machining operation of the components, said abrasive bristles having abrasive particles impregnated therein.
6. The apparatus as claimed in claim 5, wherein the size of the abrasive particles of the abrasive bristles is adjustable, to minimise variability in the size of a fillet machined on the components [50].
7. The apparatus as claimed in claim 5, wherein the density of the abrasive particles per unit area of the abrasive bristles is adjustable, to achieve a desired quality of surface finish of the fluted components [50].
8. The apparatus as claimed in claim 1, wherein the brush stack [10] is configured to be displaced linearly in an operative transverse direction [T] of the apparatus [1000] with respect to said finishing station [100].
9. The apparatus as claimed in claim 1, wherein the first end [102] and the second end [104] of the bed [101] are both configured to receive said plurality of pallets [60] having the components [50], and transfer the components [50] to the finishing station [100] for carrying out machining operation.
10. The apparatus as claimed in claim 1, wherein said finishing station [100] is located at an operative central location along the length of the bed [101] of the apparatus [1000].
11. The apparatus as claimed in claim 1, wherein said finishing station [100] has a canopy [105] to prevent possibility of injury to the workperson by the burr released during machining operation of the components [50].
12. The apparatus as claimed in claim 1, wherein the components [50] are fluted components with the flutes inclined to the axis [A] of the component [50].
Dated this 18th day of April, 2023

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant