CA1220032A - Means for attaching a replaceable stone and/or guide assembly to a master holder - Google Patents

Abstract

ABSTRACT OF THE DISCLOSURE
A mounting assembly for attaching a first member to a second member such as for attaching a disposable work engaging assembly to a master holder assembly comprising a first member having opposed surfaces and at least one opening extending therethrough between the opposed surfaces, a second member formed of a malleable material having a corresponding number of tubular portions projecting therefrom at locations to register with and to be insertable into the openings in the first member, each of the tubular portions having a passageway extending therethrough formed at least in part by a non-round portion in the area thereof that extends through the opening in the first member, and a tool member having a work engaging end portion adapted to be positioned extending respectively into each of the passageways extending through the tubular portions, rotation of the tool member forcing the tool work engaging end portion into engagement with the non-round portion of the passageway extending through each of the tubular portions thereby permanently plastically deforming the non-round portion of each tubular portion and radially expanding each tubular portion outwardly into engagement with the corresponding opening in the first member to make a tight connection therebetween.

Description

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IMPROVED MEANS FOR ATTAC~ING A REPLACEABLE

The present invention relates to an improved means for attaching replaceable stone and/or guide assemblies to master holders and, more particularly, to nove] attaching rneans wherein ; each stone and/or guide assembly includes spaced tubu]ar projections formed on one surface thereof at locations to register with and to be insertable into corresponding openings extendiny through the associated master holder, said tubular projections being made of a malleable or ductile materia] and each including an opening extending therethrough having at least a portion thereof irregularly shaped. A simple novel swaging tool is utilized to permanently plastically upset and expand the ma]leable or ductile material associated with the irregularly shaped por~ion of the tubular projections so as to force said material outwardly into the corresponding openings in the master holder to which it is being attached. The camming action produced by rotation of the swaging tool cams the respective surfaces of the tubu]ar projections and the openings through the master holder against each other thereby providing a positive driving connection therebetween. Simple remova] means for detaching the disposab]e stone ~nd/or guide assemblies from their respective master holders are a]so disclosed.
E~oning mandrels and other similar devices having stone and guide assemblies mounted thereon are well known and have been used for many years. A wide variety of mandrels and like devices have been designed and manufactured so as to be adjustable to maintain the stone and/or guide assemblies in contact under pressure with the work surfaces being honed. Typical of such mandre] constructions are those devices which utilize sing]e radialJy adjustable stone assemblies, while other such devices utilize a plurality of circumferentially spaced stone and/or guide assemblies, one or more -1-- J~

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of which are radially adjustable during a particular honing operation to maintain the stone and/or guide assemblies in contact under pressure with a work surface being honed.
Many known stone and guide assemblies and stone and guide assembly movement means have been devised and used in the past including those disclosed in Sunnen U. S. Patent Nos.
RE 18,763; 1,902,194; 1,90~,336; 1,946,041; 1,982,836;

2,040,281; 2,815,615; 3,378,962; co-pending Canadian Patent Applica-tion Serial No. 409,590, filed August 17, 1982, and co-pending Canadian Patent Application Serial No. 426,989, filed April 29, 1983, both of which are assigned to appli-cants' assignee, Sunnen Products Company. Some of the known constructions have the stone and guide members fixedly mounted on holder members which are then mounted on a honing mandrel or head, or other similar device, in various ways.
With such known constructions, as the stones and guides wear out, the stone and/or guide assemblies, which usually include the mounting means therefor, are either discarded or the old stones and guides are removed therefrom and new members attached thereto. These procedures are wasteful and expen-sive to the user especially in those cases where the stone and guide assemblies include expensive metal backing and support means.
Although the attachment means disclosed in co-pending Sunnen Canadian Patent Application Serial No. 409,590 seeks to overcome such waste and expense by teaching the construction and attachment of a novel replaceable honing stone assembly, certain disadvantages and shortcomings still exist. For example, Sunnen Canadian Patent Application Serial No. 409,590 discloses a work engaging stone assembly for mounting on a honing mandrel or like device comprising a replaceable stone assembly and a reusable master stone A

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holder, the stone assembly including spaced tubular projec-tions formed on one surface thereof at locations to register - 2a -~l ~ ~ 2~ t witll and to be inserta~]e into respective space~ openings formed in the master stone ho].der. Threaded fastener members or a special threaded tool are uti.]ized LOr threading into each respective tubular projection when said projections are positioned extending into the spaced openings formed in the master stone holder. When so threaded, the fastener members or the threaded too] form threads into the tubu]ar projecti.ons of the stone assemb].y and simultaneously expand said tubular projections outward].y into the respective openinys in the master stone holder to make a firm tiyht connection therewith. The various methods disclosed in the above-identiEied pending case for attaching a rep].aceable stone assembly to a master stone holder typically require the threaded members and/or the threaded too]. to be rotated through numerous revolutions in order to sufficiently thread said members through the tubular projections of the stone assemb].y so as to adequately permanently plastically flare outwardly the soft material associated therewith against the wal.].s of the master stone holder. In addition, it has been found that rotation of the threaded fastener members and/or the specia] threaded too] is sti~l somewhat time consuming due to the fact that these members must be rotated through numerous revolutions. This operation, a].though a great improvement, still requires some manual dexterity and physical strength in manipulating the associated threaded members and/or the inserting tool for achieving both proper attachment and removal of the stone assembly to and from its corresponding master ho].der. This is not true of the present construction as wil] be hereinafter explained.
The present construction overcoMes these and other di.sadvantages and shortcomings of the known constructions by teachiny nove] means for driving]y attaching a replaceable stone and/or guide assemb].y to a master ho]der without the use of threaded

