Machining tool
Contents
1. 0018 In some embodiments the support structure has a bottom the table having a top sufficiently above the bottom of the support structure that the machining tool can be placed on a first selected surface with the table top providing a second surface a space being disposed between the first and second surfaces and receiving the distal end of the bit below the table for accommodating side cutting operations per formed by a side portion of the bit displaced from the distal end of the drill bit 0019 In some embodiments the first speed is about 1000 rpm to about 5000 rpm and the second speed is about 10 000 rpm to about 35 000 rpm 0020 In some embodiments the bit has an effective diameter substantially less than approximately 0 20 inch 0021 In some embodiments the electric tool has a plug for connecting the electric tool to a power source the control apparatus comprising a power regulator and an outlet the outlet being adapted to receive such plug of the electric tool 0022 In some embodiments the chuck has a chuck input shaft extending upwardly from the chuck the chuck input shaft communicating with the rotatable output shaft of the electric tool 0023 In some embodiments the rotatable output shaft of the electric tool has an axis of rotation the chuck input shaft having an axis of rotation generally coaxial with such axis of rotation of the rotatable output shaft 0024 In some embodiments the chuck input2. 0046 The invention is not limited in its application to the details of construction or the arrangement of the components set forth in the following description or illustrated in the drawings The invention is capable of other embodiments or of being practiced or carried out in other various ways Also it is to be understood that the terminology and phraseology employed herein is for purpose of description and illustra tion and should not be regarded as limiting Like reference numerals are used to indicate like components DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS 0047 Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure The scope of the invention is defined by the claims appended hereto 0048 FIGS 1 4 refer to embodiments of machining tools 1 of the invention which are used for both plunge drilling of and high speed spiral cutting of a workpiece Generally the embodiment of FIGS 1 4 is a machining tool 1 The machining tool comprises a table 3 which supports a workpiece 47 standard 9 which supports orients and mounts tool holder 13 in relation to table 3 Tool holder 13 is adapted to receive electric rotary tool 25 0049 The combination of table 3 standard 9 and tool holder 13 enables the user to perform drilling and cutting operatio
3. a drive shaft drivably connected to the chuck the electric tool having a rotatable output shaft and electric speed control apparatus controlling speed of the electric tool rotatable output shaft for varying speed of rotation of the electric tool rotatable output shaft 0028 In some embodiments the electric speed control apparatus comprises a speed control which controls the electric tool rotatable output shaft to rotate at speeds from a relatively slower speed of about 1000 rpm to about 5000 rpm to a relatively higher speed of about 10 000 rpm to about 35 000 rpm 0029 In some embodiments the electric speed control apparatus controls the electric tool rotatable output shaft to rotate with speed variability of at least about eight to one 0030 In some embodiments the tool holder guide recip rocates along an axis which is substantially perpendicular to the table and wherein a line of sight between a person using the apparatus and the bit in contact with a workpiece is generally unobstructed 0031 In a third family of embodiments the invention comprehends a method of cutting a workpiece comprising gripping a bit in a chuck driven by an electric rotary tool having a rotatable output shaft rotating the rotatable output shaft of the electric rotary tool and correspondingly rotating the bit at a first speed while rotating the rotary electric tool at the first speed advancing the bit a first distance longitu dinally along an ax
4. shaft has a diameter D1 and the rotatable output shaft of the electric tool has a diameter D2 the chuck being adapted to receive a bit with a diameter up to D3 the diameter D3 being greater than at least one of diameter D1 and diameter D2 0025 In a second family of embodiments the invention comprehends a machining tool comprising support struc ture a table mounted to the support structure a tool holder support supported by the support structure and extending upwardly therefrom a tool holder mounted to the tool holder support the tool holder comprising a guide and a chuck the tool holder guide accommodating movement of the tool holder toward and away from the table rotating drive apparatus for rotating the chuck the rotating drive apparatus superposing the chuck whereby the drive apparatus is adapted to communicate with a rotary tool removably mounted to the tool holder 0026 In some embodiments the machining tool further comprises an aperture in the table in alignment with an axis of rotation of the chuck and a space between a bottom of the support structure and a top of the table the space receiving a distal end of the bit below the table thereby to facilitate May 12 2005 side cutting operations performed by portions of the bit which are displaced from the distal end of the bit 0027 In some embodiments the rotating drive apparatus comprises an electric tool removably mounted in the tool holder guide and having
