阅读说明：本技术 用于由未对准孔形成对准孔的设备、系统和方法 (Apparatus, system, and method for forming an alignment hole from a misaligned hole ) 是由 J·P·沙伊贝尔 J·L·谢勒 M·A·沃德 于 2021-04-12 设计创作，主要内容包括：本发明涉及一种用于由未对准孔形成对准孔的设备、系统和方法。该设备包括具有恒定直径的第一部分和锥形的第二部分的扩孔钻。恒定直径的导向构件连接到扩孔钻。锥形部可以被构造成使扩孔钻居中并且减小该设备与由未对准孔产生的虚拟孔的中心线之间的偏移。导向构件的恒定直径对应于虚拟孔,并且扩孔钻的第一部分的恒定直径对应于清理孔,该清理孔被构造成接收过大尺寸紧固件并且完全包围未对准孔。如果导向构件不能穿过未对准孔,则需要具有较小直径的导向构件和较大直径的扩孔钻的设备来产生完全包围未对准孔的清理孔。(The present invention relates to an apparatus, system and method for forming an alignment hole from a misaligned hole. The device includes a reamer having a first portion of constant diameter and a second portion that is tapered. A constant diameter guide member is connected to the reamer. The taper may be configured to center the reamer and reduce the offset between the device and the centerline of the virtual hole created by the misaligned hole. The constant diameter of the guide member corresponds to the virtual hole and the constant diameter of the first portion of the reamer corresponds to a clearance hole configured to receive the oversized fastener and completely surround the misaligned hole. If the guide member cannot pass through the misaligned hole, a device having a smaller diameter guide member and a larger diameter reamer is required to create a clearance hole that completely surrounds the misaligned hole.)

1. An apparatus (100) for forming a plurality of aligned holes from a plurality of unaligned holes, the apparatus comprising:

a reamer (101) having a first portion (110) and a second portion (120), the first portion having a first constant diameter (111) and the second portion having a first end (121) and a second end (122), the first end of the second portion being adjacent the first portion of the reamer, the second portion of the reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; and

a guide member (130) connected to the second end of the second portion of the reamer, the guide member having a second constant diameter (131).

2. The device of claim 1, wherein the second portion (120) of the reamer (101) is configured to center the reamer on a centerline (205) of a Virtual Hole (VH).

3. The device of claim 2, wherein the taper of the second portion (120) of the reamer (101) is configured to reduce an offset between a central longitudinal axis (102) of the device and the centerline (205) of the Virtual Hole (VH).

4. The device of claim 1, wherein the taper of the second portion of the reamer includes a starting diameter (123) that is greater than a final diameter (124), the taper of the second portion tapering from the final diameter to the starting diameter at an angle (125) of between about 0.5 degrees and about 1.0 degrees on each side.

5. The apparatus of claim 1, wherein the second constant diameter (131) corresponds to a first virtual hole (VH-a), and wherein the first constant diameter (111) corresponds to a first clearance hole (230A) that receives a first oversized fastener.

6. The apparatus of any of claims 1-5, wherein the second constant diameter (131) corresponds to a second virtual hole (VH-B), and wherein the first constant diameter (111) corresponds to a second clearance hole (230B) that receives a second oversized fastener.

7. The apparatus of any of claims 1-5, wherein the second constant diameter (131) corresponds to a third virtual hole (VH-C), and wherein the first constant diameter (111) corresponds to a third clearance hole (230C) that receives a third oversized fastener.

8. A method for creating an aligned hole from a plurality of misaligned holes (211, 221), the method comprising:

attempting (310) to insert a first guide member (130A) through the plurality of misaligned holes, the first guide member connected to a first reamer (101A) having a first portion (110A) and a second portion (120A), the second portion having a first end (121A) and a second end (122A), wherein the first end is adjacent to the first portion of the first reamer, the first portion of the first reamer having a first constant diameter (111A), and the second portion is tapered, the second portion having a varying diameter (123A-124A) that decreases from the first end to the second end, wherein the first guide member is connected to the second end of the second portion of the first reamer, and wherein the first guide member has a second constant diameter (131A) that corresponds to a first virtual hole (VH-A), and wherein the first constant diameter of the first reamer corresponds to a first clearance hole (230A) that receives a first fastener; and

cutting (320) the first cleaning hole through the plurality of misaligned holes with the first reamer as the first guide member is inserted into the plurality of misaligned holes.

9. The method of claim 8, wherein if the first guide member cannot be inserted through the plurality of misaligned holes, the method further comprises:

attempting to insert a second guide member (130B) into the plurality of misaligned holes, the second guide member connected to a second reamer (101B) having a first portion (110B) and a second portion (120B), the second portion of the second reamer having a first end (121B) and a second end (122B), wherein the first end of the second portion of the second reamer is adjacent the first portion of the second reamer, the first portion of the second reamer having a third constant diameter (111B), and the second portion of the second reamer is tapered and has a varying diameter (123B-124B) that decreases from the first end of the second portion of the second reamer to the second end of the second portion of the second reamer, wherein the second guide member is connected to the second end of the second portion of the second reamer, and wherein the second guide member has a fourth constant diameter (131B) corresponding to a second virtual hole (VH-B), and wherein the third constant diameter of the second reamer corresponds to a second clearance hole (230B) receiving a second fastener; and

cutting the second clearance hole through the plurality of misaligned holes with the second reamer as the second guide member is inserted into the plurality of misaligned holes.

10. The method of claim 9, wherein if the second guide member cannot be inserted through the plurality of misaligned holes, the method further comprises:

attempting to insert a third guide member (130C) into the plurality of misaligned holes, the third guide member connected to a third reamer (101C) having a first portion (110C) and a second portion (120C), the second portion of the third reamer having a first end (121C) and a second end (122C), wherein the first end of the second portion of the third reamer is adjacent to the first portion of the third reamer, the first portion of the third reamer having a fifth constant diameter (111C), and the second portion of the third reamer is tapered and has a varying diameter (123C-124C) that decreases from the first end of the second portion of the third reamer to the second end of the second portion of the third reamer, wherein the third guide member is connected to the second end of the second portion of the third reamer, and wherein the third guide member has a sixth constant diameter (131C) corresponding to a third virtual hole (VH-C), and wherein the fifth constant diameter of the third reamer corresponds to a third clearance hole (230C) that receives a third fastener; and

cutting the third clearance hole through the plurality of misaligned holes with the third reamer as the third guide member is inserted into the plurality of misaligned holes.

Technical Field

Examples described herein relate to apparatuses, systems, and methods for forming a plurality of aligned holes from a plurality of unaligned holes.

Background

When multiple objects are connected together, fasteners of various sizes are typically used. Circular holes are drilled in each object, and the objects are then placed adjacent to each other such that the respective holes overlap. Ideally, holes through the objects are aligned and designated fasteners can be inserted through the holes to secure the objects together. However, when a hole through an object is misaligned, a given fastener may not be inserted through the hole, depending on the degree of misalignment.

A common technique for correcting the misaligned hole is to drill or ream a clearance hole (clearance hole) through the misaligned hole. The clearance holes are generally centered over one of the misaligned holes and are preferably large enough in diameter to completely surround all of the misaligned holes. Once the clearance hole has been created, larger fasteners may be used to secure multiple objects together. Conventionally, clearance holes are created on a trial and error basis in which progressively larger clearance holes are drilled or reamed until the clearance holes completely surround the misaligned hole. This is a time consuming process and may also result in larger than necessary clearance holes being formed through multiple objects. Other disadvantages may exist.

U.S. patent No.9,573,209 describes a method for forming a pair of aligned holes. The method includes determining a diameter of a clearance hole associated with the plurality of misaligned holes, where the clearance hole diameter may also correspond to a fastener diameter. In addition, a tapered reamer is at least partially inserted into the gap defined by the plurality of misaligned holes. The tapered reamer has a longitudinal axis and may be configured such that when the tapered reamer is inserted into the gap defined by the plurality of misaligned holes, the longitudinal axis is aligned with the center of the cleaning hole. The plurality of misaligned holes may then be reamed with a tapered reamer to form a clearance hole defined by a plurality of aligned holes having the same center and the same diameter.

U.S. patent No.10,213,855 describes a method for forming a plurality of aligned holes that includes aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole is at least partially aligned with the second hole to form a gap. A virtual hole diameter is measured, where the virtual hole diameter is the diameter of a virtual hole through the gap, and the virtual hole diameter is the smallest bisector of the gap. A first purge hole having a first purge hole diameter is formed through the gap in response to the dummy hole diameter having the first dummy hole diameter, wherein the first purge hole is concentrically aligned with the dummy hole. A first fastener having a first size is inserted into the first clearance hole and the first surface is attached to the second surface using the first fastener.

Disclosure of Invention

The present disclosure relates to devices, systems, and methods for forming a plurality of aligned holes from a plurality of misaligned holes.

One example of the present disclosure is an apparatus for forming a plurality of aligned holes from a plurality of unaligned holes. The device includes a reamer. The reamer has a first portion having a first constant diameter and a second portion having a first end and a second end. The first end of the second portion is adjacent the first portion of the reamer. The second portion of the reamer is tapered and has a varying diameter that decreases from the first end to the second end. The device includes a guide member coupled to the second end of the second portion of the reamer. The guide member has a second constant diameter.

The second portion of the reamer may be configured to center the reamer on a centerline of the virtual hole. The taper of the second portion of the reamer may be configured to reduce an offset between a central longitudinal axis of the device and a centerline of the virtual hole. The tapered portion of the second portion of the reamer may include a starting diameter that is greater than the final diameter. The tapered portion of the second portion may taper from the final diameter to the starting diameter at an angle of between about 0.5 degrees and about 1.0 degrees on each side.

The second constant diameter may correspond to a first virtual hole, and the first constant diameter may correspond to a first clearance hole that receives a first oversized fastener. The second constant diameter may correspond to a second virtual hole, and the first constant diameter may correspond to a second clearance hole that receives a second oversized fastener. The second constant diameter may correspond to a third virtual hole, and the first constant diameter may correspond to a third clearance hole that receives a third oversized fastener.

One example of the present disclosure is a system for forming a plurality of aligned holes from a plurality of unaligned holes. The system includes a first reamer having a first portion and a second portion. The first portion of the first reamer has a first constant diameter. The second portion of the first reamer has a first end and a second end. The first end of the second portion of the first reamer is adjacent the first portion of the first reamer. The second portion of the first reamer is tapered, the second portion having a varying diameter that decreases from the first end to the second end. The system includes a first guide member coupled to the second end of the second portion of the first reamer. The first guide member has a second constant diameter corresponding to the first virtual hole, and the first constant diameter of the first reamer corresponds to the first clearance hole that receives the first oversized fastener.

