METHOD AND APPARATUS FOR CUTTING ONE OR MORE GROOVES IN A CYLINDRICAL ELEMENT

Abstract

Embodiments of the subject invention relate to a method and apparatus for cutting one or more grooves in a cylindrical element. In specific embodiments, the one or more grooves are cut into an outer surface of the cylindrical element. The cylindrical element can be solid, or can have one or more hollow portions. In a specific embodiment, the cylindrical element is a hollow tube. Embodiments also pertain to a cylindrical element having one or more grooves cut in an outer surface of the cylindrical element. Further specific embodiments are directed to cylindrical elements having one or more grooves that can be utilized as a drapery or curtain tube, where the one or more grooves, in combination with rotation of the cylindrical element, can be used for moving the drapery to one or more positions along the tube, such as from an open position for the drapery or curtain to a closed position for the drapery or curtain, by engaging an interconnecting element between the drapery or curtain and the one or more grooves while rotating the tube.

Description

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional Application Ser. No. 61/702,093, filed Sep. 17, 2012, which is hereby incorporated by reference herein in its entirety, including any figures, tables, or drawings.

BACKGROUND OF INVENTION

Embodiments of the invention relate to cutting one or more grooves in a cylindrical element.

U.S. Pat. No. 4,125,057 (Cox) teaches a motor driven milling and boring machine used primarily for forming screw threads of any selected pitch, external to cylindrical or conic projection or within similar-shaped bore of workpiece, particularly workpieces such as are too large or irregular-shaped to be themselves rotated. A tubular housing, upstanding or tiltably disposable, journals a longitudinally displaceable and rotatable hanger which in turn axially journals a power-driven spindle having a selectively offset-positionable stub portion, terminally carrying a thus radially extensible drive segment which distally positions a rotary milling cutter. A second or planetary tracking motor jointly operates a pair of selectively coupled ring gears of the housing, which in conjunction with a master nut fixed along the housing axis, move the hanger respectively annularly and axially so that the distal cutter may follow a helical path, the pitch of which path is determined by the chosen velocity ratio give the two ring gears. A particular velocity ratio results from the choice of gearing assembled in a detachable twin-segment gear train cassette insertable between the pair of ring gears. While remaining in place, the gear train may be disengaged from one drive component of the hanger to enable arcuate resetting for production of multi-start threads, or alternately to provide annular or linear movement of the cutter. A collar-shaped electromagnetic support base has associated tactile means for centering it, and hence centering the milling machine subsequently mounted thereupon, relative to the preformed bore of a workpiece which is to be threaded. Radial thrust-retraction means are provided for quick-withdrawal of a cutter head from a workface so that it can then be lifted out of a bore without retracing the helical entrance path.

U.S. Pat. No. 4,212,568 (Minicozzi) teaches a rotary cutting tool blank comprising a cutting portion having a longitudinal axis and a plurality of teeth extending the length of said cutting portion, with each of the teeth having a cutting face and a trailing face and a land surface bridging the cutting and trailing faces. The land surfaces are interrupted by a plurality of spaced transverse depressions of relatively large radius arcuate cross section to form a plurality of cutting edge portions at the junction of the cutting face and the uninterrupted portions of the land surface. The cutting edge portions have a positive rake angle, and the trailing and cutting faces of each tooth have surfaces which undulate generally sinusoidally from one end of the cutting portion to the other so that the rake angle of each cutting edge portion varies continuously along its length. The cutting tool blank can be transformed to a cutting tool ready for use simply by suitably relieving the land surfaces to form cutting edges at the aforementioned cutting edge portions.

U.S. Pat. No. 4,996,861 (Kellum) teaches an apparatus including an externally threaded spindle to which one end of a thin walled metal tube is detachably secured. The spindle is rotated to wind the tube into the external thread, thereby producing a helix. As the tube is wound onto the spindle, it is pressed into the thread grooves by an auxiliary roller.

U.S. Pat. No. 5,263,381 (Shirai) teaches a ball screw comprising a threaded rod and a ball nut making a rectilinear motion around the rod as the rod is rotated. A first load ball groove and a second load groove which have an offset relation to each other are formed in the inner surface of the ball nut. A pre-load is imparted to ball bearings rolling in these two load grooves. The ball nut has a resilient portion between the first and second load ball grooves. The resilient portion can be displaced axially. Any excessive pre-load created by the error introduced either in the lead of the ball-rolling groove or in the lead of the first or second load ball groove is absorbed by the resilient portion. Consequently, the novel ball screw is superior in accuracy to the prior art ball screw, and is easier to fabricate.

U.S. Pat. No. 5,775,187 (Nikolai et al) teaches a method of machining and a tool is used for obtaining patterns in the form of alternating ridges, pads, cells, and ridges of a triangular cross section on the surface of a blank. The method facilitates selection of the geometrical parameters of the tool and the machining mode for the tool to obtain alternating ridges and depressions with parallel sides of the profile at predetermined intervals and predetermined heights and angles of slope. The width of the space between projections can be varied in the range of millimeters and micrometers.

U.S. Pat. No. 5,971,045 (Watanabe) teaches a veneer lathe comprising a knife (2) for peeling a log (1), which is secured rotatably to a knife stock, and a roller bar (3) disposed to press a circumferential surface of the log (1) at an upstream side, in relative to said knife (2), of a rotational direction of the log (1). The roller bar (3) has a diameter of not more than 30 mm, and is provided on the circumferential surface thereof with a large number of projections (5) whose height is not higher than the circumferential surface of the roller bar (3). The roller bar (3) is sustained in a sliding bearing (9) and adapted to receive a rotational force from a driving source. The roller bar (3) functions not only as a pressure bar but also as a power transmitting media to rotate the log (1), thereby preventing the generation of lathe check of veneer to be produced.

