AU2021106902A4

AU2021106902A4 - A restoration assembly and method

Info

Publication number: AU2021106902A4
Application number: AU2021106902A
Authority: AU
Inventors: Chelsea Ann Morgan; Martin Lee Morgan; Matthew John Morgan
Original assignee: Gr & Cc Morgan Pty Ltd
Current assignee: Gr & Cc Morgan Pty Ltd
Priority date: 2021-02-02
Filing date: 2021-08-24
Publication date: 2021-11-25
Anticipated expiration: 2029-08-24
Also published as: AU2022215327A1; AU2022215327A9; WO2022165549A1

Abstract

Disclosed is an assembly and method for restoring a tapered bore. The assembly for restoring a tapered bore formed in a body to an originally manufactured diameter, comprises a frame including an upper mounting plate provided to an upper face of the body and a lower mounting plate provided to a lower face of the body. The upper and lower mounting plates are joined together to align with the tapered bore. C) C) CIA

Description

C) C) CIA A RESTORATION ASSEMBLY AND METHOD

Technical Field

[0001] The present invention generally relates to a restoration assembly and method, and more particularly to a restoration assembly and method for restoring a tapered bore to an originally manufactured diameter.

Background

[0002] Tapered bore arrangements are commonly used in coupling arrangements for vehicles and the like. For example, tapered bores may be used in heavy vehicle steering couplings. The use of tapered bores in coupling arrangements, opposed to straight bores, in such arrangements seeks to provide a tightly fitted coupling, which in turn reduces stress and wear to the coupling. However, despite the use of tapered bores, over time and through subjection to high loads, the steering coupling components still experience elongation, resulting in loosening of the coupling and increased wear.

[0003] As such, it is common for the steering couplings to be restored to a functional capacity. Current methods for restoring tapered bores includes reaming the tapered bore to a diameter that is larger than its original diameter and then using a larger stud, or pin, to suit the larger tapered bore. However, there are limited to the number of times that a tapered bore can undergo this process as removing too much material from reaming can reduce the structural integrity of the coupling. Thus, even using current restoration methods, the coupling will eventually require complete replacement.

[0004] The preferred embodiments of the present invention seek to address one or more of these disadvantages.

[0005] The reference in this specification to any prior publication (or information derived from the prior publication), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from the prior publication) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

Summary

[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0007] According to a first example form, there is provided an assembly for restoring a tapered bore formed in a body to an originally manufactured diameter, the assembly comprising; a frame including an upper mounting plate provided to an upper face of the body and a lower mounting plate provided to a lower face of the body, the upper and lower mounting plates being joined together to align with the tapered bore.

[0008] According to one example the upper mounting plate and the lower mounting plate each include a tooling aperture that aligns with an upper opening and a lower opening of the tapered bore.

[0009] According to one example the upper mounting plate and the lower mounting plate each include a pair of joining apertures, each aperture in the pair being provided on either side of the tooling aperture.

[0010] According to one example the assembly includes a pair of elongate joining fixtures arranged to pass through both pairs of joining apertures and join the upper and lower mounting plates together.

[0011] According to one example the upper mounting plate includes a recessed portion around the tooling aperture.

[0012] According to one example the recessed portion includes a first recess edge and a second recess edge, the second recess edge being arranged within the first recess edge.

[0013] According to one example the first recess edge and the second recess edge define counterbored portion of the tooling aperture.

[0014] According to one example the lower mounting plate includes a base portion arranged to be at least partially received within the tooling aperture in the lower mounting plate.

[0015] According to one example the base portion includes a lip portion and an upwards protruding portion, the lip portion arranged to abut a first side of the lower mounting plate and the upwards protruding portion being arranged to pass through the tooling aperture in the lower mounting plate.

[0016] According to one example the upwards protruding portion protrudes past the lower mounting plate towards the lower face.

[0017] According to one example the assembly includes a torque alignment portion arranged to connect to the upper mounting plate of the frame.

[0018] According to one example the torque alignment portion includes an alignment arm, the alignment arm arranged to connect to a first end of the pair of elongate joining fixtures.

[0019] According to one example the alignment arm includes an alignment aperture.

[0020] According to one example the torque alignment portion includes a pair of collars, the pair of collars being arranged to receive the pair of elongate joining fixtures and space apart the alignment arm from the upper mounting plate.