5. user to fabricate more intricate designs than when a larger bit must be used Having the bit held laterally stationary enables the user to manipulate the workpiece with both hands on a stationary surface whereby precision of the cuts being made is enhanced Where a small diameter bit is used e g about 0 06 inch to about 0 20 inch the small bit size further contributes to the intricate detain which can be embodied in the finished product 0083 Speed controller 31 also enables the user of machining tool 1 to perform conventional drilling proce dures operations Accordingly machining tool 1 enables a user to perform more operations upon a workpiece than can be performed by a conventional rotary tool As one example the user operates machining tool 1 to perform a plunge drilling operation The user inserts a conventional twist drill bit into chuck 27 and adjusts speed controller 31 to a relatively lower rotational speed adapted to produce desired drilling results for the specific size of bit being used when considering the material composition of workpiece 47 US 2005 0097717 Al 0084 As a further example machining tool 1 enables the user to rotate a plunge drilling bit at a relatively lower speed to bore holes into through a metallic workpiece preferably using cutting oil or other liquid lubricant penetrant to lubri cate and reduce temperature of the workpiece 0085 As another example machining tool 1 enables a user to bore
6. variable resister e g a potentiometer alterna tively a rheostat which varies the resistance and correspond ingly varies the voltage in the circuit and thus varies the speed of rotation of rotary tool 25 at output shaft 26 0080 In some embodiments the user rotates a dial 34 alternatively manipulates a slide on speed controller 31 to correspondingly control the rotational speed created by rotary tool 25 In other embodiments the user pivots a foot pedal to regulate speed controller 31 which correspondingly controls the rotational speed created by rotary tool 25 Suitable foot pedals e g foot switches are presently avail able from Conntrol International Inc headquartered in Putnam Conn 0081 Speed controller 31 also enables a user to vary the speed of rotary tool 25 thus the user can perform consecu tive different functions using machining tool 1 For example an initial relatively low speed plunge drill step penetrates workpiece 47 followed by raising rotational speed of bit 33 and performing a high speed cutting operation using the side cutting elements of the bit 0082 Bits which combine both drilling and cutting fea tures and are of relatively small diameter e g Ys inch or smaller are preferred for performing a combination func tion the combination function consisting of an initial plunge drilling action followed by a rotational side cutting action Performing such operations with such small bits enable the
7. 5 Slide 19 is reciprocably mounted to base 17 Accordingly slide 19 reciprocates relative to the tool holder base 17 along a longitudinal axis 21 that is perpen dicular to table 3 0067 Referring now to FIGS 1 2 and 3 reciprocation of slide 19 along base 17 is achieved by pivoting rotating handle 23 e g by a conventional rack and pinion system to convert rotating motion into linear motion Rotating handle 23 correspondingly rotates a gear within base 17 The rotating gear in base 17 engages a rack affixed to slide 19 forcing the rack and thus slide 19 to either climb upwardly away from table 3 or downwardly toward table 3 depend ing on the direction of rotation of the rotating gear in base 17 0068 In some embodiments electric rotary tool 25 is removably attached to tool holder slide 19 Electric rotary tool 25 is e g clamped to holder slide 19 to align the rotary tool 25 with aperture 7 In preferred embodiments electric rotary tool 25 has a rotating output shaft 26 capable of high speed rotation e g 35 000 rpm alternatively greater than 35 000 0069 Known high speed rotary tools are adapted to accept bits into the rotating mechanism at the distal end of the rotating output shaft 26 by means of a compression fit using a Sleeve structure e g a collet A bit is inserted into the collet which is accepted into the rotating mechanism The collet nut is tightened which corresponding compresses the collet the compresse
8. US 20050097717A1 a Patent Application Publication co Pub No US 2005 0097717 Al as United States Rasmussen 43 Pub Date May 12 2005 54 MACHINING TOOL CH US CL ra 29 26 A 409 236 408 237 29 558 76 Inventor Bret Rasmussen Neenah WI US Correspondence Address 57 ABSTRACT WILHELM LAW SERVICE S C 100 W LAWRENCE ST THIRD FLOOR APPLETON WI 54911 21 Appl No 10 703 260 22 Filed Nov 6 2003 Publication Classification 51 Int CII ee B23P 13 04 A machining tool comprises a support structure and a standard extending therefrom The standard comprises a tool holder adapted to removably receive a rotary tool The tool holder employs a reciprocating mechanism to move such rotary tool nearer to or further from a workpiece Such rotary tool is removably connected to a chuck the chuck being adapted to accommodate a bit of larger diameter than the rotary tool is adapted to receive The machining tool having a mechanism adapted to control the speed of such rotary tool Patent Application Publication May 12 2005 Sheet 1 of 7 US 2005 0097717 A1 Patent Application Publication May 12 2005 Sheet 2 of 7 US 2005 0097717 A1 Patent Application Publication May 12 2005 Sheet 3 of 7 US 2005 0097717 A1 Patent Application Publication May 12 2005 Sheet 4 of 7 US 2005 0097717 A1 Patent Application Publication May 12 2005 Sheet 5 of 7 US 2005 0097717 A1 Patent Application Publication May 12 2005 S
9. ations a relatively slow speed for plunge drilling operations and a much higher speed for side cutting operations The combination drill and cutting bit 33 both makes an initial hole in the workpiece and cuts along a desired path 51 to cut the complete opening The small diameter of the bit enables small radius corners namely almost sharp corners to be produced in the open ings 0093 It will also be recognized that in addition to the superior performance of the machining tool 1 construction of a tool of the invention is such as to be of modest cost in comparison to the benefits provided by the tool In fact the machining tool quickly pays for itself because of increased productivity 0094 Those skilled in the art will now see that certain modifications can be made to the apparatus and methods herein disclosed with respect to the illustrated embodiments without departing from the spirit of the instant invention And while the invention has been described above with respect to the preferred embodiments it will be understood that the invention is adapted to numerous rearrangements modifications and alterations and all such arrangements modifications and alterations are intended to be within the scope of the appended claims 0095 To the extent the following claims use means plus function language it is not meant to include there or in the instant specification anything not structurally equivalent to what is shown in the emb
