Patents by Inventor Gregory A. Hyatt

Gregory A. Hyatt has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20190270247
    Abstract: Systems and methods for forming a three-dimensional build object on a substrate include controlling an energy beam source in a first mode during a first processing step during which additive material is deposited. Additionally, the method includes controlling the energy beam source in a second mode during a second processing step during which additive material is not deposited. During the first processing step, a feature may be formed by melting additive material as it is deposited into a target area.
    Type: Application
    Filed: June 13, 2017
    Publication date: September 5, 2019
    Applicant: DMG MORI CO., LTD
    Inventors: Gregory A. HYATT, Jennifer L. BENNETT
  • Publication number: 20190201980
    Abstract: A system for manufacturing a build object includes an additive manufacturing tool configured to utilize a powdered reactive material to construct the build object. The powdered reactive material includes a plurality of powder beads, wherein each powder bead has a bead diameter that is substantially similar to an ideal bead diameter. The system further includes apparatus configured to selectively shield the build object during additive manufacturing of the build object, by the additive manufacturing tool, using an inert gas. The ideal bead diameter is configured to be a bead diameter at which ignition of the powdered reactive material is inhibited, upon oxidation of the powdered reactive material.
    Type: Application
    Filed: May 16, 2017
    Publication date: July 4, 2019
    Applicant: DMG Mori USA
    Inventors: Gregory A. Hyatt, Karl Hranka
  • Patent number: 10254746
    Abstract: A system is provided for manufacturing a part. The system includes a manufacturing machine that includes at least one additive manufacturing tool. The system further includes a computer numerical control (CNC) controller operatively associated with the manufacturing machine and configured to control the at least one additive manufacturing tool based on computer aided manufacturing (CAM) instructions. The system further includes a CAM controller operatively associated with the CNC controller and configured to determine the CAM instructions based on computer aided drafting (CAD) instructions, the CAM instructions including a plurality of CAM operation control functions, each of the plurality of CAM operation control functions correlated with at least one of a plurality of CAD operation control functions of the CAD instructions.
    Type: Grant
    Filed: June 26, 2015
    Date of Patent: April 9, 2019
    Assignee: DMG MORI SEIKI USA
    Inventors: Nitin Chaphalkar, Gregory A. Hyatt
  • Patent number: 10226917
    Abstract: A powder delivery system for use in an additive manufacturing device includes a powder control valve configured to selectively divert at least a portion of an input fluid flow to a return line while a remainder of the input flow is delivered to a delivery nozzle. In some embodiments, the powder delivery valve may be modulated to alter the percentage of input flow diverted to the return line. Alternatively, the powder delivery valve may be either fully open or closed. In each embodiment, the powder delivery valve permits rapid changes in the amount of powder delivered to the nozzle.
    Type: Grant
    Filed: July 27, 2016
    Date of Patent: March 12, 2019
    Assignee: DMG MORI SEIKI USA
    Inventors: Gregory A. Hyatt, Jennifer Lynn Bennett
  • Publication number: 20170205806
    Abstract: A system is provided for manufacturing a part. The system includes a manufacturing machine that includes at least one additive manufacturing tool. The system further includes a computer numerical control (CNC) controller operatively associated with the manufacturing machine and configured to control the at least one additive manufacturing tool based on computer aided manufacturing (CAM) instructions. The system further includes a CAM controller operatively associated with the CNC controller and configured to determine the CAM instructions based on computer aided drafting (CAD) instructions, the CAM instructions including a plurality of CAM operation control functions, each of the plurality of CAM operation control functions correlated with at least one of a plurality of CAD operation control functions of the CAD instructions.
    Type: Application
    Filed: June 26, 2015
    Publication date: July 20, 2017
    Applicant: DMG Mori Seiki USA
    Inventors: Nitin Chaphalkar, Gregory A. Hyatt
  • Publication number: 20170123408
    Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.
    Type: Application
    Filed: January 11, 2017
    Publication date: May 4, 2017
    Applicant: Mori Seiki Co., LTD.