The system includes a second reamer having a first portion and a second portion. The first portion of the second reamer has a third constant diameter. The second portion of the second reamer has a first end and a second end. The first end of the second portion of the second reamer is adjacent the first portion of the second reamer. The second portion of the second reamer is tapered and has a varying diameter that decreases from the first end to the second end. The system includes a second guide member. The second guide member is connected to the second end of the second portion of the second reamer. The second guide member has a fourth constant diameter corresponding to the second virtual bore. The third constant diameter of the second reamer corresponds to a second clearance hole that receives a second oversized fastener. The second oversized fastener has a larger diameter than the first oversized fastener.

The tapered portion of the second portion of the first reamer may be configured to center the first reamer on a centerline of the first virtual hole. The tapered portion of the second reamer may be configured to center the second reamer on a centerline of the second virtual bore. The tapered portion of the second portion of the first reamer may have a first starting diameter and a first final diameter. The first starting diameter may be substantially the same as the first constant diameter and the first final diameter may be substantially the same as the second constant diameter. The tapered portion of the second reamer may have a second starting diameter and a second final diameter. The second starting diameter may be substantially the same as the third constant diameter and the second final diameter may be substantially the same as the fourth constant diameter.

The second portion of the first reamer may taper from the first final diameter to the first starting diameter at an angle of between about 0.5 degrees and about 1.0 degrees on each side. The second portion of the second reamer may taper from the second final diameter to the second starting diameter at an angle of between about 0.5 degrees and about 1.0 degrees on each side.

The system may include a third reamer having a first portion and a second portion. The first portion of the third reamer has a fifth constant diameter. The second portion of the third reamer has a first end and a second end. The first end of the second portion of the third reamer is adjacent the first portion of the third reamer. The second portion of the third reamer is tapered, the second portion having a varying diameter that decreases from the first end to the second end. The system may include a third guide member coupled to the second end of the second portion of the third reamer. The third guide member has a sixth constant diameter corresponding to the third virtual hole, and the fifth diameter of the third reamer corresponds to the third clearance hole that receives the third oversized fastener. The third oversized fastener has a larger diameter than the second oversized fastener. The tapered portion of the second portion of the third reamer may have a third starting diameter and a third final diameter. The third starting diameter may be substantially the same as the fifth constant diameter and the third final diameter may be substantially the same as the sixth constant diameter. The second portion of the third reamer may taper from the third final diameter to the third starting diameter at an angle of between about 0.5 degrees and about 1.0 degrees on each side.

One example of the present disclosure is a method for producing an aligned hole from a plurality of misaligned holes. The method includes attempting to insert a first guide member through the plurality of misaligned apertures. The first guide member is connected to a first reamer including a first portion and a second portion. The second portion of the first reamer has a first end and a second end. The first end of the second portion is adjacent the first portion of the first reamer. The first portion of the first reamer has a first constant diameter. The second portion of the first reamer is tapered, the second portion having a varying diameter that decreases from the first end to the second end. The first guide member is connected to the second end of the second portion of the first reamer. The first guide member has a second constant diameter corresponding to the first virtual hole diameter, and the first constant diameter of the first reamer corresponds to the first clearance hole that receives the first fastener. The method includes cutting a first cleaning hole through the plurality of misaligned holes with a first reamer as the first guide member is inserted into the plurality of misaligned holes.

If the first guide member cannot be inserted through the plurality of misaligned holes, the method may include attempting to insert a second guide member into the plurality of misaligned holes. The second guide member is connected to a second reamer including a first portion and a second portion. The second portion of the second reamer has a first end and a second end. The first end of the second portion of the second reamer is adjacent the first portion of the second reamer. The first portion of the second reamer has a third constant diameter. The second portion of the second reamer is tapered, the second portion having a varying diameter that decreases from the first end to the second end. The second guide member is connected to the second end of the second portion of the second reamer. The second guide member has a fourth constant diameter corresponding to the second virtual hole, and wherein the third constant diameter of the second reamer corresponds to the second clearance hole that receives the second fastener. The method may include cutting a second clearance hole through the plurality of misaligned holes with a second reamer as the second guide member is inserted into the plurality of misaligned holes.

If the second guide member cannot be inserted through the plurality of misaligned holes, the method may include attempting to insert a third guide member into the plurality of misaligned holes. The third guide member is connected to a third reamer having a first portion and a second portion. The second portion has a first end and a second end. The first end of the second portion is adjacent the first portion of the third reamer. The first portion of the third reamer has a fifth constant diameter and the second portion of the third reamer is tapered, the second portion having a varying diameter that decreases from the first end to the second end. The third guide member is connected to the second end of the second portion of the third reamer. The third guide member has a sixth constant diameter corresponding to the third virtual hole, and the fifth constant diameter of the third reamer corresponds to the third clearance hole that receives the third fastener. The method may include cutting a third cleaning hole through the plurality of misaligned holes with a third reamer as the third guide member is inserted into the plurality of misaligned holes. The method may include inserting a first oversized fastener through a first clearance hole. Other embodiments also exist.

Drawings

FIG. 1 is a schematic diagram of an example apparatus for forming a plurality of aligned holes from a plurality of misaligned holes.

Fig. 2 is a schematic view of two components, each having holes, which are aligned.

Fig. 3A to 3C are schematic views showing two holes misaligned.

Fig. 4A-4C are schematic diagrams of example apparatus for forming a plurality of aligned holes from a plurality of misaligned holes.

Fig. 5A-5C are schematic diagrams of a system for forming a plurality of aligned holes from a plurality of misaligned holes.

FIG. 6 is a flow diagram of an example method for forming a plurality of aligned holes from a plurality of misaligned holes.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the disclosure is not intended to be limited to the particular forms disclosed. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure as defined by the appended claims.