10. aximum opening diameter D3 of inch which enables a user of machining tool 1 to insert individual bits each having a shank diameter up to inch into chuck 27 In other embodiments chuck 27 has a maximum opening diameter D3 of 1 inch which enables a user of machining tool 1 to insert individual bits each having a shank diameter up to inch into chuck 27 0076 Chuck 27 enables a user of machining tool 1 to utilize bits having diameters up to inch alternatively bits having diameters up to inch for drilling and cutting operations thus increasing the versatility of a conventional May 12 2005 high speed rotary tool 25 Machining tool 1 enables a user to have both the high speed capabilities of a conventional high speed rotary tool 25 in combination with the bit size accommodation versatility of chuck 27 0077 As show in FIG 1 some embodiments of machin ing tools 1 include a an electronic control apparatus which can be a power regulator e g speed control 31 0078 In preferred embodiments speed control 31 has a power cord and a plug which connects speed control 31 to an alternating current source at an outlet 32 The power cord of rotary tool 25 is plugged into the outlet on speed control 31 Auser of machining tool 1 uses speed control 31 to vary the motor rotational speed of rotary tool 25 0079 Alternating current motor speed controllers are widely available In some embodiments speed controller 31 employs a
11. cut on its sides not at a point The side cutting force on the bit can jerk the router in the user s hands Moreover it is difficult to control the size and location of the initial hole Consequently another tool such as an electric drill with a twist drill bit is usually used to form the initial hole Another problem with the machine of the U S Pat No 6 223 794 was that the line of sight from the user to the bit was partially blocked by elements of the router 0003 U S Pat No 5 853 036 discloses a cutting appa ratus for routing the ends of molding sections The router bit is in view during operation However the longitudinal axis of the router bit is always oblique to the plane of the workpiece and oblique to the directions of movement of the router bit 0004 To the inventor s knowledge no machine is avail able that has both a range of speeds sufficient to effectively utilize both the plunge drilling capabilities and the side cutting capabilities of a combination bit and the bit size accepting versatility to accept both a relatively smaller diameter combination bit and or side cutting bit and a relatively larger diameter bit e g a conventional plunge drilling bit 0005 A further limitation regarding known combination bits is that known bits are not available in diameters smaller than about 0 25 inches That size is too large to produce many intricate openings in artistic workpieces such as craft items 0006 C
12. d collet grippingly securing the bit within the rotating mechanism US 2005 0097717 Al 0070 Known high speed rotary tools utilize bits with a side cutting surface such as sharpened flutes The conven tional side cutting bit is rotated at high speeds e g 30 000 35 000 which enables a user to move the bit through work material using the side cutting elements of a conventional high speed rotary tool bit e g an Advantage High Speed Rotary Saw bit or a Spiral Saw Zip bit A preferred rotary tool 25 is produced by the Roto Zip Tool Corporation under the trademark Roto Zip 0071 Such high speed rotary tool can only receive a bit with a shank diameter corresponding to the size of the collet However conventional collets are of limited sizes which correspond to the size of the rotating apparatus e g rotating output shaft 26 Conventional collects used in high speed rotary tools are 1 4 inch or 4 some collets being smaller Accordingly conventional high speed rotary tools typically do not accommodate bits having shank diameters greater than 1 4 inch as limited by the diameter of the rotating mechanism e g output shaft diameter D1 The user of a conventional high speed rotary tool is correspondingly lim ited to performing functions which can be performed using a bit of up to 1 4 inch diameter 0072 Referring again to FIG 1 in some embodiments tool holder 13 has guide 29 formed therein Guide 29 has an annular
13. eed range including a relatively high rotational speed e g 30 000 rpm US 2005 0097717 Al 0036 It is another object of the invention to provide a machining tool for cutting drilling or otherwise machining a workpiece which enables a user to removably attach an electric tool to a chuck 0037 It is yet another object to provide a method of cutting a workpiece wherein a user rotates a tool at a first relatively slower rotational speed so as to perform a plunge drilling action into a workpiece subsequently while rotating the tool at a second relatively higher rotational speed the user advances the workpiece along a selected path BRIEF DESCRIPTION OF THE DRAWINGS 0038 FIG 1 shows a first perspective view of a first embodiment of machining tools of the invention 0039 FIG 2 shows a second perspective view of the embodiment of FIG 1 0040 FIG 3 shows a third perspective view of the embodiment of FIG 1 making a plunge cut hole 0041 FIG 4 shows a fourth perspective view of the embodiment of FIG 1 making a side cut 0042 FIG 5 shows a top view of a typical workpiece worked on by machine tools of the invention 0043 FIG 6 shows a side elevation view of a portion of a bit useful in machining tools of the invention 0044 FIG 7 shows an exploded perspective view of a portion of the machining tool of FIG 1 0045 FIG 8 shows a perspective view of a portion of the machining tool of FIG 1