[0021] According to one example the alignment aperture includes an inner surface including a plurality of teeth, the plurality of teeth being arranged to engage with at least a portion of a rotary drive mechanism.

[0022] According to one example the assembly further includes a welder mounting portion, the welder mounting portion is arranged to connect to lower mounting plate of the frame.

[0023] According to one example the welder mounting portion includes an elongate tube, wherein a welding tool is arranged to pass through the elongate tube and access the tapered bore.

[0024] According to one example the torque alignment portion is further arranged to receive a spotfacing tool.

[0025] According to one example form there is provided a method for restoring a tapered bore formed in a body to an originally manufactured diameter, the method comprising the steps of: installing a lower mounting plate provided to a lower face of the body; installing an upper mounting plate provided to an upper face of the body; joining the upper and lower mounting plates together such that the upper and lower mounting plates are aligned with the tapered bore; installing a torque alignment portion and a reaming tool received therein; reaming an interior surface of the tapered bore using the reaming tool, wherein the tapered bore is reamed to provide a diameter of the tapered bore that is larger than the originally manufactured diameter; removing the reaming tool and torque alignment portion; installing a welding mounting portion for a welding tool; welding weld material to the interior surface of the tapered bore using the welding tool to provide a diameter that is smaller than the originally manufactured diameter; removing the welding mounting portion; re-installing the torque alignment portion and reaming tool; and reaming the weld material provided to interior surface of the tapered bore using the reaming tool, wherein the tapered bore is reamed to provide a diameter that is the same or approximately the same as the originally manufactured diameter.

[0026] According to one example, the method further comprises the steps of: remove the torque alignment portion and the reaming tool from the upper mounting plate; re-installing the torque alignment portion and a spotfacing tool received therein; and spotfacing a face of the body around an opening of the tapered bore.

[0027] According to one example, the step of welding new material further comprises the steps of; arranging the weld material on the interior surface of the tapered bore in an overlapping spiral arrangement; welding the weld material to the inner surface of the tapered bore; and cooling the body and weld material.

[0028] According to one example, the step of welding the new material to the inner surface of the tapered bore is completed by progressing the weld from an upper end of the tapered bore to a lower end of the body.

[0029] According to one example, the step of welding the new material to the inner surface of the tapered bore is completed by progressing the weld from a lower end of the tapered bore to an upper end of the body.

[0030] According to one example, the step of cooling the body and weld material includes cooling the body and weld material slowly until the body and weld material come to room temperature.

[0031] According to one example the body and weld material are encased in vermiculite and/or a thermal blanket.

Brief Description of Figures

[0032] Example embodiments are apparent from the following description, which is given by way of example only, of at least one non-limiting embodiment, described in connection with the accompanying figures.

[0033] Figure 1 illustrates a perspective view of an embodiment of the present invention.

[0034] Figure 2 illustrates a front section view of an embodiment of the present invention.

[0035] Figure 3 illustrates a perspective view of an embodiment of the present invention.

[0036] Figure 4 illustrates a front section view of an embodiment of the present invention.

[0037] Figure 5 illustrates an exploded view of an embodiment of the present invention.

[0038] Figure 6 illustrates a perspective view of an embodiment of the present invention.

[0039] Figure 7 illustrates a front section view of an embodiment of the present invention.

[0040] Figure 8 illustrates an exploded view of an embodiment of the present invention.

[0041] Figure 9 illustrates a side section view of an embodiment of the present invention.

[0042] Figure 10 illustrates a side section view of an embodiment of the present invention.

[0043] Figure 11 illustrates a perspective view of an embodiment of the present invention.

[0044] Figure 12 illustrates a front section view of an embodiment of the present invention including Detailed section A and Detailed section B.

[0045] Figure 13 illustrates a perspective view of a cutting head used for spot facing used in an embodiment of the present invention.

[0046] Figures 14 to 16 illustrate non-limiting examples of couplings that may include a tapered bore.

Detailed Description

[0047] The following modes, given by way of example only, are described in order to provide a more precise understanding of one or more embodiments. In the figures, like reference numerals are used to identify like parts throughout the figures.