Detailed Description

Embodiments described herein may be used to form a plurality of aligned holes from a plurality of misaligned holes. As used herein, a plurality of misaligned holes refers to two or more holes through which a particular fastener may not be fully inserted due to misalignment of the holes. As used herein, an oversized fastener is a fastener having a diameter that is larger than the diameter of a given fastener that is intended to be inserted through a plurality of holes to fasten two or more components together.

FIG. 1 is a schematic diagram of an example apparatus 100 for forming a plurality of aligned holes from a plurality of misaligned holes. Device 100 includes reamer 101. Reamer 101 has a first portion 110 and a second portion 120. The first portion 110 has a first constant diameter 111. The second portion 120 has a first end 121 and a second end 122. First end 121 of second portion 120 is adjacent to first portion 110 of reamer 101. The second portion 120 of reamer 101 is tapered 126 having a varying diameter 123-124 that decreases from the first end 121 to the second end 122. Device 100 includes a guide member 130 coupled to second end 122 of second portion 120 of reamer 101. The guide member 130 has a second constant diameter 131.

First portion 110 of reamer 101 has a first length 112. The guide member 130 has a second length 132. Second portion 120 of reamer 101 is configured to center reamer 101 on centerline 205 of virtual hole VH. The taper 126 of the second portion 120 of the reamer 101 is configured to reduce the offset between the central longitudinal axis 102 of the device 100 and the centerline 205 of the virtual hole VH. The tapered portion 126 of the second portion 120 of reamer 101 may include a starting diameter 123 that is greater than a final diameter 124. The taper 126 of the second portion 120 tapers from the final diameter 124 to the starting diameter 123 at an angle 125 of between about 0.5 degrees and about 1.0 degrees on each side.

The second constant diameter 131 may correspond to the first virtual bore VH-a and the first constant diameter 111 may correspond to the first clearance bore 230A that receives the first oversized fastener. The second constant diameter 131 may correspond to the second virtual bore VH-B and the first constant diameter 111 may correspond to the second clearance bore 230B that receives a second oversized fastener. The second constant diameter 131 may correspond to a third virtual hole VH-C and the first constant diameter 111 may correspond to a third clearance hole 230C that receives a third oversized fastener.

Fig. 2 is a schematic view of a system 200 having two components 210, 220, each having an aperture 211, 221, wherein the apertures 211, 221 are aligned. The holes 211, 221 form a virtual hole VH having a diameter 240 and a centerline 205. If the holes 211, 221 are aligned, the virtual hole VH is the same as the respective diameter of each of the holes 211, 221. Fasteners designated to connect the two components 210, 220 together can be inserted through the holes 211, 221 to secure the components 210, 220 together. As the degree of misalignment between the two holes 211, 221 increases, the area of the virtual hole VH passing through the plurality of holes 211, 221 decreases.

At a certain degree of misalignment, a given fastener will not be able to be inserted through both apertures 211, 221. In this case, an apparatus such as apparatus 100 of fig. 1 may produce a cleaning hole having a diameter that encompasses each of the misaligned holes 211, 221. The clearance holes will enable oversized fasteners to be inserted through the clearance holes to secure the two components 210, 220 together. The number, size, location, shape and/or configuration of the components 210, 220, the dummy holes VH and the holes 211, 221 in fig. 2 are shown for illustrative purposes and may vary depending on the application.

Fig. 3A is a schematic diagram showing two holes 211, 221 misaligned. For clarity, other parts are not included in the schematic. The misalignment of the two holes 211, 221 results in a first virtual hole VH-a having a diameter 240A that is smaller than the diameter of each of the two holes 211, 221. The first virtual aperture VH-a has a centerline 205A. When the two holes 211, 221 are misaligned to create the first virtual hole VH-a, the first cleaning hole 230A needs to surround the two holes 211, 221. First clearance hole 230A is configured to enable insertion of a first oversized fastener through first clearance hole 230A.

Fig. 3B is a schematic view showing two holes 211, 221 that are misaligned to a greater degree than the two holes 211, 221 shown in fig. 3A. For clarity, other parts are not included in the schematic. The misalignment of the two holes 211, 221 results in a second virtual hole VH-B having a diameter 240B that is smaller than the diameters of the two holes 211, 221. The diameter 240B of the second virtual aperture VH-B is also smaller than the diameter 240A of the first virtual aperture VH-A. The second virtual aperture VH-B has a centerline 205B. When the two holes 211, 221 are misaligned to create a second virtual hole VH-B, the second cleaning hole 230B needs to surround the two holes 211, 221. The second cleaning holes 230B are larger than the first cleaning holes 230A. Second clearance hole 230B is configured to enable a second oversized fastener to be inserted through second clearance hole 230B. The diameter of the second oversized fastener is greater than the diameter of the first oversized fastener.

Fig. 3C is a schematic view showing two holes 211, 221 that are misaligned to a greater degree than the two holes 211, 221 shown in fig. 3B. For clarity, other parts are not included in the schematic. The misalignment of the two holes 211, 221 results in a third virtual hole VH-C having a diameter 240C that is smaller than the diameters of the two holes 211, 221. The diameter 240C of the third virtual aperture VH-C is also smaller than the diameter 240B of the second virtual aperture VH-B. The third virtual aperture VH-C has a centerline 205C. When the two holes 211, 221 are misaligned to create the third virtual hole VH-B, the third cleaning hole 230C needs to surround the two holes 211, 221. The third cleaning holes 230C are larger than the second cleaning holes 230B. Third clearance hole 230C is configured to enable a third oversized fastener to be inserted through third clearance hole 230B. The diameter of the third oversized fastener is greater than the diameter of the second oversized fastener.

