Method for repairing vehicle axles

Abstract

A boring apparatus and method for in-situ repair of motor vehicle axles includes a universal mounting plate assembly for attachment to a vehicle axle, both longitudinal (on-axis) and transverse (radial) adjustment assemblies, a bearing assembly and a boring bar and drive assembly having a pair of motor drive units for rotating (speed) and axially advancing (feed) the boring bar. The longitudinal and transverse adjustment assemblies facilitate use of the boring apparatus on a wide variety of vehicle and truck axles from virtually all manufacturers to repair broken axles or damaged bearing surfaces.

1 - 20 . (canceled)  
   
   
       21 . A method for repairing a vehicle axle comprising the steps of: 
 providing a boring apparatus having axial and transverse adjustment assemblies, a boring bar defining an axis and a boring bar drive assembly;    mounting said boring apparatus on a brake flange of an axle and adjusting said assembly to align said boring bar axis with an axis of said axle;    boring said axle to accommodate a replacement spindle;    installing said replacement spindle in said bored axle, and    welding said replacement spindle to said bored axle.    
   
   
       22 . The method of  claim 21  wherein said boring bar drive assembly rotates and axially translates said boring bar.  
   
   
       23 . The method of  claim 21  wherein said transverse adjustment assembly adjusts said axis of said boring bar relative to said axis of said axle.  
   
   
       24 . The method of  claim 21  wherein a cutting speed of said boring bar is adjustable.  
   
   
       25 . The method of  claim 21  wherein said welding extends fully about said replacement spindle.  
   
   
       26 . The method of  claim 21  wherein said welding step includes providing at least two plug welds between said replacement spindle and said axle.  
   
   
       27 . The method of  claim 21  further including the step of providing at least one ball bearing support for said boring bar.  
   
   
       28 . A method of repairing a vehicle axle comprising the steps of: 
 providing a boring apparatus having a radial adjustment assembly, a boring bar defining an axis and a boring bar drive assembly;    mounting said boring apparatus on a brake flange of an axle defining an axis;    aligning said boring bar axis with said axis of said axle;    boring said axle with said boring bar to accommodate a replacement axle portion;    installing said replacement axle portion in said bored axle; and    welding said replacement axle portion to said axle.    
   
   
       29 . The method of  claim 28  wherein said boring bar drive assembly rotates and axially translates said boring bar.  
   
   
       30 . The method of  claim 28  wherein said radial adjustment assembly radially adjusts said axis of said boring bar relative to said axis of said axle.  
   
   
       31 . The method of  claim 28  wherein a cutting speed of said boring bar is adjustable.  
   
   
       32 . The method of  claim 28  wherein said welding extends fully about said replacement axle portion.  
   
   
       33 . The method of  claim 28  wherein said welding step includes providing at least two plug welds between said replacement axle portion and said axle.  
   
   
       34 . The method of  claim 28  further including the step of providing at least one ball bearing support for said boring bar.  
   
   
       35 . A method of repairing a vehicle axle comprising the steps of: 
 providing a boring apparatus having an axial adjustment assembly, a radial adjustment assembly, a boring bar defining an axis and a boring bar drive assembly;    mounting said boring apparatus on a brake flange of an axle defining an axis;    aligning said boring bar axis with said axis of said axle by adjusting said radial adjustment assembly;    boring a circular opening within said axle with said boring bar to accommodate a stub axle;    installing said stub axle in said circular opening of said axle; and    welding said stub axle to said axle.    
   
   
       36 . The method of  claim 35  wherein said boring bar drive assembly rotates and axially translates said boring bar.  
   
   
       37 . The method of  claim 35  wherein said radial adjustment assembly radially adjusts said boring bar axis relative to said axle axis.  
   
   
       38 . The method of  claim 35  wherein said welding extends fully about said stub axle.  
   
   
       39 . The method of  claim 35  wherein said welding step includes providing at least two plug welds between said stub axle and said axle.  
   
   
       40 . The method of  claim 35  wherein said axial adjustment assembly include a plurality of sets of bushings, each of said sets of bushings having distinct thicknesses.