U.S. Pat. No. 6,186,756 (Kojima) teaches a rotor 1 forming screw teeth projectingly provided at its outer end 2 on the axis thereof with a center shaft 3. The center shaft 3 is provided at its outer end 4 with a smaller-diameter shaft 5 or a concaved fitting hole. A separate rotor shaft 6 which is to be fitted over the smaller-diameter shaft 5 or fitted into the concaved fitting hole is provided with another concaved fitting hole 7 or smaller-diameter shaft. A metal shaft around which synthetic resin is molded is formed at its peripheral surface with a spiral groove or corrugated groove in the opposite revolutional direction with respect to the revolutional direction of the screw rotor. The spiral groove is formed with smooth arc curved line connecting profiles of adjacent grooves. The shaft is provided with a step, and synthetic resin is molded around the shaft surface to form a screw rotor.

U.S. Pat. No. 6,289,595 (Galestien) teaches the determination of the complete two-dimensional axial cross section of internal and external screw threads and similar workpieces, wherein in a plane through the centerline of the workpiece, two screw thread profiles which are located diametrically opposite each other are measured through two two-dimensional scan measurements in this plane or through arithmetic construction based on two profile depth measurements with a measuring ball or measuring wire, further on the basis of the assumption that the screw thread profiles in question further have a known dimension and geometry, whereafter these two opposite profiles are linked to each other by performing one or more linked measurements such as, for instance, the outside diameter in the case of external screw thread and the core diameter in the case of internal screw thread. If a proper concentricity of the core diameter, the outside diameter and flank diameter is involved, it may suffice to measure or scan only one profile and one or more linked measurements.

U.S. Pat. No. 7,849,769 (Akiyama) teaches a precision roll turning lathe which can form a pattern including three-dimensionally shaped portions, such as three-sided pyramids, on the surface of a roll, with high accuracy. Specifically, a tool post is provided with a tool turning axis (A axis) which is used to turn a tool such that, when forming a spiral groove cut through the roll, a cutting face of a tip of the tool is oriented perpendicular to a direction along which the spiral groove extends.

U.S. Pat. No. 8,308,463 (Kataoka) teaches providing a screw rotor including a resin rotor formed around a metallic shaft without generation of cracks. Spiral chamfers are formed on surfaces of metallic shafts around which resin rotors are formed. Preferably the surfaces of the shafts may be sandblasted, and after the surfaces of the shafts are preliminarily coated with resin and then the rotors may be molded.

The prior art teaches several methods to form helical or spiraling grooves in or on the outer surface of a shaft or tube. Some of these methods are complicated and time consuming ways of forming or machining the grooves. Accordingly, there is a need for a method and apparatus for more efficiently and/or more accurately machining grooves in an outer surface of a cylindrical shaft or tube.

BRIEF SUMMARY

Embodiments of the subject invention relate to a method and apparatus for cutting one or more grooves in a cylindrical element. In specific embodiments, the one or more grooves are cut into an outer surface of the cylindrical element. The cylindrical element can be solid, or can have one or more hollow portions. In a specific embodiment, the cylindrical element is a hollow tube. Embodiments also pertain to a cylindrical element having one or more grooves cut in an outer surface of the cylindrical element. Further specific embodiments are directed to cylindrical elements having one or more grooves that can be utilized as a drapery or curtain tube, where the one or more grooves, in combination with rotation of the cylindrical element, can be used for moving the drapery to one or more positions along the tube, such as from an open position for the drapery or curtain to a closed position for the drapery or curtain, by engaging an interconnecting element between the drapery or curtain and the one or more grooves while rotating the tube.

A specific embodiment involves machining two grooves, 180 degrees apart, around the outer surface of a cylindrical shaft or tube with a right hand, or clockwise, twist, and/or two grooves, 180 degrees apart, around the outer surface of the cylindrical shaft or tube with a left hand, or counter clockwise, twist.

Specific embodiments of the subject method and apparatus can incorporate one or more of the following features: machining multiple single direction (right hand or left hand) grooves in the shaft or rod at the same time; machining two grooves using two single point tools spaced a distance ½ the length of the lead; machining a groove using multiple single point tools where each single point tool machines a portion of the groove, such as a single point tool machining a rough cut depth and a further single point tool machining a finish cut depth; machining multiple right hand, or clockwise, grooves in one pass along the shaft or tube and, optionally, machining multiple left hand, or counter clockwise, grooves using an opposite directional single pass along the shaft or tube, where if more than one single point tool is used for each groove, the positions of the rough cut depth tools and the finish cut depth tools are reversed between the pass and the opposite directional pass; machining two grooves in each direction within two minutes for a ten foot shaft or tube; minimum set up time; machining either multiple grooves in a single direction or multiple groove in two directions; machining a groove using two or more tools in a single pass, which reduces tool changes compared with making a separate pass for each tool; and machining two or more grooves in a single pass using different tools for each groove, such that the alignments of the grooves are more accurate compared with machining each of the two or more grooves in separate passes.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of an apparatus for cutting one or more grooves in a cylindrical element, where the apparatus is cutting a unidirectional set of grooves.

FIG. 2 is an enlarged perspective view of the embodiment shown in FIG. 1.

FIG. 3 is an enlarged top view of the embodiment shown in FIG. 1, showing the tool holder, with a portion of a cylindrical tube shown with a cutaway in order to show the placement of the tools.

FIG. 4 is a perspective view of the apparatus of FIG. 1, where the apparatus is cutting bidirectional sets of grooves.

FIG. 5 is an enlarged perspective view of the embodiment shown in FIG. 4.

FIG. 6 is an enlarged top view of the tool holder, with a portion of a cylindrical tube shown with a cutaway in order to show the placement of the tools.

FIG. 7 shows a unidirectional pair of grooves cut in a cylindrical tube in accordance with an embodiment of the subject invention.

FIG. 8 is an enlarged end view of the cylindrical tube of FIG. 7.

FIG. 9 shows two bidirectional pairs of grooves cut in a cylindrical tube in accordance with an embodiment of the subject invention.

FIG. 10 is an enlarged end view of the cylindrical tube of FIG. 9.