    Inventors: Gregory A. Hyatt, Nitin Chaphalkar
  • Publication number: 20170057011
    Abstract: A processing head assembly is provided for use with a movable tool holder of a machine tool. The processing head assembly includes an upper processing head coupled to the movable tool holder and having a body defining a socket, and a feed powder/propellant port coupled to the body and operably coupled to a feed powder/propellant supply. The processing head assembly further includes a lower processing head having a base configured to be releasably coupled to the socket, and a nozzle coupled to the base and defining a feed powder/propellant interface configured to detachably couple to the feed powder/propellant port and a nozzle exit orifice.
    Type: Application
    Filed: February 20, 2015
    Publication date: March 2, 2017
    Applicant: DMG Mori Advanced Solutions Development
    Inventors: Gregory A. Hyatt, Nitin Chaphalkar, Karl Hranka, Michael J. Panzarella
  • Patent number: 9575485
    Abstract: A method of machining a workpiece may include continuously rotating the workpiece, continuously rotating a tool having at least one cutting surface, and positioning the tool relative to the workpiece so that the at least one cutting surface engages the workpiece at a first discrete location at a periphery of the workpiece. The method may further include continuing to rotate the workpiece and the tool so that the at least one cutting surface engages a second discrete location at the periphery of the workpiece, and controlling a tool surface velocity VT relative to the workpiece surface velocity VW so that the first and second discrete locations are discontinuous. The tool may make multiple iterative passes over the workpiece to engage subsequent discrete locations, wherein the first discrete location, second discrete location, and multiple subsequent discrete locations may form a machined surface that extends continuously around the workpiece.
    Type: Grant
    Filed: November 7, 2011
    Date of Patent: February 21, 2017
    Assignee: MORI SEIKI CO., LTD.
    Inventors: Gregory A. Hyatt, Nitin Chaphalkar
  • Publication number: 20170028631
    Abstract: A powder delivery system for use in an additive manufacturing device includes a powder control valve configured to selectively divert at least a portion of an input fluid flow to a return line while a remainder of the input flow is delivered to a delivery nozzle. In some embodiments, the powder delivery valve may be modulated to alter the percentage of input flow diverted to the return line. Alternatively, the powder delivery valve may be either fully open or closed. In each embodiment, the powder delivery valve permits rapid changes in the amount of powder delivered to the nozzle.
    Type: Application
    Filed: July 27, 2016
    Publication date: February 2, 2017
    Applicant: DMG Mori Seiki USA
    Inventors: Gregory A. Hyatt, Jennifer Lynn Bennett
  • Publication number: 20170008127
    Abstract: Methods and apparatus for performing additive manufacturing processes using a machine tool may include controlling an orientation of a processing head to control the tangential angle of a fabrication energy beam, a feed powder nozzle, or both. The orientation of a non-circular energy beam may be control to more evenly distribute the energy beam across a width of a tool path. Additionally or alternatively, the orientation of the feed powder nozzle may be controlled to project toward a powder target that is spaced from a beam target. The powder target may be directed to a trailing edge of a beam spot formed by the energy beam to increase the amount of powder incorporated into a melt pool formed by the energy beam. Alternatively, the powder target may be directed to a leading edge of the beam spot to provide a self-correcting feature to address thickness errors formed in previous layers of added material.
    Type: Application
    Filed: February 20, 2015
    Publication date: January 12, 2017
    Applicant: DMG MORI ADVANCED SOLUTIONS DEVELOPMENT
    Inventors: Gregory A. Hyatt, Nitin Chaphalkar, Karl Hranka, Michael J. Panzarella
  • Patent number: 9539698
    Abstract: A method of grind hardening a workpiece is provided. The method may include securing the workpiece in a workpiece retainer and a grind tool in a tool retainer, rotating the grind tool in a first angular direction at a first angular speed, controlling the workpiece and tool retainers such that the grind tool engages the workpiece, and controlling the workpiece and tool retainers such that the grind tool is guided along a grinding track of the workpiece. The grind tool may engage and/or disengage the workpiece at portions of sacrificial material disposed thereon. Coolant and cleaning nozzles may be provided and controlled such that at least a portion of the coolant from the coolant nozzle is diverted to the cleaning nozzle in a manner which reduces heat dissipation, improves thermal efficiency of the grind hardening and reduces loading of the grind tool.