[0048] In general terms, the present invention provides a restoration assembly and method for a coupling. The coupling may include a steering coupling for a vehicle, where the coupling is between the steering/suspension arrangement and the steering knuckle and wheel hub. For example, the steering coupling may include the steering "Y" piece, outer steering arm links and/or the chassis steering box and other such tapered couplings capable of receiving tapered ball studs or pins. For instance, non-limiting examples are provided where Figure 14 shows an example of a chassis steering "Y" piece, Figure 15 shows an outer steering arm link, and Figure 16 shows a chassis steering box, where each of these examples include at least one tapered bore.

[0049] Referring to Figures 1, 2 and 5, an example assembly 100 for restoring a tapered bore 102 for a body 104 of a coupling is provided, wherein the assembly 100 is used to restore the tapered bore 102 to its originally manufactured diameter. The term originally manufactured diameter is used to refer to the diameter of the tapered bore that is the same dimension as it was when first manufactured. The assembly 100 may comprise a frame 103 arranged to encompass the body and the tapered bore therein. The frame 103 may be arranged to include an upper mounting plate 106 provided to an upper face 108 of the tapered bore 102 and a lower mounting plate 110 provided to a lower face 112 of the tapered bore 102, where the upper mounting plate 106 and the lower mounting plate 110 are joined together.

[0050] In an embodiment, the upper mounting plate 106 includes an upper tooling aperture 114 arranged to align with an upper opening of the tapered bore 102. Further, the lower mounting plate 110 may include a lower tooling aperture 116 arranged to align with a lower opening of the tapered bore 102. That is, both the upper mounting plate 106 and the lower mounting plate 110 each include the tooling aperture that each align with the openings of the tapered bore 102.

[0051] Moreover, in an embodiment, the upper mounting plate 106 and the lower mounting plate 110 each include a pair of joining apertures 118. Each aperture in the pair of joining apertures 118 is provided to pass through the upper mounting plate 106 and lower mounting plate 110 on either side of the respective tooling aperture 114,116.

[0052] In an embodiment, the assembly 100 includes a pair of elongate joining fixtures 120 arranged to pass through both pairs of joining apertures 118 and join the upper mounting plate 106 and lower mounting plate 110 together. In an example embodiment, the upper mounting plate 106 and the lower mounting plate 110 may be formed in a vesica piscis or leaf shape, where the each aperture in the pair ofjoining apertures 118 is provided proximate to the relatively narrower ends of the mounting plates 106, 110 and the tooling apertures 114, 116 are provided in the relatively wider middle region of the mounting plates 106, 110. Other shapes may also be used, such as circular, ellipse or square.

[0053] The pair of elongate joining fixtures 120 may include a threaded portion that extends at least partially along the length of the fixtures to enable the pair of elongate joining fixtures 120 to bejoined to the upper mounting plate 106 and the lower mounting plate 110 by means of threaded helix nuts 122, or other such similar mechanical devices. Further, the elongate joining fixtures 120 may include at least one pair of stops that may be arranged to locate along the lengths of the elongate joining fixtures 120. For example, the at least one pair of stops may include a hex bolt 124 integrally formed along the length of both the elongate joining fixtures 120 such that the hex bolt 124 is arranged to locate between the upper face 108 of the tapered bore 102 and the lower mounting plate 110 when assembled. The hex bolt 124 and the threaded helix nuts 122 may hold the lower mounting plate 110 in position on the elongated joining fixtures 120. Such an arrangement may be provided to secure the various components of the assembly with respect to the tapered bore 102 once the components are correctly aligned, as described below. Alternatively, the hex bolts 124 may be used to hold the upper mounting plate 106 with threaded helix nuts 122.

[0054] In an embodiment, the upper mounting plate 106 includes a recessed portion around the upper tooling aperture 114. The recessed portion may be arranged to include a first recess 126 edge and a second recess edge 128, the second recess edge 128 being arranged within the first recess edge 126. In other words, the first recess edge 126 and the second recess edge 128 define a counterbored portion of the upper tooling aperture 114. In an embodiment, the part of the tooling aperture 114 between the second recess edge 128 and the upper face 108 of the body 104 may be arranged to have the same or similar diameter of the tapered bore 102 at the upper face 108. The part of the tooling aperture 114 between the first recess edge 126 and the second recess edge 128 may be arranged to have a relatively larger diameter than the diameter of the tapered bore 102 at the upper face 108.