Fig. 4A-4C are schematic diagrams of example apparatus for forming a plurality of aligned holes from a plurality of misaligned holes. The apparatus of fig. 4A may be used to form a plurality of aligned holes from a plurality of misaligned holes 211, 221 forming a first virtual hole VH-a. The apparatus of fig. 4B may be used to form a plurality of aligned holes from a plurality of misaligned holes 211, 221 forming a second virtual hole VH-B smaller than the first virtual hole VH-a. The apparatus of fig. 4B may be used to form a plurality of aligned holes from a plurality of misaligned holes 211, 221 forming a third virtual hole VH-C smaller than the second virtual hole VH-B.

Fig. 4A is a schematic diagram of an example apparatus 100A for forming a plurality of aligned holes from a plurality of misaligned holes. Device 100A includes a first reamer 101A. First reamer 101A has a first portion 110A and a second portion 120A. The first portion 110A has a first constant diameter 111A. The second portion 120A has a first end 121A and a second end 122A. First end 121A of second portion 120A is adjacent first portion 110A of first reamer 101A. Second portion 120A of first reamer 101A is tapered 126A having a varying diameter 123A-124A that decreases from first end 121A to second end 122A. Device 100A includes a first guide member 130A coupled to second end 122A of second portion 120A of first reamer 101A. The first guide member 130A has a second constant diameter 131A.

First portion 110A of first reamer 101A has a first length 112A. The first guide member 130A has a second length 132A. Second portion 120A of first reamer 101A is configured such that first reamer 101A is centered on centerline 205A of first virtual hole VH-a. The taper 126A of the second portion 120A of the first reamer 101A is configured to reduce the offset between the central longitudinal axis 102A of the device 100A and the centerline 205A of the first virtual hole VH-a. The taper 126A of the second portion 120A may taper from the final diameter 124A to the starting diameter 123A at an angle 125A of between about 0.5 degrees to about 1.0 degrees on each side.

The second constant diameter 131A corresponds to the minimum diameter 240A of the first virtual bore VH-A, and the first constant diameter 111A corresponds to the first clearance bore 230A configured to receive a first oversized fastener. The second constant diameter 131A is configured to correspond to the maximum misalignment between the two holes 211, 221 that may still be surrounded by the first cleaning hole 230A. In other words, the second constant diameter 131A is configured to correspond to the minimum diameter 240A of the first virtual hole VH-a, which will still enable the clearance hole 230A created by the first portion 110A of the first reamer 101A to completely surround each of the misaligned holes 211, 221. If first guide member 130A cannot be inserted through the virtual hole VH-A created by misaligned holes 211, 221, then clearance hole 230A created by first reamer 101A will not completely surround each of the misaligned holes 211, 221.

Fig. 4B is a schematic diagram of an example apparatus 100B for forming a plurality of aligned holes from a plurality of misaligned holes. Device 100B includes a second reamer 101B. Second reamer 101B has a first portion 110B and a second portion 120B. The first portion 110B has a third constant diameter 111B. The second portion 120B has a first end 121B and a second end 122B. First end 121B of second portion 120B is adjacent first portion 110B of second reamer 101B. The second portion 120B of the second reamer 101B is tapered 126B having a varying diameter 123B-124B that decreases from the first end 121B to the second end 122B. Device 100B includes a second guide member 130B coupled to second end 122B of second portion 120B of second reamer 101B. The second guide member 130B has a fourth constant diameter 131B.

First portion 110B of second reamer 101B has a third length 112B. The second guide member 130B has a fourth length 132B. Second portion 120B of second reamer 101B is configured to center second reamer 101B on centerline 205B of second virtual hole VH-B. The taper 126B of the second portion 120B of the second reamer 101B is configured to reduce the offset between the central longitudinal axis 102B of the device 100B and the centerline 205B of the second virtual hole VH-B. The taper 126B of the second portion 120B may taper from the final diameter 124B to the starting diameter 123B at an angle 125B of between about 0.5 degrees and about 1.0 degrees on each side.

The fourth constant diameter 131B corresponds to the minimum diameter 240B of the second virtual bore VH-B, and the third constant diameter 111B corresponds to the second clearance bore 230B configured to receive a second oversized fastener. The fourth constant diameter 131B is configured to correspond to the maximum misalignment between the holes 211, 221 that may still be surrounded by the second cleaning hole 230B. In other words, the fourth constant diameter 131B is configured to correspond to the minimum diameter 240B of the second virtual hole VH-B that will still enable the clearance hole 230B created by the first portion 110B of the second reamer 101B to completely surround each of the misaligned holes 211, 221. If second guide member 130B cannot be inserted through the virtual hole VH-B created by misaligned holes 211, 221, then clearance hole 230B created by second reamer 101B will not completely surround each of the misaligned holes 211, 221.

Fig. 4C is a schematic diagram of an example apparatus 100C for forming a plurality of aligned holes from a plurality of misaligned holes. Device 100C includes a third reamer 101C. Third reamer 101C has a first portion 110C and a second portion 120C. The first portion 110C has a fifth constant diameter 111C. The second portion 120C has a first end 121C and a second end 122C. First end 121C of second portion 120C is adjacent first portion 110C of third reamer 101C. A second portion 120C of the third reamer 101C is tapered 126C having a varying diameter 123C-124C that decreases from the first end 121C to the second end 122C. Device 100C includes a third guide member 130C coupled to second end 122C of second portion 120C of third reamer 101C. The third guide member 130C has a sixth constant diameter 131C.

First portion 110C of third reamer 101C has a fifth length 112C. The third guide member 130C has a sixth length 132C. Second portion 120C of third reamer 101C is configured to center third reamer 101C on centerline 205C of third virtual hole VH-C. The taper 126C of the second portion 120C of the third reamer 101C is configured to reduce the offset between the central longitudinal axis 102C of the device 100C and the centerline 205C of the third virtual hole VH-C. The tapered portion 126C of the second portion 120C may taper from the final diameter 124C to the starting diameter 123C at an angle 125C of between about 0.5 degrees and about 1.0 degrees on each side.

The sixth constant diameter 131C corresponds to the minimum diameter 240C of the third virtual bore VH-C, and the fifth constant diameter 111C corresponds to the third clearance bore 230C configured to receive a third oversized fastener. The sixth constant diameter 131C is configured to correspond to the maximum misalignment between the holes 211, 221 that may still be surrounded by the third cleaning hole 230C. In other words, the sixth constant diameter 131C is configured to correspond to the minimum diameter 240C of the third virtual hole VH-C that will still enable the clearance hole 230C created by the first portion 110C of the third reamer 101C to completely surround each of the misaligned holes 211, 221. If the third guide member 130C cannot be inserted through the virtual hole VH-C created by the misaligned holes 211, 221, the clearance hole created by the third reamer 101C will not completely surround each of the misaligned holes 211, 221.

Fig. 5A-5C are schematic side views of a system 200 for forming a plurality of aligned holes from a plurality of misaligned holes 211, 221. The hole 211 through the first member 210 is not aligned with the hole 221 through the second member 220. Fig. 5A shows the guide member 130 positioned within two misaligned apertures 211, 221. A guide block 250 may be positioned on top of the first part 210 to guide the apparatus 100 to position the guide member 130 within the two misaligned apertures 211, 221. The guide member 130 has a second constant diameter 131 that corresponds to a predetermined minimum virtual bore VH as discussed herein.

If guide member 130 is able to pass through both of the misaligned holes 211, 221, then the clearance holes 230A, 230B, 230C that would be created by first portion 110 of reamer 101 would surround both of the misaligned holes 211, 221. If guide member 130 cannot pass through both of the misaligned holes 211, 221, then a clean up hole surrounding both of the misaligned holes 211, 221 would need to be made using apparatus 100 with the smaller guide member 130 and the larger first portion 110 of reamer 101. The first and second members 210, 220 having two apertures 211, 221 are shown in fig. 5A-5C for illustrative purposes and may vary depending on the application. For example, the apparatus 100 may be used to form a plurality of alignment holes in two or more components.

Fig. 5B shows a portion of second portion 120 of reamer 101 positioned within misaligned holes 211, 221 of first component 210 and second component 220. The second portion 120 of reamer 101 is tapered 126 having a varying diameter 123-124 that decreases from the first end 121 to the second end 122. Second portion 120 of reamer 101 will begin to form clearance holes 230A, 230B, 230C to the extent that tapered portion 126 of second portion 120 of reamer 101 contacts the sidewalls of both misaligned holes 211, 221. Second portion 120 of reamer 101 is configured to center reamer 101 on centerline 205 of virtual hole VH created by misaligned holes 211, 221. The taper 126 of the second portion 120 of the reamer 101 is configured to reduce the offset between the central longitudinal axis 102 of the device 100 and the centerline 205 of the virtual hole VH.

Fig. 5C shows first portion 110 of reamer 101 inserted through both first section 210 and second section 220 to cut two aligned clearance holes through sections 210, 220. First portion 110 of reamer 101 includes a constant diameter 111 configured such that two aligned holes in components 210, 220 create two aligned clearance holes through components 210, 220 that completely surround misaligned holes 211, 221.

Fig. 6 is a flow chart of an example of a method 300 for generating a plurality of aligned holes from a plurality of misaligned holes. Method 300 includes attempting to insert first guide member 130A through the plurality of misaligned holes 211, 221, first guide member 130A being coupled to first reamer 101A, at 310. First reamer 101A includes a first portion 110A and a second portion 120A. Second portion 120A has a first end 121A and a second end 122A adjacent first portion 110A of first reamer 101A. First portion 110A of first reamer 101A has a first constant diameter 111A. The second portion 120A is tapered 126A having a varying diameter 123A-124A that decreases from the first end 121A to the second end 122A. First guide member 130A is coupled to second end 122A of second portion 120A of first reamer 101A. The first guide member 130A has a second constant diameter 131A corresponding to the first virtual bore VH-a. First constant diameter 111A of first portion 110A of first reamer 101A corresponds to first clearance hole 230A that receives a first oversized fastener.

Method 300 includes cutting first clearance hole 230A through the plurality of misaligned holes 211, 221 with first reamer 101A. For example, at 320, first cleaning hole 230A is cut with first reamer 101A as first guide member 130A is inserted into plurality of misaligned holes 211, 221. If first guide member 130A cannot pass through the plurality of misaligned holes 211, 221, method 300 may include, at 330, attempting to insert second guide member 130B into the plurality of misaligned holes, the second guide member 130B being coupled to second reamer 101B. Second reamer 101B includes first portion 110B and second portion 120B. Second portion 120B has a first end 121B and a second end 122B adjacent first portion 110B of second reamer 101B. First portion 110B of second reamer 101B has a third constant diameter 111B. The second portion 120B is tapered 126B having a varying diameter 123B-124B that decreases from the first end 121B to the second end 122B. Second guide member 130B is coupled to second end 122B of second portion 120B of second reamer 101B. The second guide member 130B has a fourth constant diameter 131B corresponding to the second virtual bore VH-B. The third constant diameter 111B of the first portion 110B of the second reamer 101B corresponds to the second clearance hole 230B that receives the second oversized fastener.

Method 300 may include cutting second clearance hole 230B through the plurality of misaligned holes 211, 221 with second reamer 101B. For example, at 340, second cleaning hole 230B is cut with second reamer 110B as second guide member 130B is inserted through the plurality of misaligned holes 211, 221. If second guide member 130B cannot pass through the plurality of misaligned holes 211, 221, method 300 may include, at 350, attempting to insert third guide member 130C through the plurality of misaligned holes 211, 221, the third guide member 130C being connected to the third reamer 101C.

Third reamer 101C includes first portion 110C and second portion 120C. Second portion 120C has a first end 121C and a second end 122C adjacent first portion 110C of third reamer 101C. First portion 110C of third reamer 101C has a fifth constant diameter 111C. The second portion 120C is tapered 126C having a varying diameter 123C-124C that decreases from the first end 121C to the second end 122C. Third guide member 130C is coupled to second end 122C of second portion 120C of third reamer 101C. The third guide member 130C has a sixth constant diameter 131C corresponding to the third virtual bore VH-C. Fifth constant diameter 111C of first portion 110C of third reamer 101C corresponds to third clearance hole 230C that receives a second oversized fastener.

Method 300 may include cutting a third clearance hole 230C through the plurality of misaligned holes 211, 221 with a third reamer 101C as the third guide member 130C is inserted through the plurality of misaligned holes 211, 221, at 360. The method 300 may include inserting a first oversized fastener through a first clearance hole, at 370. The method 300 may include inserting a second oversized fastener through a second clearance hole at 380. The method 300 may include inserting a third oversized fastener through a third clearance hole at 390.

Further, the present disclosure includes implementations according to the following examples:

example 1. an apparatus for forming a plurality of aligned holes from a plurality of unaligned holes, the apparatus comprising: a reamer having a first portion and a second portion, the first portion having a first constant diameter and the second portion having a first end and a second end, the first end of the second portion being adjacent the first portion of the reamer, the second portion of the reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; and a guide member connected to the second end of the second portion of the reamer, the guide member having a second constant diameter.

Example 2. the device of example 1, wherein the second portion of the reamer is configured to center the reamer on a centerline of a virtual hole.

Example 3. the device of example 2, wherein the taper of the second portion of the reamer is configured to reduce an offset between a central longitudinal axis of the device and the centerline of the virtual hole.

Example 4. the device of any of examples 1 to 3, wherein the tapered portion of the second portion of the reamer includes a starting diameter that is greater than a final diameter, the tapered portion of the second portion tapering from the final diameter to the starting diameter at an angle of between about 0.5 degrees and about 1.0 degrees on each side.

Example 5 the apparatus of any of examples 1-4, wherein the second constant diameter corresponds to a first virtual hole, and wherein the first constant diameter corresponds to a first clearance hole that receives a first oversized fastener.

Example 6 the apparatus of any of examples 1-5, wherein the second constant diameter corresponds to a second virtual hole, and wherein the first constant diameter corresponds to a second clearance hole that receives a second oversized fastener.

Example 7 the apparatus of any of examples 1-6, wherein the second constant diameter corresponds to a third virtual hole, and wherein the first constant diameter corresponds to a third clearance hole that receives a third oversized fastener.

Example 8 a system for forming a plurality of aligned holes from a plurality of misaligned holes, wherein the reamer of any of examples 1-7 is a first reamer and the guide member of any of examples 1-7 is a first guide member, the system comprising: a second reamer having a first portion and a second portion, the first portion of the second reamer having a third constant diameter, the second portion of the second reamer having a first end and a second end, the first end of the second portion of the second reamer being adjacent the first portion of the second reamer, the second portion of the second reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; and a second guide member connected to the second end of the second portion of the second reamer, the second guide member having a fourth constant diameter corresponding to a second virtual hole, and wherein the third constant diameter of the second reamer corresponds to a second clearance hole that receives a second oversized fastener having a larger diameter than the first oversized fastener.

Example 9. a system for forming a plurality of aligned holes from a plurality of unaligned holes, the system comprising: a first reamer having a first portion and a second portion, the first portion of the first reamer having a first constant diameter, the second portion of the first reamer having a first end and a second end, the first end of the second portion of the first reamer being adjacent the first portion of the first reamer, the second portion of the first reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; a first guide member connected to the second end of the second portion of the first reamer, the first guide member having a second constant diameter corresponding to a first virtual hole, and wherein the first constant diameter of the first reamer corresponds to a first clearance hole that receives a first oversized fastener; a second reamer having a first portion and a second portion, the first portion of the second reamer having a third constant diameter, the second portion of the second reamer having a first end and a second end, the first end of the second portion of the second reamer being adjacent the first portion of the second reamer, the second portion of the second reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; and a second guide member connected to the second end of the second portion of the second reamer, the second guide member having a fourth constant diameter corresponding to a second virtual hole, and wherein the third constant diameter of the second reamer corresponds to a second clearance hole that receives a second oversized fastener having a larger diameter than the first oversized fastener.

Example 10. the system of examples 8 or 9, wherein the taper of the second portion of the first reamer is configured to center the first reamer on a centerline of a first virtual hole, and wherein the taper of the second portion of the second reamer is configured to center the second reamer on a centerline of a second virtual hole.