    Type: Grant
    Filed: March 15, 2013
    Date of Patent: January 10, 2017
    Assignee: MORI SEIKI CO., LTD.
    Inventors: Nils Niemeyer, Tobias Foeckerer, Nitin Chaphalkar, Gregory A. Hyatt
  • Patent number: 9427843
    Abstract: An apparatus for obtaining information about a workpiece may include a measuring device having a nozzle defining an orifice in fluid communication with a source of incompressible fluid. A fluid monitoring apparatus may monitor a parameter of the substantially incompressible fluid, and a pump may be fluidly coupled to the source and configured to supply incompressible fluid to the orifice. The pump may have a pump chamber with a first displacement setting having a first fixed volume, so that operation of the pump at a first pump speed with the pump chamber in the first displacement setting generates a first fluid flow having a substantially constant first volumetric rate. The pump may have more than one displacement setting, or the pump may be operated at different speeds to change the volumetric flow rate. The nozzle may include multiple, independent orifice sets that may be selectively provided fluid, thereby to obtain information on different parts of the workpiece with a single placement of the nozzle.
    Type: Grant
    Filed: March 1, 2011
    Date of Patent: August 30, 2016
    Assignee: Mori Seiki Co., LTD
    Inventors: Gregory A. Hyatt, Nitin Chaphalkar
  • Publication number: 20160129528
    Abstract: A machine for additive manufacturing positions a film having additive material relative to a substrate. The additive material is melted onto the substrate or previously formed layers of a workpiece using a laser. The substrate/workpiece and/or the film can be positioned in multiple axes so that complex shapes can be formed without extraneous supporting structures. The film-based delivery of the additive material allows deposition in orientations other than horizontal as is required for powder-only additive manufacturing and also avoids the inconvenience of collecting and recycling unused loose powdered metal.
    Type: Application
    Filed: November 11, 2015
    Publication date: May 12, 2016
    Applicant: DMG Mori USA
    Inventors: Gregory A. Hyatt, Gideon N. Levy, Makoto Fujishima, Michael J. Panzarella, Masahiko Mori
  • Publication number: 20160096230
    Abstract: Gear machining apparatus and methods are configured to produce gaps between gear teeth having portions formed by two different machining processes. A rough cutting process may be used to form a root portion of the gap, while a finish cutting process may be used to form final tooth faces. The apparatus and methods may further be configured to machine one or more gear tooth profile modifications.
    Type: Application
    Filed: May 5, 2014
    Publication date: April 7, 2016
    Applicant: DMG MORI SEIKI ADVANCED SOLUTIONS, INC.
    Inventors: Gregory A. Hyatt, Nitin Chaphalkar
  • Patent number: 8776357
    Abstract: Machine tool systems and methods include methods of synchronizing cutting tools with a workpiece retainer. In some embodiments, the methods and systems provide at least two cutting tools that are synchronized to machine a common surface of a workpiece in a quick and efficient manner. A controller having a single line of code for controlling both cutting tools and the workpiece retainer may be used. The cutting tools may be synchronized such that they engage substantially opposite portions of the workpiece, thereby to reduce resulting forces in the workpiece that may tend to induce workpiece deflection and/or chatter. In other embodiments, a cutting tool is synchronized with a split workpiece holder that may be controlled to induce a compression, tension, or torsion pre-load in the workpiece.
    Type: Grant
    Filed: April 29, 2010
    Date of Patent: July 15, 2014
    Assignee: Mori Seiki Co. Ltd
    Inventors: Gregory A. Hyatt, James Lankford, Jeffrey D. Wallace
  • Patent number: 8573901
    Abstract: A cutting insert rotated about its axis may be utilized during a metalworking operation and applied against the rotating workpiece to enhance tool performance. The cutting insert is secured within a toolholder having features to secure the insert but at the same time make for efficient removal of the insert from the toolholder.
    Type: Grant
    Filed: December 14, 2007
    Date of Patent: November 5, 2013
    Assignee: Kennametal Inc.