FIG. 11A shows an embodiment of a prior art bit or tool.

FIG. 11B shows an embodiment of a bit or tool in accordance with a specific embodiment of the subject invention.

FIG. 11C shows an embodiment of a bit or tool in accordance with a specific embodiment of the subject invention.

FIGS. 12A, 12B, and 12C show an embodiment of a tool holder that incorporates two rows of tools.

DETAILED DISCLOSURE

Embodiments of the subject invention relate to a method and apparatus for machining one or more grooves on an outer surface of a cylindrical element. The terms rod or shaft can refer to a solid cylindrical object that may be made of a single material or multiple materials, and may be homogeneous or may be inhomogeneous, such as having layers or changes in materials, densities, and/or other material properties, along the length of the cylinder and/or as a function of radius and/or rotational position with respect to the longitudinal axis of the cylindrical element. The term tube can refer to a hollow cylindrical element that can have one or more features cut into or on an inner surface of the hollow passageway through the hollow cylindrical element. Other types of cylindrical elements can also be machined in accordance with embodiments of the subject invention, including, but not limited to, cylindrical elements having one or more partial or full bores through the cylindrical elements, and/or one or more features cut into or on an outer surface of the cylindrical element. Specific embodiments relate to machining a single spiraling groove or multiple spiraling grooves. For embodiments with multiple grooves, the grooves may all have the same handedness, or may differ in handedness. Embodiments having two grooves are provided as an example to teach certain features of various embodiments, where embodiments having a single groove to machine more than two grooves, or alternatively, a single groove.

Specific embodiments include, but are not limited to, the following:

• • (i) machining one or more grooves around the outer surface of a shaft or tube with a right hand, or clockwise, twist or with a left hand, or counter clockwise, twist, which, in a further specific embodiment, allows the shaft or tube to be used to drive a carrier along the shaft or tube when the shaft or tube is rotated.
  • (ii) machining two or more grooves around the outer surface of a shaft or tube, where at least one groove has a right hand, or clockwise, twist and at least one other groove has a left hand, or counter clockwise, twist, which, in a further specific embodiment, allows the shaft or tube to be used to drive a right hand and/or a left hand carrier along the shaft or tube when the shaft or tube is rotated.
  • (iii) machining one or more grooves, in accordance with (i), including machining at least two grooves.
  • (iv) machining two or more grooves, in accordance with (ii), including machining at least two right hand grooves and at least two left hand grooves.
  • (v) machining one or more grooves, in accordance with (i), where the one or more grooves are 180 degrees apart.
  • (vi) machining one or more grooves, in accordance with (i) and/or (ii), where the one or more grooves are cut by a 0.250 inch diameter cutter at a depth of 0.040 inches.
  • (vii) machining grooves, in accordance with (i) and/or (ii), wherein the grooves are 180 degrees apart.
  • (viii) machining grooves, in accordance with (i) and/or (ii), using a rough cut tool to cut a rough portion of each groove and a finish cut tool to cut a finish portion of each groove, where the spacing of the rough cut tool and the finish cut tool is one half the lead of the groove.

A specific embodiment of the subject invention will be described to illustrate several features that can be incorporated with various embodiments of the invention. Referring to FIGS. 1-3, an embodiment of an apparatus set up for cutting a pair of spiraling grooves 12 on a rod or tube 1 is shown, with the rod or tube 1 placed and secured on a lathe 10. The handedness of the grooves 12 can be right handed (clockwise) or left handed (counterclockwise). The handedness of the grooves, for a certain rotational direction of the rod or tube, can be selected by the directional engagement of the directional lever 7, where the directional lever controls the direction the cutting tool moves with respect to the rotating cylindrical element. The traversing speed of the tool post 5 is set by one of the speed adjusters, which, for a given rotation speed and cylinder radius, will also set the traversing lead of the groove 12, where the traversing lead is the angle the groove 12 makes with respect to an axis parallel to the longitudinal axis of the cylindrical element. Lever 6 is used to engage the lead screw, which is geared to the chuck or spindle to generate the desired lead.

The groove cutting tools 11 are secured in the tool holder 9 on the tool post 5. The rod or tube 1 is placed in the chuck 8 of the lathe 10. A vertical backup roller 4 is placed against the top surface of the rod or tube 1 and a horizontal back up roller 3 is placed against the back side of the rod or tube 1 to support the rod while the grooves 12 are cut, as known in the art. The tool 11 cutting depth can be set differently for each set of tools 11, as shown in FIG. 3. While several settings can be used, in the shown embodiment the first, or rough, cutter cuts into the cylindrical element to an initial depth, which is more than half of the total groove depth, and the last, or finish, cutter cuts further into the cylindrical element to deepen the groove 12. Although the rough cutter cuts into the cylindrical element more than the finish cutter in this embodiment, in other embodiments the finish cutter can cut more than half of the groove's depth. In an embodiment, the top of the cutter, which can be flat is perpendicular to a plane tangent to the drive element at the point of contact between the cutter and the drive element.

In the embodiment shown in FIG. 3, the cylindrical element is rotating such that the top surface of the cylindrical element is coming out of the page, and the tool post 5 is moving from right to left with respect to the element 1. There are four cutters, with the first two cutters, shown on the left, making the rough depth cuts, set at a certain depth, for two separate grooves 12, and the two finish cutters, shown on the right, cutting farther into the respective groove. In the embodiment shown in FIG. 3, the rough cuts (on left in FIG. 3) are 0.030 inches deep, while the finish cut (on right in FIG. 3) adds an additional 0.010 inches of depth to the groove for a final groove depth of 0.040 inches.