14. erein the rotating the bit at the second relatively greater speed comprises rotating the bit at a speed of about 10 000 rpm to about 35 000 rpm 27 Amethod as in claim 25 wherein rotating the bit at the second relatively greater speed comprises rotating the bit at a second speed which is at least about eight times faster than the first speed 28 A method as in claim 25 wherein the advancing of the bit comprises advancing the bit in a direction substantially perpendicular to a surface of the workpiece and the advanc ing of the workpiece is accompanied by a relatively unob structed view of the bit where the bit is in cutting contact with the workpiece
15. he workpiece 47 and also on the diameter of the bit 33 The operator holds the workpiece with one hand and pivots the tool holder lever 23 with the other hand 0089 Referring now to FIG 2 as the user pivots the tool holder lever 23tool slide 19 advances toward the workpiece in the manner of a conventional drill press Upon contact of the bit end 37 with the workpiece with the bit rotating the operator exerts sufficient force on the tool holder handle to cause the distal end of bit 33 to penetrate through the workpiece and enter the table hole 7 That action causes an initial hole such as initial hole 49 in FIG 5 to be drilled through the workpiece The tool holder lever is further pivoted to position the side cutting edges 43 of the bit in the initial hole 49 The operator then locks the tool holder slide 19 to the base 17 0090 The operator then adjusts the speed controller 31 to energize the electric tool to a very high speed of perhaps approximately 30 000 rpm Using two hands the operator slides the workpiece 47 on the table 3 along a desired path to cut the perimeter 51 of an opening such as the opening A of FIGS 4 and 5 At all times the combination drilling and cutting bit 33 as well as the perimeter 51 of the workpiece opening A are in full view of the operator The small diameter of the bit enables small radius curves namely almost sharp corners to be cut in the opening 0091 As soon as the opening A has been full c
16. heet 6 of 7 US 2005 0097717 A1 Wo Q pj EL Ct Cr 45 33 jo Patent Application Publication May 12 2005 Sheet 7 of 7 US 2005 0097717 A1 FIG 8 US 2005 0097717 Al MACHINING TOOL BACKGROUND 0001 In woodworking and other crafts it is often nec essary to cut intricate openings through a piece of wood or other material Known processes for cutting such openings are time consuming and laborious In a typical known process an initial hole is first drilled through the workpiece Then a scroll saw blade is threaded through the initial hole and mounted to the scroll saw After the cut is made the saw blade is removed from the machine and the workpiece opening re threaded through another pre drilled initial hole and remounted to the machine The process is repeated for each opening required The multiple set up and take down steps necessary for each opening result in substantial lost time 0002 Another method of cutting openings in a piece of material involved a conventional router in combination with a stand such as is shown in U S Pat No 6 223 794 The stand holds the router over a table that supports the work piece The initial hole for the opening is drilled prior to using the router Alternately the initial hole is formed by manually tilting the router and bit at an angle to the workpiece and then manually plunging the bit into the material That operation is dangerous because a router bit is designed to
17. hining tool 1 0052 In some embodiments table 3 is made of other metallic materials e g steel Non stainless steel alloys are relatively less resistant to corrosion but are also less costly Thus a user of machining tool 1 maintains a corrosion free surface of table by painting or lightly oiling the surface of table 3 when resistance to corrosion is desired or by maintaining a low moisture environment about machining tool 1 In some embodiments table 3 is painted alternatively powder coated prior to retail sale of machining tool 1 In other embodiments table 3 is galvanized or otherwise zinc plated to resist corrosion 0053 In some embodiments table 3 comprises a wood based material Some embodiments include a solid wood table 3 Solid wood table 3 is preferably a hard wood such as oak for the relative strength and durability the hard wood provides to support structure 2 Preferred embodiments include a wood table 3 comprising an engineered wood product which offers dimensional stability e g resists expanding contracting warping cupping as compared to natural wood table 3 under conditions of varying ambient temperature and or varying humidity 0054 Table 3 has at least one alternatively a plurality of apertures 7 formed therethrough At least one of the aper tures 7 is positioned below electric tool 25 in axial align ment with bit 33 which is driven by electric tool 25 Aperture 7 defines an opening sufficiently
18. hining tool as in claim 4 wherein the second speed is at least eight times faster that the first speed 10 Machining tool as in claim 4 wherein said bit has an effective diameter substantially less than approximately 0 20 inch 11 Machining tool as in claim 1 said electric tool having a plug for connecting said electric tool to a power source said control apparatus comprising a power regulator and an outlet said outlet being adapted to receive a such plug of said electric tool 12 Machining tool as in claim 1 said chuck having a chuck input shaft extending upwardly from said chuck said chuck input shaft communicating with said rotatable output shaft of said electric tool 13 Machining tool as in claim 12 wherein said rotatable output shaft of said electric tool has an axis of rotation said May 12 2005 chuck input shaft having an axis of rotation generally coaxial with such axis of rotation of said rotatable output shaft 14 Machining tool as in claim 12 wherein said chuck input shaft has a diameter D1 and said rotatable output shaft of said electric tool has a diameter D2 said chuck being adapted to receive a bit having a diameter up to D3 said diameter D3 being greater than at least one of diameter D1 and diameter D2 15 Machining tool for performing drilling and cutting operations on a workpiece said machining tool comprising a support structure b a table mounted to said support structure c a tool holder