    Inventors: Ruy Frota de Souza Filho, Adam South, Gregory A. Hyatt, Paul Brown, Linn Andras, Ted R. Massa, Nitin Chaphalkar
  • Publication number: 20130273811
    Abstract: A method of grind hardening a workpiece is provided. The method may include securing the workpiece in a workpiece retainer and a grind tool in a tool retainer, rotating the grind tool in a first angular direction at a first angular speed, controlling the workpiece and tool retainers such that the grind tool engages the workpiece, and controlling the workpiece and tool retainers such that the grind tool is guided along a grinding track of the workpiece. The grind tool may engage and/or disengage the workpiece at portions of sacrificial material disposed thereon. Coolant and cleaning nozzles may be provided and controlled such that at least a portion of the coolant from the coolant nozzle is diverted to the cleaning nozzle in a manner which reduces heat dissipation, improves thermal efficiency of the grind hardening and reduces loading of the grind tool.
    Type: Application
    Filed: March 15, 2013
    Publication date: October 17, 2013
    Inventors: Nils Niemeyer, Tobias Foeckerer, Nitin Chaphalkar, Gregory A. Hyatt
  • Patent number: 8246026
    Abstract: Disclosed are a tool indexer assembly, a computer numerically controlled machine that includes such tool indexer assembly, and associated methods. The assembly in one embodiment includes a turret and an indexer, the indexer including a portion that is movable with respect to the turret and that includes plural tool station configured to receive plural tool structures. The tool indexer is disposed on a facet of the turret, and, in some embodiments includes a table that is rotatable about an axis that is generally orthogonal to the axis of rotation of the turret. In another embodiment, a tool indexer includes a clamping mechanism having a source of pressurized fluid and a piston that is hydraulically actuated by the pressurized fluid and movable to a clamping position. The assembly further includes a conduit for delivery of the pressurized fluid proximal the tool structure as coolant fluid.
    Type: Grant
    Filed: October 10, 2008
    Date of Patent: August 21, 2012
    Assignee: Mori Seiki USA, Inc.
    Inventors: Gregory Hyatt, Abhijit Sahasrabudhe
  • Patent number: 8234958
    Abstract: A toolholder with a controllable critical angle, such as a lead, trailing, rake or clearance angles, includes a tool spindle for retaining the toolholder in a tool rest of a machine tool. The machine tool includes at least one linear axis, for example, three mutually perpendicular axes, a rotary axis and a rotation axis. The rotary axis and/or rotation axis is controllable to move to a specified position in synchronization with a movement of one of the linear axes. An adaptor supports a cutting tool that is retained in the adaptor by a clamp. The cutting tool defines a critical angle, such as a lead angle, a trailing angle, a rake angle and a flank clearance angle, wherein the critical angle is corrected as a vector of movement of at least one of the linear axis is changed. In addition, the cutting tool can be positioned on opposite side of a centerline of rotation of the workpiece to effectively double the life of the cutting tool. A method of controlling a toolholder is also disclosed.
    Type: Grant
    Filed: July 8, 2008
    Date of Patent: August 7, 2012
    Assignee: Kennametal Inc.
    Inventors: Gregory A. Hyatt, Ted R. Massa, Linn R. Andras, James J. Stohr
  • Publication number: 20120152069
    Abstract: Computer numerically controlled (CNC) machines, adjustable material-working tools, and methods of operating an adjustable tool with a CNC machine are presented herein. An adjustable tool for a material-working machine is disclosed. The adjustable tool includes an elongated housing, and one or more cutting inserts at least partially disposed within the housing. Each cutting insert is selectively transversely repositionable with respect to the housing. A wedge is selectively longitudinally repositionable with respect to the housing. The wedge mates with the cutting insert(s) such that longitudinal movement of the wedge effectuates transverse movement of the cutting insert(s). A control arm is movably mounted to the housing. The control arm is configured to mechanically couple the wedge to a prime mover of the material-working machine such that motive force is transferred from the prime mover through the control arm to the wedge for the selective repositioning thereof.
    Type: Application
    Filed: December 14, 2011
    Publication date: June 21, 2012
    Applicant: Mori Seiki Co., Ltd.
    Inventors: Gregory Hyatt, Abhijit Sahasrabudhe