In an embodiment, the two rough cutters are spaced one-half of a lead from each other and the two finish cutters are spaced one-half of a lead from each other, such that the two grooves are spaced 180°, or one-half of a lead, apart, where a lead is defined as the linear distance along the axis of the shaft or tube that is covered by one 360° rotation of the groove. Any number of cutters can be used to cut each groove, but to avoid two passes of the tool post 5 down the rotating element when two cutters (e.g., rough and finish) are used for each groove, two cutters are needed for each groove. The embodiment shown in FIG. 3 produces a pair of spiraling grooves as shown in FIGS. 7-8. In this embodiment, the two grooves are spaced 180°, or one-half of a lead, apart, but other embodiments have spacing greater than or less than 180°.

Referring to FIGS. 4-6, the apparatus from FIGS. 1-3 is shown being used for cutting two opposing pairs of spiraling grooves 12 on a rod or tube, with the rod or tube 1 still in place and secured on a lathe 10 and the tool post 5 traveling in the other direction after the first pair of grooves were finished. FIG. 1 shows the point where a little less than half the length of the first pair of grooves have been cut and the tool post 5 is moving from right to left. The vertical backup roller 4 is again placed against the top surface of the rod or tube 1 and a horizontal roller 3 is placed against the back side of the rod or tube 1 to support the rod while the grooves 12 having the opposite handedness of the pair of grooves shown being cut in FIG. 3 are cut, as known in the art.

The grooves 12 of opposite handedness can be cut over (intersecting) the original grooves 12 by switching the rough cutter tool holder 9 (e.g., 9R in FIGS. 2 and 3) and the finish cutter tool holder 9 (e.g., 9F in FIGS. 2 and 3) and reversing the directional lever 6 such that the tool post 5 is moved in the opposite direction with respect to the rotating cylindrical element as when the original grooves were cut. The traversing speed of the tool post 5 can remain the same as during the first pass and the rotation speed of the cylindrical element can remain the same as during the first pass, such that the traversing lead stays the same. If the same cutters are used for rough and finish cutting, rather than switching the rough cutters tool holder 9 (e.g., 9R in FIGS. 2 and 3) and the finish cutters tool holder 9 (e.g., 9F in FIGS. 2 and 3), the cutting depth of the groove cutting tools 11 can be changed, such that cutters set to the rough depth on the first pass (11A and 11B in 9R in FIG. 3) are set to the finish depth on the second pass (11A and 11B in 9F in FIG. 6) and the cutters set to the finish depth on the first pass (11A and 11B in 9F in FIG. 3) are set to the rough depth on the second pass (11A and 11B in 9R in FIG. 6), and secured in the tool holder 9 on the tool post 5. In the embodiment shown in FIGS. 7-8, there are four cutters with the first two cutters making a rough depth cut set at a rough depth and the finish cutters cutting farther into the groove to the final depth. In the embodiment shown in FIGS. 7-8, the rough cut is 0.030 inches deep while the finish cut cuts an additional 0.010 inches resulting in a depth of 0.04 inches for the groove.

Again, the two rough cutters are spaced one-half a lead from each other and the two finish cutters are spaced one-half of a lead from each other. As before, any number of cutters can be used, but to avoid needing two passes of the tool post 5 down the rotating element when two tools are used for each groove, two rough cutters and two finish cutters are needed. For embodiments having two right hand grooves and two left hand grooves, and using a rough cutter and a finish cutter for each groove, four cutters are needed to accomplish the four grooves in two passes. This produces two opposing pairs of spiraling grooves as shown in FIGS. 9-10. In this embodiment, the grooves are spaced 180° apart, as measured around the perimeter of the rod, but other embodiments having spacing greater than or less than 180° are contemplated.

In regard to the tolerance of the groove “pitch” spacing, embodiments of the subject tool holder ensure such spacing is consistent. In an embodiment, a 4.0″ lead works well in relation to speeds and feed capability of the curtain, but other leads are also utilized. An embodiment has a tolerance of +/−0.12″ on the pitch, which is based on the feed speed of the machine (lathe) cutting the grooves and should be very consistent.

The groove radius can be based on a 0.125 Radius tool, by using a machining center to cut the groove and a ¼″ ball end mill. In embodiments using a lathe, different cutters are used. The actual finished shape of the groove is approximately a true radius at 0.118″. Different tools can be used for each cut on the tube such that the finished groove is 0.118 Radius.

In an embodiment using a lathe, the tolerances for the groove depth are +/−0.010″.

FIG. 11A shows a perspective view of a stock bit, or tool, 11 used to cut a portion of an outer surface or a tube or shaft to create a groove in the outer surface of the tube or shaft, where the angle θ that the bit's front portion ball 13, which faces the outer surface of the tube or shaft, make with respect to a line 14 perpendicular to the top surface 15 at the bit 11. The angle θ for a specific stock bit 11 is approximately 11°. FIG. 11B shows an embodiment of bit 11 that can be utilized to cut a portion of a groove 12 in accordance with an embodiment of the subject invention, which has an θ>30°. The increase angle allows the bit to cut a portion of a groove that has a lead angle that might cause the standard bit to rub the side of the groove during cutting, particularly for the bit 11 cutting a finish portion, or deepest portion, of the groove. FIG. 11C shows an embodiment of a bit 11 in accordance with the subject invention having an angle θ of 45°. Specific embodiments of the invention can utilize bits 11 having an angle θ>15°, θ>20°, θ>25°, θ>30°, θ>35°, θ>40°, θ>45°, 15°>θ>20°, 20°>θ>25°, 25°>θ>30°, 30°>θ>35°, 35°>θ>40°, and/or 40°>θ>45°. The bit can be produced by, for example, grinding away a portion of a standard bit having an angle θ=11°. Various embodiments can utilize rough cutter bits and finish cutter bits that are the same or different, two cutter bits for two grooves that are the same or different, in shape, size, material, or other properties.