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fastener members to accomp]ish the same and without requiring threaded members to be ~eft on the assemb]ies. Instead, the replaceab]e stone and/or guide assemblies of the present invention each include at least one and usua].].y two or more spaced tubu]ar projections forrned on one surface thereof at ]ocations to register with and to be insertab]e into corresponding openings extendiny through the master holders, said tubu]ar projectlons each inc]uding an opening extending therethrough having at ]east a portion of its ]ength of an irregular or non-round cross-sectional shape defined by sidewa]] portions of varying contour extending therearound. The replaceable stone and/or yuide assemb]ies of the present invention are attached to master ho]ders by using a simple nove] swaging too]
which includes a camming surface at one end portion thereof adaptab]e for engaging the openings in the projections and, when rotated, to permanently upset and p]astically expand the rnalleable or ducti]e material associated with the i.rregu]ar shaped portions of the tubu]ar projection openings so as to force said materia]
outwardly or sideways into engagement with the respective openings in the master holder for achieving a tight firm connection therewith. Simp]e rotation of the swaging tool through approximately 180 of rotation cams and permanently deforms the relative surfaces of the tubular projections and the openings through the master holder against each other, and such manner of attachment does not require the use of any threaded rnembers or the like as previously disc]osed in the above-identified pending caseO
Additiona].ly, since the camming surface of the swaging tool is only squeezing and reshaping the malleable or ducti].e ~etal associated : with the tubular projections of the replaceab]e stone and/or guide assemblies and such too] is not physically forming threads as previously required in using the special tool described in the 3~

above-identified pending case, rotation of the swaging tool of the present inventi~n i5 considerably easier and less time consuming and can be conveniently and easily accomp]ished by users possessing ordinary manual skil]s and by persons having ]ittle training or abi]ity. The presen~ method therefore can be quick]y and easi].y accomplished while at the same time providing a positive driving connection under pressure between the replaceab].e stone and/or guide assemblies and thei~ master holders.

When the stones of the present device wear and need replacin~, the replaceable stone and/or guide assemblies can be quick]y separated from their respective master ho]ders and can be replaced by another similar stone and/or guide assemb]y. This results in minimal waste to the customer and, because of the inexpensive cost of the replaceab]e stone and/or guide assemb]ies, makes it uneconomical to remount stones and/or guides on existing backing members which is time consuming, expensive and requires specia] equipment and materia]s. A3so, since the backing materia]
to which the stones and/or guides are attached is relatively inexpensive and is normally damaged by use, there is little to be ~n lost by discarding it rather than trying to reuse it by removing the worn stones or shoes and replacing them with new ones.
It is therefore a principal object of the present invention to provide improved means for attaching members toget~er.
Another object is to provide a relativeJy inexpensive replaceable stone and/or guide assemb3.y for mounting on master holders, which assemblies are driving3y connected to their respective master ho]ders without re~uiring or using threaded members.

Another object is to provide nove] means for attaching a disposable stone assemb].y to a master stone holder.

Another object is to provide nove] means for attaching a replaceab]e yuide assembly to a master guide ho]der.
Another object is to reduce the time and effort required to instal] a honing stone and/or guide assemb]y on a ho~der device in order to restore a honing device to a ]ike-new operatiny condition.
Another object is to make it possib]e to attach a replaceab]e stone and/or guide assemb]y to a master holder using a simple nove] swaging too].

Another object is to teach the construction of a simple novel swaging tool for use in attaching replaceable stone and/or guide assemblies to master ho]ders, said swaging too] being easily and quickly inserted and rotated within openings extending through the tubu]ar projections formed within the stone and/or guide assemblies to effect a positive driving connection between the stone and/or guide assemblies and their respective master holders.
Another cbject is to make it possible to attach a rep]aceable stone and/or guide assemb]y to a master ho]der by a one time rotation of a swaging too] through a predetermined angle usua]]y about 180.
Another object is to prevent mounting a stone and/or guide assembly in a wrong position on a master holder.
Another object is to provide novel means for attaching and detaching replaceable stone and/or guide assemblies to and from reusable master ho]ders without requiring that the entire honing assembly be removed from the mandre] or honing head on which it is mounted.
Another object is to reduce the expense of maintaining a honing mandrel in an operative condition.

Another object is to provide nove] means for removing the disposab]e stone and/or guide assemb]ies from their respective 3~
master holders.
Another object is to make it uneconornical to remount stones and/or guides on existing holder devices.
Another object is to provide a novel attaching means which may be utilized in other applications.
In summary, the present invention can be said to include means for attaching a first member to a second member comprising a first member having opposed surfaces and at least one opening located extending therethrough. A second member has at least one portion pxojecting therefrom which mates with and is extendable into the opening of the first member.
The number of projecting portions on the second corresponds in number to the number of openings extending through the first member. Each of the projection portions has an opening extending therethrough and at least a portion of which has an irregular cross-sectional shape defined by side wall portions, that is~ that extend radially outwardly from the center thereof, a distance further than other side wall portions associated therewith. The irregularly shaped portions being located in the area of the openings that extend through the openings in the first portion. Means are insertable respectively in each of the projection portions to radially expand the irregularly shape portions thereof outwardly into engagement with the corresponding openings of the first member.
In the drawings which illustrate em~odiments of the invention:
Figure 1 is an exploded perspective view of a honing -~ stone assembly and a master holder therefor constructed according to the teachings of the present invention;