19. holes into through a wood workpiece To bore a hole into through a wood workpiece the user rotates a plunge drilling bit at a relatively higher speed than the rotational speed required to bore a hole into through a metallic workpiece 0086 Machining tool 1 enables a user to perform side cutting operations in addition to plunge drilling operations To perform a side cutting operation a user rotates a side cutting bit or combination bit at a relatively higher speed than the speed required to perform a hole plunge drilling operation upon a workpiece 0087 Referring specifically to the process of cutting out the pattern in workpiece 47 as illustrated in FIG 5 the machining tool 1 is placed on the top surface of a conven tional work bench The short height of the legs 5 as illustrated in FIG 1 locates the table 3 so as to be approximately as convenient to the operator as the work bench top surface itself Further the heavy weight of the frame 2 maintains the machine in place on the work bench without moving from its desired location A workpiece 47 is placed on the machine table 3 An area A that is to be cut out of workpiece 47 is placed in alignment with the tool holder axis 21 0088 A desired combination drill and cutting bit 33 is mounted in chuck 27 The speed controller 31 is adjusted to energize the electric tool 25 at a relatively slow speed such as approximately 3 000 rpm The actual speed is dependent on the material of t
20. id bit having a distal end adapted for plunge drilling and a side cutting portion disposed away from the distal end said electric speed control apparatus controlling the speed of the electric tool rotatable output shaft between a first relatively slower speed for plunge type drilling using the drill point of the bit and a second relatively higher speed for side cutting using the side cutting portion of said bit 5 Machining tool as in claim 4 wherein said bit has a diameter of approximately 0 06 inch 6 Machining tool as in claim 4 wherein the longitudinal axis of said tool holder is substantially perpendicular to said table and a view of said bit during the drilling and cutting operations is generally unobstructed to a person using the machining tool 7 Machining tool as in claim 4 wherein said support structure has a bottom said table having a top sufficiently above the bottom of said support structure that said machin ing tool can be placed on a first selected surface with said table top providing a second surface a space being disposed between the first and second surfaces and receiving the distal end of said drill bit below said table for accommodating side cutting operations performed by a side portion of said bit displaced from said distal end of said drill bit 8 Machining tool as in claim 4 wherein the first speed is about 1000 rpm to about 5000 rpm and wherein the second speed is about 10 000 rpm to about 35 000 rpm 9 Mac
21. is of rotation of the bit and thereby drilling a through hole in the workpiece as a plunge drilling action and advancing the bit beyond the first distance to a stop locus rotating the bit at a second speed substantially greater than the first speed while rotating the bit at the second speed advancing the workpiece along a selected path while contacting a side portion of the bit and thereby making an elongate linear cut in the workpiece 0032 In some embodiments the rotating of the bit at the first relatively slower speed comprises rotating the bit at a speed of about 1000 rpm to about 5000 rpm and the rotating of the bit at the second relatively greater speed comprises rotating the bit at a speed of about 10 000 rpm to about 35 000 rpm 0033 In some embodiments the bit at the second rela tively greater speed rotates the bit at a speed which is at least about eight times faster than the first speed 0034 In some embodiments the advancing of the bit comprises advancing the bit in a direction substantially perpendicular to a surface of the workpiece and the advanc ing of the workpiece is accompanied by a relatively unob structed view of the bit where the bit is in cutting contact with the workpiece 0035 Itis an object of the invention to provide a machin ing tool for cutting drilling or otherwise machining a workpiece which accommodates a wide variety of bit sizes and is adapted for variable speed use the variable sp
22. large that bit 33 can penetrate the aperture 7 When the bit is performing a side cutting operation after penetrating aperture 7 the end 37 of bit 33 is generally below the surface of table 3 exposing side cutting edges 43 of bit 33 to workpiece 47 0055 Extending downwardly from table 3 are legs 5 In some embodiments legs 5 are relatively short e g 2 6 inches The bottom of each of legs 5 is in supportive communication with an underlying support structure com monly found in a workshop such as a table workbench Legs 5 elevate table 3 a sufficient distance above the top of US 2005 0097717 Al the supporting structure to enable a user of machining tool 1 to descend the end 37 of bit 33 into and through aperture 7 without the end 37 of bit 33 penetrating an underlying surface of the support structure e g a workbench 0056 In some embodiments legs 5 are relatively long e g 36 42 inches alternatively longer shorter The bottom of each of legs 5 is in supportive communication with a ground surface e g the floor of a shop Where machining tool 1 is supported from a ground lever surface the lengths of legs 5 support the working elements of the machining tool 1 at a height whereby the user can comfortably control the machining tool 1 while the machining tool 1 is being used for its intended purpose 0057 In some embodiments legs 5 are adjustable to enable the user to sequentially position machining tool 1 on support surface