FIGS. 12A, 12B, and 12C show an embodiment of a tool holder 9 that incorporates two rows of tools 11, a top row that has tools 11 for cutting grooves in a tube or shaft where the tool holder 9 is moved right to left with respect to the rotating tube or shaft, and a bottom row that has tools 11 for cutting grooves in a tube or shaft where the tool holder 9 is moved left to right with respect to the rotating tube or shaft, where for both the top row and bottom row, rough cutters start cutting the grooves and finish cutters finish the grooves. The embodiment shown in FIGS. 12A-12C incorporates 5 pairs of cutters where each pair, having a left cutter and a right cutter, cuts further than the adjacent pair, and the five left cutters of the five pairs cuts a first groove and the five right cutters of the five pairs cuts a second groove, and the top row cuts a pair of grooves of a first handedness and the bottom row cuts a pair of grooves of the opposite handedness.

Embodiments of the invention are directed to a method and apparatus for cutting one or more grooves into an outer surface of a cylindrical element. A specific embodiment, which can be referred to as Embodiment 1, involves:

rotating a cylindrical element about a longitudinal axis of the cylindrical element;

where, while rotating the cylindrical element about the longitudinal axis, further incorporating:

moving a rough cutter and the rotating cylindrical element with respect to each other in a direction parallel to the longitudinal axis, where the rough cutter moves from a rough start position to a rough end position, wherein the rough start position has a rough axial start position along a length of the cylindrical element and a rough rotational start position about the longitudinal axis, where the rough end position has a rough axial end position along a length of the cylindrical element and a rough rotational end position about the longitudinal axis; and

moving a finish cutter and the rotating cylindrical element with respect to each other in a direction parallel to the longitudinal axis, wherein the finish cutter moves from a finish start position to a finish end position, where the finish start position has a finish axial start position along the length of the cylindrical element and a finish rotational start position about the longitudinal axis, where the finish end position has a finish axial end position along a length of the cylindrical element and a finish rotational end position about the longitudinal axis;

where, while moving the rough cutter from the rough start position to the third position, positioning the rough cutter with respect to an outer surface of the cylindrical element such that the rough cutter cuts away a rough portion of the outer surface,

where, while moving the finish cutter from the finish start position to the finish end position, positioning the finish cutter with respect to the outer surface of the cylindrical element such that the finish cutter cuts away a finish portion of the outer surface,

where, cutting away the rough portion and cutting away the finish portion creates a groove in the outer surface of the cylindrical element.

Moving the cutters and the rotating element can be accomplished by rotating the element in place and moving the cutters along the outer surface of the rotating element, holding the cutters in place and moving the rotating element, or moving both the cutters and the rotating element. The rough cutter and finish cutter can be started at the same rotational positions or at different rotational positions, these rotational positions can remain the same as the cutters and rotating element are moved relative to each other, or can vary, and the speed of such relative movement can vary or be constant. The rotating element can be rotated at a constant rotational speed or the rotational speed can vary while the rotating element and cutters move with respect to each other. The cutters can remain in constant contact with the outer surface of the rotating element or can be disengaged from contact with the outer surface, the cutters can cut to a constant depth when engaged with the outer surface or the depth can vary while engaged with the outer surface, the rough cutter and the finish cutter can move at the same speed or different speed and such speeds can be constant or vary. Likewise, embodiments using two rough cutters and/or two finish cutters can have the rough cutters and/or the finish cutters move at the same speed or different speeds, during the relative motion of the rotating element and the cutters. Two passes can be made in the same direction or in opposite directions, as desired. The cylinder can be rotated in either direction, with an appropriate position of the cutters.

In specific embodiments, incorporating the limitations of Embodiment 1, when the finish rotational start position is the same as the rough rotational start position, the finish axial start position is axially separated from the rough axial start position by n leads, where a lead is an axial distance covered by one 360° rotation of the groove in the outer surface of the cylindrical element and n is an integer having a value of 1 or greater. This allows the finish cutter to cut further into the groove started by the rough cutter. In a specific embodiment, n=1, and the axial start positions are separated by one lead.

In a specific embodiment, which can be referred to as the second embodiment, wherein the rough rotational end position is the same as the rough rotational start position, wherein the finish rotational end position is the same as the finish rotational start position, wherein the finish rotational start position is the same as the rough rotational start position, where while moving the rough cutter from the rough start position to the rough end position, the rough cutter is maintained at the rough rotational start position, where while moving the finish cutter from the finish start position to the finish end position, the finish cutter is maintained at the finish rotational start position, where rotating the cylindrical element comprises rotating the cylindrical element at a constant speed of rotation, where moving the rough cutter from the rough start position to the rough end position comprises moving the rough cutter from the rough start position to the rough end position at a first axial speed, wherein the first axial speed is a constant axial speed, where moving the finish cutter from the finish start position to the finish end position comprises moving the finish cutter from the finish start position to the finish end position at the first axial speed, where the finish axial start position is axially separated from the rough axial start position by n leads, where a lead is an axial distance covered by one 360° rotation of the groove in the outer surface of the cylindrical element and n is an integer having a value of 1 or greater, where n=1.

In a further embodiment, which can be referred to as the third embodiment, incorporating the limitations of Embodiment 1, while rotating the cylindrical element about the longitudinal axis, further including:

moving a second rough cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, wherein the second rough cutter moves from a second rough start position to a second rough end position, where the second rough start position has a second rough axial start position along the length of the cylindrical element and a second rough rotational start position about the longitudinal axis, where the second rough end position has a second rough axial end position along the length of the cylindrical element and a second rough rotational end position about the longitudinal axis; and

moving a second finish cutter and the rotating cylindrical element with respect to each other in a direction parallel to the longitudinal axis, wherein the second finish cutter moves from a second finish start position to a second finish end position, where the second finish start position has a second finish axial start position along the length of the cylindrical element and a second finish rotational start position about the longitudinal axis, where the second finish end position has a second finish axial end position along the length of the cylindrical element and a second finish rotational end position about the longitudinal axis;

where while moving the second rough cutter from the second rough start position to the second rough end position, positioning the second rough cutter with respect to the outer surface of the cylindrical element such that the second rough cutter cuts away a second rough portion of the outer surface,

where while moving the second finish cutter from the second finish start position to the second finish end position, positioning the second finish cutter with respect to the outer surface of the cylindrical element such that the second finish cutter cuts away a second finish portion of the outer surface,

where cutting away the second rough portion and cutting away the second finish portion creates a second groove in the outer surface of the cylindrical element.

