Roller burnishing apparatus having directly driven, coaxially disposed burnishing head assembly
BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates to a burnishing apparatus, and more particularly to a burnishing apparatus having a motor which includes a tubular output shaft and a burnishing head assembly driven directly by the output shaft of the motor without any intermediate gears, drive chains or drive belts. 
     2. Discussion 
     Burnishing and bearingizing machines are used in a wide variety of applications to smooth cylindrical shaped work surfaces. Roller burnishing tools typically operate by using tapered rolls which rotate and bear on an inversely tapered mandrel to apply a steady rolling pressure against the work surface. This pressure causes high &#34;peaks&#34; in the surface of the metal workpiece to &#34;flow&#34; into the microscopic &#34;valleys&#34; present on the work surface. This provides extremely accurate sizing while simultaneously providing a very fine finish, as well as work hardening the part surfaces. 
     Until the present time, burnishing machines have typically incorporated a motor which is coupled to some form of burnishing head assembly or tool by an intermediate gear assembly, drive chain, drive belt, etc. The intermediate assembly typically operates to couple the output shaft of the motor to the burnishing head assembly to thereby drive the race of the tool rotationally. Obviously, the intermediate coupling assembly represents an added component, and therefore an added expense, in the overall machine. The intermediate coupling assemblies also sometimes require periodic adjustment and/or maintenance to maintain acceptable operation. 
     In view of the above, it is a principal object of the apparatus and method of the present invention to provide a machine tool capable of burnishing the surfaces of cylindrical workpieces which has a burnishing head assembly thereof coupled directly to the output shaft of the motor of the tool to thereby obviate the need for an intermediate gear assembly, drive belt arrangement or drive chain arrangement heretofore required by such tools. 
     It is another object of the present invention to provide an apparatus and method for performing burnishing operations on cylindrical workpieces which includes a burnishing head assembly for burnishing the surface of the workpiece, where the burnishing head assembly is coupled directly to the output shaft of the motor of the apparatus and coaxially disposed with the output shaft of the motor. 
     It is still another object of the present invention to provide a machine tool capable of providing burnishing operations which incorporates a tubular output shaft coupled directly to a burnishing head assembly to allow an elongated, cylindrical workpiece to be fed directly into the burnishing head assembly and through the output shaft. 
     It is still another object of the present invention to provide a machine tool capable of providing a burnishing operation in which the machine tool includes a motor having tubular output shaft coupled directly to an armature of the motor, with the output shaft being coupled directly to a burnishing head assembly such that an elongated, cylindrical workpiece may be fed directly into the burnishing head assembly directly into contact with a plurality of rolls of the tool being driven rotationally by rotational movement of the race being driven by the output shaft, through the output shaft and out the rear of the machine tool. In this manner, no intermediate gear assembly, drive belt or drive chain assembly would be needed to couple the output shaft of the motor to the burnishing head assembly. 
     SUMMARY OF THE INVENTION 
     The above and other objects are accomplished by a machine tool apparatus and method having a directly driven, coaxially disposed burnishing head assembly in accordance with a preferred embodiment of the present invention. The apparatus generally comprises a motor having a tubular output shaft coupled directly to an armature thereof, and a burnishing head assembly coupled directly to the tubular output shaft. The apparatus of the present invention thus does not require any form of intermediate gear assembly for driving the burnishing head assembly, nor any form of drive belt or gear chain as needed with prior developed machine tool devices. The burnishing head assembly is driven directly by the output shaft of the motor. In the preferred embodiment the burnishing head assembly includes a plurality of rolls which are disposed for rotational movement, a cage for holding the rolls, a race and a coupling assembly for allowing the tubular output shaft to drive the race, and thus the rolls, rotationally when the motor is turned on. 
     In operation, a cylindrical workpiece or part is fed into the burnishing head assembly while the motor is turned on. The part is inserted until it comes into contact with the rolls. The rolls are further disposed concentrically with the race, cage and output shaft such that as the part is inserted into the burnishing head assembly a surface of the part comes into contact with the rolls. When the rolls make contact with the surface of the part they cause the part to rotate. In this manner, surface finishing of the part can be accomplished. 
     In the preferred embodiment the rolls comprise a plurality of tapered rolls which are supported in spaced apart relation to one another within the cage. The cage is fixedly coupled to an adjustable collar of the burnishing head assembly. The race comprises a tapered race which is fixedly coupled to the output shaft. The collar may be adjusted such that the cage is urged laterally relative to the race, which causes the tapered rolls to be urged inwardly towards the output shaft of the motor as well as inwardly relative to the axis of rotation of the output shaft. In this manner the diameter formed by the rolls can be adjusted (i.e., either enlarged or reduced) to accommodate parts of varying diameters. 
     The preferred embodiment described herein forms a very effective, yet relatively low cost roller burnishing tool for performing roller burnishing operations on cylindrical metal parts. Additionally, while the preferred embodiment shows a burnishing head assembly adapted to roller burnish an outer surface of a cylindrical part, the apparatus could be adapted to work the inner surface of a tubular part if so desired with suitable modifications. 