23. le advancing workpiece 47 relative to bit 33 during cutting operation 0063 In some embodiments standard 8 includes down wardly dependent arm 15 extending downwardly from gen erally longitudinal arm 11 The length of arm 15 generally corresponds to the length of post 9 In some embodiments post 9 is relatively long and arm 15 is correspondingly relatively long In other embodiments post 9 is relatively short and arm 15 is correspondingly relatively short The distance between table 3 and the intersection of post 9 and arm 11 in combination with the downward displacement of arm 15 from the intersection of arm 15 and arm 11 positions holder 13 electric tool 25 and bit 33 at an appropriate height above table 3 0064 In some embodiments standard 8 is of one piece construction with post 9 arm 11 and arm 15 being integral with post 9 Standard 8 is made of e g round tubular steel bent at approximately 90 degree at two loci to accommodate suspending electric tool 25 and thus bit 33 above table 3 0065 In some embodiments standard 8 is an assembly comprised of post 9 arm 11 and arm 15 in combination with suitable connections and or connectors Post 9 is then attached to arm 11 and arm 11 is attached to arm 15 by e g welding riveting bolting screwing or by other conven tional affixation means 0066 Insome embodiments tool holder 13 is attached to arm 15 Tool holder 13 has a base 17 which is fixedly mounted to arm 1
24. ns to workpiece 47 with electric rotary tool 25 while minimizing the utilization of the user s human motor func May 12 2005 tion resources e g hand manipulation needed to support control manipulate and orient electric rotary tool 25 Thus machining tool 1 enables a user to allocate the user s manual dexterity towards workpiece 47 enabling the user to intri cately control manipulation of workpiece 47 relative to electric rotary tool 25 0050 Referring specifically now to the drawings FIG 1 illustrates a first embodiment of machining tool 1 Machin ing tool 1 has support structure 2 which includes table 3 Table 3 is supported by a plurality of legs 5 In some embodiments table 3 comprises a metallic material Metal table 3 is advantageous because of the strength rigidity of the metallic material and relatively heavy weight of the metallic material which contributes to overall stability of machining tool 1 0051 Preferred metallic materials of table 3 are materi als which resist corrosion In some embodiments table 3 is made of stainless steel which resists corrosion and which provide strength rigidity to support structure 2 In other embodiments table 3 is made of aluminum which resists corrosion and provides strength rigidity to support structure 2 Aluminum is relatively light as compared to steel so aluminum table 3 contributes to the portability of machining tool 1 enabling a user to more easily move mac
25. odiments disclosed in the speci fication Having thus described the invention what is claimed is 1 A machining tool adapted to perform drilling and cutting operations on a workpiece said machining tool comprising a a support structure comprising a table said table having at least one aperture formed therethrough b a tool holder support extending upwardly from said support structure US 2005 0097717 Al c a tool holder mounted to said tool holder support said tool holder comprising a slide which is reciprocable along a longitudinal axis of said tool holder wherein the longitudinal axis is aligned with one of such at least one aperture formed through said table d an electric tool removably mounted to said tool holder slide said electric tool having a rotatable output shaft e a chuck mounted on one of said electric tool and said tool holder and connected for rotation to said rotatable output shaft and f electric speed control apparatus controlling the speed of rotation of the rotatable output shaft of said electric tool between a first relatively slower speed and a second relatively higher speed 2 Machining tool as in claim 1 wherein the second speed is at least eight times faster than the first speed 3 Machining tool as in claim 1 wherein said tool holder support extends upwardly from said table 4 Machining tool as in claim 1 said machining tool further comprising a bit gripped in said chuck sa
26. onnecting at least 2 of legs 5 leaving the entire upper surface of table 3 unobstructed 0061 In some embodiments post 9 is pivotally attached to support structure 2 Pivotally attached post 9 enables a user of machining tool 1 to pivot standard 8 and thus electric tool 25 laterally away from table 3 when vertical clearance above table 3 is desirable e g as a user initially positions a large workpiece 47 upon table 3 In preferred embodiments the pivotal attachment of post 9 includes a detent to snap lock post 9 into the position in which bit 33 superposes aperture 7 thus providing an audible or visible or touch detectable feedback indicating to the user that bit 33 has bee accurately oriented over aperture 7 preferably after work piece 47 has been positioned upon table 3 with the work piece visually covering aperture 7 0062 In preferred embodiments arm 11 extends from and is perpendicular to post 9 The length of arm 11 corresponds to the distance between post 9 and aperture 7 so as to orient bit 33 above aperture 7 Arm 11 has enough strength rigidity to provide effective load bearing support to holder 13 and electric tool 25 Arm 11 transfers forces May 12 2005 applied to holder 13 and electric tool 25 into support structure 2 via post 9 Such forces include gravitational forces torsional forces created by the rotating mechanisms of electric tool 25 and forces transferred from a user through workpiece 47 whi