In a further specific embodiment, which can be referred to as the fourth embodiment, incorporating the limitations of Embodiment three, the second finish axial start position is axially separated from the second rough axial start position by m leads, where m is an integer having a value of 1 or greater. In this way the second finish cutter follows in the groove started by the second rough cutter. In a specific embodiment, m=1.

In a further specific embodiment, which can be referred to as embodiment five, incorporating the limitations of Embodiment four, where the second rough axial start position is axially separated from the finish axial start position by (p+½) leads, where p is an integer having a value of zero or greater, where p=0.

In a further specific embodiment, which can be referred to as Embodiment six, incorporating the limitations of Embodiment 1, while rotating the cylindrical element about the longitudinal axis, further incorporating:

moving a second rough cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, where the second rough cutter moves from a second rough start position to a second rough end position, where second rough start position has a second rough axial start position along the length of the cylindrical element and a second rough rotational start position about the longitudinal axis, where second rough end position has a second rough axial end position and a second rough rotational end position; and

moving the second finish cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, where the second finish cutter moves from a second finish start position to an second finish end position, where the second finish start position has a second finish axial start position along the length of the cylindrical element and a second finish rotational start position about the longitudinal axis, where the second finish end position has a second finish axial end position and a second finish rotational end position;

where while moving the second rough cutter from the second rough start position to the second rough end position, positioning the second rough cutter with respect to the outer surface of the cylindrical element such that the second rough cutter cuts away a second rough portion of the outer surface,

where while moving the second finish cutter from the second finish start position to the second finish end position, positioning the second finish cutter with respect to the outer surface of the cylindrical element such that the second finish cutter cuts away a second finish portion of the outer surface,

where cutting away the second rough portion and cutting away the second finish portion creates a second groove in the outer surface of the cylindrical element.

A specific embodiment, which can be referred to as Embodiment seven, relates to a method and apparatus for cutting two grooves into an outer surface of a cylindrical element, involving:

rotating the cylindrical element about the longitudinal axis of a cylindrical element;

moving a first cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, where the first cutter moves from a first start position to a first end position, where the first start position has a first axial start position along a length of the cylindrical element and a first rotational start position about the longitudinal axis, where the first end position has a first axial end position along a length of the cylindrical element and a first rotational end position about the longitudinal axis; and

moving a second cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, where the second cutter moves from a second start position to a second end position, where the second start position has a second axial start position along the length of the cylindrical element and a second rotational start position about the longitudinal axis, where the second end position has a second axial end position along a length of the cylindrical element and a second rotational end position about the longitudinal axis;

where while moving the first cutter from the first start position to the first end position, positioning the first cutter with respect to an outer surface of the cylindrical element such that the first cutter cuts away a first portion of the outer surface,

where while moving the second cutter from the second start position to the second end position, positioning the second cutter with respect to the outer surface of the cylindrical element such that the second cutter cuts away a second portion of the outer surface,

where cutting away the first portion creates a first groove in the outer surface of the cylindrical element, and

where cutting away the second portion creates a second groove in the outer surface of the cylindrical element.

In a further specific embodiment, which can be referred to as Embodiment eight, incorporating the limitations of Embodiment seven, the first rotational end position is the same as the first rotational start position, the second rotational end position is the same as the second rotational start position, the second rotational start position is the same as the first rotational start position, where while moving the first cutter from the first start position to the first end position, the first cutter is maintained at the first rotational start position, where while moving the second cutter from the second start position to the second end position, the second cutter is maintained at the second rotational start position, where the second rotational start position is the same as the first rotational start position, where rotating the cylindrical element comprises rotating the cylindrical element at a constant speed of rotation, where moving the first cutter from the first start position to the first end position comprises moving the first cutter from the first start position to the first end position at a first axial speed, where the first axial speed is a constant axial speed, wherein moving the second cutter from the second start position to the second end position comprises moving the second cutter from the second start position to the second end position at the first axial speed, where the second axial start position is axially separated from the first axial start position by a separation axial distance, where the second groove is separated from the first groove by the separation axial distance, where the separation axial distance is (k+½) leads, where a lead is an axial distance covered by one 360° rotation of the first groove in the outer surface of the cylindrical element and k is an integer having a value of zero or greater, where k=0.

Aspects of the invention, such as controlling the transverse, and proximity to the rotating cylindrical element, of the tool box 5, and the rotation of the cylindrical element, may be described in the general context of computer-executable instructions, such as program modules, being executed by a computer. Generally, program modules include routines, programs, objects, components, data structures, etc., that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that the invention may be practiced with a variety of computer-system configurations, including multiprocessor systems, microprocessor-based or programmable-consumer electronics, minicomputers, mainframe computers, and the like. Any number of computer-systems and computer networks are acceptable for use with the present invention.

Specific hardware devices, programming languages, components, processes, protocols, and numerous details including operating environments and the like are set forth to provide a thorough understanding of the present invention. In other instances, structures, devices, and processes are shown in block-diagram form, rather than in detail, to avoid obscuring the present invention. But an ordinary-skilled artisan would understand that the present invention may be practiced without these specific details. Computer systems, servers, work stations, and other machines may be connected to one another across a communication medium including, for example, a network or networks.

As one skilled in the art will appreciate, embodiments of the present invention may be embodied as, among other things: a method, system, or computer-program product. Accordingly, the embodiments may take the form of a hardware embodiment, a software embodiment, or an embodiment combining software and hardware. In an embodiment, the present invention takes the form of a computer-program product that includes computer-useable instructions embodied on one or more computer-readable media.