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FIGURE 2 is a front elevational view, partly in section, of the stone assembly and master holder of FIGURE 1 showing said members in attached conditioni FIGURE 3 is a right end elevational view of the construction shown in FIGURE 2i FIGURE 4 is a front elevational view, partly in section, of the master holder only shown in FIGURES 1-3i FIGURE 5 is a top plan view of the master holder shown in FIGURE 4;
FIGURE 6 is a top plan view of the backing portion of a replaceable stone assembly upon which a honing stone is mounted;
FIGURE 7 is a left end elevational view of the backing member shown in FIGURE 6;
FIGURE 8 is a front elevational view of the backing member shown in FIGURE 6;
FIGURE 9 is an enlarged cross-sectional view taken along line 9-9 of FIGURE 6;
FIGURE 10 is a bottom plan view of the backing member shown in E'IGURES 6-9;
FIGURE 11 is a perspective view of one embodiment of a - 7a -3~Z

swaging too] for use in attaching a rep]aceable stone assemb]y to a master holder;
FIGURE 12 iS a cross-sectiona~ view showing a r~p].aceab] e stone assembly with a swaging too] positioned therein in position to attac'n the assemb]y to a master holder;
FIGURE ]3 is a perspective view showing another embodiment of a special tool for attaching a replaceab]e stone assembly to a master holder;
FIGURE ].4 is a prespective view of still another embodiment of a swaging tool similar to the swaging tool shown in FIGURE ] 1, FIGURE ].5 is a cross-sectiona] view showing the swaging tool of FIGURE 14 being used in a way to remove a stone assembly from a master holder;
FIGURE 16 is a perspective view of an alternative embodiment of the construction shown in FIGURES 1-3, said embodiment having notches formed therein to accommodate a too] used to remove a stone assembly from its master holder;
FIGURE ]7 i~ a perspective view similar to FIGUR~ ]6 wherein the notches are formed at another location between the stone assembly and the master holder;
FIGURE 18 is a partial perspective view of stil] another embodiment of the notch constructions shown in FIGURES 16 and 17;
FIGURE 19 is a perspective view of one embodiment of a replaceable work engaging guide member for attaching to a master holder according to the teachings of the present invention;
FIGURE 20 is a perspective view, part]y in section, of a modified stone assembly constructed according to the teaching.s of the present invention; and FIGURE 2] is a cross-sectiona~ view taken on line 21-21 of FIGURE 20 and showing the assemb].y mounted on a master holder~

Referring to the drawinys more particular]y by reerence numbers wherein like numerals refer to Jike parts, FIGURE 1 illustrates a construction lO comprising a reusab]e master holder ]2 and a rep]aceab]e stone assemb]y ]4 for mountiny thereon, both of which are constructed according to the teachings of the present invention. The master holder ]2 inc]udes an elon~ated substantial]y rectangular plate 16 upon which the stone assembly 14 is mounted, and it has attached thereto adjacent its opposite end portions spaced mounting members which are shown as rack gear members 38 and 20 as i]lustrated in FIGURES 1-4. A]though the gear members 18 and 20 may be attached to the p]ate 16 by any suitable meansF it is genera]]y preferred that these attachments be made by staking as at 21 so as to make a secure connection therebetween. The gear mernbers 1~ and 20 a]so include a plurality of gear teeth such as the teeth 22 (FIGURE 3) formed along corresponding sides thereof to engage with a pinion gear (not shown) located in a honiny mandrel or other similar device. The pinion gear operates to radially move the stone assemb]y ]4 duriny a honing operation so as to both maintain the stones associated therewith engaged with the work surface under pressure and retract the stones when the mandre~ is to be withdrawn from or inserted into a work piece. The plate 16 of the master holder ~2 is shown having a pair of simi]ar openings or bores 24 extending therethrough as shown in FIGU~S ], 4 and 5, which bores 24 are u~i3ized for mounting the replaceab]e stone assembly 14 onto the master holder 12 as will be e~plained. The bores 24 are shown as being cylindrical o~er a portion of their length and are tapered outwardly over at ]east a portion thereof as at 25, the intersection of said portions forming a lip or edge 27 as best shown in FIGURE 4O In some embodiments the ]eading edge portion 23 of the p]ate 16 may be s]oped forwardly and downwardly as shown in ~a~

FIGURE 3, or in any other manrler, to increase the stiffness of the hoJder plate lG, al~hough this feature is not required and wil]. not affect the teachings and practice of the present invention.
The rep]aceab]e stone assemb]y 14 inc]udes a stone mount.ing or backing member 26, usua]].y constructed to inc]ude some of a relatively inexpensive mater.ial such as zinc, aluminum or some other like malleable or ductile materia]l with one or more honing stones such as the honing stone 28 mounted thereon. ~]though the stone 28 can be attached to the mountiny mer,lber 26 by a variety o suitab]e means, it is preferred that the stone 28 be adhesively attached to the member 26 5uch as by loca~ing and ho]ding said members in their proper joined position through the use of a jigt ].ocating ridges, or other like means. The mounting or backing member 26; the details of which are shown in FIGURES 6-10, inc]udes a surface 30 which is the surface to which the stone 28 is attached in some manner as hereinbefore explained and an opposed surface 32 (FIGURES 9 and lO) which abuts the upper surface of t~le p]ate 16 when installed thereon. The surface 30 is substantially f]at and extends the ful]
length of the member 26. An upwardly projecting stone locating ridge 34 extends partially along one side of the surface 30 adjacent each opposite end thereof and the stone 28 is positioned thereagainst to locate it as shown in FIGURES l and 3. The edge of the surface portion 30 opposite the ridges 34 extends to adjacent a sloping surface 36 and the surfaGe 36 extends therefrom to adjacent the forward or leading edge 38 of the member 26 as shown in FIGURE 9. The sloping surface 36 may also include a beveled portion 40 (FIGURE 9) adjacent the forward edge 38.
The surface 32 of the hacking member 26 includes two similar integral tubular projections 42 attached thereto and extending therefrom as clearly shown in FIGURES 7-9. Although the --] O--3~

tubu].ar projections 42 may extend through and beyond the holder plate ].6 in some app].ications as will be hereinafter explained, preferably the projections 42 extend from the surface 32 a distance slight].y less than the thickness of the p].ate member ]6, and the projections 42 are spaced apart and ~imensione~ so that they will extend into the respective bores 24 (FIGURES ]. and 2) when the assemblies 12 and 14 are p]aced in mating contact with each other.
Each projection 42 includes a cy]indrical passageway or openiny 44 formed therein and extending therethrough, each passageway 44 also extendi.ng through the body portion of the member 26 as best shown in FIGUR~ 9. Each of the tubular projections 42 also includes a pair of opposed s]ots or notches 46 formed extending partly from the free ends thereo as shown in FIGURES 8-10. A pair of spaced cavities or chambers 47 are a]so located extending from the surface 32 of the member 26 partway into the body portion of the member 26 as shown in FIGURES 8 and ]0. The cavities 47 are positioned and sized to accommodate the staking projections 2] when the stone assembly 14 is mounted flush on the master ho].der 12.