27. onventional high speed rotary tools those with operating speed of around 30 000 rpm and higher enable users to make a cut into a workpiece using the side cutting surface of a rotary tool bit Conventional high speed rotary tools accept bits of a limited size variety as compared to conventional relatively lower speed drills and drill presses A conventional rotary tool uses a collet to secure a bit thereby limiting the usable bit size to a size which corresponds to the collet whereas a conventional drill uses May 12 2005 an adjustable chuck the adjustable chuck accommodating a wider variety of bit sizes than a rotary tool collet 0007 Typically high speed rotary tools are manipulated with both hands of a user The tool is advanced or otherwise maneuvered relative to a workpiece thus the workpiece remains still and tool is moved to achieve the desired result 0008 Some conventional high speed rotary tools are multi speed or variable speed devices The speed control mechanism is typically located on the rotary tool itself By locating the rotary tool speed control on the rotary tool during use of a conventional rotary tool the user utilizes only one of his or her hands to control the rotary tool as the other hand adjusts the speed control which can be danger ous SUMMARY 0009 A machining tool comprises a table a standard a tool holder to hold a high speed rotary tool and a chuck Some embodiments include an a
28. opening formed therethrough which accommodates a bearing alternatively a set of bearings to be installed The bearings in guide 29 are adapted to have a rotatable shaft inserted therethrough 0073 In some embodiments chuck 27 is rotatably attached to tool holder 13 at guide 29 Chuck 27 has a tool facing end and a bit facing end Fixedly attached to the tool facing end of chuck 27 is a rotatable input shaft 28 Rotation of the rotatable chuck input shaft 28 correspondingly rotat ably drives chuck 27 Rotatable chuck input shaft 28 extends from chuck 27 through the bearings in guide 29 and terminates above the top of guide 29 leaving a portion of chuck input shaft 28 exposed above guide 29 0074 In preferred embodiments chuck input shaft 28 has a diameter D2 of no greater than 1 4 inch When attaching rotary tool 25 to holder slide 19 the user inserts chuck input shaft 28 into the collet of rotary tool 25 and subsequently tightens the collet nut thereby removably attaching the rotating mechanism of rotary tool 25 to chuck 27 Once rotary tool 25 and chuck 27 are coupled rotating mechanism of rotary tool 25 correspondingly rotates chuck 27 0075 Referring specifically to FIG 7 In some embodi ments chuck 27 is a conventional chuck as used in portable drills and drill press machines Chuck 27 has a variable diameter opening to accommodate individual bits having different shank diameters In some embodiments chuck 27 has a m
29. pparatus to control the speed of the high speed rotary device 0010 Machining tools of the present invention enable a user to perform both plunge drilling operations and high speed rotational cutting operations without having to change bits and without having to manually stabilize and or manipulate the high speed rotary tool relative the workpiece Accordingly machining tools of the invention enable a user to use both his or her hands to manipulate the workpiece while performing a machining operation on the workpiece Alternatively the user can adjust the speed of the rotary tool without having to simultaneously hold support and control the rotary tool because support is provided by the machin ing tool 0011 In some embodiments the speed control apparatus is located sufficiently far from the rotary tool to enable a user to adjust the speed without positioning his ro her appendages near the rotating mechanism of the rotary tool 0012 Ina first family of embodiments a machining tool has a support structure comprising a table the table having at least one aperture formed therethrough a tool holder support extending upwardly from the support structure a tool holder mounted to the tool holder support the tool holder comprising a slide which is reciprocable along a longitudinal axis of the tool holder wherein the longitudinal axis is aligned with one of such at least one aperture formed through the table an electric tool removabl
30. s having different heights A user adjusts legs 5 to a relatively longer length to accommodate being placed on a relatively short work bench and adjusts legs 5 to a relatively shorter length to accommodate being placed on a relatively taller work bench In some embodiments adjust able legs 5 comprise telescoping leg sections which use detents or friction mechanisms e g stop bolts to retain the telescoping sections at the desired positions 0058 Extending upwardly from support structure 2 spe cifically from table 3 is standard 8 Standard 8 comprises upwardly oriented post 9 horizontally oriented arm 11 and downwardly oriented arm 15 Attached to the portion of arm 15 which is most remote from arm 11 is tool holder 13 0059 In some embodiments post 9 extends upwardly from the surface of table 3 Post 9 is connected to table 3 near alternatively adjacent to the back edge of table 3 distal from aperture 7 The position of post 9 relative to the upper surface area of table 3 enables a user of machining tool 1 to utilize substantially the entire surface area of the table as a working surface Thus a user can manipulate work piece 47 across and upon the entire upper surface of table 3 0060 In some embodiments not shown post 9 extends upwardly from support structure 2 but not through table 3 Rather post 9 is attached to and extends upwardly from the outermost surface of one of legs 5 alternatively from a bracket c
31. support supported by said support structure d a tool holder mounted to said tool holder support said tool holder comprising a guide and a chuck said tool holder guide accommodating movement of said tool holder toward and away from said table and e a chuck input shaft for rotating said chuck said chuck input shaft superposing said chuck whereby said chuck input shaft is adapted to communicate with an electric tool removably mounted to said tool holder 16 Machining tool as in claim 15 further comprising an aperture in said table in alignment with an axis of rotation of said chuck and a space between a bottom said support structure and a top of said table said space receiving a distal end of a bit held in said chuck below said table for accommodating side cutting operation performed by por tions of said bit which are displaced from said distal end of said drill bit 17 Machining tool as in claim 15 wherein said rotating drive apparatus comprises an electric tool removably mounted in said tool holder guide and having a drive shaft drivably connected to said chuck said electric tool having a rotatable output shaft and electric speed control apparatus controlling speed of the electric tool rotatable output shaft for varying speed of rotation of said electric tool rotatable output shaft 18 Machining tool as in claim 17 wherein said electric speed control apparatus comprises a speed control which controls said electric tool ro