[0055] Referring now to the lower mounting plate 110, an embodiment is provided where the lower mounting plate 110 may include a circular base portion 130. The base portion 130 may be arranged to be at least partially received within the tooling aperture 116 in the lower mounting plate 110. For example, the base portion 130 may be arranged to include a lip portion 132 and a protruding portion 134, the lip portion 132 being arranged to abut the lower mounting plate 110 and the protruding portion 134 being arranged to pass upwards through the lower tooling aperture 116 in the lower mounting plate 110. The base portion 130 may further include a base aperture 136, the base aperture 136 being arranged to be of a diameter that is relatively large than the diameter of the tapered bore 102 at the lower face 112 (i.e. the narrow end of the tapered bore).

[0056] The base portion 130 may also include a plurality of attachment apertures arranged around the base aperture 136, where the attachment apertures are arranged to align with other attachment apertures provided in the lower mounting portion 110, such that mechanical fasteners or fixtures, such as screws, bolts and the like, may pass through both sets of attachment apertures and join the base portion 130 to the underside of the lower mounting portion 110. When so arranged, the protruding portion 134 protrudes upwards past an upper face of the lower mounting plate 110.

[0057] In an embodiment, the assembly 100 may further include other parts that may be arranged to removably connect to the above described frame 103, where the other parts may be configured to facilitate different steps within the restoration process. For example, referring to Figures 3 to 5, an embodiment is provided where the assembly 100 includes a torque alignment portion 138 being arranged to connect to the upper mounting plate 106. The torque alignment portion 138 may be provided to support and guide a reaming tool 140 to ream of the tapered bore 102. The tapered bore 102 is typically reamed from the larger end, that is, from the upper mounting plate 106. However, in some embodiments, the tapered bore 102 may be reamed from the smaller end of the tapered bore 102, which is the lower mounting plate 110 as shown.

[0058] In an embodiment, the torque alignment portion 138 may include an alignment arm 142. The alignment arm 142 may be arranged to connect to a first end of the pair of elongate joining fixtures 120 by means of passing through a pair offixture apertures 144. The alignment arm 142 may be attached to the elongated fixtures 120 using a sliding clearance fit. Alternatively, a threaded surface may be used. Further, the torque alignment portion 140 may also include a pair of collars 146, the pair of collars 146 being arranged to receive the pair of elongate joining fixtures 120 and space apart the alignment arm 142 from the upper mounting plate 106.

[0059] In an embodiment, the alignment arm 142 includes an alignment aperture 148. The alignment aperture 148 may be configured to engage with a portion of a rotary drive mechanism driven by pneumatics, hydraulics or an elective motor and may include a rad gun, torque multiplier device or electric drill that is in connection with the reaming tool 140. For example, alignment aperture 148 may include an inner surface including a plurality of teeth, the plurality of teeth being arranged to engage with at least a portion of the torque multiplier to ensure that the torque multiplier remains in alignment with respect to the assembly 100 and the tapered bore 102.

[0060] In an embodiment, the reaming tool 140 may include a reaming portion 150 and a drive coupling portion 152. The reaming portion 150 and the drive coupling portion 152 may be connected together to form the reaming tool 140, which is operated by the torque multiplier device to ream the interior of the tapered bore 102.

[0061] In another embodiment, the assembly 100 further includes another arrangement of parts removably connected to the above described frame 103, where the parts may be configured to facilitate different steps within the restoration process. For example, referring to Figures 6 to 8, an embodiment is provided where the assembly 100 includes a welder mounting portion 154 being arranged to connect to the lower mounting plate 110.

[0062] The welder mounting portion 154 may be arranged to include an elongate tube 156 and a connection lip 158. The elongate tube 156 is arranged to protrude downwards from connection lip 158 and is arranged to receive a welding tool therein. The connection lip 158 may be arranged to be attached to the base portion 130 by means of mechanical fixtures 160, which may include screws, bolts and the like. The elongate tube 156 is provided at a length and diameter relative to the lower mounting plate 110 and the base portion 130 to ensure that the welding tool is able to effectively weld additional material to the interior of the tapered bore 102 in a spiral manner. For example, Figure 9 shows a welding tool 161 inserted from the underside of the assembly 100 being used to weld overlapping strips of weld material to the interior of the tapered bore 102 in a spiral manner moving from the upper face 108 to the lower face 112. Alternatively, as shown in Figure 10, another embodiment may enable the welding tool 161, inserted from the top of the assembly 100, being used to weld overlapping strips of weld material to the interior of the tapered bore 102 in a spiral manner moving from the lower face 112 to the upper face 108. When welding from the top of the assembly 100, the welder mounting portion 154 may be modified to connect to the upper mounting plate 106.

