The Boeing Company

Gary Alan Lipczynski

Eric Whinnem

Wesley Edward Holleman

Nicholas Ryan Farrell

James Darryl Gamboa

William Paul Zanteson

Daniel W Barnett

Branko Sarh

Alan Frank Stewart

John A Baumann

John Rubrecht Lowell

Stephen Richard Dark

Michael L Caldarera

Mark Steven Denman

A method of assembling an aircraft assembly having a first member and a second member includes drilling at least one first opening through the first member, the at least one opening having a first diameter, and drilling at least one second opening through the second member, the at least one second opening having the first diameter. The method also includes forming a chamfer on the at least one first opening and the at least one second opening, the chamfer having a chamfer diameter, and positioning the first and second members to align the at least one first opening and the at least one second opening. The method further includes drilling the at least one first opening and the at least one second opening to a second diameter, wherein the second diameter is greater than the first diameter.

Method of assembling members of an assembly

A combination cutting and burnishing orbital drilling tool may include an elongate tool body including a cutting end and extending along a longitudinal axis. The tool body may include a burnishing portion spaced from the cutting end and configured to induce residual stress in a side wall of a hole without removing material. The tool body may further include a cutting portion interposed between the cutting end and the burnishing portion. The cutting portion may be configured to remove material from a workpiece, thereby creating the hole, during an orbital drilling process.

Machining/burnishing dual geometry orbital drilling tool

A machining tool incorporates a shaft having a first end configured to fit into a machining collet. A cutting portion extends from a second end of the shaft. A residual stress inducer is located between the first and second ends and includes a torsion element joined to the shaft at a connection end. A carbide tip is present on a free end opposite the connection end and the torsion element is configured such that a selected rotational speed, altered from a normal cutting speed, causes the carbide tip of the torsion element to contact a workpiece surface.

Roto peening orbital drilling tool

A cutting tool for use in an orbital drilling machine may include a cutting-tool body having a longitudinal axis and a plurality of cutting edges supported on the cutting-tool body and distributed circumferentially around the cutting-tool body. Each cutting edge may extend along the longitudinal axis in a respective helix. A circumferential spacing may be defined between each pair of circumferentially adjacent cutting edges for each position of the longitudinal axis along which the cutting edges extend. The circumferential spacing between at least first and second cutting edges of the plurality of cutting edges may be different at spaced-apart first and second positions along the longitudinal axis.

Orbital cutting tool having cutting edges with axially varying circumferential spacing

A hybrid laser machining and metrology method that enables one-up assembly of a work piece is disclosed. The hybrid machining and metrology method may include interleaving a first laser output to remove material from the work piece with a second laser output to measure material removed from the work piece.

Hybrid laser machining of multi-material stack-ups

A hole cleaning apparatus includes a member, a brush, and a vacuum source. The brush rotates around a longitudinal axis of the member, or translates in a direction which is substantially parallel to the longitudinal axis of the member. The vacuum source provides vacuum suction within the member.

Hole cleaning apparatus and method

A debris removal apparatus for a milling machine. In one embodiment, the debris removal apparatus includes a hollow, cylindrical suction member that attaches to a tool shaft which holds an end mill to rotate with the tool shaft. The debris removal apparatus further includes a nonrotating canister that applies a suction force to the suction member. The suction member is dimensioned to fit within a hole being cut by the end mill as the end mill is fed into the hole, and to extract debris created by the end mill via the suction force.

Debris collection for a milling process

Within examples, systems and methods for forming a hole through at least one layer of a material are provided. An example cutting tool for forming such a hole may include a body, and a first portion of the body having a first diameter and a first radial rake angle. The cutting tool also includes a second portion of the body adjacent the first portion, the second portion having a second diameter and a second radial rake angle, wherein the second diameter is different than the first diameter, and wherein the second radial rake angle is different than the first radial rake angle.

Variable rake fatigue enhancing orbital drilling cutter

Apparatus and methods for performing and controlling the sequence of steps in a multi-step machining process utilizing a plurality of drilling units, where each drilling unit is configured to perform at least one step of the multi-step machining process. Air pressure sensors in each drilling unit measure air pressures at the surface of a workpiece where the cutting tool of the drilling unit is engaged, which measured air pressures indicate air flow at the surface. These air flows in turn indicate the state of the machining at the surface of the workpiece, and based on the state of the machining, a machine control system will determine whether a drilling unit can perform its particular machining operation in the proper sequence on the workpiece.

Multi-step drilling apparatus and methods utilizing air flow sensing control

One aspect of the disclosure relates to a cutting tool for forming a final opening in a stack that includes at least two layers and a pilot opening having a pilot-opening dimension and extending through at least one of the at least two layers. The cutting tool includes a shank. The cutting tool also includes a first portion including at least one of a first coating or the first coating and a second coating, wherein the first coating at least partially covers the first portion. The cutting tool also includes a second portion between the shank and the first portion, wherein the second portion includes the second coating, and wherein the second coating at least partially covers the second portion.

Systems and methods for forming an opening in a stack

A method for performing operations on a structure. A moveable platform may be positioned in an area relative to the structure to define a working envelope. The moveable platform may be connected to a tool that may be moved around a plurality of axes within the working envelope using the moveable platform. The tool may be moved to a plurality of locations within the working envelope using the moveable platform. An operation may be performed with the tool through the working envelope at each of the plurality of locations using the moveable platform.

Automated hole generation

An apparatus for aligning a machine tool with a target location on a structure. A machine plate positionable on the structure has a plate bushing providing a hole through the plate. The apparatus also includes a nosepiece for guiding a distal end of the tool through the plate bushing to the target location. The nosepiece has a collet configured to be moved at least partly through and sideward in the plate bushing to center the nosepiece on an element projecting from the structure at the target location. The nosepiece can be attached to the plate bushing to establish normality of the tool relative to the projecting element.

Growing community of inventors

Garden Grove, CA, United States of America

Gary Alan Lipczynski