32. tatable output shaft to rotate at speeds from a relatively slower speed of about 1000 rpm to about 5000 rpm to a relatively higher speed of about 10 000 rpm to about 35 000 rpm 19 Machining tool as in claim 17 wherein said electric speed control apparatus comprises a speed control which controls said electric tool rotatable output shaft to rotate with speed variability of at least about eight to one 20 Machining tool as in claim 16 wherein the tool holder guide reciprocates along an axis which is substantially perpendicular to said table and wherein a line of sight between a person using said machining tool and said bit in contact with a workpiece is generally unobstructed 21 Machining tool as in claim 17 said electric tool having a plug for connecting said electric tool to a power source said control apparatus comprising a power regulator and an outlet said outlet being adapted to receive a such plug of said electric tool 22 Machining tool as in claim 17 said chuck having a chuck input shaft extending upwardly from said chuck said chuck input shaft communicating with said rotatable output shaft of said electric tool US 2005 0097717 Al 23 Machining tool as in claim 22 wherein said rotatable output shaft of said electric tool has an axis of rotation said chuck input shaft having an axis of rotation generally coaxial with such axis of rotation of said rotatable output shaft 24 Machining tool as in claim 22 wherein said ch
33. uck input shaft has a diameter D1 and said rotatable output shaft of said electric tool has a diameter D2 said chuck being adapted to receive a bit having a diameter up to D3 said diameter D3 being greater than at least one of diameter D1 and diameter D2 25 A method of cutting a workpiece comprising a gripping a bit in a chuck driven by an electric tool the electric tool having a rotatable output shaft b rotating said rotatable output shaft of said electric rotary tool and correspondingly driving the bit at a first speed c while rotating the rotatable output shaft of the electric tool at the first speed and thereby driving the bit at the first speed advancing the bit a first distance longitudi nally along an axis of rotation of the bit and thereby drilling a through hole in the workpiece as a plunge drilling action and advancing the bit beyond the first distance to a stop locus May 12 2005 d rotating the bit at a second speed substantially greater than the first speed and e while rotating the bit at the second speed and while holding the bit at the stop locus advancing the work piece along a selected path while contacting the work piece at a side portion of the bit and thereby making an elongate linear cut in the workpiece 26 A method as in claim 25 wherein the rotating of the bit at the first relatively slower speed comprises rotating the bit at a speed of about 1000 rpm to about 5000 rpm and wh
34. ut out the tool holder slide 19 is unlocked The handle 23 is reverse pivoted to withdraw the combination drill and cutting bit 33 May 12 2005 from and to a position above the opening so as to enable moving the workpiece fully about table 3 without the bit doing any cutting of the workpiece Such withdrawal of the bit comprehends vertical movement The workpiece 47 is slid on the frame table 3 until a desired next opening B is under the bit The speed controller 31 is adjusted to lower the electric tool speed to that suitable for plunge drilling the next initial hole for the opening B and the process is repeated In that manner multiple openings are cut in the workpiece without removing either the bit 33 from the chuck 27 or the electric tool 25 from the tool holder 13 0092 In summary the advantages of conventional elec tric tools 25 such as a Roto Zip electrical tool can now be more fully realized and supplemented The machining tool 1 of the invention provides both rapid cutting of intricate openings in a workpiece 47 as well as convenience to an operator This desirable result comes from using the com bined functions of the machine frame 2 and the electric control 31 The heavy frame enables the workpiece to be slid laterally on the table at a convenient location but without the table moving relative an underlying work bench The elec tric control adjusts the speed of the electric tool for two distinctly different cutting oper
35. y mounted to the tool holder slide the electric tool having a rotatable output shaft a chuck mounted on one of the electric tool and the tool holder and connected for rotation to the rotatable output shaft and electric speed control apparatus controlling the speed of rotation of the rotatable output shaft of the electric tool between a first relatively slower speed and a second relatively higher speed 0013 In some embodiments the second speed is at least eight times faster than the first speed 0014 In some embodiments the tool holder support extends upwardly from the table 0015 In some embodiments the apparatus further com prises a bit gripped in the chuck the bit having a distal end adapted for plunge drilling and a side cutting portion dis posed away from the distal end the electric speed control US 2005 0097717 Al apparatus controlling the speed of the electric tool rotatable output shaft between a first relatively slower speed for a plunge type drilling operation using the drill point of the bit and a second relatively higher speed for a side cutting operation using the side cutting portion of the bit 0016 In some embodiments the bit has a diameter of approximately 0 06 inch 0017 In some embodiments the longitudinal axis of the tool holder is substantially perpendicular to the table and a view of the bit during the drilling and cutting operations is generally unobstructed to a person using the apparatus
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