[0063] In another embodiment, the assembly 100 further includes another arrangement of parts removably connected to the above described frame 103, where the parts may be configured to facilitate different steps within the restoration process. For example, referring to Figures 11 to 13, an embodiment is provided where the assembly 100 includes a spotfacing tool 162. In an embodiment, the torque alignment portion 138 is further arranged to receive the spotfacing tool 162. As shown, the spotfacing tool 162 is arranged to spotface the lower face 112 around the openings of the tapered bore 102 as the area will be in contact with other parts. In an embodiment, the spotfacing tool 162 includes a cutter head 164 that is arranged to spotface the area of the body 104 around the opening of the tapered bore 102. The cutter head 164 is shown in Figure 13. Further, the spotfacing tool 162 may also include a shaft 166 that is connected to the cutter head 164 and received within the tapered bore 102. Referring to Detail B, the shaft 166 may include a bearing portion 168, such as a bronze bush. Further, at a location proximate to the cutter head 164, the shaft 166 may include a seal 170 to prevent impurities from contaminating the bearing portion 168.

[0064] In another aspect, there is provided a method for restoring a tapered bore using the above described assembly 100. Prior to restoration, the tapered bore 102 is disconnected from other devices or parts, inspected and measured. Then, the tapered bore 102 is cleaned to remove all oil, grease and paint from the interior surface of the bore 102. Further, the tapered bore may be subject to magnetic particle testing to ensure no cracking or other structural issues are present in the body 104. Further, the interior of the tapered bore 102 may also be machined to remove corrosion, pitting, smeared ball stud material and other debris.

[0065] The aforementioned method may comprise the step of installing the frame 103 on the body 104 through which the tapered bore 102 passes. Installing the frame 103 may include attaching the base portion 130 to the lower mounting plate 110, then inserting the pair of elongate joining fixtures 120 through the lower mounting plate 110. Then, the pair of elongate joining fixtures 120 are loosely attached to the upper mounting plate 106, such that the upper mounting plate 106 is proximate to the upper face 108 and the lower mounting plate 110 is proximate to the lower face 112. A mandrill may be inserted through the tooling aperture 148 to align the upper and lower mounting plates 106, 110 with the tapered bore 102, and once so aligned, the various fasteners fastening the frame 103 together are tightened, after which, the mandrill is removed.

[0066] Once the frame 103 is attached to the body 104, the method further comprises the step of connecting the torque alignment portion 138, including the reaming tool 140, to the frame 103. The assembly 100 including the torque alignment portion 138, the reaming tool 140 and the frame 103 are then used to ream an interior surface of the tapered bore 102. This may be done by connecting the aforementioned rotary drive mechanism, such as rad gun or torque multiplier device, to the reaming tool 140 and operate the machine to remove material from the body 104 such that the tapered bore 102 is reamed to provide a diameter that is larger than the originally manufactured diameter of the tapered bore 102.

[0067] Once the material has been removed, the torque alignment portion 138, including the reaming tool 140, is removed from the frame 103 and the welding mounting portion 154 is attached to the lower mounting plate 110. Once so attached, the method further comprises the step of welding weld material to the interior surface of the tapered bore 102 using the welding tool.

[0068] In an embodiment, the step of welding new material may further comprise the steps of firstly arranging the weld material to be welded on the interior surface of the tapered bore 102 in an overlapping spiral arrangement. A portion of additional weld material at one of the ends of the tapered bore 102 may be included as an optional "run on" ring or a "run off' ring, for example being made from mild steel, which is to be machined off in a later step. Further, the step of welding new material may further comprise preheating both the body 104 and the weld material by means of flame heat, electrical induction (heat beads) or a combination of both or other such types of heating. For example, the body and weld material may be heated to above 200°C.