Computer-readable media include both volatile and nonvolatile media, transitory and non-transitory, removable and nonremovable media, and contemplate media readable by a database, a switch, and various other network devices. By way of example, and not limitation, computer-readable media comprise media implemented in any method or technology for storing information. Examples of stored information include computer-useable instructions, data structures, program modules, and other data representations. Media examples include, but are not limited to, information-delivery media, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile discs (DVD), holographic media or other optical disc storage, magnetic cassettes, magnetic tape, magnetic disk storage, and other magnetic storage devices. These technologies can store data momentarily, temporarily, or permanently.

The invention may be practiced in distributed-computing environments where tasks are performed by remote-processing devices that are linked through a communications network. In a distributed-computing environment, program modules may be located in both local and remote computer-storage media including memory storage devices. The computer-useable instructions form an interface to allow a computer to react according to a source of input. The instructions cooperate with other code segments to initiate a variety of tasks in response to data received in conjunction with the source of the received data.

The present invention may be practiced in a network environment such as a communications network. Such networks are widely used to connect various types of network elements, such as routers, servers, gateways, and so forth. Further, the invention may be practiced in a multi-network environment having various, connected public and/or private networks.

Communication between network elements may be wireless or wireline (wired). As will be appreciated by those skilled in the art, communication networks may take several different forms and may use several different communication protocols. And the present invention is not limited by the forms and communication protocols described herein.

All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.

It should be understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application.

REFERENCE NUMBERS

• • 1. Cylindrical element (rod or tube)
  • 2. Backup rollers holder
  • 3. Horizontal backup roller
  • 4. Vertical backup roller
  • 5. Tool post
  • 6. Lever to engage lead screw
  • 7. Directional lever
  • 8. Chuck, part holder
  • 9. Tool holder
  • 10. Lathe
  • 11. Tool
  • 12. Groove
  • 13. Bit front portion
  • 14. Line
  • 15. Bit top surface

Claims

1. A method of cutting one or more grooves into an outer surface of a cylindrical element, comprising:

rotating a cylindrical element about a longitudinal axis of the cylindrical element;

wherein while rotating the cylindrical element about the longitudinal axis, further comprising:

moving a rough cutter and the rotating cylindrical element with respect to each other in a direction parallel to the longitudinal axis, wherein the rough cutter moves from a rough start position to a rough end position, wherein the rough start position has a rough axial start position along a length of the cylindrical element and a rough rotational start position about the longitudinal axis, wherein the rough end position has a rough axial end position along a length of the cylindrical element and a rough rotational end position about the longitudinal axis; and

moving a finish cutter and the rotating cylindrical element with respect to each other in a direction parallel to the longitudinal axis, wherein the finish cutter moves from a finish start position to a finish end position, wherein the finish start position has a finish axial start position along the length of the cylindrical element and a finish rotational start position about the longitudinal axis, wherein the finish end position has a finish axial end position along a length of the cylindrical element and a finish rotational end position about the longitudinal axis;

wherein while moving the rough cutter from the rough start position to the third position, positioning the rough cutter with respect to an outer surface of the cylindrical element such that the rough cutter cuts away a rough portion of the outer surface,

wherein while moving the finish cutter from the finish start position to the finish end position, positioning the finish cutter with respect to the outer surface of the cylindrical element such that the finish cutter cuts away a finish portion of the outer surface,

wherein cutting away the rough portion and cutting away the finish portion creates a groove in the outer surface of the cylindrical element.

2. The method according to claim 1, wherein the rough rotational end position is the same as the rough rotational start position.

3. The method according to claim 2, wherein the finish rotational end position is the same as the finish rotational start position.

4. The method according to claim 3, wherein the finish rotational start position is the same as the rough rotational start position.

5. The method according to claim 2, wherein while moving the rough cutter from the rough start position to the rough end position, the rough cutter is maintained at the rough rotational start position.

6. The method according to claim 3, wherein while moving the finish cutter from the finish start position to the finish end position, the finish cutter is maintained at the finish rotational start position.

7. The method according to claim 4, wherein while moving the rough cutter from the rough start position to the rough end position, the rough cutter is maintained at the rough rotational start position, wherein while moving the finish cutter from the finish start position to the finish end position, the finish cutter is maintained at the finish rotational start position.

8. The method according to claim 1, wherein rotating the cylindrical element comprises rotating the cylindrical element at a constant speed of rotation.

9. The method according to claim 7, wherein rotating the cylindrical element comprises rotating the cylindrical element at a constant speed of rotation.

10. The method according to claim 9, wherein moving the rough cutter from the rough start position to the rough end position comprises moving the rough cutter from the rough start position to the rough end position at a first axial speed, wherein the first axial speed is a constant axial speed, wherein moving the finish cutter from the finish start position to the finish end position comprises moving the finish cutter from the finish start position to the finish end position at the first axial speed.

11. The method according to claim 10, wherein the finish axial start position is axially separated from the rough axial start position by n leads, where a lead is an axial distance covered by one 360° rotation of the groove in the outer surface of the cylindrical element and n is an integer having a value of 1 or greater.

12. The method according to claim 11, wherein n=1.

13. The method according to claim 12, wherein while rotating the cylindrical element about the longitudinal axis, further comprising:

moving a second rough cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, wherein the second rough cutter moves from a second rough start position to a second rough end position, wherein the second rough start position has a second rough axial start position along the length of the cylindrical element and a second rough rotational start position about the longitudinal axis, wherein the second rough end position has a second rough axial end position along the length of the cylindrical element and a second rough rotational end position about the longitudinal axis; and

moving a second finish cutter and the rotating cylindrical element with respect to each other in a direction parallel to the longitudinal axis, wherein the second finish cutter moves from a second finish start position to a second finish end position, wherein the second finish start position has a second finish axial start position along the length of the cylindrical element and a second finish rotational start position about the longitudinal axis, wherein the second finish end position has a second finish axial end position along the length of the cylindrical element and a second finish rotational end position about the longitudinal axis;

wherein while moving the second rough cutter from the second rough start position to the second rough end position, positioning the second rough cutter with respect to the outer surface of the cylindrical element such that the second rough cutter cuts away a second rough portion of the outer surface,

wherein while moving the second finish cutter from the second finish start position to the second finish end position, positioning the second finish cutter with respect to the outer surface of the cylindrical element such that the second finish cutter cuts away a second finish portion of the outer surface,

wherein cutting away the second rough portion and cutting away the second finish portion creates a second groove in the outer surface of the cylindrical element.