At least a portion of each opening 44 which extends through 2a the tubular projections 42 has an irregular cross-sectional shape defined by one or more sidewall portions that extend radial]y outwardly from the center thereof a ~istance further than other sidewall portions such as the si.dewall portions 48 shown in FIG~RE 9. This means that the projections 42 will have different thicknesses at the locations of the portions 48. These irregular portions 48 are important to the present invention because it is these portions oE the assembly 14 which are able to be forced sideways into engagement with the bores 24 of the master holder plate 16 as wi]l be explained. Once the tubular projections 42 are positioned extending into respective ones of the bores 24, pressure -- ] ]

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is app].ied agai.nst the sidewa]] porti.ons 48 by means of a tool to be described la~er so as to permanent].y upset and expand the malleable or ducti]e material in the projections 42 and in so doing to force said material plastica]ly sidewardly into engagement with the bores 24. Use of a simp]e swagirlg tool such as any one of the tools 50, 64, and 72 shown in FIGURES 11, 13 and 14 as wi].l be hereinafter explained can be used to effectively upset, expand and permanently deform the malleab]e or ductile material associated with the sidewall portions 48 into engagement with the bores 24.
It is important to note that as the sidewall portions 48 are forced sidewardly into engagement with ~he bores 24, some of the materia] associated therewith will be forced outwardly further than the rest so as to move into the larger diameter tapered portions 25 thereof. This makes for an even more positive connection between the stone assembly 14 and the master ho]der 12 which prevents them from coming apart, and it also makes for a relatively inexpensive construction that is easily and quickly insta]led. ~he bores 24 may also be countersunk or counterbored and this will produce substantially the same result as tapering the bores 24 as previously 2~ explained. In addition, in some app]ications, it may also be desirable to have the projections 42 extend through and beyond the back surface of the master holder plate 16 such that when the side wa]l portions 48 are expanded into engagement with the bores 2~
some of the malleable material associated with the sidewa]ls 48 will be forced outward].y and sideward].y 50 as to move beyond the termina].
ends of the bores 24 and onto the back surface thereof. This will likewise make for an even more positive connection between the stone assemblies 14 and the master holder 1~.

The i.rregular shape oE the portions 48 of the openings 44 are shown as being substantially oval in shape for illustrative ~12-lZZ~ D3~

purposes but it is ~lso recogniæed th~t the portions 48 may be fashioned înto a wide variety of shapes and conEigurations including, for example, a triangular, elipti.cal, hexagona], or other non-round cross-sectional shape without departiny from the teachings and practice of the present invention. The important thing is that the contour of the openings 44 in the area where they extend through the openings 24 in the plate 16 be such that they can be permanently plastically forced outward].y causing permanent deformation thereto to e~fect the desired connection.
FIGURE ].]. discloses one embodiment of a relatively simple swaging tool 50 which may be used for attaching the stone assemb]y ]4 to the master holder 12. The tool 50 is substantial]y L-shaped and includes a handle portion 52 and a work engaging end portion 54. The end portion 54 includes a transition portion 56 and a swaging or camming portion 58. The transition portion 56 is tapered ].ongitudina]ly becoming narrowest toward the end of the too]
and extends to adjacent an intermediate edge 57 which is shown as being substantial].y oval in cross-section. The edge 57 is transversely dimensioned so as to be slightly ]arger than the diameter of the openings 44 such that when the end portion 54 of the tool 50 is inserted into and through the openings 44, the edge 57 will abut the surface 36 of the member 26 thereby preventing the end portion 54 from being further inserted. This therefore controls the penetration of the tool 50 into the projections 42 an~ establishes the proper position for the tool when it is used to complete the connection between the members 26 and 16.
The camming portion 58 of the tool 50 is likewise substantially oval or elongated in cross section and inc]udes a relief portion 60 and a working or camming surface portion 62. The relief portion 60 is reverse tapered as shown in FIGURE ]1 such that the end portion thereof which ]ies adjacent the edge 57 is the sma]1er end. The camming portion 58 is likewise diJnensioned so as to be compatible with and insertable into and through the irregular portions 48 of the openings 44 in one direction on~y so that rotation of the too] portion 58 when so positioned wi]1 force the sidewa]J portions 4~ outward]y into enyagement with the bores 24.
The shape including the tapering and size of the re]ief portion 60 is important to the present tool construction because it is these features which a]low the tool portion 58 to not disturb the juxtaposition of the stone assembly ]4 upon the master holder 12 during the attaching operation while using only ordinary attention to aligning the tooJ squarely with the openings 44. This provides a better latitude in alignment when inserting the tool into the openings 44 The said shape also facilitates easy remova] of the tool from the openings 44 after use without jamming, binding or otherwise interfering with the sidewal]s of the openings 44. The tool portion S4 is preferably of a one piece construction and is made of a relatively hard material such as steel or other simiJar material so that it can be repeatedly used with minima] wear.
FIGURE ]2 il]ustrates the position of the tooJ 50 in readiness for use. Once the tubular projections 42 are positioned in the respective bores 24 of the master holder 12, the working end of the tool 50 is inserted within the openings 44 on the accessible side thereof and into the irreyu]ar bore portions 48 as described.
When so inserted, the edge 57 abuts the surface 36 (F~GURES 9 and 12) and prevents further insertion and the too] is ready for use. This is important because when the tooJ 50 is so positioned, the cammillg surface 62 is positioned adjacent the irregular portions 48 of the openings 44. In this regard, it is important that the camrning surface 62 fully traverses the irregular shaped 3~

surface portions 48 as shown in FIGURE ] 2 . The surface portions 48 may also be cut away or re]ieved as at 49 (FIGURE 9) to a].Jow the working portion 58 of the tool 50 to move easily therethrough. It should also be noted ~hat the slots or no~ches 46 are preferably located on the projections 42 so that when the too]. portion 54 i5 inserted within the openings 44, the opposite end portions of the too] portion 58 a3.ign with the slots 46. The slots 46 faci]itate the radial expansion of the relatively soft malleab]e or ductile material of the projections 42 during the camminy action.
Once ~he too] 50 is inserted as shown in FIGURE 12, the handle portion 52 can be used to forceab].y turn itD usua].ly through approximately 180 of rotation/ causing the camming surface portion 62 to upset and permanent]y plastically expand outwardly the relatively soft material from which the members 26 are formed. ~nce the camming action is accomplished for each projection 42, the tool 50 can be easily removed and inserted into any remaining openings 44 to effect engagement thereof with the master holder 12 in the same manner. This process is repeated until a].l of the irregular portions 48 associated with the openings 44 in the tubu]ar projections 42 are engaged with the master ho]der 12. If the irregular shaped portions 48 of the openings 44 are ashioned into configurations other than ova] configurations as shown~ the shape of the work engaging end portion 54 of the tool 50 will usually be reshaped and dimensioned accordingly.
Since the swaging or camming portion 62 of the too] 50 need only be rotated approximate]y 180 within the irregular shaped bore portions 48, un]ike the special tool disc]osed in pending sunnen U.S. Patent Application Serial No. 314,856, much less effort need be used with the present tool to complete the attachment. In addition, since the tool portion 58 is only app]ying force to the metal in the -]5-area of the irregular portions 48, and it is not forming threads, rotation of the tool 50 is more easily accomplished. The present manner of attachment therefore can be quickly and easily accomplished while at the same time providing a positive driviny connection between the master holder 12 and the replaceab]e stone assembly 14.
It is usually advantageous to dimension the tool portion 58 such that it does not extend or protrude appreciably beyond the ree end portion of the tubular projections 42. This will eliminate the need for modifying certain mandrel bodies where the tool is to be used to make the attachments while the master ho]ders remain attached to a honing mandrel. Additionally, although the pro~ections 42 are shown and described as having the slots or notches 46, the slots 46 are not essential to the practice of the invention so long as the too] portion 5B is dimensioned so as to be insertable within the irregular portions 48 of the openings 44 and can be rotated therewithin to effect the necessary camrlling action as hereinbefore discussed. By the same token the number of notches 46 can be increased or decreased as desired.
FIGURE ]3 illustrates an alternate embodiment oE a tool 64 which can be uti]ized for attaching the stone assemb]y 14 to the master holder 12. The tool 64 is a punch form type swaging too]
having a substantia]ly elongated cylindrical body 66 and a work engaging end portion 68. The work engaging portion 6~ is substankially cylindrical in shape and is of a diameter substantially equal to or slight]y less than the diameter of the openings 44 into which it will be inserted. In addition, the work engaging portion 68 must be of sufficient diameter or otherwise dimensioned such that when the tool 64 is moved through the respective openings 44~ the tool portion 63 including especially the ~2~ 3Z

beveled or rounded end portion 70 thereof contacts the irregular bore portions 4~ and is ab]e to expand said portions outward]y into engagement wi.th the bores 24 of the master holder 12 when axiaJ
force is applied to the member 64 by an instrument such as a hammer or press. Since the body portion 66 of the too] 64 is substantially sma]ler than the openings 44, once the mal]eab~.e or ductile material associated with the irregular portions 48 is expanded into enyagement with the master holder 12, the tool body 66 wil] be ab~e to ~reely pass therethrough for removal. This method of attachment is advantageous in some cases because use of the tooJ. 64 requires no tool rotation and can be easily and quickly driven through the irregular portions 48 of the openings 44 to effect engagement with the master ho]der 12. This form of tool however, may not be as suitable for making attachments when the master holder is on a mandrel when the attachment is made.
FIGURE 14 illustrates stil] another embodiment of a too] 72 which can be utilized for both attaching the stone assembly 14 to and detaching it from the master holder 12. The tool. 72 is L-shaped and includes a handle portion 73, a work engaging portion 74 and a threaded end portion 78. The end portion 74 is ]ike the end portion 54 of the tool 50 and the threaded portion 78 is provided to detach the rep]aceable stone assembly 14 from a master holder 12 as will be explained.
In order to detach the stone assembly 14 from the master holder 12 as shown in FIGURF 15, one or more counterbores or cavities such as counterbores 80 (FIGURES ], 6, 7, and ]5) are provided in the stone assemb]y 14 at spaced locations from the tubular projections 42 and at locations that are spaced from the honing stone or stones 28 as il]ustrated in FIGURES 1-6. The bores 80 are preferably non-threaded, although they can be threaded qD3~

if desired, and are dimensioned to threading]y receive the threaded end portion 78 of the too] 72. When the tool is turned into one of the counterbores 80 it wi]l form its own thYeads into the wa]]s thereof as it advances therethrough and eventual]y wi]] bear against the closed bottom 82 oE the counterbore 80 punching it free and pushing it against the master ho]der 12 and in doing so prying the members 12 and 14 apart. The threads at the free end of the too]
portion 78 may be tapered somewhat to facilitate starting said portion into the counterbores 80.
It is preferred that the counterbores or cavities 80 not extend all the way through the backing member 26 but have a narrow bottom portion or membrane such as the bottom portion 82. This means that when the threaded end portion 78 of the tool 72 is rotated within the respective counterbores 80, the end portion 78 will move against the portions 82 and no~ against the naster holder 12. This operates to transfer the force applied by the hard too] throuyh the softer membrane against the rnaster holder plate ]6 thereby minimizing damage to the master holder such as by wearing an identation into or otherwise scarin~ the master holder p]ate 16. It has been found that i the bores 80 stop approximately .010 to .015 inches short of the opposite side of the members 26, the portions of material 82 will easily separate therefrom as ~he tool portion 78 is rotated within each respective bore 80 to cushion the force app]ied against the master holders. One such counterbore or cavity 80 can be located adjacent to each of the tubu]ar projections 42 as shown in FIGURES 1 and 6, although in some cases a single counterbore usual]y central]y ]ocated may be al] that is necessary. The Jneans described above can be uti]ized to separate any of the various stone and/or guide assemb]ies described herein from their respective master ho]ders. It is anticipated, however, to use bores or -]8 3~

cavities 80 that extend completely through the backing members 26 but this i5 not general]y preferred because it may result in some damage to the master holders after repeated use.
It is important to the present invention that the master holder 12 be reusable since this portion is preferably made of relatively hard stee~ and is a relatively expensive part. The on]y replaceable portion is the stone assembly 14 which incJudes the re]atively inexpensive backiny member 26, which is mo]ded or die cast, and the stones 28 which are the portions that engaye the work surface and undergo wear. The stone assemblies 14 can be mass produced relatively inexpensively, the backing 26 being of a ma]leab]e or ductile material which can be upset and permanently deformed without breaking as aforesaid. It is expected that some irreparable damage wi]l occur to the tubu~ar projections 42 on the stone assemblies when the assemblies 14 are detached from the master ho]ders 12. This ]imits the ability to reattach the same stone assembly 14 repeatedly, although it may be possible in some cases if care is used to reattach a stone assembly a time or two but this is usually not feasible. Therefore, in the usual situation, once the stone assemb]y 14 has been attached to the master ho]der ]2, it wi]]
not be necessary or desirable to reattach the same stone assembly to the same or to a different master ho]der.
The size and/or spacing and/or locations of the bores 24 and of the tubular projections 42 may be selected to prevent both improper mounting and the mounting of wrong stone assemblies on a master holder. For examp]e, if the locations of the bores 24 and the respective tubular projections 42 are offset toward one end of the device or toward one side the operator wil] be prevented from accidentally or inadvertently mounting a stone assembly backwards on a master holder.

_]9_ 1'3~

FIGURE 16 is a perspective view of an a].ternative embodiment 84 of the construction 10 shown in FIGURES ]-3. The embodiment 84 includes a reusable master holder 86 and a rep].aceab]e stone assembly 88 for ~nounting thereon, both of which are drivingJ.y attached to each other according to the teachings of the present invention~ The master ho].der 86 may be substantia].ly identica]. in construction and operation to the master holder 12 shown in FIGURES 1-5 and the stone assemb]y 88 is very simi]ar to the stone assembly 14 but differs therefrom in that it includes one or more notches 90 formed in ~he surface thereof that is adjacent to the master holder 860 The notches 90 are shown positioned adjacent to the side 89 of the stone assembly 88 that is behind the stone. The ; notch 90 has a step in it so that it forms two different width slot or notch portions 92 and 94 with the adjacent master holder 86. The wider slot portion g2 is dimensioned such that at least the end portion 58 (or 77) of the too3. 50 (or 72) is insertable therewithin to enable ~rying the members apart. The slot portion 94 communicates with the wider slot portion 92 and wil] accommodate the tool end portion 58 (or 77) to comp]ete the prying apart of the members 86 and 88 after they are initia]ly partly separated. It is genera]ly preferred that a notch 90 be located a]ong the side 89 of the stone assembly 88 in the near vicinity of each respective tubular projection (FIGURE 16). The specific locations and shape of the ~otches 90 as hereinbefore exp]ained will enable sufficient prying force to be exerted in the vicinity of each respective attachment point so as to easily separate the members 86 anc] 88.
FIGURES 17 and 18 i]]ustrate other embodiments including other locatiolls for the notches 90 in the replaceable stone assemblies for prying it loose from the master holder. FIGURE 17 discloses an embodiment 96 which is substantially si.milar to the )3~

embodiment 84 (FIGU~E ] 6) except that the notches 90 are located at one or both ends of the stone assembly 98 rather than along a side thereoE. In a]] other respects, the construction and operation of the stone assembly 98 is substantially ~he same as described above.
FIGURE 18 il]ustrates an embodiTnent ]02 wherein the stone assembly 104 includes the notches 90 located on one or both ends and along one side of the assembly J04 to provide an option as to which notches to use to pry the assernbly looseO The stone assembl~ iO4 also includes one or more bores or cavities 80 as dlscussed aboveO
The ernbodiment 102 therefore incorporates all of the above disclosed means usuable for detaching a stone assembly from its respective master ho]der.
FIGURE l9 discloses a replaceable and disposab]e work engaging guide member 106 which may be attached to and detached from a master holder such as the holders 12~ 86 and lO0 in a manner similar to the way the stone assemblies are attached. The guide member 106 includes an e]ongated backing or support portion 108 having a relatively non-abrasive upstanding work engaging portion 110 projecting from one surface thereof and adjacent one side edge, usually the trailing side edge thereof, as shown. The surface 111 of the supporting member ]08 opposite the guide portion 110, like the surface 32 of the stone assembly 26, is shaped and dimensioned to mate flush with the adjacent surface o~ the master holder plate upon which it is to be mountedl and the contour of the opposite surface lO9 of the member 108 may be as shown although other contours may be used as desired.
The guide member 106, like the stone assemblies, inc]udes two or more tubu]ar projections 112 extendiny thereErom for cooperation with bores in the master holder as aforesaid and are expanded in the same way using a tool such as described to make the -2]-3~2~3~

attachment. ~emoval of the member ]06 from its master holder may likewise be accomp]ished by any one of the remova] methods hereinbefore discussed.
The upstanding work enyaging guide portion 1]0 on the member 106 is shown as having a wavy construction for illustrative purposes~ This is done to reduce the amount of materia] necessary to form the guide without substantially weakening the construction.
It is contemp]ated, however, that the guide portion ]lO cou]d have other shapes as well including being an elongated member with parallel sides without departing from the teachings and practice of the present invention. The guide member ]06, like the backiny member 26 of the stone assembly 14, is preferab]y constructed of a relative]y inexpensive malleable or ductile materia3 such as materia]s that include zinc or zinc al]oys which is characteri2ed by being relatively non-abrasive and more lilcely to slide on a work surface than to abrade it. Zinc is also a relatively easy material to cast and is generally preferred although other relative]y non-abrasive materials such as bronze, brass, certain plastic materials or even wood cou]d be used.
FI~URES 20 and 2] i]]ustrate another embodiment of a honing stone assemb]y ]14 which can be mounted to a master ho]der in the manner of the present construction. The assemb]y 114 is shown having two spaced parallel stones 116 mounted thereon. The stone assembly 114 is also shown having two spaced tubular projections ]]8 similar to those described above which cooperate with corresponding bores 120 in master holder plate 122. The construction and operation of the tubular projections ]18 and the way they cooperate with the bores ]20 to make the attachment or detachment using a suitab]e tool is substantially identical to the contruction and operation of the projections 42 and the bores 24 previous]y described.
As hereinbefore discussed, the p~esellt invention teaches a novel means for attaching replaceable stone and/or guide assemblies to master holders without the use of threaded fastener members or additional parts to accomp]ish the same. In addition~ the present means for attaching and detaching can be accomp]ished without requiring any dissassembly of the honing mandrel or even removal from the mandrel of the master holders. This can represent a substantial savings in operator time thereby increasing the honiny efEiciency. The present invention ther2fore not only provides a simple means or easily and quickly rep]acing worn stone and/or guide assemblies but it does so in a manner which estab]ishes a positive driving connection between the assemblies and the master ho]ders to which they are attached. It should a3so be clear that the present mounting means can be utilized for a~taching and detaching a wide variety of devices including various disposable machine tool parts and is not limited to attaching honing assemblies and guide assemblies to master holders.
Thus there has been shown and described several different embodiments of a nove] mounting means inc~uding novel means for mounting work engaging members and ~he like on support structures therefor which means fulfi]l all of the objects and advantages sought therefor. Many changes, modifications, variations, and other uses and applications of the present mounting means will, however;
become apparent to those skil]ed in the art after considering this specification and the accompanying drawings, and aJ] such changes~
modifications, variations, and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is ]imited on]y by the claims which follow.

Claims (29)

The embodiments of the invention in which an exclusive property or priviledge is claimed are defined as follows:

1. Means for attaching a first member to a second member comprising a first member having opposed surfaces and at least one opening located extending therethrough, a second member having at least one portion projecting therefrom which mates with and is extendible into the opening in said first member, the number of projecting portions on said second member corresponding in number to the number of openings extending through said first member, each of said projecting portions having an opening extending therethrough at least a portion of which has an irregular cross-sectional shape defined by sidewall portions that extend radially outwardly from the center thereof a distance further than other sidewall portions associated therewith, said irregularly shaped portions being located in the area of said openings that extend through the openings in said first member, and means insertable respectively into each of said projecting portions to radially expand the irregularly shaped portions thereof outwardly into engagement with the corresponding openings in said first member.

2. The means defined in claim 1 wherein said second member and the projecting portions associated therewith are formed of a malleable material.

3. The means defined in claim 1 wherein said insertable means includes a tool member having a portion thereof positioned for extending into the openings extending through said projecting portions, rotation of said tool when said tool portion is positioned extending into one of said projection openings exerting outward pressure on the irregularly shaped portions thereof forcing said portions outwardly into intimate engagement with the openings in said first member.

4. The means defined in claim 3 wherein said tool portion has means associated therewith engageable with said first member to limit penetration thereof into the openings in said projecting portions.

5. The means defined in claim 3 wherein said tool portion has a cross-sectional shape that permits it to be freely insertable respectively into operative position into each of the openings through said projecting portions in certain positions of angular orientation only.

6. The means defined in claim 1 wherein the opening through the first member has portions of different diameter.

7. The means defined in claim 1 including means forming a slot in said second member into which a wedging tool can be inserted between said first and second members for applying pressure therebetween to wedge said members apart.

8. The means defined in claim 1 wherein the projecting portions of said second member extend outwardly therefrom a distance less than the distance between the opposed surfaces of said first member.

9. The means defined in claim 1 wherein the projecting portions of said second member extend outwardly therefrom a distance greater than the distance between the opposed surfaces of said first member.

10. The means defined in claim 1 including at least one counterbore formed in said second member at a location spaced from the projecting portions associated therewith for receiving a threaded member used for separating apart said first and second members.

11. Means for attaching a member formed of a malleable material to a support member, said support member having opposite surfaces and an opening extending therethrough, said malleable member having a projecting portion of a cross-sectional shape adapted to be received into the opening of said support member, said projecting portion having an opening therein which extends into the opening of said support member when said projecting portion is placed in registration therewith, the opening in said projecting portion having an irregular cross-sectional shape defined by portions of varying cross-sectional contour, said irregular opening portions being located so as to lie within the opening in said support member when said projecting portion extends into said support member opening, and a tool having a first portion extendible into the opening in the projecting portion of said malleable member, said first tool portion having a cross-sectional contour that enables it to extend into said opening but prevents it from freely turning therein, said tool having a second portion forming a handle thereon which, when rotated, enables said first tool portion to be forced into engagement with said irregular opening portions whereby said portions are forced to permanently plastically expand under pressure outwardly into intimate engagement with the opening in said support member.

12. The means defined in claim 11 wherein the projecting portion of said malleable member is dimensioned to closely fit into the corresponding opening through said support member.

13. The means defined in claim 11 wherein the projecting portion has a first end attached to said malleable member and an opposite free end, and at least one axially extending notch formed extending pertly therein from the free end thereof to facilitate radial expansion thereof when the first portion of said tool is rotated therein.

14. The means defined in claim 11 wherein the opening extending through said support member is tapered axially over at least a portion of the length thereof.

15. Means for attaching a first member to a second member comprising a first member of plate like construction having at least one bore extending therethrough at an intermediate location, said bore being tapered outwardly over at least a portion of the length thereof, a second member of plate like construction having a projection formed thereon at an intermediate location to register with and be extendible into said bore in said first plate like member, said projection having an outer cross-sectional diameter that corresponds to the cross-sectional diameter of the bore through said first plate like member at the location of the smallest diameter thereof, said projection having an axial passageway extending therethrough formed at least in part by a non-round portion located in the area thereof that extends through the bore in said first plate like member, and a tool member having an operator end portion adapted to be positioned extending through the passageway in said projection, rotation of said tool member when said tool operator end portion is positioned extending through the projection of said second plate like member forcing said operator end portion against the non-round portion of the passageway to reshape the non round portion of said passageway thereat into a more nearly round shape and in so doing forcing some of the material contained therein radially outwardly into engagement with the bore in said first plate like member to form a connection between said first and second members.

16. The means defined in claim 15 wherein the first plate like member is formed of a relatively hard material.

17. The means defined in claim 15 wherein the second plate like member and the projection formed thereon are formed of a ductile material.

18. The means defined in claim 17 wherein said ductile material includes some zinc.

19. The means defined in claim 15 wherein the non round portion of the passageway extending through said projection is substantially oval in cross-section, and the operator end portion of said tool has a cross-sectional shape that permits it to be freely insertable into operative position in said passageway in certain positions of angular orientation only.

20. The means defined in claim 15 wherein the operator end portion of said tool includes means thereon engageable with the first plate like member to limit penetration thereof into the passageway in said projection.

21. The means defined in claim 15 wherein the first and second plate like members have adjacent side edges and means forming a slot extending from said adjacent side edges to form a space between said first and second members into which a wedging tool can be inserted and used for applying pressure to wedge said members apart after joinder.

22. The means defined in claim 15 wherein said second plate like member includes a counterbore formed extending wherein at a location spaced from said projection and on the opposite side thereof from said projection, and a threaded member threadable into the counterbore for applying pressure against the first plate like member in a direction to separate said second plate like member from said first plate like member.

23. Means for attaching and detaching a disposable work engaging assembly to a master holder assembly for use on a honing mandrel or the like comprising a disposable work engaging assembly formed of a malleable material including an elongated member having opposed surfaces, at least two spaced tubular projections attached extending outwardly from one of said opposed surfaces to opposite free ends, each of said tubular projections having a substantially cylindrical outer surface and a passageway extending therethrough said passageway having a portion adjacent the free end of said tubular projections which is non-circular in cross-section, said master holder assembly including an elongated member formed of a relatively hard material having at least two spaced openings extending therethrough at locations to register with and to receive respective ones of the spaced tubular projections on the disposable work engaging assembly, the openings on said master holder member each having at least some portions thereof of different diameter, and an elongated tool. having a first end portion adapted to be freely positioned extending substantially through the passageways in said tubular projections, said tool having a handle portion connected to said first end portion for rotating said tool when said first end portion is positioned extending through the passageway in one of said tubular projections, rotation of said tool handle portion forcing the non-circular portion of each of said respective tubular projection passageways into a more nearly cylindrical shape whereby at least some of the malleable Material associated therewith is permanently plastically forced outwardly into intimate engagement with the respective opening in said master holder assembly.

24. The means defined in claim 23 wherein said disposable work engaging assembly is a honing stone assembly.

25. The means defined in claim 23 wherein said disposable work engaging assembly is a honing guide assembly.

26. The means defined in claim 23 including means forming an exposed slot between the work engaging assembly and the master holder assembly for inserting a portion of a wedging tool therebetween for applying pressure to wedge said members apart.

27. The means defined in claim 23 wherein said disposable work engaging assembly includes at least one counterbore formed in the work engaging assembly at a location therein spaced from said tubular projections and on the opposite side of the assembly from said projections for cooperatively receiving a threaded member used for applying pressure against the master holder assembly to separate said disposable work engaging assembly therefrom.

28. The means defined in claim 27 wherein said elongated tool includes a threaded end portion on said handle portion, said threaded end portion being threadedly engageable with said counterbore.

29. Means for attaching a first member formed of a malleable material to a second harder support member having opposite surfaces and at least one opening extending therethrough between said opposite surfaces, said malleable member having a projecting portion formed thereon at a location and of a size to register with and to be received into the opening through said support member, said projecting portion having an opening therethrough at least a portion of which is smaller in cross-sectional size than the rest of said opening and non-round in shape, the smaller cross-sectional opening portion being located so as to lie within the opening in said support member when the projecting portion is positioned extending therein, and means including a tool having a work engaging portion adapted to be forced into engagement with the reduced cross-sectional opening portion to permanently plastically deform and force the malleable material thereat to expand outwardly into intimate engagement with the opening in said support member.