Methods and apparatus for machining a coupling

Abstract

A method facilitates fabricating a coupling including a first annular coupling member and a second annular coupling member. The method comprises coupling the first coupling member to a machine assembly that includes a plurality of grinding wheels coupled to a tool storage member, machining a plurality of troughs in the first coupling member using at least one of the plurality of grinding wheels, such that at least one projection is defined between adjacent troughs, coupling the second coupling member to the machine assembly, and machining a plurality of troughs in the second coupling member using at least one of the plurality of grinding wheels, such that the second coupling member is configured to rotatably couple to the first coupling member.

1 . A method for fabricating a coupling including a first annular coupling member and a second annular coupling member, said method comprising: 
 coupling the first coupling member to a machine assembly that includes a plurality of grinding wheels coupled to a tool storage member;    machining a plurality of troughs in the first coupling member using at least one of the plurality of grinding wheels, such that at least one projection is defined between adjacent troughs;    coupling the second coupling member to the machine assembly; and    machining a plurality of troughs in the second coupling member using at least one of the plurality of grinding wheels, such that the second coupling member is configured to rotatably couple to the first coupling member.    
   
   
       2 . A method in accordance with  claim 1  wherein machining a plurality of troughs in the first coupling member further comprises supplying coolant to the grinding wheel through a coolant passageway defined in the grinding wheel.  
   
   
       3 . A method in accordance with  claim 1  wherein machining a plurality of troughs in the first coupling member further comprises: 
 machining a plurality of troughs in the first coupling member using an abrasive grinding surface extending from at least one of the grinding wheels; and    supplying coolant to the abrasive grinding surface through a coolant passageway defined in the grinding wheel    
   
   
       4 . A method in accordance with  claim 1  wherein machining a plurality of troughs in the first coupling member further comprises: 
 machining a plurality of troughs in the first coupling member using an abrasive grinding surface extending from at least one of the grinding wheels; and    supplying coolant to the abrasive grinding surface through a plurality of openings formed in the grinding wheel.    
   
   
       5 . A method in accordance with  claim 1  further comprising dressing at least one of said plurality of grinding wheels using a dressing assembly coupled to the machine assembly.  
   
   
       6 - 20 . (canceled)  
   
   
       21 . A method for fabricating a coupling, said method comprising: 
 providing a machine assembly that includes a machine base, a machine tool, and a pallet assembly;    coupling a first coupling member to the pallet assembly;    forming a plurality of troughs in the first coupling member using at least one of a plurality of grinding wheels, such that at least one projection is defined between each pair of adjacent troughs;    coupling a second coupling member to the pallet assembly; and    forming a plurality of troughs in the second coupling member using at least one of the plurality of grinding wheels, such that the second coupling member is configured to rotatably couple to the first coupling member.    
   
   
       22 . A method in accordance with  claim 21  wherein coupling a first coupling member to the pallet assembly comprises removably coupling the first coupling member to one of a plurality of fixtures coupled to the pallet assembly.  
   
   
       23 . A method in accordance with  claim 21  wherein forming a plurality of troughs in the first coupling member comprises: 
 forming a plurality of troughs in the first coupling member using an abrasive grinding surface that extends from at least one of the plurality of grinding wheels; and    supplying coolant to the abrasive grinding surface through a coolant chamber defined in the grinding wheel.    
   
   
       24 . A method in accordance with  claim 24  wherein supplying coolant to the abrasive grinding surface comprises channeling coolant across an upstream surface of a coolant plate that includes a plurality of openings that channel the coolant towards the abrasive grinding surface.  
   
   
       25 . A method in accordance with  claim 21  wherein coupling a first coupling member to the pallet assembly comprises coupling a first coupling member to a dressing roll, wherein the dressing roll is coupled to one of a plurality of fixtures coupled to the pallet assembly.  
   
   
       26 . A method in accordance with  claim 25  further comprising simultaneously positioning at least one of the plurality of grinding wheels with respect to the first coupling member, and dressing the grinding wheel using the dressing roll.  
   
   
       27 . A method in accordance with  claim 21  wherein forming a plurality of troughs in the first coupling member comprises: 
 locating a desired grinding wheel from the plurality of grinding wheels; and    coupling the desired grinding wheel to a chuck.    
   
   
       28 . A method in accordance with  claim 25  further comprising locating a selected pallet that contains an predetermined dressing roll for dressing a selected grinding wheel of the plurality of grinding wheels.  
   
   
       29 . An apparatus for machining a coupling, said apparatus comprising a machine base, a machine tool, and a pallet assembly, said apparatus configured to: 
 receive a first coupling member onto a selected fixture of a plurality of fixtures, wherein said fixture is coupled to a fixture tower of said pallet assembly;    machine a plurality of troughs in the first coupling member using at least one of a plurality of grinding wheels, such that at least one projection is defined between each pair of adjacent troughs;    receive a second coupling member onto a selected fixture of said plurality of fixtures; and    machine a plurality of troughs in the second coupling member using at least one of said plurality of grinding wheels, such that the second coupling member is formed to rotatably couple to the first coupling member.    
   
   
       30 . An apparatus in accordance with  claim 29  further comprising an automatic tool changer, wherein said apparatus is further configured to: 
 use said automatic tool changer to locate a desired grinding wheel from said plurality of grinding wheels; and    couple said desired grinding wheel to a chuck.    
   
   
       31 . An apparatus in accordance with  claim 29  further comprising an automatic pallet changer, wherein said apparatus is further configured to: 
 use said automatic pallet changer to locate a first desired pallet comprising a dressing roll that corresponds to a desired grinding wheel of said plurality of grinding wheels;    align said dressing roll with said desired grinding wheel; and    dress said desired grinding wheel using said dressing roll.    
   
   
       32 . An apparatus in accordance with  claim 31  wherein said apparatus is further configured to: 
 use said automatic pallet changer to locate a second desired pallet comprising the first coupling member; and    align the first coupling member with said desired grinding wheel.    
   
   
       33 . An apparatus in accordance with  claim 31  wherein said apparatus is further configured to: 
 use said automatic pallet changer to locate a third desired pallet comprising the second coupling member; and    align the second coupling member with said desired grinding wheel.    
   
   
       34 . An apparatus in accordance with  claim 29  wherein each grinding wheel of said plurality of grinding wheels comprises an abrasive surface, a coolant passageway, and a coolant chamber, wherein said apparatus is further configured to supply coolant to said abrasive grinding surface through said coolant chamber.  
   
   
       35 . A method in accordance with  claim 34  wherein said apparatus is further configured to supply coolant to said abrasive grinding surface by channeling coolant across an upstream surface of a coolant plate that comprises a plurality of openings that channel the coolant towards said abrasive grinding surface.