[0069] The method further comprises the step of electric arc welding the weld material to the inner surface of the tapered bore 102. This step may be performed by welding the weld material to the inner surface of the tapered bore 102 by progressing the weld from the upper face 108 to the lower face 112 (i.e. moving downwards) or may be performed by welding the weld material to the inner surface of the tapered bore 102 by progressing the weld from the lower face 112 to the upper face 108 (i.e. moving upwards).

[0070] For example, for a body 104 made of cast steel, such as but not limited to AS2074 Grade C7A-3 or equivalent, the weld consumable may include copper wiring. The welding process may be conducted within a range of 203 to 248 Amps and 22.3 to 25.7 Volts and the interpass temperature may be in the range of 200°C to 330°C. Further, the welding process may be carried out using a shielding gas, such as but not limited to a mixture of Argon and 23% C02. The weld is performed such that the when the tapered bore 102 includes the weld material, the diameter of the tapered bore 102 post welding is smaller than its original diameter.

[0071] Some bores, or tapered bores, may have a gap in the bore such as the bore 180 of Figure 14 which has a gap 182. When welding bores, or tapered bores, with a gap, a spacer may be fitted to the gap and aligned with the bore to temporarily fill the gap. Welding is then performed and the spacer can reduce shrinkage of the bore during welding. The spacer may also enable smooth placement of weld over the gap. Once welding of the bore is complete, the spacer may be removed and the welds at the edge of the gap cleaned up.

[0072] Once the welding has been completed, the body 104 is cooled. For example, the step of cooling the tapered bore and weld material may include cooling the body 104 slowly until the tapered bore 102 is at room temperature. This may be performed by encasing the body 104 in vermiculite and/or a thermal blanket.

[0073] Once cooled, the method further comprises the step of once again connecting the torque alignment portion 138, including the reaming tool 140, to the frame 103. The assembly 100 is then used to ream the interior surface of the tapered bore 102 using the rotary drive mechanism. The tapered bore 102 is reamed to remove the weld material from the body 104 until the tapered bore 102 is of a diameter that is the same or approximately the same as the originally manufactured diameter, taking into account any further removal of material in finishing the work surface as discussed further below.

[0074] The tapered bore 102 may then be inspected and checked for size. For example, by measuring the size of the tapered bore 102 using a precision ground Taper Gauge and conventional measuring techniques and/or using a ball joint or other connective fixture that it would normally engage with during normal use and the results of the inspection and measurement are recorded.

[0075] In some cases, the lower face 112 may require spotfacing around the opening of the tapered bore 102. As such, the method may further comprise the step of spotfacing the tapered bore 102. Spotfacing the tapered bore 102 may further include installing the spotfacing tool 162 into the tapered bore 102, where the spotfacing tool 162 may include the cutter head 164, the shaft 166, the bearing portion 168 and the seal 170 as discussed above. The spotfacing tool 162 is attached to the upper mounting plate 106 using retaining bolts

176. Once in place, the torque alignment portion 138 is connected to the frame 103 and the rotary drive mechanism is connected to the spotfacing tool 162.

[0076] Once so arranged, the rotary drive mechanism is operated by a user to spotface the lower face 112 to provide a smooth, flat and accurately located surface around the opening of the tapered bore 102 on the lower face 112. The spotfacing may be performed using the cutter head 164 with a cut depth adjusted by a threaded, knurled collar 172, or alternatively a nut, attached to a threaded portion of the shaft 166. Force applied by the knurled collar 172 is transferred via a thrust bearing 174, shown in Detail A, to the spotfacing tool 162. The knurled collar 172 lifts the shaft 166, which lifts the cutter head 164 attached to the shaft 166. Once the body 104 has been spotfaced, the rotary drive mechanism is removed, the torque alignment portion 138 is disconnected from the frame 103 and the spotfacing tool 162 uninstalled from the tapered bore 102. Additional grinding or other means of machining the body 104 may then be performed to remove any edges or to achieve a certain finish.

[0077] Optionally, the torque alignment portion 138 may be arranged to receive a finishing reaming tool in the same may as mentioned above in respect to the reaming tool 140, wherein a finishing reaming tool is of a relatively finer grade than the reaming tool 140 used previously. Using the finishing reaming tool, the tapered bore 102 may be reamed or otherwise machined to remove any edges or to achieve a certain finish. Further the finishing reaming tool may be used remove the weld material from the interior surface of the tapered bore 102 until the tapered bore 102 is of a diameter that is the same or approximately the same as the originally manufactured diameter as discussed above.

