Abstract: An electrode guide for use in electrical discharge machining is described, along with methods for construction and use. A notch can be made in a portion of the guide to allow for greater maneuverability in situations of small clearances. An alternative embodiment uses a bridge offset to achieve greater maneuverability and range of motion.

Abstract: A pre-process simulation may calculate operating conditions of a machine tool by simulating a NC program and calculate predicted values indicative of the operating conditions. A real time monitoring system may compare actual values from the actual operation of a machine tool actually executing the NC program to the predicted values and determine whether to initiate a response. The operating conditions may be machine tool operating conditions. The comparison of actual values to predicted values may be based on a dynamic limit within which the predicted values fall which may vary based on the tool position, and the dynamic limit may include upper and lower limit boundaries.

Abstract: A method for performing a milling operation includes providing a milling cutter and a workpiece having an non-machined workpiece surface; receiving a set of milling cutter geometry parameters; creating a curvilinear profile from the workpiece surface; extracting a radius parameter from the curvilinear profile; determining an initial step-over value in response to the set of milling cutter geometry parameters; determining a surface roughness value in response to the set of milling cutter geometry parameters, the curvilinear profile of the workpiece surface, the radius parameter, and an initial tool inclination angle; determining a minimum surface roughness value in response to the cutter inclination angle value; and adjusting a calculated step-over value in response to the minimum surface roughness value where the calculated step-over value and the calculated inclination angle value are applied to operating the milling cutter.

Abstract: A tool may be used to form an engine cylinder bore in a compacted graphite iron workpiece using helical interpolation. The tool may be rotated about a first axis while orbiting about a second axis that is parallel to the first axis. While rotating and orbiting, the tool may be advanced into the workpiece. This helical interpolation may be used to successively engage cutting or honing elements of the tool with the workpiece. The elements may thereby be permitted to cool between each successive engagement, which may reduce wear on the tool. Various operating parameters associated with the process may have certain relationships that may be exploited in certain ways to obtain ideal results. For instance, a helical interpolation process may be used to perform an act of rough cutting on the workpiece and finish honing on the workpiece, without having to perform an intermediary step of semi-finish boring.

Abstract: A tool for working a workpiece comprises an elongate member and a cam member. The elongate member comprises at least two extremities comprising at least one blade member. The at least two extremities are operable to separate in response to a pressurized medium. A conduit is in fluid communication with the extremities, and a pair of vents are in fluid communication with the conduit. The vents are operable to expel fluid communicated through the conduit. The cam member comprises an inner surface defining an opening. The inner surface of the cam resists expulsion of fluid from the vents, such that the cam and vents are operable to vary the pressure of fluid communicated through the conduit. The pressure variation varies the separation of the extremities as the elongate member is advanced through the cam toward a workpiece. The tool may be used to create bores having a non-cylindrical profile.

Abstract: A tool has a slot provided between a pair of extremities at its distal end. The extremities have cutting blades mounted thereon. The slot is configured to receive a plate. The tool has a conduit running along its axis for communication of pressurized fluid to the slot and plate. The plate directs flow of the pressurized fluid outward toward the extremities. The resulting outward force causes the extremities to bend outward, thereby urging the cutting blades outward for cutting, reaming, or other working of the workpiece. The resilience of the tool causes the extremities to return back inward when the fluid pressure is reduced. A plate may be configured to receive a wafer for transferring force from the pressurized fluid to the extremities. Some embodiments of the plate have an adjustment feature that is operable to selectively adjust the flow rate or pressure of fluid directed toward the extremities.

Abstract: A tool for working a workpiece comprises an elongate member and a cam member. The elongate member comprises at least two extremities comprising at least one blade member. The at least two extremities are operable to separate in response to a pressurized medium. A conduit is in fluid communication with the extremities, and a pair of vents are in fluid communication with the conduit. The vents are operable to expel fluid communicated through the conduit. The cam member comprises an inner surface defining an opening. The inner surface of the cam resists expulsion of fluid from the vents, such that the cam and vents are operable to vary the pressure of fluid communicated through the conduit. The pressure variation varies the separation of the extremities as the elongate member is advanced through the cam toward a workpiece. The tool may be used to create bores having a non-cylindrical profile.

Abstract: A rotating cutting tool is selectively biasable in the radial direction based on the angular orientation of the cutting blade, which may be used to create a non-axis symmetric feature in a bore. The radial position of the cutting blade may be controlled by selectively pressurized fluid whose pressure is varied based on the angular orientation of the tool. A plurality of vents may be selectively covered and uncovered to vent pressurized fluid to vary the pressure thereof.

Abstract: A tool for working a workpiece has a slot provided between a pair of extremities at its distal end. The extremities have cutting blades mounted thereon. The slot is configured to receive a plate. The tool has a conduit running along its axis for communication of pressurized fluid to the slot and plate. The plate directs flow of the pressurized fluid outward toward the extremities. The resulting outward force causes the extremities to bend outward, thereby urging the cutting blades outward for cutting, reaming, or other working of the workpiece. The resilience of the tool causes the extremities to return back inward when the fluid pressure is reduced. A plate may be configured to receive a wafer for transferring force from the pressurized fluid to the extremities.