     The apparatus of the present invention provides a more compact and less costly tool for burnishing metal parts. Since no intermediate gear assembly, drive belt or drive chain is needed to drive the burnishing head assembly, a more positive driving of the burnishing head assembly is accomplished together with even further increased reliability. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The various advantages of the present invention will become apparent to one skilled in the art by reading the following specification and subjoined claims and by referencing the following drawings in which: 
     FIG. 1 is an elevational side view of a machine tool apparatus having a directly driven burnishing head assembly in accordance with a preferred embodiment of the present invention; 
     FIG. 2 is an end view of the apparatus of FIG. 1 taken in accordance with directional line 2--2; 
     FIG. 3 is a cross sectional side view in accordance with section line 3--3 in FIG. 2 of the motor and burnishing head assembly, and also showing a cylindrical part extending through the burnishing head assembly and through the tubular output shaft of the motor; and 
     FIG. 4 is a partial cross sectional view of the burnishing head assembly illustrating the teeth on the locking collar and the teeth on the adjusting collar, and the intermeshing arrangement of these teeth which help adjustment of the burnishing head assembly to be effected and maintained. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to FIGS. 1 and 2, a machine tool apparatus 10 in accordance with a preferred embodiment of the present invention is shown. The apparatus 10 generally comprises a motor 12, a burnishing head assembly 14 coupled directly to the motor so as not to require any intermediate gear assembly, drive belt or drive chain, a frame 16 for supporting the motor 12, and a plurality of foot members 18 for adjustably supporting the frame 16 on a support surface such as a floor or a table top. The frame 16 further includes a fitting 20 for allowing a conduit 22 to be coupled to the frame 16. Within the conduit extends an electric cable (not shown) for supplying current to the motor 12. The frame 16 further includes a conduit 24, an elbow 26 and a fitting 28 for allowing the current carrying cable extending through the conduit 22 to be directed through the conduit 24 to the motor 12. An on/off switch 30 is also mounted on the frame 16 and in series with the current carrying cable to allow the motor 12 to be turned on and off conveniently. 
     With specific reference to FIG. 1, the motor 12 includes a rear fan guard 32 and a tubular (i.e., hollow) output shaft 34 extending coaxially therethrough into direct coupling with the burnishing head assembly 14. Since the output shaft 34 is tubular, a cylindrical metal part may be slid directly into the burnishing head assembly 14 and through the output shaft 34 from a first end 36 of the motor 12 until the part extends completely through the interior of the motor 12 and exits the output shaft 34. 
     From FIGS. 1 and 2, it will be appreciated that the apparatus 10 forms a very compact and relatively low cost tool for finishing the surface of a cylindrical metal part. The finishing procedure accomplished by the apparatus 10 is generally known in the art as &#34;roller burnishing&#34; which removes the &#34;peaks&#34; from the surface of a workpiece by forcing the metal forming the peaks into valleys in the surface of the part. 
     Referring now to FIGS. 3 and 4, the internal components of the motor 12 and the burnishing head assembly 14 can be seen. Initially, it will be appreciated that the burnishing head assembly 14 is coupled to the motor 12 so as to be concentrically aligned with a longitudinal axis of rotation of the motor 12. With specific reference to FIG. 3, the motor 12 includes a housing 38, a field coil 40 secured to the housing 38, an armature 42 secured fixedly to the tubular output shaft 34 and a fan 44 enclosed within the rear fan guard 32. The tubular output shaft 34 and armature 42 are supported for rotational movement within the housing 38 by a pair of bearings 46. It will be noted that the output shaft 34 has an overall length sufficient to allow an output end 48 to extend outwardly of a second end portion 37 of the motor 12 and an input end portion 50 to extend outwardly of the first end portion 36 of the motor 12 into at least a portion of the burnishing head assembly 14. The inner diameter of the tubular output shaft 48 is of a predetermined size to enable a cylindrical part or workpiece 54 to be inserted thereinto once urged through the burnishing head assembly 14. 
     With specific reference to FIG. 4, the structure of the burnishing head assembly 14 will now be described. Burnishing head assembly 14 generally includes a flange 56 which is coupled to the housing 38 of the motor 12 via a plurality of threaded screws 58. The flange 56 includes a threaded end portion 60 which engages with a threaded portion of an adjusting collar 62. Accordingly, the adjusting collar 62 can be threadably advanced towards the flange 56 or rotated in the opposite direction to move threadably away from the flange 56. 
     With further reference to FIG. 4, the flange 56 includes an annular recessed portion 64 in which a coil spring 66 is disposed. A locking collar 68 is positioned over the coil spring 66 and movable slidably laterally relative to the flange 56. The locking collar 68 includes an opening 70 into which a pin 72 is disposed. A lowermost end portion 74 of the pin 72 rides within a slot 76 within the flange 56 when the locking collar 68 is moved laterally to the left or right as viewed in FIGS. 3 and 4. 