[0078] Optional embodiments may also be said to broadly include the parts, elements, steps and/or features referred to or indicated herein, individually or in any combination of two or more of the parts, elements, steps and/or features, and wherein specific integers are mentioned which have known equivalents in the art to which the invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.

[0079] While the above embodiments have been described as being performed to return the parts to the originally manufactured diameter, other diameters may also be possible. For example, the parts may be dimensioned to fit a new ball joint with variation from the originally manufactured diameter. The process is able to restore a tapered bore to an intended or desired diameter that that is smaller than an unrepaired diameter of the tapered bore.

[0080] Although a preferred embodiment has been described in detail, it should be understood that modifications, changes, substitutions or alterations will be apparent to those skilled in the art without departing from the scope of the present invention.

[0081] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprised", "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0082] As used herein, a, an, the, at least one, and one or more are used interchangeably, and refer to one or to more than one (i.e. at least one) of the grammatical object. By way of example, "an element" means one element, at least one element, or one or more elements.

[0083] In the context of this specification, the term "about" is understood to refer to a range of numbers that a person of skill in the art would consider equivalent to the recited value in the context of achieving the same function or result.

Advantages

[0084] The embodiments described herein provide a novel means of restoring a tapered bore to its original diameter. This means that the original ball joint and other parts can be reused and are not required to be oversized to fit the over-reamed bores that are the result of current methods.

[0085] Further, the method as set out above enables the original diameter to be restored in a way that does not sacrifice the structural integrity of the coupling body. As such, the method and assembly as set out above enables a coupling to be reconditioned multiple times back to the standards as originally manufactured by the original manufacturer.

[0086] The method also enables cost and time savings compared to replacing components. Typically, a tapered bore can be machined once before requiring replacement as the bore diameter is no longer within tolerance when machined more than once. Replacement of the tapered bore may be time consuming and expensive. In some circumstances, the tapered bore may be located on a chassis of equipment, such as a vehicle used in mining. To replace such a tapered bore may require a section of the chassis to be cut out and replaced. Such an operation may require extensive fabrication and down time for the equipment. The method described above allows for the diameter of the tapered bore to be restored to the original size with less downtime for the equipment. In some circumstances, the repair of the tapered bore may be performed on site which is advantageous for less mobile equipment.

Claims

The claims defining the invention are as follows:

1. An assembly for restoring a tapered bore formed in a body to an originally manufactured diameter, the assembly comprising; a frame including an upper mounting plate provided to an upper face of the body and a lower mounting plate provided to a lower face of the body, the upper and lower mounting plates being joined together to align with the tapered bore.

2. The assembly in accordance with claim 1, wherein the upper mounting plate and the lower mounting plate each include a tooling aperture that aligns with an upper opening and a lower opening of the tapered bore.

3. The assembly in accordance with claim 2, wherein the upper mounting plate and the lower mounting plate each include a pair of joining apertures, each aperture in the pair being provided on either side of the tooling aperture.

4. A method for restoring a tapered bore formed in a body to an originally manufactured diameter, the method comprising the steps of:

installing a lower mounting plate provided to a lower face of the body;

installing an upper mounting plate provided to an upper face of the body;

joining the upper and lower mounting plates together such that the upper and lower mounting plates are aligned with the tapered bore;

installing a torque alignment portion and a reaming tool received therein;

reaming an interior surface of the tapered bore using the reaming tool, wherein the tapered bore is reamed to provide a diameter of the tapered bore that is larger than the originally manufactured diameter;

removing the reaming tool and torque alignment portion;

installing a welding mounting portion for a welding tool; welding weld material to the interior surface of the tapered bore using the welding tool to provide a diameter that is smaller than the originally manufactured diameter; removing the welding mounting portion; re-installing the torque alignment portion and reaming tool; and reaming the weld material provided to interior surface of the tapered bore using the reaming tool, wherein the tapered bore is reamed to provide a diameter that is the same or approximately the same as the originally manufactured diameter.

5. The method in accordance with claim 4, wherein the method further comprises the steps of:

remove the torque alignment portion and the reaming tool from the upper mounting plate;

re-installing the torque alignment portion and a spotfacing tool received therein; and

spotfacing a face of the body around an opening of the tapered bore.