Abstract: An apparatus comprises a rotating member having one or more rollers. The one or more rollers have a plurality of protuberances. The rollers may be advanced toward a surface during rotation of the rotating member, such as toward a bore surface. The protuberances are configured to make a pattern of discrete indentations in the surface upon engagement of the protuberances with the surface. The apparatus is particularly suited for creating oil-retention pockets in the surface of an engine cylinder and other uses. The apparatus may be used to create a pattern of oil-retention pockets or other pockets in a cylinder with varying pocket density in a single pass.

Abstract: A tool for working a workpiece has a slot provided between a pair of extremities at its distal end. The extremities have cutting blades mounted thereon. The slot is configured to receive a plate. The tool has a conduit running along its axis for communication of pressurized fluid to the slot and plate. The plate directs flow of the pressurized fluid outward toward the extremities. The resulting outward force causes the extremities to bend outward, thereby urging the cutting blades outward for cutting, reaming, or other working of the workpiece. The resilience of the tool causes the extremities to return back inward when the fluid pressure is reduced. A plate may be configured to receive a wafer for transferring force from the pressurized fluid to the extremities.

Abstract: A tool for working a workpiece has a slot provided between a pair of extremities at its distal end. The extremities have cutting blades mounted thereon. The slot is configured to receive a plate. The tool has a conduit running along its axis for communication of pressurized fluid to the slot and plate. The plate directs flow of the pressurized fluid outward toward the extremities. The resulting outward force causes the extremities to bend outward, thereby urging the cutting blades outward for cutting, reaming, or other working of the workpiece. The resilience of the tool causes the extremities to return back inward when the fluid pressure is reduced. A plate may be configured to receive a wafer for transferring force from the pressurized fluid to the extremities.

Abstract: An instrument is adapted to be attached to a rotational member of an instrument station for obtaining information about a workpiece. The instrument includes at least one orifice adapted to be placed in selective fluid communication with a source of fluid. An instrument station may also be provided to include an instrument and a rotational member connected to the instrument for rotating the instrument about a rotational axis. The instrument station may also include a source including fluid, wherein the fluid source is in fluid communication with the instrument and a monitoring apparatus. An apparatus may also include an instrument and a source of substantially incompressible fluid wherein the source is in fluid communication with the instrument. Methods of obtaining information about a workpiece and methods for determining the center of a bore are also disclosed.

Abstract: A tool including a working portion with a working member, a side surface and an end surface. The working portion includes a passage passing through the side surface and the end surface. At least one seal is adapted to restrict fluid flow through the side surface and the end surface and at least partially defines a pressure chamber. The working member is adapted to be selectively pivotally positioned by selectively pressurizing the pressure chamber. The tool similarly enables unique methods of working workpieces.

Abstract: Tools for brushing an inner surface of a hole are provided including a rotatable shaft, an inlet in fluid communication with a source of pressurized fluid, at least one outlet positioned so as to wet an inner surface of a hole, and a flow path extending between the inlet and the outlet. The tool further includes at least one brush being radially moveable relative to the shaft to an extended position and a retracted position.

Abstract: Honing devices configured for use with a source of pressurized fluid. The honing device includes a honing body with a base extending along an longitudinal axis. The base may include a distal end and a proximal end adapted for fluid communication with a source of pressurized fluid. The honing body further includes a plurality of leaves with a first end attached to the distal end of the base and a second end spaced from the distal end. The outer surface of at least one of the plurality of leaves includes an abrasive work engaging surface. Pressurized fluid may encourage the second end of at least one of the plurality of leaves to move away from the longitudinal axis in order to hone the interior surface of the workpiece. Methods of honing the interior surface of a bore hole are also provided.

Abstract: A tool including a working portion with a working member, a side surface and an end surface. The working portion includes a passage passing through the side surface and the end surface. At least one seal is adapted to restrict fluid flow through the side surface and the end surface and at least partially defines a pressure chamber. The working member is adapted to be selectively pivotally positioned by selectively pressurizing the pressure chamber. The tool similarly enables unique methods of working workpieces.

Abstract: Cutting tool, such as a gun reamer or a drill, with a rotating cutting blade and a rotating support member for supporting the workpiece, where at least one of the cutting blade and the support member are selectively biased. The selective bias on the blade and/or the support member is preferably effected by selectively pressurized fluid which bears on the blade member and/or the support member.

Abstract: A tool with a fluid axis wherein the fluid axis is controlled based on reference information from other tool axes, such as positional information relating to other tool axes. The reference information may be directly measured or may be determined from a control program used to control the tool with respect to the other axis or axes. Feedback information from the fluid axis itself, such as fluid pressure of the fluid axis, may also employed as to help determine the reference signal for controlling the fluid axis.

Abstract: A grinding tool for use with an automatic tool changing system in conjunction with a machine spindle and a source of cutting fluid. A preferred embodiment of the grinding tool includes a tool holder adapted for attaching the grinding tool to a machine spindle, and an attachment structure for placing the grinding tool in fluid communication with a source of pressurized fluid. The grinding tool further can comprise a fluid distribution passageway having a central supply tube formed within the tool holder, an annular space and guide channels formed within the body of the grinding wheel, and a plurality of non-perpendicular fluid delivery openings formed in the grinding surface so that coolant fluids at pressures of 200 psi and greater can be received within the fluid distribution passageway and delivered in a controlled manner toward the grinding surface via the delivery openings for either cleaning the grinding surface, for cooling and otherwise lubricating the workpiece and the grinding tool, or both.