14. The method according to claim 13, wherein the second rough rotational start position, the second finish rotational start position, the second rough rotational end position, and the second finish rotational end position are the same as the rough rotational start position.

15. The method according to claim 14, wherein while moving the second rough cutter from the second rough start position to the second rough end position, the second rough cutter is maintained at the second rough rotational start position wherein while moving the second finish cutter from the second finish start position to the second finish end position, the second finish cutter is maintained at the second finish rotational start position.

16. The method according to claim 15, wherein moving the second rough cutter from the second rough start position to the second rough end position comprises moving the second rough cutter from the second rough start position to the second rough end position at the first axial speed, wherein moving the second finish cutter from the second finish start position to the second finish end position comprises moving the second finish cutter from the second finish start position to the second finish end position at the first axial speed.

17. The method according to claim 16, wherein the second finish axial start position is axially separated from the second rough axial start position by m leads, where m is an integer having a value of 1 or greater.

18. The method according to claim 17, wherein m=1.

19. The method according to claim 18, wherein the second rough axial start position is axially separated from the finish axial start position by (p+½) leads, wherein p is an integer having a value of zero or greater.

20. The method according to claim 19, wherein p=0.

21. The method according to claim 1, wherein while rotating the cylindrical element about the longitudinal axis, further comprising:

moving a second rough cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, wherein the second rough cutter moves from a second rough start position to a second rough end position, wherein second rough start position has a second rough axial start position along the length of the cylindrical element and a second rough rotational start position about the longitudinal axis, wherein second rough end position has a second rough axial end position and a second rough rotational end position; and

moving the second finish cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, wherein the second finish cutter moves from a second finish start position to an second finish end position, wherein the second finish start position has a second finish axial start position along the length of the cylindrical element and a second finish rotational start position about the longitudinal axis, wherein the second finish end position has a second finish axial end position and a second finish rotational end position;

wherein while moving the second rough cutter from the second rough start position to the second rough end position, positioning the second rough cutter with respect to the outer surface of the cylindrical element such that the second rough cutter cuts away a second rough portion of the outer surface,

wherein while moving the second finish cutter from the second finish start position to the second finish end position, positioning the second finish cutter with respect to the outer surface of the cylindrical element such that the second finish cutter cuts away a second finish portion of the outer surface,

wherein cutting away the second rough portion and cutting away the second finish portion creates a second groove in the outer surface of the cylindrical element.

22. A method of cutting two grooves into an outer surface of a cylindrical element, comprising:

rotating the cylindrical element about the longitudinal axis of a cylindrical element;

moving a first cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, wherein the first cutter moves from a first start position to a first end position, wherein the first start position has a first axial start position along a length of the cylindrical element and a first rotational start position about the longitudinal axis, wherein the first end position has a first axial end position along a length of the cylindrical element and a first rotational end position about the longitudinal axis; and

moving a second cutter and the rotating cylindrical element with respect to each other in the direction parallel to the longitudinal axis, wherein the second cutter moves from a second start position to a second end position, wherein the second start position has a second axial start position along the length of the cylindrical element and a second rotational start position about the longitudinal axis, wherein the second end position has a second axial end position along a length of the cylindrical element and a second rotational end position about the longitudinal axis;

wherein while moving the first cutter from the first start position to the first end position, positioning the first cutter with respect to an outer surface of the cylindrical element such that the first cutter cuts away a first portion of the outer surface,

wherein while moving the second cutter from the second start position to the second end position, positioning the second cutter with respect to the outer surface of the cylindrical element such that the second cutter cuts away a second portion of the outer surface,

wherein cutting away the first portion creates a first groove in the outer surface of the cylindrical element, and

wherein cutting away the second portion creates a second groove in the outer surface of the cylindrical element.

23. The method according to claim 22, wherein the first rotational end position is the same as the first rotational start position.

24. The method according to claim 23, wherein the second rotational end position is the same as the second rotational start position.

25. The method according to claim 24, wherein the second rotational start position is the same as the first rotational start position.

26. The method according to claim 22, wherein while moving the first cutter from the first start position to the first end position, the first cutter is maintained at the first rotational start position.

27. The method according to claim 24, wherein while moving the second cutter from the second start position to the second end position, the second cutter is maintained at the second rotational start position.

28. The method according to claim 25, wherein while moving the first cutter from the first start position to the first end position, the first cutter is maintained at the first rotational start position, wherein while moving the second cutter from the second start position to the second end position, the second cutter is maintained at the second rotational start position.

29. The method according to claim 28, wherein the second rotational start position is the same as the first rotational start position.

30. The method according to claim 22, wherein rotating the cylindrical element comprises rotating the cylindrical element at a constant speed of rotation.

31. The method according to claim 29, wherein rotating the cylindrical element comprises rotating the cylindrical element at a constant speed of rotation.

32. The method according to claim 31, wherein moving the first cutter from the first start position to the first end position comprises moving the first cutter from the first start position to the first end position at a first axial speed, wherein the first axial speed is a constant axial speed, wherein moving the second cutter from the second start position to the second end position comprises moving the second cutter from the second start position to the second end position at the first axial speed.

33. The method according to claim 32, wherein the second axial start position is axially separated from the first axial start position by a separation axial distance, wherein the second groove is separated from the first groove by the separation axial distance.

34. The method according to claim 33, wherein the separation axial distance is (k+½) leads, where a lead is an axial distance covered by one 360° rotation of the first groove in the outer surface of the cylindrical element and k is an integer having a value of zero or greater.

35. The method according to claim 34, wherein k=0.