     With continued reference to FIG. 4, the input end 50 of the tubular output shaft 34 is coupled via a plurality of threaded set screws 78 to a housing member 80. The housing member 80 is in turn coupled via a set screw 82 to a race 84. The race 84 is in contact with a plurality of tapered rolls 86 disposed for rotational movement within a cage 88. Accordingly, rotational movement of the tubular output shaft 34 causes a corresponding rotational movement of the housing member 80 and the race 84 to thus drive each of the rolls 86 rotationally. As shown in FIG. 3, when the cylindrical part 54 is inserted in between the rolls 86 while the output shaft 34 is rotating, the rolls 86 &#34;grab&#34; the portion of the part 54 in contact therewith and cause the part 54 to rotate while bearing down on the outer surface of the part 54. 
     With further reference to FIG. 4, the cage 88 is coupled to the adjusting collar 62 via a roll pin 90 which is inserted into an opening 92 in the adjusting collar 62. The roll pin 90 serves to hold the cage 88 stationary while the race 84 is being rotated by the tubular output shaft 34 during operation of the apparatus 10. The cage 88 is further secured to the adjusting collar 62 by an end plate 94 which is secured to the adjusting collar 62 via a plurality of threaded screws 96. 
     With specific reference to FIG. 4, adjustment of the adjusting collar 62 is accomplished by grabbing the locking collar 68 with one hand and pulling it towards the motor 12 against the biasing force of the coil spring 66. This causes a plurality of teeth 68a of the locking collar 68 to become disengaged with a plurality of teeth 62a of the adjusting collar 62. While the locking collar 68 is being held in this disengaged position, the adjusting collar 68 can be rotated threadably with the other hand either towards or away from the motor 12. Moving the adjusting collar 62 rotationally one tooth 68a at a time results in the tapered rolls 86 being urged towards or away from the motor 12, which either increases or decreases the diameter formed by the rolls 86 by about 0.0001 inch per each tooth 68a moved. In other words, the rolls are urged either axially inwardly or outwardly relative to an imaginary longitudinal axis of rotation extending through the tubular output shaft 34 and the diameter formed by the rolls 86. In this manner the rolls 86 can be adjusted to accommodate varying diameters of parts inserted through the tubular output shaft 34. 
     Referring further to FIGS. 3 and 4, the operation of the apparatus 10 will now be described. Initially, an operator inserts the cylindrical part 54 into the burnishing head assembly 14 while the motor 12 is turned on. The operator continues to insert the part 54 until the part 54 comes into contact with the rolls 86. During this time the tubular output shaft 34 is rotating, thus causing the race 84 to rotate, which in turn causes the rolls 86 to be driven rotationally. When the rolls 86 contact the outer surface of the part 54 they begin applying an axially inward force to the outer surface of the part 54 which effects a burnishing action on the outer surface of the part 54. 
     With further reference to FIG. 4, once the rolls 86 have made contact with the outer surface of the part 54, the angle of the rolls 86 to the longitudinal centerline, which is known in the art as a &#34;helix&#34; angle, causes the rolls 86 to draw the part 54 into the tubular output shaft 48 and completely through the motor 12. In this regard it can be said that the angle of the rolls 86 effects an &#34;automatic feeding&#34; of the part 54 through the apparatus 10. It will be appreciated, however, that if it is desired to effect a burnishing of only a small length of the part 54, that a suitable stop mechanism could be employed with minor modifications to the burnishing head assembly 14 to urge the rolls 86 out of contact with the part 54 after a predetermined portion of the part 54 has fed through the rolls 86. Such structure is available on other forms of burnishing tools available from the assignee of the present application. 
     From the foregoing description it will be appreciated that the apparatus 10 requires no form of intermediate gear assembly, drive belt or drive chain to coupled the output shaft 48 of the motor 12 to the burnishing head assembly 14. This is a significant advantage over prior developed burnishing tools which, while having proven to be effective for the purposes for which they have been employed, have still required additional components to couple an output shaft of the motor to the structure representing the burnishing tool. The apparatus 10 thus enables a burnishing tool to be constructed less expensively and with less complexity than previously developed burnishing tools. The apparatus 10 further forms a very compact unit which is relatively easy to operate and which provides for a small degree of adjustability to accommodate workpieces or parts having varying diameters. From the above description it will also be appreciated that the burnishing head assembly 14 could be modified so as to allow an inside surface of the tubular part or workpiece to be roller burnished if desired. At the present time it is anticipated that most applications for which the apparatus 10 will be employed will involve roller burnishing an outer surface of a workpiece but the burnishing of inner surfaces of tubular workpieces is certainly possible with suitable modifications which will be appreciated by those of ordinary skill in the art. 
     The apparatus 10 of the present invention could further be modified by the inclusion of a suitably shaped arbor to provide a bearingizing of the outer surface of the part 54. Still further, as will be appreciated by those of ordinary skill in the art, the burnishing head assembly 12 could be modified to provide a bearingizing effect to an inner surface of a tubular part if desired. Again, however, it is anticipated that the apparatus 10 will be used in most applications to effect roller burnishing of an outer surface of a cylindrical part. 
     Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims.