Method and apparatus for registering a torque-transmitting tool in a fixture and for forming a diagonal bore in the tool

Abstract

A torque transmitting tool is machined by registering the torque transmitting tool using a shoulder between the shank and the out-of-round drive portion of the tool as a reference. First and second seating surfaces are milled on first and second opposed surfaces of the tool, and then first and second bores are drilled into the drive stud, starting from the first and second seating surfaces, respectively. The first and second bores intersect within the drive stud to form a stepped diagonal bore in the tool. Alternately, all machining operations are performed from one side of the tool.

1 . A method for registering a torque-transmitting tool comprising:
 (a) providing a torque-transmitting tool comprising a shank portion, an out-of-round drive portion, and a shoulder intermediate the shank portion and the drive portion;   (b) referencing at least one machined surface of the tool drive with respect to at least one reference surface on the shoulder.   
   
   
       2 . The method of  claim 1  wherein (b) comprises
 (b1) registering the tool in a fixture that engages the reference surface on the shoulder; and   (b2) machining the at least one machined surface of the tool.   
   
   
       3 . (canceled) 
   
   
       4 . A method for forming a diagonal bore in a torque-transmitting tool comprising a longitudinal axis and a first surface on one side of the longitudinal axis, said method comprising:
 (a) forming a seating surface on the tool at a point of intersection between the first surface and a drilling axis that intersects the first surface at an oblique angle, said seating surface being rotationally asymmetrical about the drilling axis and shaped to reduce any tendency of a drill bit to skate in a subsequent drilling operation along the drilling axis as compared with the first surface; and   (b) drilling a bore in the tool along the drilling axis through the seating surface.   
   
   
       5 . The method of  claim 3  or  4  further comprising:
 (c) center drilling the seating surface along the drilling axis after (a) and before (b).   
   
   
       6 . A method for forming a diagonal bore in a torque-transmitting tool comprising a longitudinal axis and first and second surfaces on different sides of the longitudinal axis, said method comprising:
 (a) drilling a first bore in the tool from the first surface along a first drilling axis, said first drilling axis intersecting the first surface at a first oblique angle; and   (b) drilling a second bore in the tool from the second surface along a second drilling axis, said second drilling axis intersecting the second surface at a second oblique angle, said first and second drilling axes oriented such that the first and second bores meet in the tool.   
   
   
       7 . The method of  claim 6  wherein the first and second surfaces are substantially parallel to one another. 
   
   
       8 . The method of  claim 6  wherein the first bore is larger in diameter than the second bore, and wherein the first and second bores meet at a shoulder in the tool. 
   
   
       9 . The method of  claim 6  wherein the first and second drilling axes are substantially co-linear. 
   
   
       10 . The method of  claim 6  wherein the first and second oblique angles are substantially equal to one another. 
   
   
       11 . The method of  claim 6  further comprising
 forming a first seating surface at a point of intersection between the first surface and the first drilling axis prior to (a).   
   
   
       12 . The method of  claim 11  further comprising
 forming a second seating surface at a point of intersection between the second surface and the second drilling axis prior to (b).   
   
   
       13 . (canceled) 
   
   
       14 . The method of  claim 6  wherein (a) comprises
 supporting a first drill with a first drill bushing aligned with the first drilling axis to a position closely adjacent to the first surface.   
   
   
       15 . The method of  claim 14  wherein (b) comprises
 supporting a second drill with a second drill bushing aligned with the second drilling axis to a position closely adjacent to the second surface.   
   
   
       16 . A system for machining a torque-transmitting tool, said tool comprising a shank, an out-of-round drive portion, and a shoulder therebetween, said system comprising:
 at least one machine tool; and   a fixture selectively positioned with respect to each machine tool, said fixture comprising at least one sensing element configured to sense the shoulder to register the tool with respect to the fixture and each machine tool.   
   
   
       17 . The system of  claim 16  wherein the fixture further comprises an out-of-round opening configured to receive the drive portion. 
   
   
       18 . A system for machining a diagonal bore in a drive stud of a torque-transmitting tool, said system comprising:
 tool comprising a longitudinal axis and first and second surfaces on different sides of the longitudinal axis;   a fixture configured to hold the tool in a selected position;   a first drill oriented with respect to the fixture when in an operative position to drill a first bore in the tool from the first surface along a first drilling axis, said first drilling axis intersecting the first surface at a first oblique angle;   a second drill oriented with respect to the fixture when in an operative position to drill a second bore in the tool from the second surface along a second drilling axis, said second drilling axis intersecting the second surface at a second oblique angle, said first and second drilling axes oriented such that the first and second bores meet in the tool.   
   
   
       19 . The system of  claim 18  wherein the first and second surfaces are parallel to one another. 
   
   
       20 . The system of  claim 18  wherein the first and second bores meet at a shoulder in the tool. 
   
   
       21 . The system of  claim 18  or  20  wherein the first and second drilling axes are substantially co-linear. 
   
   
       22 . The system of  claim 21  wherein the first bore is larger in diameter than the second bore. 
   
   
       23 . The system of  claim 18  wherein the first and second oblique angles are substantially equal to one another. 
   
   
       24 . The system of  claim 18  further comprising:
 a first mill oriented with respect to the fixture when in an operative position to form a first seating surface at a point of intersection between the first surface and the first drilling axis.   
   
   
       25 . The system of  claim 24  further comprising:
 a second mill oriented with respect to the fixture when in an operative position to form a second seating surface at a point of intersection between the second surface and the second drilling axis.   
   
   
       26 . (canceled) 
   
   
       27 . The system of  claim 18  wherein the fixture comprises a first drill bushing positioned closely adjacent the first surface and aligned with the first drilling axis to support the first drill. 
   
   
       28 . The system of  claim 27  wherein the fixture comprises a second drill bushing positioned closely adjacent the second surface and aligned with the second drilling axis to support the second drill. 
   
   
       29 - 30 . (canceled) 
   
   
       31 . A method for forming a diagonal bore in a torque-transmitting tool comprising a longitudinal axis and first and second surfaces on different sides of the longitudinal axis, said method comprising:
 (a) drilling a first bore in the tool from the first surface along a first drilling axis, said first drilling axis intersecting the first surface at a first oblique angle; and   (b) drilling a second, smaller bore in the tool from the first surface along the first drilling axis, said second bore forming with the first bore a step within the tool, said second bore passing through the second surface at a second oblique angle.   
   
   
       32 - 39 . (canceled)