Example 11. the system of any of examples 8 to 10, wherein the taper of the second portion of the first reamer has a first starting diameter and a first final diameter, the first starting diameter being substantially the same as the first constant diameter, and the first final diameter being substantially the same as the second constant diameter.

Example 12. the system of example 11, wherein the taper of the second portion of the second reamer has a second starting diameter and a second final diameter, the second starting diameter being substantially the same as the third constant diameter, and the second final diameter being substantially the same as the fourth constant diameter.

Example 13. the system of examples 11 or 12, wherein the second portion of the first reamer tapers from the first final diameter to the first starting diameter at an angle of between about 0.5 degrees to about 1.0 degrees on each side.

Example 14. the system of examples 12 or 13, wherein the second portion of the second reamer tapers from the second final diameter to the second starting diameter at an angle of between about 0.5 degrees to about 1.0 degrees on each side.

Example 15 the system of any one of examples 8 to 14, further comprising: a third reamer having a first portion and a second portion, the first portion of the third reamer having a fifth constant diameter, the second portion of the third reamer having a first end and a second end, the first end of the second portion of the third reamer being adjacent the first portion of the third reamer, the second portion of the third reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; and a third guide member connected to the second end of the second portion of the third reamer, the third guide member having a sixth constant diameter corresponding to a third virtual hole, and wherein the fifth constant diameter of the third reamer corresponds to a third clearance hole that receives a third oversized fastener having a larger diameter than the second oversized fastener.

Example 16. the system of example 15, wherein the taper of the second portion of the third reamer has a third starting diameter and a third final diameter, the third starting diameter being substantially the same as the fifth constant diameter, and the third final diameter being substantially the same as the sixth constant diameter.

Example 17. the system of example 16, wherein the second portion of the third reamer tapers from the third final diameter to the third starting diameter at an angle of between about 0.5 degrees and about 1.0 degrees on each side.

Example 18 a method for generating an aligned hole from a plurality of misaligned holes, the method comprising: attempting to insert the guide member of any of examples 1 to 7 through a plurality of misaligned holes; and cutting a first clearance hole through the plurality of misaligned holes with the reamer of any of examples 1-7 as the guide member is inserted into the plurality of misaligned holes.

Embodiment 19. a method for creating an aligned hole from a plurality of misaligned holes, the method comprising: attempting to insert a first guide member through the plurality of misaligned holes, the first guide member coupled to a first reamer having a first portion and a second portion, the second portion having a first end and a second end, wherein the first end is adjacent to the first portion of the first reamer, the first portion of the first reamer having a first constant diameter, and the second portion is tapered, the second portion having a varying diameter that decreases from the first end to the second end, wherein the first guide member is connected to the second end of the second portion of the first reamer, and wherein the first guide member has a second constant diameter corresponding to the first virtual bore, and wherein the first constant diameter of the first reamer corresponds to a first clearance hole that receives a first fastener; and cutting the first clearance hole through the plurality of misaligned holes with the first reamer as the first guide member is inserted into the plurality of misaligned holes.

Example 20 the method of examples 18 or 19, wherein if the first guide member cannot be inserted through the plurality of misaligned holes, the method further comprises: attempting to insert a second guide member into the plurality of misaligned holes, the second guide member coupled to a second reamer having a first portion and a second portion, the second portion having a first end and a second end, wherein the first end is adjacent to the first portion of the second reamer, the first portion of the second reamer having a third constant diameter, and the second portion of the second reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end, wherein the second guide member is connected to the second end of the second portion of the second reamer, and wherein the second guide member has a fourth constant diameter corresponding to the second virtual bore, and wherein the third constant diameter of the second reamer corresponds to a second clearance hole that receives a second fastener; and cutting the second clearance hole through the plurality of misaligned holes with the second reamer as the second guide member is inserted into the plurality of misaligned holes.

Example 21 the method of example 20, wherein if the second guide member cannot be inserted through the plurality of misaligned holes, the method further comprises: attempting to insert a third guide member into the plurality of misaligned holes, the third guide member coupled to a third reamer having a first portion and a second portion, the second portion having a first end and a second end, wherein the first end is adjacent to the first portion of the third reamer, the first portion of the third reamer having a fifth constant diameter, and the second portion of the third reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end, wherein the third guide member is connected to the second end of the second portion of the third reamer, and wherein the third guide member has a sixth constant diameter corresponding to a third virtual bore, and wherein the fifth constant diameter of the third reamer corresponds to a third clearance hole that receives a third fastener; and cutting the third clearance hole through the plurality of misaligned holes with the third reamer as the third guide member is inserted into the plurality of misaligned holes.

Example 22 the method of any of examples 18 to 21, further comprising inserting a first oversized fastener through the first clearance hole.

Example 23a method for creating an aligned hole from a plurality of misaligned holes using the system of any of examples 8-17 when a first guide member cannot be inserted through the plurality of misaligned holes, the method comprising: attempting to insert the first guide member through the plurality of misaligned apertures; cutting the first cleaning hole through the plurality of misaligned holes with the first reamer as the first guide member is inserted into the plurality of misaligned holes; attempting to insert the second guide member into the plurality of misaligned apertures; and cutting the second clearance hole through the plurality of misaligned holes with the second reamer as the second guide member is inserted into the plurality of misaligned holes.

While the present disclosure has been described in terms of certain embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of the present disclosure. Accordingly, the scope of the disclosure is to be defined only by the following claims and their equivalents.